0.1.manual Reparatii Si Intretinere FORD FOCUS PDF

1/2430
10/30/2018 Print
General Information - Information - Overview

Print
Description and Operation
Focus
WARNING: Before beginning any service procedure in this manual, refer to health and safety
warnings in section 100-00 General Information. Failure to follow this instruction may result in
serious personal injury.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
1/1
2/2430
10/30/2018 Print
General Information - About this Manual

Print
Introduction
This manual covers diagnosis and testing and repair procedures.
It is structured into groups and sections, with specific system sections grouped 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.
Within Etis, the navigation tree will list the groups. After selecting a group the navigation tree will
then list the sections within that group. Each section has a contents list detailing Specifications,
Description and Operation, Diagnosis and Testing, General Procedures, Disassembly and Assembly,
Removal and Installation.
References to LH (left-hand) and RH (right-hand)
All LH and RH references to the vehicle are taken from a position sitting in the driver seat looking
forward.
Vehicle LH and RH definition
Item Part Number Description

1 - LH
2 - RH
All LH and RH references to the engine are taken from a position at the flywheel looking towards the
crankshaft pulley.
Powertrain LH and RH definition
1/13
3/2430
10/30/2018 Print

1 - front
2 - right hand
3 - rear
4 - left hand
How to use Repair Procedures

This manual has been written in a format that is designed to meet the needs of technicians
worldwide. It provides general descriptions for accomplishing repair work with tested and effective
techniques.
Important Safety Instructions
Appropriate service methods and correct repair procedures are essential for the safe and reliable
operation of all vehicles as well as the personal safety of the individual carrying out the work.
Anyone who departs from the instructions provided in this manual must first establish that personal
safety or vehicle integrity is not compromised by the choice of method, tools or components.
Warnings, Cautions and Notes in This Manual
WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result
in personal injury.
NOTICE: Cautions are used to indicate that failure to follow a procedure correctly may result in
damage to the vehicle or equipment being used.
NOTE: Notes are used to provide additional essential information required to carry out a complete
and satisfactory repair.
Generic warnings or cautions are in their relevant description and operation procedure within section
100-00. If the generic warnings or cautions are required for a procedure, there will be a referral to
the appropriate description and operation procedure.
If a warning, caution or note only applies to one step, it is placed at the beginning of the specific step.
Global Authoring Standards (GAS) Repair Procedures
NOTE: GAS style procedures can be identified by steps that have no accompanying step text and
the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
A GAS removal and installation procedure uses a sequence of color illustrations to indicate the order
to be followed when removing/disassembling or installing/assembling a component.
Many of the GAS procedures will have the installation information within the removal steps. These
procedures will have the following note at the beginning of the procedure:
2/13
4/2430
10/30/2018 Print
NOTE: Removal steps in this procedure may contain installation details.

Reuse of fasteners and seals and gaskets
The workshop manual assumes the following rules, unless specified differently in the procedure:
Reuse standard fasteners.

Replace fasteners with self-locking features.
- Examples of fastener self-locking coatings or mechanical locking (with the locking features
highlighted yellow) are shown in illustration.
Replace fasteners with torque angle specifications (those tightened a specified number of degrees).
Replace seals and gaskets.
Types of self-locking nuts and bolts

NOTE: There are more types of self-locking fasteners available than shown in following illustration.

1 - Completely coated self-locking bolt
2 - Partially coated self-locking bolt
3 - Self-locking bolt with a locking washer
4 - Self-locking nut with a plastic locking insert
5 - Self-locking nut with thread deformation (3 indentations)
6 - Self-locking nut with thread deformation (to oval shape)
7 - Self-locking nut with integrated locking ring
Reuse of exterior trim parts
All type of glued exterior trim parts or parts fastened with adhesive tape must be discarded and new
parts installed unless otherwise stated within the procedure.
Specification data
Specification procedures will only contain technical data that is not already part of a repair procedure.
Sequence of tasks
If components must be removed or installed in a specific sequence, the sequence will be identified
numerically in a graphic and the corresponding text will be numbered accordingly.
Special Tools, Equipment, Materials and Torque Figures
Special tools will be shown with the tool numbers in the illustration. The special tool numbers, general
equipment, materials and torque figures used for the procedure step will be shown in the text
column.
3/13
5/2430
10/30/2018 Print
GAS Graphics
NOTE: Colors used in the graphic are as follows:

1 - Blue - Target or primary component to be removed/installed (or
disassembled/assembled).
2 - Green - Components that need to be removed prior to or installed after the
target/primary.
3 - Brown - Components that need to be removed prior to or installed after the
target/primary.
4 - Yellow - Components to be set aside only, that remains in the vehicle. Also
highlighted areas to inspect or adjust.
5 - Magenta - Electrical connectors and fasteners such as nuts, bolts, clamps, or clips
to be: detached, attached, loosened, moved, removed or installed.
6 - Pale Blue - Special tool(s), general equipment, or common tools (used in an
uncommon way).
One illustration may have multiple steps assigned to it.
Numbered pointers are used to indicate the number of electrical connectors and fasteners such as
nuts, bolts, clamps and clips.
Items in the illustration can be transparent or use cutouts to show hidden details.
4/13
6/2430
10/30/2018 Print
5/13
7/2430
10/30/2018 Print
6/13
8/2430
10/30/2018 Print
GAS Service Action Icon

Symbols are used inside the graphics and in the text area to enhance the information display. The
following paragraphs describe the various types and categories of symbols.
For additional information, refer to: Symbols Glossary (100-00 General Information, Description and
Operation).
Prohibition symbols advise on prohibited actions to either avoid damage or health and safety related
risks. These symbols are:
Health and Safety symbols recommend the use of particular protection equipment to avoid or at least
reduce the risk or severity of possible injuries.
7/13
9/2430
10/30/2018 Print
Warning symbols are used to indicate potential risks resulting from a certain component or area.
Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent to a
component.
8/13
10/2430
10/30/2018 Print
Location symbols are used to show the location of a component or system within the vehicle.
Gearshift lever or selector lever position symbols are used to show which gearshift lever or selector
lever position is to be set.
9/13
11/2430
10/30/2018 Print
Pointer symbols are used to draw attention to components and give special instructions such as a
required sequence or number of components. The number of components is reflected by the value
inside the luty arrow. A sequence number is located inside the circle. Numbers inside circles are also
used to allocate special information such as tightening torques or chemicals to a particular
component.
Movement arrows are used to show three dimensional or rotational movements. These movements
can include specific values inside the symbol if required.
10/13
12/2430
10/30/2018 Print
Standard tool symbols recommend the use of certain standard tools. These tools can include
dimension values if required.
The following graphic illustrates a set of symbols that are used to provide detailed information on
where to apply a material.
11/13
13/2430
10/30/2018 Print
Measurement symbols provide detailed information on where to carry out a specific measurement.
These symbols can include specific values if required.
How to use Diagnosis and Testing procedures

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.
12/13
14/2430
10/30/2018 Print
The boxed numbers indicate the order in which the described action is to be carried out.
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 carried out 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.
13/13
15/2430
10/30/2018 Print
General Information - Symbols Glossary

Print
Symbols are used inside the graphics and in the text area to enhance the information display.
Movement Symbols
Movement symbols provide detailed information to a required component movement. These
component movements can be rotational or 1-3 dimensional movements.

1 - Minor component movement clockwise/counterclockwise
2 - Major component movement clockwise/counterclockwise
3 - Component movement to the left/right/up/down
4 - Component movement towards/away
5 - 3 dimensional component movement
6 - 2 dimensional component movement
7 - 3 dimensional component rotation
8 - 3 dimensional component cycling
Turn Symbols
Turn symbols are used to provide further information on the direction or angle of component turns.
1/21
16/2430
10/30/2018 Print

1 - Turn the component clockwise through 45°
2 - Turn the component counterclockwise through 45°
7 - Turn the component clockwise through 2 complete turns
8 - Turn the component counterclockwise through 2 complete turns
Steering Wheel Symbols

Steering wheel symbols are used to provide further information to a required steering wheel position
or steering column lock status.
2/21
17/2430
10/30/2018 Print

1 - Steering wheel in straight ahead position
2 - Steering column lock locked
3 - Steering column lock unlocked
4 - Turn the steering wheel to the 90° left position
5 - Turn the steering wheel to the 90° right position
6 - Turn the steering wheel to the left-hand end position
7 - Turn the steering wheel to the right-hand end position
Body Types
Body type symbols are used to identify different body configurations.
3/21
18/2430
10/30/2018 Print

1 - 3, 4, 5-door body style
2 - Wagon body style
3 - Sports utility vehicle body style
4 - Coupe body style
5 - Convertible body style
6 - Van body style
7 - 3, 4, 5-door body style - Top View
8 - Wagon body style - Top View
9 - Underview
10 - Right-hand drive (RHD) vehicle
11 - Left-hand drive (LHD) vehicle
Gearshift lever and selector lever position symbols

Gearshift lever and selector lever position symbols are used to show the lever position that is required
to be selected to carry out a procedure step.
4/21
19/2430
10/30/2018 Print

1 - Replaced by symbol 9
9 - Set the selector lever to the park (P) position
10 - Set the selector lever to the reverse (R) position
11 - Set the selector lever to the neutral (N) position
12 - Set the selector lever to the drive (D) position
13 - Set the selector lever to the drive (S) position
14 - Set the selector lever to the drive (M) position
15 - Set the selector lever to the drive (-) position
16 - Set the selector lever to the drive (+) position
5/21
20/2430
10/30/2018 Print
17 - Set the gearshift lever to the neutral (N) position

18 - Further gearshift lever positions that may appear in illustrations
Screwdriver symbols
The screwdriver symbols are used to show which screwdriver bit is recommended to carry out a
procedure step.

1 - Screwdriver
2 - Cross bladed screwdriver / Cross bladed Bit Socket
3 - Flat bladed screwdriver / Flat bladed Bit Socket
4 - Hexagonal screwdriver / Hexagonal Bit Socket
5 - TORX screwdriver / TORX Bit Socket
6 - Polydrive screwdriver / Polydrive Bit Socket
7 - Ball drive hex bit
Pliers symbols
The pliers symbols are used to show which pliers is recommended to carry out a procedure step.
6/21
21/2430
10/30/2018 Print

1 - Combination pliers
2 - Side cutter pliers
3 - Securing ring - inner
4 - Securing ring - outer
5 - Hose clamp pliers
6 - Locking pliers
7 - Long nose pliers
Drill symbols
The drill symbols are used to show which type and size of drill bit is recommended to carry out a
procedure step.
7/21
22/2430
10/30/2018 Print

1 - Drill bit with a specified diameter
2 - Hole saw with a specified diameter
3 - Stepped drill bit with a specified diameter
4 - Tap with a specified diameter
5 - Die with a specified diameter
6 - Scraper for circular holes
7 - Scraper for straight edges
Cutting tool symbols

The cutting tool symbols are used to show which type of cutting tool is recommended to carry out a
procedure step.
8/21
23/2430
10/30/2018 Print

1 - Cutting knife
2 - Air body saw
3 - Scissors
4 - Grinder
5 - Jig saw
6 - Plasma cutter
7 - Sanding Paper
8 - Wire brush
9 - Belt Sander
10 - Tin Snipes
Apply Chemical or load symbols

The apply chemical or load symbols are used to show where to apply which type of chemical or load
to carry out a procedure step.
9/21
24/2430
10/30/2018 Print

1 - Apply the substance from the specified tube
2 - Apply the substance from the specified cartridge
3 - Apply the specified chemical with a brush
4 - Apply the specified load to the specified component
5 - Apply a bead with a specific diameter from the specified tube
6 - Apply a bead with a specific diameter from the specified cartridge
7 - Apply the specified chemical with a roller
8 - Apply hot glue to the specified component
9 - Apply the specified amount of fluid from the fluid can
10 - Apply fluid from the fluid can
11 - Clean the specified component with the specified material
12 - Apply a broken bead from the specified tube
13 - Apply the specified chemical from a spray can
14 - Apply the specified lubricant to the specified component
15 - Apply spot welds to the specified component
16 - Apply a continuous weld to the specified component
10/21
25/2430
10/30/2018 Print
17 - Handle the fluid using a syringe

18 - Extract the specified amount of fluid using a syringe
Measurement symbols
The measurement symbols are used to show where to measure which type of measurement to carry
out a procedure step.

1 - Measure the current using a digital multimeter
2 - Measure the voltage using a digital multimeter
3 - Measure the resistance using a digital multimeter
4 - Measure the length/distance
5 - Check that the specified pressure is available using a suitable pressure gauge
6 - Measure the pressure at the specified port using a suitable pressure gauge
7 - Measure the time using a suitable stopwatch
8 - Wait for the specified period of time
9 - The specified task requires the specified minimum temperature
11/21
26/2430
10/30/2018 Print
10 - The specified task requires the specified maximum temperature not to be

exceeded
11 - The specified task requires the specified temperature range
12 - The specified task requires the specified temperature
13 - Measure and check for the specified value using a dial indicator gauge
14 - Measure and check for the specified MAX value using a dial indicator gauge
15 - Measure and check for the specified MIN value using a dial indicator gauge
General equipment symbols

The general equipment symbols are used to show where to use which type of general equipment to
carry out a procedure step.

1 - Hot air gun
2 - Soldering iron
3 - Scraper
4 - Scriber
5 - Securing strap
12/21
27/2430
10/30/2018 Print
6 - File with a specified size

7 - Center punch
8 - Marker
9 - Mallet
10 - Hose clamp
11 - Interior trim remover
12 - Vacuum cleaner
13 - Strap wrench
14 - Wedge
15 - Pin Punch
16 - Air blow gun
17 - Relocate and support the component
18 - C-clamp

1 - Plastic scraper
Welding symbols
13/21
28/2430
10/30/2018 Print
These symbols indicate the type of welding to be used.

1 - Metal inert gas (MIG) / Metal active gas (MAG) welding equipment
2 - Metal inert gas (MIG) welding equipment
3 - Metal inert gas (MIG) brazing equipment
4 - Apply a continuous weld to the specified component
5 - Apply spot welds to the specified component
6 - C-clamp
Drilling and grinding symbols

These symbols indicate the type of drilling or grinding to be used.
14/21
29/2430
10/30/2018 Print

1 - Drill through first body layer with a suitable diameter
2 - Drill through first body layer with the specified diameter
3 - Drill through the indicated number of body layers with a suitable diameter
4 - Drill through the indicated number of body layers with the specified diameter
5 - Drill through the indicated number of body layers with a suitable diameter
6 - Drill through the indicated number of body layers with the specified diameter
7 - Drill through all body layers with a suitable diameter
8 - Drill through all body layers with the specified diameter
9 - Grind one layer
10 - Grind two layers
11 - Grind to last layer
12 - Grind all layers
13 - Material thickness > Xmm
Material symbols
15/21
30/2430
10/30/2018 Print
The material symbols are used to show where to use which type of material to carry out a procedure
step.

1 - Remove/Install the specified blind rivet
2 - Apply tape to the specified component/area
3 - Remove/Install the specified cable tie
Miscellaneous symbols
These symbols provide further information that is required to carry out a procedure step.
16/21
31/2430
10/30/2018 Print

1 - Set the ignition switch to the 0 position
2 - Set the ignition switch to the II position
3 - The procedure step requires the aid of the specified number of supporting
technicians
4 - Self contained breathing apparatus
5 - General prohibition used in combination with another symbol
6 - Do not use power tools
7 - Visual check
8 - Noise check
9 - Dispose the specified component
10 - Replaced by item 9 (Dispose the specified component)
11 - Set the engine speed to the specified value
12 - Fully apply the parking brake lever
13 - Fully release the parking brake lever
14 - Do not dispose of batteries into the waste bin
15 - Visual check using a mirror
17/21
32/2430
10/30/2018 Print
16 - Area/component must be dry
Mandatory Protective equipment - Health and safety symbols

The protective equipment symbols advise to use a mandatory protective equipment to avoid or at
least reduce possible health and safety risks.

1 - Wear protective gloves
2 - Wear face guard
3 - Wear safety goggles
4 - Wear ear protectors
5 - Wear safety goggles and ear protectors
6 - Wear a respirator
Prohibition - Health and safety symbols and component damage

The prohibition symbols are used to prohibit the specified actions to avoid or at least reduce possible
component damage and health and safety risks.
18/21
33/2430
10/30/2018 Print

1 - General prohibition symbol
2 - No naked flames
3 - No smoking
4 - No water
5 - Do not touch
6 - Do not switch
7 - No grinding
Warning symbols - Health and safety and component damage

The warning symbols are used to advise on hazardous conditions to avoid or at least reduce possible
component damage and health and safety risks.
19/21
34/2430
10/30/2018 Print

1 - Hazardous voltage/Electrical shock/Electrocution
2 - Fire Hazard/Highly flammable
3 - Burn hazard/Hot surface
4 - Automatic start-up
5 - Toxic
6 - Explosive material
7 - Battery hazard
8 - Corrosive material
9 - Lifting hazard
10 - Hand crush/Force from above
11 - Cutting of fingers or hand
12 - Pressure hazard
13 - Invisible laser radiation. Do not view directly with optical instruments
(magnifiers). Class 1M laser product
Control Diagram symbols - Description and Operation procedures

These symbols provide further information on the type of connectivity, direction of flow or type of
data bus of a system.
20/21
35/2430
10/30/2018 Print

1 - Mid-speed Controller Area Network (CAN)
2 - High-speed Controller Area Network (CAN)
3 - Local Interconnect Network (LIN)
4 - Wires crossing not connected
21/21
36/2430
10/30/2018 Print
General Information - Health and Safety

Precautions
Print
General Service Warnings

Review carefully the information below before beginning any repair. Following these warnings is a list
of specific system warnings that must be reviewed before beginning work on any listed system.
WARNINGS:
Wear eye and ear protection when servicing a vehicle. Failure to follow this instruction may
result in serious personal injury.
Wear protective gloves when handling components or parts that have pointed or sharp edges.
Failure to follow this instruction may result in serious personal injury.
Chemicals or materials specified in this manual, if used improperly, may present a personal
health hazard. Always consult the material safety information sheet before using any material
specified by this manual. Failure to follow this instruction may result in serious personal injury.
Do not work under the hood of a vehicle with a damaged cooling fan, as it can separate during
operation. With the ignition OFF, inspect all cooling fans for damage, cracks or separation and
replace with a new fan as necessary. Failure to follow this instruction may result in serious personal
injury.
Cooling fans may run with the ignition off. Disable the fans before working nearby. On electric
vehicles, disconnect the charging cable to prevent unexpected fan operation. Failure to follow this
instruction may result in personal injury.
Vehicles with engine auto start-stop technology may start automatically with the ignition on.
Make sure the ignition is off when servicing or working in close proximity to rotating engine parts.
Serious injury may occur if the engine is accidently started by another person during service
work. Remove the key from the vehicle to prevent unauthorized starts. Failure to follow this
instruction may result in serious personal injury.
Before lifting the vehicle with a jack, make sure the jack capacity is adequate for the vehicle
weight, including any vehicle cargo or modifications. Identify the correct jacking points in section
100-02 of this manual. Position the vehicle on a hard, level surface. After jacking, always support
vehicle with jack stands. Never get under a vehicle supported only by a jack. Set the parking brake
and block all wheels remaining on the ground. Failure to follow these instructions may result in
unintended vehicle movement and serious personal injury or death.
Before raising the vehicle on a hoist, make sure the hoist capacity is adequate for the vehicle
weight, including any vehicle cargo or modifications. Always position the hoist lift arms as shown in
section 100-02 of this manual. Do not use the engine to power the drive wheels unless all drive
wheels are elevated off the ground. Incorrect hoist arm positioning or drive wheels in contact with
the ground can cause unintended vehicle movement. Failure to follow these instructions may result
in serious personal injury or death.
Removal of heavy components (such as engines, transmissions or axles) while the vehicle is
lifted on a hoist may create a dangerous weight imbalance. Restrain the vehicle on the hoist with
chains or straps to prevent vehicle movement. Failure to follow this instruction may result in serious
personal injury or death.
Always secure transmission, transfer case, and axle assemblies to their service jack. Avoid
obstructions while lowering and raising the jack. Improperly secured assemblies or contact with
obstructions may cause the assembly to fall off the jack, which could result in serious personal
injury.
1/14
37/2430
10/30/2018 Print
Always secure engines, transmissions, or other heavy components to the support fixture with
straps and wooden support blocks. Improperly secured assemblies could fall off the fixture,
resulting in serious personal injury.
Never support an engine by the intake or exhaust manifolds. The engine may drop suddenly.
Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any
object under the vehicle. Never place your hand between the power running board and the vehicle.
Extended power running boards will retract when doors are closed. Failure to follow these
instructions may result in serious personal injury.
Keep solvents away from ignition sources. Solvents may be flammable and can ignite or
explode if not handled correctly. Failure to follow this instruction may result in serious personal
injury.
Use tools, not fingers, to hold flagnuts. Flagnuts may slip or spin unexpectedly when removing
fasteners. Failure to follow this instruction may result in injured fingers.
Carefully review the safety warnings for each system before beginning any service or repair.
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.
2/14
38/2430
10/30/2018 Print
Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an
approved chemical waste site.
For additional information, refer to: Pyrotechnic Device Health and Safety Precautions (100-00
General Information, Description and Operation).
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.
For additional information, refer to: Climate Control System Health and Safety Precautions (100-00
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.
3/14
39/2430
10/30/2018 Print
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.
For additional information, refer to: Engine Cooling System Health and Safety Precautions (100-00
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.
For additional information, refer to: Battery and Battery Charging Health and Safety Precautions
(100-00 General Information, Description and Operation).
Brake and Clutch Linings and Pads
See Asbestos.
Brake Fluids (Polyalkylene Glycols)
See also Fire.
For additional information, refer to: Brake and Clutch Systems Health and Safety Precautions (100-00
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
4/14
40/2430
10/30/2018 Print
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
Do carefully read and observe hazard and precaution warnings given on material containers (labels)
and in any accompanying leaflets, posters or other instructions. Material health and safety data
sheets can be obtained from manufacturers.
Do remove chemical materials from the skin and clothing as soon as practicable after soiling.
Change heavily soiled clothing and have it cleaned.
Do organize work practices and protective clothing to avoid soiling of the skin and eyes; breathing
vapors, aerosols, dusts or fumes; inadequate container labeling; fire and explosion hazards.
Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling
chemical materials.
Do keep work areas clean, uncluttered and free of spills.
Do store chemical materials according to national and local regulations.
Do keep chemical materials out of the reach of children.
Chemical Materials - Do Nots
Do not mix chemical materials except under the manufacturers instructions; some chemicals can
form other toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when
mixed together.
Do not spray chemical materials, particularly those based on solvents, in confined spaces, for
example when people are inside a vehicle.
Do not apply heat or flame to chemical materials except under the manufacturers instructions.
Some are highly flammable and some may release toxic or harmful fumes.
Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than air and will accumulate in confined areas such as pits.
Do not transfer chemical materials to unlabelled containers.
Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry
the skin and may cause irritation leading to dermatitis or be absorbed through the skin in toxic or
harmful quantities.
Do not use emptied containers for other materials except when they have been cleaned under
supervised conditions.
Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic
or harmful.
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.
5/14
41/2430
10/30/2018 Print
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:
switch off the power supply before approaching the victim.

if this is not possible push or drag the victim from the source of electricity using dry non-conductive
material.
commence resuscitation if trained to do so.
SUMMON MEDICAL ASSISTANCE.
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.
6/14
42/2430
10/30/2018 Print
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)
7/14
43/2430
10/30/2018 Print
Highly flammable - observe No Smoking policy.

For additional information, refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety
Precautions (100-00 General Information, Description and Operation).
Gas-oil (Diesel Fuel)
For additional information, refer to: Diesel Fuel System Health and Safety Precautions (100-00
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.
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
8/14
44/2430
10/30/2018 Print
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:
Inform Service personnel who may come into contact with these vehicle fluids (hazard
communication).
Summarise appropriate workplace control measures and personal protective equipment
requirements.
Draw attention to the existence of Material Safety Datasheets (MSDS's) for the fluids (available
from Ford Customer Service Division). These MSDS's contain detailed information on hazards and
appropriate controls.
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.
9/14
45/2430
10/30/2018 Print
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.
10/14
46/2430
10/30/2018 Print
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
NOTICE: Never improvise lifting tackle.

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.
11/14
47/2430
10/30/2018 Print
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.
12/14
48/2430
10/30/2018 Print
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.
1. Components or assemblies displaying the caution triangle and open book symbol advise
consultation of the relevant section of the owner literature before touching or attempting
adjustments of any kind.
2. Components or assemblies displaying the warning triangle with the `electrified' arrow and open
book symbol give warning of inherent high voltages. Never touch these with the engine
running or the ignition switched on. See Electric Shock in this subsection.
3. Vehicles and replacement components which contain asbestos are identified by this symbol. See
Asbestos in this subsection.
13/14
49/2430
10/30/2018 Print
4. Components or assemblies displaying this symbol give warning that the component contains a
corrosive substance. See Acids and Alkalis in this subsection.
5. Displaying the caution circle with a deleted lighted match symbol, caution against the use of
naked lights or flames within the immediate vicinity due to the presence of highly flammable
or explosive liquids or vapors. See Fire in this subsection.
6. Displaying this symbol (normally in conjunction with 5 above) warn of the presence of
potentially explosive matter within the immediate vicinity.
7. Displaying this symbol warn that children should not be allowed in the immediate vicinity
unsupervised.
White Spirit
See Solvents.
14/14
50/2430
10/30/2018 Print
General Information - Solvents, Sealants and

Adhesives
Print
Introduction
WARNING: Always handle all solvents, sealers and adhesives with extreme care. Some contain
chemicals or give off fumes which can be dangerous to health. Always follow the manufacturers
instructions. If in doubt about any substance, particularly a solvent, DO NOT use it.
NOTICE: If in doubt about the suitability of any proprietary solvent or sealer for a particular
application, contact the manufacturer of the product for information regarding storage, handling
and application.
The Health and Safety Precautions subsection refers to some commonly used chemicals and
materials, hazards associated with their use, and safety measures to be taken.
1/1
51/2430
10/30/2018 Print
General Information - Road/Roller Testing

Print
Road or roller testing may be carried out for various reasons and a procedure detailing pre-test
checks, engine starting and stopping, pre-driving checks, on-test checks and final checks to be
completed on completion of the test is given below.
Unless complete vehicle performance is being checked, the full road test procedure need not be
carried out. Instead, those items particularly relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a
hydraulic leak is found, do not attempt to road test the vehicle until the reason for the low fluid
level, excessive pedal travel or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as brakes, lights and steering, should always be carried
out before the road or roller test.
With the ignition switched off, check:
the engine oil level.

the engine coolant level.
the tires, for correct pressure, compatible types and tread patterns, and wear within limits.
that there is sufficient fuel in the tank to complete the test.
all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks.
Make a note of any apparent leaks and wipe off the surrounding areas to make it easier to identify
the extent of the leak on completion of the test.
Starting the Engine

NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the vehicle has attained a minimum speed of 25 km/h (15
miles/h). Never operate at high engine speed or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check:
that the parking brake is applied.

that the gear lever is in the neutral position.
that all instrument gauges (except fuel gauge) read zero.
With the ignition switched on, check:
that the ignition controlled warning lamps are illuminated.

that the engine temperature gauge registers a reading compatible with the engine temperature.
that the fuel gauge registers a reading appropriate to the fuel level in the tank.
the operation of the parking brake warning lamp and fluid level warning indicator.
Road or Roller Testing
NOTICE: If road testing, check the brake operation while still traveling at low speed before
continuing with the test. If the brakes pull to one side, or appear to be otherwise faulty, do not
continue with the road test until the fault has been found and rectified.
During the road or roller test, check:
that the clutch pedal operation is not stiff or heavy.

that the initial gear engagement is smooth and there is no evidence of clutch drag.
that the parking brake control operates smoothly and releases quickly and completely.
that the clutch takes up the drive smoothly, without slip or judder.
that gear changing is smooth with no abnormal noises or vibrations from the transmission.
the engine power output is satisfactory, full power is achieved, acceleration is smooth and pedal
operation is not stiff or heavy, and engine speed returns to idle correctly.
there is no excessive or abnormally colored smoke from the engine under normal driving, heavy
load or overrun conditions.
1/2
52/2430
10/30/2018 Print
that steering operation, including power steering (if equipped), is smooth, accurate, not excessively
heavy or with excessive free play or vibration.
that the steering does not pull to one side and self centers smoothly after cornering.
that the speedometer, coolant temperature gauge and tachometer (if equipped) register the correct
readings and operate correctly.
that the switches and controls operate smoothly and positively, warning and indicator lamps operate
correctly and the direction indicator control self cancels when the steering is returned to the straight
ahead position.
that the heating and ventilation systems operate correctly and effectively.
the brake operation and efficiency.
Brake Testing
WARNING: When brake testing, avoid breathing the fumes from hot brakes, this may contain
asbestos dust which is hazardous to health. Failure to follow this instruction may result in personal
injury.
For additional information, refer to: Health and Safety Precautions (100-00 General Information,
Description and Operation).
NOTICE:
Avoid brake testing on busy roads where it may cause inconvenience or danger to other road
users.
Brake testing which includes heavy brake applications should not be carried out with new
brake pads/discs or linings/drums until the components have bedded-in. New brake friction
components will not reach full efficiency until the bedding-in process is complete.
Test the brakes at several speeds within the normal operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or drag, and any undue delay in application or release.
Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a period of heavy braking), carefully check the brake
temperature. A brake disc or brake drum that feels hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for:
oil, coolant, hydraulic, air and fuel leaks.

abnormal temperature of any moving components or assemblies, for example wheel hubs,
transmission and axle, which might indicate over tightness or lack of lubrication.
2/2
53/2430
10/30/2018 Print
General Information - Climate Control System

Health and Safety Precautions
Print
WARNINGS:
Only qualified technicians are allowed to work on air conditioning (A/C) systems.
Air conditioning (A/C) system components can become particularly hot or cold.
Make sure that the air conditioning (A/C) system is at ambient temperature before carrying
out any repair.
When handling refrigerants, always wear protective goggles and gloves made of
fluoroelastomer. Leather or fabric gloves are not suitable.
SKIN CONTACT: If liquid refrigerant comes into contact with the skin, it produces severe
frostbite. Immediately flush affected areas with plenty of cold running water for 15 minutes. Seek
medical attention.
EYE CONTACT: If refrigerant comes into contact with the eyes, immediately flush the eyes with
plenty of running water for 15 minutes. Seek medical attention.
INHALED: Toxic gases generated when refrigerant is heated are hazardous to health. The
gases have an irritating smell and can cause lung damage. The symptoms can continue for a long
time after having been in contact with the gases. The gases can cause lung damage even if the
amount of gas in the air is too small to smell.
Refrigerant is flammable and explosive.
Make sure that refrigerant bottles are not exposed to temperatures greater than 45°C.
Make sure that the local regulations regarding work on air conditioning (A/C) systems are
adhered to.
Make sure that refrigerant bottles are closed properly.
Gaseous refrigerant has a higher density than air. There is a danger of suffocation when
working close to the ground or in workshop pits.
Provide adequate ventilation when handling refrigerant.
Never release refrigerant into the atmosphere.
Only use special tools, equipment and lubricants that are approved for the type of refrigerant
being used.
Always follow the manufacturer’s instructions for the correct servicing unit operating
procedure.
NOTICE:
Do not mix refrigerant oils for different types of refrigerant.
Never mix different types of refrigerant or equipment intended for them.
Only use refrigerant in gas form when filling the system through the low-pressure connection.
Only use refrigerant in liquid form when filling the system through the high-pressure
connection.
Refrigerant attacks certain plastics. Only use seals suitable for refrigerant.
1/2
54/2430
10/30/2018 Print
If the air conditioning (A/C) compressor is damaged, the fixed orifice tube can become blocked
with metal particles.
Any sort of blockage in the refrigerant circuit will damage the air conditioning (A/C)
compressor irreparably.
If the air conditioning (A/C) system has been opened for a period greater than 2 hours, a new
receiver drier must be installed and the evacuating time to be increased by a minimum of 2 hours.
NOTE: New air conditioning (A/C) compressors are delivered prefilled.
NOTE: Refrigerant oil in new air conditioning (A/C) compressors can contain Teflon, visible as white
particles, which will not harm the system.
2/2
55/2430
10/30/2018 Print
General Information - Battery and Battery

Charging Health and Safety Precautions
Print
WARNINGS:
Batteries contain sulphuric acid, avoid contact with skin, eyes or clothing. Wear safety goggles
when working near the battery to protect against possible splashing of the acid solution.
EYE CONTACT: If acid comes into contact with the eyes, flush immediately with plenty of
running water for a minimum of 15 minutes. Seek immediate medical attention.
SKIN CONTACT: If acid comes into contact with the skin, flush immediately with plenty of
running water for a minimum of 15 minutes. Seek immediate medical attention.
SWALLOWED: If acid is swallowed, rinse the mouth with plenty of water and then drink plenty
of water or milk. Do not induce vomiting. Seek immediate medical attention.
Batteries normally produce explosive gases. Do not allow naked flames, sparks or lighted
substances to come near the battery.
When charging the battery shield your face and wear safety goggles. Provide adequate
ventilation.
NOTICE: Boost charging with excessive current or voltage above 16 volts will damage the
battery.
1/1
56/2430
10/30/2018 Print
General Information - Brake and Clutch

Systems Health and Safety Precautions
Print
WARNINGS:
EYE CONTACT: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the
eyes. Wash hands thoroughly after handling. If brake fluid comes into contact with the eyes, flush
the eyes with plenty of cold running water for 15 minutes. Seek medical attention for any persistent
eye irritation or abnormality.
SWALLOWED: Brake fluid contains polyglycol ethers and polyglycols. If swallowed, drink plenty
of water. Seek immediate medical attention.
INHALED: Dust from friction materials can be harmful if inhaled.
Only use new specified brake fluid from airtight containers.
NOTICE: If brake fluid is spilled on the paintwork, the affected area must be immediately
washed down with cold water.
1/1
57/2430
10/30/2018 Print
General Information - Engine Cooling System

Print
WARNINGS:
Extreme care must be exercised when handling hot fluids. Always wash off spilled fluids from
affected areas of skin immediately.
Vapors may be given off from antifreeze when heated. Avoid breathing these vapors.
SKIN CONTACT: Antifreeze may be absorbed through the skin in toxic or harmful quantities.
SWALLOWED: If antifreeze is swallowed, drink plenty of water, induce vomiting. Seek

immediate medical attention.
Antifreeze must not be used in any cooling or industrial water system that is connected or
linked to general water supplies.
1/1
58/2430
10/30/2018 Print
General Information - Gasoline and Gasoline-

Ethanol Fuel Systems Health and Safety
Precautions
Print
WARNINGS:
Fuel may not give adequate warning before toxic or harmful effects arise.
Exposure to fuel can be harmful and can cause severe health damage or death.
Extreme care must be exercised when handling hot fluids. Always wash off spilled fluids from
affected areas of skin immediately.
Highly flammable mixtures are always present and may ignite when working on fuel systems.
Do not allow naked flames, sparks or lighted substances to come near fuel related components.
Fuel must not be used as a cleaning agent.
Keep fuel containers tightly closed, out of direct sunlight and in a cool area. Keep away from
heat sources, ignition sources and oxidizing agents.
SKIN CONTACT: Excessive or prolonged skin contact with diesel fuel may cause serious skin
disorders including skin cancer.
SKIN CONTACT: Fuel is mildly irritating to the skin and may cause dermatitis due to defatting
effect. Remove contaminated clothing. Wash affected areas of skin with soap and water. Seek
medical attention for any persistent skin irritation or abnormality. Wash contaminated clothing
before reuse.
EYE CONTACT: Fuel is mildly irritating to the eyes. Flush with plenty of running water, blinking
as often as possible. Do not force the eyelid open. Seek medical attention for any persistent eye
irritation or abnormality.
SWALLOWED: Fuel is moderately toxic and tends to foam on vomiting. If drawn into the lungs,
inflammation may develop. Do not induce vomiting. If spontaneous vomiting occurs place the victim
in a forward position to reduce the risk of fuel being drawn into the lungs. Give nothing by mouth. If
breathing but unconscious, place in the recovery position. If breathing has stopped, apply artificial
respiration. Seek immediate medical attention.
INHALED: Fuel is toxic to the respiratory and other body systems. Exposure may result in
various symptoms including drowsiness, unconsciousness or severe health damage. Move a victim
to fresh air. Keep a victim warm and at rest. If unconscious, place in the recovery position. If not
breathing, apply artificial respiration. Give cardiac massage if necessary. Seek immediate medical
attention.
NOTICE:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components.
Make sure that the workshop area in which the vehicle is being worked on is as clean and as
dust free as possible.
1/1
59/2430
10/30/2018 Print
General Information - Diesel Fuel System

Print
WARNING: Do not work on the fuel system until the pressure has been released and the engine
has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-
pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these
instructions may result in serious personal injury.
1/1
60/2430
10/30/2018 Print
General Information - Liquefied Petroleum Gas

(LPG) and Compressed Natural Gas (CNG) Fuel
Systems Health and Safety Precautions
Print
WARNINGS:
Service of Compressed Natural Gas (CNG) or Liquefied Petroleum Gas (LPG) vehicle systems is
restricted to qualified personnel and authorized workshops. The required qualifications vary by
region. Always observe local laws and legislative directives regarding CNG or LPG vehicle service.
Failure to follow this instruction may result in serious personal injury or death.
Compressed Natural Gas (CNG) or Liquefied Petroleum Gas (LPG) is highly flammable and
toxic when contained in unventilated work areas. Work in a dedicated area with good ventilation
and no sources of ignition. Failure to follow these instructions may result in serious personal injury
or death.
Liquefied Petroleum Gas (LPG) is capable of harming eyes or freezing skin. Always wear
personal protection gear, including safety goggles and gloves to avoid contact with liquid gas.
Failure to follow these instructions may result in serious personal injury.
Always observe local regulations regarding storage or indoor parking of Liquefied Petroleum
Gas (LPG) vehicles. Do not park vehicles near sources of heat, ignition or unventilated open pits.
Failure to follow these instructions may result in serious personal injury.
Liquefied Petroleum Gas (LPG) is heavier than air and will collect in low points in a building,
such as drains or work pits. Never discharge a tank inside a building. If possible, tanks should be
discharged beforehand by running the vehicle. Any discharge of gas must be done outside in well-
ventilated flat areas. Failure to follow these instructions may result in the accumulation of
combustible gas, which could cause personal injury or death in a fire or explosion.
Extreme heat such as paint drying ovens will cause an increase in Compressed Natural Gas
(CNG) or Liquefied Petroleum Gas (LPG) fuel tank pressure. The fuel tank must be removed before
using paint drying ovens with temperatures above 60° C. Failure to follow this instruction may
result in a release of combustible gas, which could cause personal injury or death in a fire or
explosion.
Liquefied Petroleum Gas (LPG) may present a personal health hazard if handled improperly.
Always consult the LPG material safety information sheet before servicing a LPG vehicle. Failure to
follow this instruction may result in serious personal injury or death.
1/1
61/2430
10/30/2018 Print
General Information - Pyrotechnic Device

Print
WARNINGS:
Service and handling of Pyrotechnic Components is restricted to qualified personnel. The

required qualifications vary by region. Always observe local laws and legislative directives regarding
Pyrotechnic Components service and handling. Failure to follow this instruction may result in serious
personal injury or death.
INHALED: Exposure to pyrotechnic residue may cause low blood pressure, severe headache,
irritation of mucous membranes, fainting, shortness of breath or rapid pulse. Move a victim to fresh
air. Seek immediate medical attention.
EYE CONTACT: Exposure to unburned pyrotechnic residue may cause irritation, burning and
etching of the eyes. Flush immediately with plenty of cold running water for at least 15 minutes.
Seek immediate medical attention.
EYE CONTACT: Exposure to burned pyrotechnic residue may cause irritation, burning and
etching of the eyes. Flush immediately with diluted boric acid solution. Seek immediate medical
attention.
SKIN CONTACT: Unburned pyrotechnic residue may be rapidly absorbed through the skin in
toxic quantities. Wash immediately with plenty of soap and water. Seek medical attention.
SKIN CONTACT: Burned pyrotechnic residue may be rapidly absorbed through the skin in toxic
quantities. Wash with plenty of water. Do not use soap. Seek medical attention.
SWALLOWED: Unburned pyrotechnic residue is extremely toxic. If conscious drink plenty of

water then induce vomiting. Seek immediate medical attention. If unconscious, or in convulsions do
not attempt to induce vomiting or give anything by mouth. Seek immediate medical attention.
SWALLOWED: Burned pyrotechnic residue is extremely toxic. Drink plenty of water and seek
immediate medical attention.
The deployment key must only be accessible to authorized personnel.
Make sure that the deployment key remains removed from the deployment equipment except
during deployment.
If permenantly disabling or enabling the passenger air bag a new seat belt for vehicles without
or with a passenger air bag must be installed.
Undeployed pyrotechnic components must not be deployed in the vehicle.
Pyrotechnic components must be deployed following local regulations.
Check thoroughly that no loose objects can be spread during the deployment of pyrotechnic
components.
Pyrotechnic components must be transported following local regulations.
Never carry out any electrical measurement on disconnected, undeployed pyrotechnic

components.
Pyrotechnic components must not be disassembled.
Pyrotechnic components are not interchangeable between vehicles.
Always carry a live air bag module away from the body with the air bag or trim cover pointing
upwards.
1/2
62/2430
10/30/2018 Print
Live air bag modules must be placed in a suitable cage when removed from the vehicle. The
air bag or trim cover must be facing upwards.
Do not install a rearward facing child safety seat to the passenger seat with an activated
passenger air bag.
NOTICE:
Pyrotechnic components must not be subjected to temperatures higher than 110°C.
Never install aftermarket accessories to the vehicle on or adjacent to the supplemental

restraint system module.
2/2
63/2430
10/30/2018 Print
General Information - Window Glass Health

and Safety Precautions
Print
WARNINGS:
Cured polyurethane (PU) adhesive can degrade if subjected to high temperatures. Isocyanide
compounds can be released when grinding or welding in close proximity to cured PU adhesive.
SKIN CONTACT: Prolonged exposure to polyurethane (PU) adhesive may cause skin irritation.
If PU adhesive comes into contact with the skin, remove any contaminated clothing. Immediately
wash the skin with soap and water. Seek medical attention for any persistent skin irritation or
abnormality.
EYE CONTACT: Polyurethane (PU) adhesive may cause severe irritation or damage. If PU
adhesive comes into contact with the eyes, immediately flush eyes with plenty of running water for
at least 15 minutes. Seek immediate medical attention.
SWALLOWED: If polyurethane (PU) adhesive is swallowed, flush the mouth thoroughly. Do not
induce vomiting. Provide rest, warmth and fresh air. Seek immediate medical attention.
INHALED: Persons having a respiratory allergy may have an allergic reaction when handling
polyurethane (PU) adhesive.
INHALED: Polyurethane (PU) adhesive can cause asthma like symptoms. Isocyanate vapor
from primer or PU adhesive can cause allergies in the respiratory tract.
INHALED: If polyurethane (PU) adhesive fumes are inhaled, move victim to fresh air. Provide
oxygen if necessary. If breathing stops, provide artificial respiration. Keep a victim warm and at
rest. Seek immediate medical attention.
NOTICE:
Make sure that the direct glazing for bonded glass cutting blades are changed where the
cutting depth changes to avoid damage to the body and trim panels.
During the curing period of the PU adhesive, the door windows must be left open to avoid a
build up of pressure when the doors are opened and closed.
1/1
64/2430
10/30/2018 Print
General Information - Body Repair Health and

Safety and General Precautions
Print
General
Appropriate repair methods and carrying out repair and paint jobs correctly is particularly important
to the operating safety of vehicles and the safety of people.
WARNING: There is danger of injury through:
High voltage when electrical welding.

- Do not perform welding work in a damp environment or on a wet substrate. Use suitable
insulation underneath.
Welding spatter and UV radiation.
- Wear protective clothing, gloves and welding mask or welding goggles.
Fire, explosion and hot surfaces in the work area.
- Always have a suitable fire extinguisher available when using welding or heating equipment.
- Remove flammable substances from the danger area. Remove the fuel tank and fuel pipes and
hoses.
- Welding and grinding near the battery presents the danger of explosion. Remove the battery
before you start working.
- During paint work there is an increased danger of fire or explosion. Prevent any sparks being
created. Fire, open light and smoking are forbidden.
- Always ventilate the workplace well and use an extraction system.
- Wear protective footwear made from anti-static material.
- Only use tools made of wood, brass or copper to clean stands and extraction ducts. Do not use
tools made of steel.
- Only fill or decant paint materials in a specially marked area.
Inhalation and/or absorption through the skin of harmful substances.
- Welding fumes grinding dusts and solvent vapours can be extremely harmful to the health.
- Sealants, underbody protection and paint residues must not be burnt down with an unshielded
flame, as this will produce harmful substances.
- Wear protective clothing.
Pyrotechnic components.
- Disconnect the battery negative clamp and cover the battery terminal.
- Remove any airbag components.
Noise
- Cutting, grinding and alignment work can cause a noise level over 85 dB (A).
- Always wear ear protection.
High Forces.
- The various body areas are subject to very high forces during realignment work. Should any
component suddenly become detached during this process, there is a very great danger of injury.
- Pulling chains and pulling shackles must be secured with arrester cables.
As well as these general instructions on the dangers in body and paint shops, you must observe:
All valid local national and international regulations governing Health and Safety at Work
Safety instructions of material equipment and tool manufacturers
For additional information, refer to: (100-00 General Information)

Solvents, Sealants and Adhesives (Description and Operation),
Climate Control System Health and Safety Precautions (Description and Operation),
Pyrotechnic Device Health and Safety Precautions (Description and Operation).
Personal protection
Besides the body and limbs, several organs vital to life are in very particular danger. Because damage
is mostly irreparable, special attention and comprehensive protection is necessary.
Protective equipment
Always use the appropriate protective equipment:
1/4
65/2430
10/30/2018 Print
Protective helmet or welding mask

Breathing protection
Protective clothes gloves and safety boots
Ear defenders
Extraction systems
Always carry out an operational check on your protective equipment every time before you start
working!
WARNING: Vapor or spray mist containing isocyanates as a paint base or hardener can cause
toxic respiratory disease (conditions similar to asthma) leading to permanent damage, even when
inhaled in the lowest concentrations
The instructions for use provided by the manufacturer must be observed when working with breathing
protection equipment.
During painting work and in the preparations for painting, gases, vapors, mists or dusts can appear in
dangerous concentrations.
Breathing protection devices which are independent of the local atmosphere are most suitable.
In these types of isolation systems, a compressed air hose carries natural air from the compressor
line into the protective mask. During supply, the air undergoes pressure reduction, water removal,
fine filtration and usually warming to natural breath temperature.

1 - Protective hood with fresh air supply
2 - Protective clothing
3 - Protective gloves
4 - Protective footwear
Only for short periods of work or minimal concentrations of hazardous substances breathing
protection devices with a combination filter is suitable as breathing protection equipment.
2/4
66/2430
10/30/2018 Print

1 - Activated charcoal filter
2 - Coarse filter
Filter masks with wadding, sponge or colloid filters and also paper masks are all unsuitable for
working with coating materials because they do not stop solvent vapors.
Eye protection
Cutting grinding welding solvents and paint bear fundamental risks for your eyes.
Damage ranging from irritation of the cornea to incurable illnesses is possible.
Solvents and paint – even water based – could not only be absorbed via your skin but also via your
eyes.
Therefore always wear the appropriate eye protection for your work.
Protective goggles must be inert toward splashes of solvent, and must have side protection. Best
protection during spray painting is offered by full mask respirators or helmet respirators with built-in
visor.
Skin protection
Spray painters must wear suitable protective work clothing (flame-proof and anti-static). Also, when
working with water based materials, comprehensive skin protection must be worn, because these
materials are very easily absorbed through the skin.
Change your protective clothing at proper intervals. Clothes contaminated with coating materials can
easily catch fire.
Do not choose clothes or underwear with a large content of easy melting synthetic fiber, because this
material considerably increases the danger and degree of injuries (melted plastic on the skin!).
For areas of the skin which are not covered by protective clothing suitable skin protection cleaning
and care agents must be used.
Ear protection
Cutting grinding compressors and extractor fans and ducts are the main sources of noise in body and
paint shops.
Always wear suitable ear protection like ear plugs or ear defenders.
Protection of the vehicle
Protect affected areas from weld spatter and dust during all welding and grinding work on the vehicle.
If metallic dust stays on the vehicle for some time, there is the likelihood of film rust formation.
Grinding produces tiny spots of damage to the paint surface, which may cause corrosion. Also use
suitable protective measures to protect the interior when performing repair operations which relate to
the inside of the vehicle.
For this reason, make sure to:
Use carbon fiber blankets to protect the vehicle body and the interior.
Use covering film to protect the vehicle body from grinding dust and metal dust.
Use covering paper to protect the interior from grinding dust.
In addition, take into account:
Remove fuel supply components as necessary.

3/4
67/2430
10/30/2018 Print
Protect working areas which are in danger of catching fire with a fireproof blanket.
Keep heat away from all components of the air conditioning system.
Remove all components in the space adjoining the repair area.
Electronic components
Increased use of comfort and safety electronics in modern vehicles requires additional attention to be
paid during body work.
Over voltages produced during welding can cause electronic systems to be damaged. In particular,
the safety instructions for performing welding work on vehicles with airbag systems must be adhered
to.
WARNING: After disconnecting the power supply and before performing further work, a wait
time of up to 15 minutes must be maintained, depending on the vehicle. Work on airbag systems
may only be performed by persons who have a relevant certificate of competence.
For additional information, refer to:
Driver Airbag (501-20B Supplemental Restraint System, Removal and Installation),
Passenger Airbag (501-20B Supplemental Restraint System, Removal and Installation),
Side Airbag (501-20B Supplemental Restraint System, Removal and Installation),
Side Curtain Airbag - 4-Door (501-20B Supplemental Restraint System, Removal and Installation),
Restraints Control Module (RCM) (501-20B Supplemental Restraint System, Removal and
Installation).
Pay attention to the following points:
Disconnect the battery negative clamp and cover the battery terminal.
Disconnect the electrical connector at the airbag control module.
If welding is to be performed directly near a control module, it must be disconnected or removed.
Never connect the negative cable of the welder near an airbag or a control module.
Connect the negative cable of the welder close to the location of the weld.
4/4
68/2430
10/30/2018 Print
General Information - Steering System Health

Print
WARNINGS:
When handling the power steering fluid, always wear protective goggles and gloves made of
nitril.
EYE CONTACT: Power steering fluid contains long chain alkyl amine thiophosphate. Avoid
contact with the eyes. Wash hands thoroughly after handling. If power steering fluid comes into
contact with the eyes, flush the eyes with plenty of cold running water for 15 minutes. Seek medical
attention for any persistent eye irritation or abnormality.
SKIN CONTACT: If power steering fluid comes into contact with the skin, remove contaminated
clothing. Wash affected areas of skin with soap and water. Seek medical attention for any persistent
skin irritation or abnormality.
INHALED: If oil mist is inhaled, move a victim to fresh air. Keep a victim warm and at rest.
Seek immediate medical attention in cases of throat irritation or coughing.
SWALLOWED: Power steering fluid contains long chain alkyl amine thiophosphate. If
swallowed, drink plenty of water. Seek immediate medical attention.
Do not activate the APA system when the vehicle is on a roller rig.
Do not activate the APA system when working on any part of the steering system.
NOTICE:
When activated, the active park assist (APA) system may control the steering system.
If the power steering fluid is spilled on the paintwork, the affected area must be immediately
washed down with cold water.
1/1
69/2430
10/30/2018 Print
Identification Codes - Identification Codes

Print
Identification Codes
The codes stamped or printed on the VIN plate during production enable the precise details of the
vehicle build specification to be established.

1 - Visible VIN
2 - VIN stamped into the front right wheel arch
3 - VIN on the Vehicle identification plate attached to the B-pillar
VIN (an example of VIN shown)

1 - VIN Position 1, 2 and 3 - World manufacturer identifier
2 - VIN Position 5 and 6 - Constant X
1/3
70/2430
10/30/2018 Print
3 - VIN Position 7 and 8 - Product source company and assembly plant

4 - VIN Position 9 - Model
5 - VIN Position 11 - Year of manufacture
6 - VIN Position 12 - Month of manufacture
7 - VIN Positions 13 to 17 - Vehicle serial number
8 - VIN Position 4 and 10 - Body type
VIN Encoding
FordEtis provides a VIN encoding on the Vehicle Lookup site. Furthermore a detailed VIN coding
explanation can be found in the parts catalog FordEcat.
YEAR OF MANUFACTURING (VIN POSITION 11)
Year VIN Position 11

2006 6
2007 7
2008 8
2009 9
2010 A
2011 B
2012 C
2013 D
2014 E
2015 F
2016 G
2017 H
2018 J
2019 K
2020 L
2021 M
MONTH OF MANUFACTURING (VIN POSITION 12)
Month Year / VIN Position 12

2006 2007 2008 2009
2010 2011 2012 2013
2014 2015 2016 2017
2018 2019 2020 2021
January L C B J
February Y K R U
March S D A M
April T E G P
May J L C B
June U Y K R
July M S D A
August P T E G
September B J L C
October R U Y K
November A M S D
December G P T E
Vehicle Certification Label or VIN Plate
2/3
71/2430
10/30/2018 Print

1 - National Approval Number
2 - Vehicle Identification Number
3 - Gross Vehicle Mass
4 - Gross Train Mass
5 - Maximum permissible front axle load
6 - Maximum permissible rear axle load
7 - Type and/or Variant and/or Version
8 - Left-Hand or Right-Hand-Drive
9 - Engine Type
10 - Gearbox Type
11 - Axle
12 - Trim Code
13 - Colour Code
14 - Emission-level
15 - Smoke Value (only Diesel)
16 - Full Vehicle Name
17 - Full Series Name
18 - Displacement and Fuel Type
19 - Horse Power (kW/PS)/Emission Level (EURO)
20 - AWD (where applicable) blank for 2WD
21 - Door Combination
22 - Chassis Code
23 - -
24 - Suspension Code
3/3
72/2430
10/30/2018 Print
Jacking and Lifting - Jacking and Lifting - Overview

Print
Jacking Points
WARNING: Follow the safety instructions in the group 100-00 General Information. Failure to
follow this instruction may result in serious personal injury.
Refer to: Gesundheits- und Sicherheitshinweise (100-00, Description and Operation).
1/1
73/2430
10/30/2018 Print
Noise, Vibration and Harshness - Noise, Vibration and Harshness

(NVH)
Print
Diagnosis and Testing
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the concern is not visually evident, verify the symptom and REFER to the Symptom Chart.
How to Use this Diagnostic Procedure Section
Noise, vibration and harshness (NVH) concerns have become more important as vehicles have
become more sensitive to these vibrations. This section is designed to aid in identifying these
concerns.
The section provides diagnostic procedures based on symptom. If the condition occurs at high
speed, for instance, the most likely place to start is under Shake and Vibration While Driving.
The road test procedure will tell how to sort the conditions into categories and how to tell a
vibration from a shake.
A series of Road Test Quick Checks are provided to make sure that a cause is either pinpointed or
eliminated.
Name the condition, proceed to the appropriate section and locate the correct diagnosis. When the
condition is identified, the job is partly done.
Follow the diagnostic procedure as outlined.
Quick Checks are described within the step, while more involved tests and adjustments are outlined
in General Procedures.
Always follow each step exactly and make notes to recall important findings later.
Customer Interview
The road test and customer interview (if available) provide information that will help identify the
concern and will provide direction to the correct starting point for diagnosis.
Identify the Condition
NVH usually occur in four areas:
tires
engine accessories
suspension
driveline
It is important, therefore, that an NVH concern be isolated into its specific area(s) as soon as
possible. The easiest and quickest way to do this is to carry out the Road Test as outlined. To assist in
the diagnosis and testing procedure(s), use a suitable approved NVH diagnosis tester.
Noise Diagnostic Procedure
Non-Axle Noise
The five most common sources of non-axle noise are exhaust, tires, roof racks, trim panels and
transmission.
Therefore, make sure that none of the following conditions are the cause of the noise before
proceeding with a driveline teardown and diagnosis.
In certain conditions, the pitch of the exhaust may sound very much like gear noise. At other times,
it can be mistaken for a wheel bearing rumble.
Tires, especially snow tires, can have a high pitched tread whine or roar, similar to gear noise.
Radial tires may have this characteristic. Also, any non-standard tire with an unusual tread
construction may emit a roar or whine noise.
Trim panels can also cause whistling or whining noise.
1/13
74/2430
10/30/2018 Print
Clunk may be a metallic noise heard when the automatic transaxle is engaged in "R" (REVERSE) or
"D" (DRIVE) or it may occur when the throttle is applied or released. It is caused by backlash
somewhere in the driveline.
Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a damaged
wheel bearing.
Noise Conditions
Gear noise is typically a howling or whining due to gear damage or incorrect bearing preload. It can
occur at various speeds and driving conditions, or it can be continuous.
Chuckle is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle
wheel. It occurs while decelerating from 64 km/h (40 mph) and can usually be heard all the way to
a stop. The frequency varies with vehicle speed.
Knock is very similar to chuckle, though it may be louder and occurs on acceleration or
deceleration. The teardown will disclose what has to be corrected.
Clicking, popping or grinding noises may be caused by the following:
worn, damaged or incorrectly installed wheel bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items before disassembling the transmission to diagnose
and correct gear noise.
The noises described under Road Test usually have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial clues are the type of noise heard on the road test
and driving conditions.
Vibration Conditions
Vibration at highway speeds may be caused by the following:
out-of-balance front or rear wheels.

out-of-round tires.
Shudder or vibration during acceleration may be caused by the following:
damaged powertrain/drivetrain mounts.

excessively high constant velocity (CV) joint operating angles caused by incorrect ride height. Check
ride height, verify correct spring rate and check items under inoperative conditions.
Road Test
A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and may be
audible at certain speeds or under various driving conditions, as on a newly paved asphalt road. The
slight noise is in no way detrimental and must be considered normal.
The road test and customer interview (if available) provide information needed to identify the
condition and give direction to the correct starting point for diagnosis.
1. Make notes throughout the diagnosis routine. Make sure to write down even the smallest bit of
information, because it may turn out to be the most important.
2. Do not touch anything until a road test and a thorough visual inspection of the vehicle have
been carried out. Leave the tire pressures and vehicle load just where they were when the
condition was first observed. Adjusting tire pressures, vehicle load or making other
adjustments may reduce the condition(s) intensity to a point where it cannot be identified
clearly. It may also inject something new into the system, preventing correct diagnosis.
3. Make a visual inspection as part of the preliminary diagnosis routine, writing down anything that
does not look right. Note tire pressures, but do not adjust them yet. Note leaking fluids, loose
nuts and bolts, or bright spots where components may be rubbing against each other. Check
the load space for unusual loads.
4. Road test the vehicle and define the condition by reproducing it several times during the road
test.
5. Carry out the Road Test Quick Checks as soon as the condition is reproduced. This will identify
the correct diagnostic procedure. Carry out the Road Test Quick Checks more than once to
verify they are providing a valid result. Remember, the Road Test Quick Checks may not tell
where the concern is, but they will tell where it is not.
2/13
75/2430
10/30/2018 Print
Road Test Quick Checks
1. 24-80 km/h (15-50 mph): with light acceleration, a moaning noise is heard and possibly a
vibration felt in the front floor panel. It is usually worse at a particular engine speed and at a
particular throttle setting during acceleration at that speed. It may also produce a moaning
sound, depending on what component is causing it. REFER to Tip-in Moan in the Driveline
Noise and Vibration Symptom Chart.
2. Acceleration/Deceleration: With slow acceleration and deceleration, a shake is sometimes

noticed in the steering wheel/column, seats, front floor panel, front door trim panel or front
end sheet metal. It is a low frequency vibration (around 9-15 cycles per second). It may or
may not be increased by applying the brakes lightly. REFER to Idle Boom/Shake/Vibration in
the Driveline Noise and Vibration Symptom Chart.
3. High Speed: A vibration is felt in the front floor panel or seats with no visible shake, but with an
accompanying sound or rumble, buzz, hum, drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise and Vibration Symptom Chart.
4. Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular rpm. It will
disappear in neutral coasts. The vibration can be duplicated by operating the engine at the
problem rpm while the vehicle is stationary. It can be caused by any component, from the
accessory drive belt to the clutch or torque converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and Vibration While Driving in the Driveline Noise and
Vibration Symptom Chart.
5. Noise and Vibration While Turning: Clicking, popping or grinding noises may be due to the
following:
worn, damaged or incorrectly installed front wheel bearing.

damaged powertrain/drivetrain mounts.
Road Conditions
An experienced technician will always establish a route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably smooth, level and free of undulations (unless a
particular condition needs to be identified). A smooth asphalt road that allows driving over a range of
speeds is best. Gravel or bumpy roads are unsuitable because of the additional road noise produced.
Once the route is established and consistently used, the road noise variable is eliminated from the
test results.
NOTE: Some concerns may be apparent only on smooth asphalt roads.
If a customer complains of a noise or vibration on a particular road and only on a particular road, the
source of the concern may be the road surface. If possible, try to test the vehicle on the same type of
road.
Vehicle Preparation
Carry out a thorough visual inspection of the vehicle before carrying out the road test. Note anything
which is unusual. Do not repair or adjust any condition until the road test is carried out, unless the
vehicle is inoperative or the condition could pose a hazard to the technician. After verifying that the
condition has been corrected, make sure all components removed have been installed.
Power Steering Conditions
Check for the noise in the following conditions to verify the customer concern.
Check for the noise in several temperature conditions.

Is the noise from when the vehicle was new?
Can the noise be repeated constantly or is it random?
Check the condition of the vehicle age, mileage and service record.
Interview the customer to find the operating condition in which the noise will occur. Test the vehicle
based on the detail(s) from the customer interview.
Follow the power steering operation noise condition tables below, to find which condition the noise
will occur.
Power Steering Operation Noise Check

3/13
76/2430
10/30/2018 Print
Step 1: Check for NVH concerns from non-steering components, which may sound like noises coming
from the steering system.
Power assisted steering operating condition

Parking Driving
Steering central/slightly Steering at a steering Driving straight ahead Cornering condition
off center lock stop
REFER to NVH concerns REFER to NVH concerns REFER to NVH concerns REFER to NVH concerns
from other components from other components from other components from other components
column A column B column C column D
NVH CONCERNS FROM OTHER COMPONENTS
NVH concerns from other condition (column A to D)

Noise Driving Condition A B C D
Pedal box knocking Drive off, stop driving and slow cornering X X O X
over uneven roads
Stabilizer bar link Drive off, driving and cornering X O O X
knocking
Engine support Drive off, driving, acceleration and X X
insulator knocking deceleration
Air conditioning Engine on, activate switch for air X X O O
knocking conditioning
Suspension knocking Drive off, driving, cornering, acceleration X O X
(Subframe, Springs) and deceleration
Constant velocity (CV) Drive off, driving, cornering, acceleration X O X
joint knocking and deceleration
Washer bottle Deceleration, acceleration and single O X
impact
Loose suspension bolts All driving conditions O O X
Instrument panel All driving conditions. Engine rpm X X X X
rattle/squeak dependant
X = Noise will most likely occur in this operating condition.

O = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
Step 2: Check for steering system NVH concerns according to operation condition described at the
customer interview.
Power assisted steering operating condition

Parking Driving Vehicle stationary with engine off
Steering Steering at a Steering Steering at a Steering Steering at a
central/slightly steering lock central/slightly steering lock stop central/slightly off steering lock stop
off center stop off center centre
REFER to REFER to REFER to REFER to REFER to steering REFER to steering
steering steering steering steering system system NVH system NVH
system NVH system NVH system NVH NVH concerns concerns column E concerns column F
concerns concerns concerns column D
column A column B column C
STEERING SYSTEM NVH CONCERNS
Steering System operation condition (column A to F)

Noise Driving condition A B C D E F
Moan Parking between lock stops, at engine idle and also X O
increased engine speed
Whine Driving, high engine rpm. Must be present from new O O X X
Hiss a) Parking between lock stops. Must be present X X O O
from new
b) Holding steering wheel against lock stops. Must X
be present from new
4/13
77/2430
10/30/2018 Print
Steering System operation condition (column A to F)

Noise Driving condition A B C D E F
Lock stop impact a) Parking at lock stop. Must be present from new X X
knock
Mechanical knock b) Parking between lock stops, engine OFF. Must be X
(power assisted present from new
steering (PAS) off)
Mechanical Knock c) Parking between lock stops, engine ON (ball joint X
(PAS on) knock)
Hammer knock d) Parking into lock stop and release (vehicle with X
hydraulic power assisted steering (HPAS) only, not
for vehicles with electro-hydraulic power assisted
steering (EHPAS))
Hydraulic knock e) Driving, cobble stones, rough road (clonk). Must O X
(clonk) be present from new
Column knock f) Parking, driving. cobble stones and rough roads X X O X X X
Column rattle Mainly driving on rough roads O X X O
Toc-toc Steering left and right at high frequency. Must be X
present from new
Grinding When turning steering wheel X O X
Zip At engine start, low temperatures below -10°C only X O
X = Noise will most likely occur in this operating condition.

O = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
Step 3: According to each identified operating condition (Column A, B, C, D, E, F), check each
possible Steering System NVH concern with the detail symptom charts below.
Before conducting a vehicle test to identify a NVH concern carry out the following checks.
1. Check the tire pressures and adjust to specification, as necessary.
2. Make sure the steering system fluid is correct, the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system temperature is the same as described at the customer
interview.
4. All evaluations must take place in a relatively quiet location.
5. The heating - air conditioning (A/C) fan and radio must be turned off during evaluations and the
windows closed.
Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle parked, transmission in neutral and all windows closed
in the following test conditions.
1. Engine speed at idle with no steering action.
2. Engine speed at idle with slow 90 degrees per second turning of the steering wheel.
3. Engine speed at 1250 +/- 50 rpm with no steering action.
4. Engine speed at 1250 +/- 50 rpm with slow 90 degrees per second turning of the steering
wheel.
Symptom Possible Sources Action
5/13
78/2430
10/30/2018 Print

Power steering lines. CHECK the routing of the
power steering lines.
CHECK the power steering
line clamps are secure.
CHECK the power steering
Power steering system moan noise lines for clearance from the
– A continuous low pitched vehicle body, front axle
humming noise occurs when the crossmember and steering
steering wheel is turned and the gear.
steering system is loaded. Noise
frequency changes with engine Incorrect power steering fluid. FLUSH the power steering system.
rpm changes. Particularly REFER to: Power Steering System
annoying at lower engine speed. Flushing (211-00, General
Procedures).
Power steering pump. Pressure pulses from the power
steering pump. Certain amount of
noise level acceptable, not a
safety critical item.
Power Steering Whine Noise
Test Condition
Listen for steering whine noise with the vehicle parked, transmission in neutral and all windows closed
2. Engine speed at 1800 +/- 50 rpm with slow 90 degrees turning of the steering wheel.
4. Engine speed at 3000 +/- 50 rpm with slow 90 degrees turning of the steering wheel.

Power steering fluid aeration. BLEED the power steering system.
REFER to: Power Steering System
Vacuum Bleeding (211-00 Steering
System - General Information,
General Procedures).
Power steering system whine
Incorrect power steering fluid. FLUSH the power steering system.
noise – a high pitched buzzing
sound like an electric motor or
Flushing (211-00, General
drill. Whine occurs at the higher
Procedures).
engine rpm, 1500 - 5000 rpm,
Overheated power steering fluid. FLUSH the power steering system.
frequency does not change if
system is loaded or not loaded.
Flushing (211-00, General
Procedures).
Hydraulic operating condition of Certain amount of noise level
the power steering pump. acceptable, not a safety critical
item.
Power Steering Hiss Noise
Test Condition
Listen for steering hiss noise with the vehicle parked, transmission in neutral and all windows closed
Symptom Possible Action

Sources
NOTE: Engine speed at idle turning the steering wheel slowly lock to Floor seal. CHECK the
lock. installation and
Power steering system hiss noise – a high frequency, continuous rush or potential damage
swish noise like escaping air from a balloon. Hiss occurs while turning of the floor seal.
between the steering lock stops, all steering angles. Noise does not change
with engine rpm and is worse at high operating temperatures.
6/13
79/2430
10/30/2018 Print

Sources
Power Certain amount of
steering noise level
gear valve acceptable, not a
design. safety critical
item.
Power Certain amount of
steering noise level
system acceptable, not a
hydraulic safety critical
design. item.
NOTE: Engine speed at idle holding the steering wheel against a Power Certain amount of
steering lock for three seconds. Do not hold for more than five steering noise level
seconds. pump acceptable, not a
Power steering system hiss noise – a continuous noise like escaping air pressure safety critical
occurs while holding the steering against a steering lock stop. relief item.
valve.
Power Steering Lock Stop Impact Knock Noise
Test Condition
Listen for steering knock noise with the engine speed at idle in the following test conditions (noise
also apparent with engine off).
1. Turn the steering wheel to the left-hand and right-hand steering locks and listen for the impact
noise.

Power steering system knock noise – a heavy loud Power steering gear Certain amount of noise
sound like a knock on a door that occurs in parking mechanical noise, metal to level acceptable, not a
condition when hitting the lock stop. metal at end of steering safety critical item.
travel.
Power Steering Mechanical Knock Noise (PAS off)
Test Condition
Listen for steering knock noise with the engine off in the following test conditions (no power assist).
1. Turn the steering wheel 90 degrees to the right, hold and then quickly release.
2. Turn the steering wheel 90 degrees to the left, hold and then quickly release.

Power steering system knock noise – a Certain amount of
damped, metallic knock noise which only noise level
Power steering system knock noise – a occurs at steering condition with engine acceptable, not a
heavy loud repeating sound like a knock off (very high efforts). safety critical item.
on a door that occurs in several driving Tolerances in the steering gear Certain amount of
and steering conditions. components. noise level
acceptable, not a
safety critical item.
Power Steering Mechanical Knock Noise (PAS on)
Test Condition
Listen for steering knock noise with the engine speed at idle in the following test conditions (power
assist).
1. Turn the steering wheel to a steering lock and return to center quickly.
2. Turn the steering wheel 90 degrees to the left and then 90 degrees to the right quickly.
7/13
80/2430
10/30/2018 Print

Power steering system knock noise – Worn tie-rod ball REFER to Steering System.
clear knock noise from steering gear joints (inner and outer REFER to: Steering System (211-00
linkage area. ball joints). Steering System - General Information,
Diagnosis and Testing).
Power Steering Hammer Knock (Hydraulic) Noise
Test Condition
Listen for steering knock noise with the engine speed at idle in the following test conditions (for
vehicles with hydraulic power assisted steering only, not electro-hydraulic power steering).
1. Turn the steering wheel to a steering lock position and return quickly.

Sources
Power steering system knock noise – loud, metallic sound if hitting Hydraulic noise Certain amount of
the suspension crossmember with a hammer (sounds like metallic created by noise level acceptable,
noise but is created by pressure impulse in gear and return line). pressure not a safety critical
impulses. item.
Power Steering Hydraulic Knock/Clonk Noise
Test Condition
Listen for steering knock/clonk noise in the following test conditions with the windows closed.
1. Drive over cobbled roads at low speed 10-30 km/h (6-20 mph) with and without turning.
2. Drive over straight tar strips road rails or 25 mm tall harshness strips at low speed 10-30 km/h
(6-20 mph) both driving straight and with moderate turning.

Power steering Certain
return lines. amount of
noise level
acceptable,
not a safety
critical item.
High power Certain
Power steering system knock/clonk noise – sounds almost identical to
assist gain of amount of
column knock that occurs when driving and cornering over cobbled stones
power steering noise level
or rough roads. Noise may appear to emanate from a location closer to the
gear valve acceptable,
floor than that for column knock (Sounds like metallic noise but is created
(steering gear not a safety
by pressure impulse in gear and return line – similar to a sound like
design - no critical item.
quickly turning off a water tap).
quality issue).
High power Certain
steering pump amount of
flow rate (by noise level
design). acceptable,
not a safety
critical item.
Power Steering Column Knock Noise
Test Condition
Listen for steering knock noise in the following test conditions with windows closed.
1. Drive over cobbled stones at low speed 16-40 km/h (10-25 mph) with and without steering
input carefully listening for knock sounds.
2. Drive over straight tar strips, road rails or 25 mm tall harshness strips at low speed 16-40 km/h
(10-25 mph) both driving straight and with moderate cornering.

Sources
8/13
81/2430
10/30/2018 Print

Sources
CHECK the steering column retaining
bolts and attachments to the steering
column and secure if necessary.
Steering
Power steering system column knock noise – a Check steering column and
column or
loose sounding rattle or vibration coming from the intermediate shaft for free play or
steering
column. Noticeable by hearing and touch. loose components.
column shaft.
REFER to: Steering System (211-00
Steering System - General
Information, Diagnosis and Testing).
Power Steering Toc-Toc Noise
Test Condition
Listen for steering toc-toc noise with the engine speed at idle and the vehicle parked, automatic
transmission in "P" (PARK) or manual transmission in neutral and the windows closed.
1. Turn the steering wheel from left to right abruptly changing direction.
2. Drive the vehicle for low speed parking manoeuvres constantly changing steering direction.

Power steering system toc-toc noise – a metallic noise Steering gear Certain amount of noise
created when changing direction of steering wheel rotation (design tolerance level acceptable, not a
during parking manoeuvre or at standstill. in steering rack). safety critical item.
Power Steering Grinding Noise
Test Condition
Listen for steering grinding noise with the engine speed at idle and the vehicle parked, automatic
transmission in "P" (PARK) or manual transmission in neutral and the windows closed.
1. Slowly turn the steering wheel from lock to lock.
2. Tilt and extend the steering column in various positions and slowly turn the steering wheel from
lock to lock.

Steering wheel Certain amount of noise level
to shroud acceptable, not a safety
interference. critical item.
Steering column Certain amount of noise level
bearing. acceptable, not a safety
critical item.
CHECK if floor covering is
Foreign material
obstructing the steering gear
in contact with
pinion.
the steering
Power steering system grinding noise – an abrasive noise column shaft. CHECK the installation of the
(like sand paper rubbing against wood) occurs between floor seal.
moving components such as steering wheel and the Clockspring. CHECK the clockspring and
steering column shroud. secure if necessary. REFER to:
(501-20B Supplemental
Restraint System)
Clockspring - Vehicles
With: Lane Departure
Warning (Removal and
Installation),
Clockspring - Vehicles
Without: Lane Departure
Warning (Removal and
Installation).
Power Steering Zip Noise

Sources
9/13
82/2430
10/30/2018 Print

Sources
High Certain amount of noise
viscosity of level acceptable, not a
power safety critical item.
steering fluid
Power steering system zip noise – occurs when hydraulic fluid at low
does not flow freely through the power steering pump supply temperature.
hose from steering fluid reservoir to power steering pump Aeration of BLEED the power steering
causing cavitation at the pump. Zip is primarily a cold weather the power system.
start-up phenomenon (below -10°C). steering REFER to: Power Steering
fluid. System Vacuum Bleeding
(211-00 Steering System -
General Information,
Driveline Noise and Vibration

Shake and vibration while driving Wheel end vibration. GO to Pinpoint Test A.
Engine/transmission.
Tip-in moan Air cleaner. GO to Pinpoint Test B.

Power assisted steering.
Powertrain.
Powertrain/drivetrain
mounts.
Exhaust system.
Idle Cable(s)/hose(s). GO to Pinpoint Test C.

boom/shake/vibration/shudder Powertrain/drivetrain
mounts.
Exhaust system.
Belt/pulleys.
Suspension Noise and Vibration

Wheel end vibration analysis Suspension. GO to Pinpoint Test D.
Wheel bearings.
Non-axle noise Trim panels. GO to Pinpoint Test E.

Air conditioning (A/C)
system.
Accessories.
Pinpoint Tests
NOTE: These Pinpoint Tests are designed to take the technician through a step-by-step diagnosis
procedure to determine the cause of a condition. It may not always be necessary to follow the chart
to its conclusion. Carry out only the pinpoint test steps necessary to correct the condition. Then
check the operation of the system to make sure the condition has been corrected.
After verifying that the condition has been corrected, make sure all components removed have been
installed.
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
Does the vibration disappear during the neutral coast test?
Yes
GO to A2.
No
GO to Pinpoint Test D.
10/13
83/2430
10/30/2018 Print
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS

1 Carry out the powertrain/drivetrain mount neutralizing procedure
Are the mounts OK?
Yes
Vehicle condition corrected. ROAD TEST as necessary.
No
INSTALL new powertrain/drivetrain mounts as necessary. ROAD TEST as
necessary.
PINPOINT TEST B : TIP-IN MOAN

CONDITIONS
B1: CHECK THE AIR CLEANER
1 Check the condition of the air cleaner mounts, inlet tube, outlet tube, resonators and
all other components associated with the air induction system for correct installation
and tightness of all connections.
Are the components OK?
Yes
GO to B2.
No
REPAIR or INSTALL new components as necessary. ROAD TEST as necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing procedure.
Is the exhaust system OK?
Yes
GO to B3.
No
REPAIR as necessary. ROAD TEST as necessary.
B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for tip-in moan.
Is the tip-in moan OK?
Yes
REPAIR the power steering as necessary.
REFER to: Steering System (211-00 Steering System - General Information, Diagnosis
and Testing).
No
GO to B4.
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
Are the powertrain/drivetrain mounts OK?
Yes
No
INSTALL new powertrain/drivetrain mounts as necessary. ROAD TEST as necessary.
PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER

CONDITIONS
C1: CHECK THE CABLE/HOSES
1 Check the engine compartment for any component that may have a touch condition
between the engine and body or chassis. For example: control cable, air conditioning
(A/C) hoses, acceleration cable.
Are the components OK?
Yes
GO to C2.
No
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings and bushings for security and condition.
Check the radiator installation for any component that may have a touch condition.
11/13
84/2430
10/30/2018 Print
Is the installation and bushings OK?

Yes
GO to C3.
No
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing procedure.
Is the exhaust system OK?
Yes
GO to C4.
No
REPAIR as necessary. ROAD TEST as necessary.
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
Are the powertrain/drivetrain mounts OK?
Yes
No
INSTALL new powertrain/drivetrain mounts as necessary. ROAD TEST as necessary.
PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS

CONDITIONS
D1: INSPECT THE WHEELS AND TIRES
1 Inspect the wheels and tires.
REFER to: Wheels and Tires (204-04A Wheels and Tires, Diagnosis and Testing).
Are the wheels and tires OK?
Yes
GO to D2.
No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
ROAD TEST as necessary.
D2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
Are the wheel bearings OK?
Yes
GO to D3.
No
INSTALL new wheel bearings as necessary. REFER to: Front Wheel Bearing (204-01
Front Suspension, Removal and Installation). ROAD TEST as necessary.
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
Is the wheel and tire runout OK?
Yes
Balance the wheels and tires. Refer to the wheel balance equipment manufacturer's
instructions. ROAD TEST as necessary.
No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
PINPOINT TEST E : NON-AXLE NOISE

CONDITIONS
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see if they are the source of the noise.
Are the vehicle trim components causing the noise?
Yes
INSTALL new trim components or REPAIR as necessary. ROAD TEST as necessary.
No
12/13
85/2430
10/30/2018 Print
GO to E2.
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Start the engine.
2 Ignition ON.
3 Check the A/C system components for noise by turning the A/C system on and off.
Is the A/C system causing the noise?
Yes
INSPECT the A/C system. REFER to: (412-00)
Climate Control System - Vehicles With: Electronic Manual Temperature Control
(EMTC) (Diagnosis and Testing),
Climate Control System - Vehicles With: Dual Automatic Temperature Control
(Diagnosis and Testing).
No
GO to E3.
E3: CHECK NON-FACTORY FITTED ACCESSORIES
1 Check any non-factory installed accessories for being the source of the noise. For
example: touch condition body-to-frame, antennas, deflectors and fog lights.
Are the accessories the cause of the noise?
Yes
ADJUST, REPAIR, or INSTALL new accessories or fasteners as required. ROAD TEST as
necessary.
No
VERIFY the customer concern.
13/13
86/2430
10/30/2018 Print
Suspension System - General Information - Specifications

Print
Specification
FRONT WHEEL ALIGNMENT (AT CURB WEIGHT) 4 DOOR AND 5 DOOR
NOMINAL OR MAXIMUMTOLERANCE NOMINAL OR MAXIMUM SETTING OR

DESCRIPTION
LEFT TOLERANCE RIGHT NOMINAL
Caster Decimal 4.28° ± 1.00° 4.28° ± 1.00° -

angle degrees
Camber Decimal -0.57° ± 1.25° -0.57° ± 1.25° -

angle degrees
Total toe Decimal - - 0.20° Toe-in ±

degrees 0.20°
FRONT WHEEL ALIGNMENT (AT CURB WEIGHT) 4 DOOR AND 5 DOOR (SPORT)

DESCRIPTION
Caster Decimal 4.29° ± 1.00° 4.29° ± 1.00° -

angle degrees
Camber Decimal -0.63° ± 1.25° -0.63° ± 1.25° -

angle degrees

degrees 0.20°
FRONT WHEEL ALIGNMENT (AT CURB WEIGHT) WAGON

DESCRIPTION
Caster Decimal 4.20° ± 1.00° 4.20° ± 1.00° -

angle degrees
Camber Decimal -0.60° ± 1.25° -0.60° ± 1.25° -

angle degrees

degrees 0.20°
FRONT WHEEL ALIGNMENT (AT CURB WEIGHT) WAGON (SPORT)
1/3
87/2430
10/30/2018 Print

DESCRIPTION
Caster Decimal 4.24° ± 1.00° 4.24° ± 1.00° -

angle degrees
Camber Decimal -0.64° ± 1.25° -0.64° ± 1.25° -

angle degrees

degrees 0.20°
REAR WHEEL ALIGNMENT (AT CURB WEIGHT) 4 DOOR AND 5 DOOR
NOMINAL OR MAXIMUM TOLERANCE NOMINAL OR MAXIMUM SETTING OR

DESCRIPTION
Camber Decimal -1.41° ± 1.25° -1.41° ± 1.25° -

angle degrees

degrees 0.20°
REAR WHEEL ALIGNMENT (AT CURB WEIGHT) 4 DOOR AND 5 DOOR (SPORT)

DESCRIPTION
Camber Decimal -1.46° ± 1.25° -1.46° ± 1.25° -

angle degrees

degrees 0.20°
REAR WHEEL ALIGNMENT (AT CURB WEIGHT) WAGON

DESCRIPTION
Camber Decimal -1.37° ± 1.25° -1.37° ± 1.25° -

angle degrees

degrees 0.20°
REAR WHEEL ALIGNMENT (AT CURB WEIGHT) WAGON (SPORT)
2/3
88/2430
10/30/2018 Print

DESCRIPTION
Camber Decimal -1.44° ± 1.25° -1.44° ± 1.25° -

angle degrees

degrees 0.20°
3/3
89/2430
10/30/2018 Print
Suspension System - General Information -

Specifications
Print
Specification
FRONT WHEEL ALIGNMENT (AT CURB WEIGHT) - 5 DOOR
NOMINAL OR MAXIMUM NOMINAL OR MAXIMUM SETTING OR

DESCRIPTION
TOLERANCE LEFT TOLERANCE RIGHT NOMINAL
Caster Decimal 4.23° ± 1.00° 4.23° ± 1.00° -

angle degrees
Camber Decimal -0.88° ± 1.25° -0.88° ± 1.25° -

angle degrees

degrees 0.20°
FRONT WHEEL ALIGNMENT (AT CURB WEIGHT) - WAGON

DESCRIPTION
Caster Decimal 4.19° ± 1.00° 4.19° ± 1.00° -

angle degrees
Camber Decimal -0.88° ± 1.25° -0.88° ± 1.25° -

angle degrees

degrees 0.20°
REAR WHEEL ALIGNMENT (AT CURB WEIGHT) - 5 DOOR

DESCRIPTION
Camber Decimal -1.35° ± 1.25° -1.35° ± 1.25° -

angle degrees

degrees 0.20°
REAR WHEEL ALIGNMENT (AT CURB WEIGHT) - WAGON
1/2
90/2430
10/30/2018 Print

DESCRIPTION
Camber Decimal -1.25° ± 1.25° -1.25° ± 1.25° -

angle degrees

degrees 0.20°
2/2
91/2430
10/30/2018 Print

Suspension System
Print
Special Tool(s)
Alignment Pins, Subframe
205-880
2. Visually inspect for obvious signs of mechanical damage.
VISUAL INSPECTION CHART
Mechanical
Tire pressure(s)
Wheel and tires
Wheel knuckles
Tie-rod ends
Front suspension lower arm ball joints
Front suspension lower arm bushings
Front strut and spring assemblies
Front and rear stabilizer bar and connecting links
Rear springs
Rear shock absorbers
Rear suspension lower arms
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
The table provides all possible symptoms related to the Suspension System. For a detailed diagnosis,
proceed to the Ford diagnostic equipment.
Symptom Possible Sources

Drift left or right Vehicle attitude incorrect (front or rear is high or low)
Steering gear or linkage worn or damaged
Brake system
Incorrect front crossmember alignment
Worn front wheel bearings
Wheels and tires
Steering wheel off- Vehicle attitude incorrect (front or rear is high or low)
center Steering gear or linkage worn or damaged
Suspension lower arm ball joint
Incorrect wheel alignment
Rough ride Front strut and spring assemblies
Front or rear stabilizer bar, connecting links or bushings
Front suspension lower arm bushings
Rear suspension arm bushings
Rear shock absorbers
Excessive noise Front strut and spring assembly or rear shock absorber and spring upper mounting
bolts or nuts loose or broken
1/3
92/2430
10/30/2018 Print
Shock absorbers leaking

Shock absorber performance incorrect
Stabilizer bar components
Strut and spring assembly and springs
Springs moving on spring upper or lower seats
Suspension bushings
Lower arm ball joint
Worn front wheel bearings
Wheels and tires / Dynamic shock absorber damper
Incorrect tire wear Front or rear suspension damage
Vibration Damaged or worn front wheel bearings
Wheels and tires
Steering gear or linkage worn or damaged
Damaged front suspension lower arm(s)
Component Tests
Raise and support the vehicle.
REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
Ball Joint Inspection
1. Firmly grasp the outer end of the suspension lower arm and try to move it up and down,
watching and feeling for any movement. Free movement will usually be accompanied by an
audible "click''. There should be no free movement.
2. If there is any free movement install a new lower arm.

REFER to: Lower Arm (204-01 Front Suspension, Removal and Installation).
3. If a new lower arm is installed it will be necessary to check and adjust the front wheel
alignment.
REFER to: Front Toe Adjustment (204-00 Suspension System - General Information, General
Procedures).
Strut or Shock Absorber Inspection
NOTE: Inspect the struts or shock absorber for signs of oil weepage or leaks. Make sure that the oil
is not from another source.
Weepage:
deposits a thin film of oil on the strut and spring assembly or shock absorber.
is normally noticed due to a collection of dust on the strut and spring assembly or shock absorber.
occurs during the normal running-in period of 4800 - 8050 km. After this period no new signs of oil
should be visible.
does not require new struts or shock absorbers to be installed.
Leakage:
covers the entire strut and spring assembly or shock absorber with oil.
will drip oil onto the surrounding suspension components.
requires new struts or shock absorbers to be installed.
Strut or Shock Absorber Testing
NOTE: Struts or shock absorbers must be tested in the vertical position.
1. Remove both strut and spring assemblies or shock absorbers. The piston rods should extend.
Disassemble the strut and spring assemblies.

REFER to: Front Strut and Spring Assembly (204-01 Front Suspension, Disassembly and
Assembly).
2. Compress the piston rods. Both piston rods should offer the same resistance when compressing.
2/3
93/2430
10/30/2018 Print
3. Compress and release the piston rods. The piston rods should extent equally.
4. Compress and pull the piston rod in the vertical position. Feel if the resistance force at the point
of direction change-over is perceptible without a lag. If a lag is perceptible it is an indication of
damper valve damage and new struts or shock absorbers must be installed. REFER to: Front
Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation).
3/3
94/2430
10/30/2018 Print

Front Toe Adjustment
Print
General Procedures
General Equipment
Wheel Alignment System
Adjustment
NOTE: Make sure that the vehicle is standing on a level surface.
1. NOTICE: Make sure that the steering wheel lock is engaged.

NOTE: Make sure that the road wheels are in the straight ahead position.
2. Use the General Equipment: Wheel Alignment System
3.
1. On both sides.
Torque: 90 Nm
2. NOTE: Do not allow the steering gear bellows to twist when the inner tie rod is rotated.
On both sides.
4.
Vehicles With: Electronic Power Assist Steering (EPAS)

5. NOTE: Resetting the compensation values is extremely important! Correction values which
have not been reset would cause the system to continue to attempt to correct a drift of the
vehicle.
Clear DTCs, reset the compensation values for the straight ahead travel correction function and for
the steering center position.
1/1
95/2430
10/30/2018 Print
Suspension System - General Information - Rear Toe Adjustment

Print
General Procedures
General Equipment
Wheel Alignment System
Adjustment
1. Check the toe setting.
Refer to: Specifications - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L

EcoBoost (92kW/125PS)/1.5L EcoBoost (110kW/150PS) - I4/1.5L EcoBoost (132kW/180PS) -
I4/1.6L Duratec-16V Ti-VCT (63kW/85PS) - Sigma/1.6L Duratec-16V Ti-VCT (77kW/105PS) -
Sigma/1.6L Duratec-16V Ti-VCT (92kW/125PS) - Sigma/1.6L Duratec-16V Ti-VCT Flex Fuel
(88kW/120PS) - Sigma/1.6L Duratorq-TDCi (77kW/105PS)/1.6L Duratorq-TDCi
(85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3)/1.6L EcoBoost (110kW/150PS) -
Sigma/1.6L EcoBoost (132kW/180PS) - Sigma/1.6L EcoBoost Flex Fuel (110kW/150PS)/2.0L
Duratec-HE (110kW/150PS) - MI4/2.0L Duratec-HE (118kW/160PS) - MI4/2.0L Duratec-HE
(125kW/170PS) - MI4/2.0L Duratec-HE Flex Fuel (125kW/170PS)/2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW (204-00 Suspension System -
General Information, Specifications).
Use the General Equipment: Wheel Alignment System
2. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3. Loosen the rear lower arm adjustment cam nut on both sides.
Torque: 8 Nm
4. Lower the vehicle.
5. Bounce the vehicle to make sure that the suspension is in its normal resting position.
6. Adjust the toe setting.
1/2
96/2430
10/30/2018 Print
7. NOTE: Only tighten the nuts and bolts when the suspension is in the normal drive position.
Torque: 90 Nm
2/2
97/2430
10/30/2018 Print
Front Suspension - Front Suspension - Component Location

Print
Item Description
1 Stabilizer thrust rod
2 Subframe attachment points
3 Stabilizer bar
4 Suspension unit
5 Shock absorber unit
6 Subframe
7 Lower arms
8 Shock absorber control wiring harness
Comments:
Focus RS only
9 Crossmember
Comments:
Focus RS only
1/1
98/2430
10/30/2018 Print
Front Suspension - Front Suspension -

Overview
Print
The front suspension is virtually identical to that of the 2011 C-MAX.

Compression struts like those on the 2011 C-MAX with 1.6L Duratec-16V Ti-VCT (Sigma) engine
are not used on this vehicle.
Dynamic shock absorber damper
Item Description
1 Damping mass.
2 Rubber mounting.
3 Retaining plate for wheel speed sensor wiring harness.
As with the 2011 C-MAX, only the Titanium equipment variant of this vehicle will be equipped with
dynamic dampers initially.
1/1
99/2430
10/30/2018 Print
Front Suspension - Front Suspension

Print
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and
Testing).
1/1
100/2430
10/30/2018 Print
Front Suspension - Disconect the Lower Arm Ball Joint from the Wheel
Knuckle
Print
General Procedures
Special Tool(s) / General Equipment

204-818
Separator, Lower Arm Ball-Joint
204-821
Protector, Lower Arm Ball-Joint
Lower Arm Down Force Lever
Disconnect
1.
2. NOTE: Depending on the Vehicle build date and plant, different knuckles are fitted. Select the
appropriate special tool side depending on the knuckle design.
Install Special Service Tool: 204-818.
1/3
101/2430
10/30/2018 Print
3. NOTE: Depending on the Vehicle build date and plant, different knuckles are fitted. Select the
appropriate special tool side depending on the knuckle design.
4.
2/3
102/2430
10/30/2018 Print
5. Remove Special Service Tool: 204-818.
6.
1. Use the General Equipment: Lower Arm Down Force Lever
2. Install Special Service Tool: 204-821.
3/3
103/2430
10/30/2018 Print
Front Suspension - Wheel Hub

Print
Removal and Installation

204-158
Collet for 205-295
204-158-01
Adapter for 204-158 (Thrust Pad)
204-348
Remover/Installer, Wheel Hub/Wheel Bearing
204-740
Remover/Installer, Wheel Hub/Bearing
205-074
Installer, Differential Bearing Cone
205-080
Installer, Differential Bearing
205-295
Remover, Bearing (Main Tool)
Hydraulic Press
Removal
1. Refer to: Wheel Knuckle (204-01 Front Suspension, Removal and Installation).
2. Use Special Service Tools: 205-080, 204-348.

Use the General Equipment: Hydraulic Press
1/5
104/2430
10/30/2018 Print
3.

2/5
105/2430
10/30/2018 Print
5. Use Special Service Tools: 204-158-01, 204-158, 205-295.
6. Check the surfaces for abrasion.
Installation
1. NOTE: Make sure that the sensor ring is correctly located.

Use Special Service Tool: 204-740.
3/5
106/2430
10/30/2018 Print
2.
3. Use Special Service Tool: 205-074.

4/5
107/2430
10/30/2018 Print
4. Refer to: Wheel Knuckle (204-01 Front Suspension, Removal and Installation).
5/5
108/2430
10/30/2018 Print
Front Suspension - Wheel Knuckle

Print

204-159
Lever, Wheel Knuckle
204-161
Installer, Halfshaft
205-071-01
211-020
Separator, Ball Joint
Puller
Removal
1.
2. Refer to: Front Wheel Speed Sensor (206-09A Anti-Lock Control, Removal and Installation).
3.
1/8
109/2430
10/30/2018 Print
4.
5. NOTICE: Make sure that no load is placed on the brake hose.

Torque: 175 Nm
2/8
110/2430
10/30/2018 Print
6. If equipped.
Torque: 11 Nm
7. NOTE: Make sure a new bolt is installed.

Torque: 83 Nm
3/8
111/2430
10/30/2018 Print
8. Refer to: Disconect the Lower Arm Ball Joint from the Wheel Knuckle (204-01 Front Suspension,
9. Use Special Service Tool: 205-071-01.

Use the General Equipment: Puller
10. NOTICE: Make sure that the ball joint ball does not rotate.
Loosen:
5 turn(s)
4/8
112/2430
10/30/2018 Print
Torque: 48 Nm
13.
14.
5/8
113/2430
10/30/2018 Print
15. Torque:
Stage 1:80 Nm
Stage 2:180°
6/8
114/2430
10/30/2018 Print
17. NOTE: This step is not necessary when installing a new component.
Refer to: Wheel Hub (204-01 Front Suspension, Removal and Installation).
Installation
1. To install, reverse the removal procedure.

Torque: 45 Nm
3. Torque: 80 Nm
4. Torque: 90°
7/8
115/2430
10/30/2018 Print
8/8
116/2430
10/30/2018 Print
Front Suspension - Front Wheel Bearing

Print
Removal
1. Refer to: Wheel Hub (204-01 Front Suspension, Removal and Installation).
Installation
1/1
117/2430
10/30/2018 Print
Front Suspension - Front Stabilizer Bar

Print

205-880
Transmission Jack
Removal


Torque: 28 Nm
3. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
4. If equipped.
1/8
118/2430
10/30/2018 Print
5. Both sides, If equipped.
Torque: 11 Nm
On both sides.
Torque: 62 Nm
2/8
119/2430
10/30/2018 Print
7. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent.
8. Torque: 24 Nm
3/8
120/2430
10/30/2018 Print
9.
1. Torque: 125 Nm
Torque: 25 Nm
4/8
121/2430
10/30/2018 Print
2.0L
11. Torque: 25 Nm
All vehicles
12. Use the General Equipment: Transmission Jack
5/8
122/2430
10/30/2018 Print
13. Remove the following items:

1. Torque: 48 Nm
2. Torque: 63 Nm
3. Torque:
Stage 1:140 Nm
Stage 2:180°
4. Torque: 115 Nm
14.
6/8
123/2430
10/30/2018 Print
15.
16. NOTE: This step is only necessary when installing a new component.
Refer to: Front Stabilizer Bar Bushing (204-01 Front Suspension, Removal and Installation).
Installation
2. 1.
2. Torque:
Stage 1:115 Nm
Stage 2:90°
3. Torque:
Stage 1:115 Nm
Stage 2:90°
7/8
124/2430
10/30/2018 Print
3. On both sides.
4. Refer to: Front Toe Adjustment (204-00 Suspension System - General Information, General
Procedures).
8/8
125/2430
10/30/2018 Print
Front Suspension - Front Stabilizer Bar Bushing

Print
General Equipment
Vise
Removal
1. Refer to: Front Stabilizer Bar (204-01 Front Suspension, Removal and Installation).
2. NOTE: Note the position of the component before removal.
Installation
1. NOTE: Make sure that the component is clean, free of foreign material and lubricant.
1. Metal strip
2. NOTE: Make sure that the component is installed to the position noted before removal.
Use the General Equipment: Vise
1/2
126/2430
10/30/2018 Print
2. Refer to: Front Stabilizer Bar (204-01 Front Suspension, Removal and Installation).
2/2
127/2430
10/30/2018 Print
Front Suspension - Front Strut and Spring Assembly

Print
Special Tool(s)
204-159
Lever, Wheel Knuckle
204-605
Separator, Lower Arm Ball Joint
Removal
2. If equipped.
Torque: 11 Nm
Vehicles with dynamic suspension

3.
1. Torque: 10 Nm
2. 2. NOTICE: Make sure that the ball joint ball does not rotate.
Torque: 48 Nm
1/6
128/2430
10/30/2018 Print
Vehicles without dynamic suspension

4.
1. Torque: 10 Nm
2. 2. NOTICE: Make sure that the ball joint ball does not rotate.
Torque: 48 Nm
All vehicles
5. Torque:
Stage 1:80 Nm
Stage 2:180°
2/6
129/2430
10/30/2018 Print
7.
1. Torque: 11 Nm
2. Torque: 35 Nm
3/6
130/2430
10/30/2018 Print
8. Torque: 35 Nm
4/6
131/2430
10/30/2018 Print
9. WARNING: This step requires the aid of another technician.
5/6
132/2430
10/30/2018 Print
Installation
6/6
133/2430
10/30/2018 Print
Front Suspension - Lower Arm

Print
Removal
2.
3. If equipped.
Torque:
1: 25 Nm
2: 48 Nm
1/5
134/2430
10/30/2018 Print
4. If equipped.
Torque: 11 Nm
5. NOTICE: Make sure that a new bolt is installed.

Torque: 83 Nm
7.
2/5
135/2430
10/30/2018 Print
Installation
2. NOTE: Only tighten the bolts finger tight at this stage.
3. 1.
2. Torque:
Stage 1:115 Nm
Stage 2:90°
3. Torque:
Stage 1:115 Nm
Stage 2:90°
3/5
136/2430
10/30/2018 Print
4.
5. Torque:
Stage 1:150 Nm
Stage 2:90°
4/5
137/2430
10/30/2018 Print
Procedures).
5/5
138/2430
10/30/2018 Print
Front Suspension - Front Lower Arm Ball Joint

Print
General Equipment
Electric Drill
Removal
NOTE: The following repair description is valid as soon the required spare parts and special tools are
available, until then the complete component must be replaced.
1. Refer to: Lower Arm (204-01 Front Suspension, Removal and Installation).
Refer to: Lower Arm RH - 2.0L Duratec-HE (110kW/150PS) - MI4/2.0L Duratec-HE (125kW/170PS)
- MI4/2.0L Duratec-HE Flex Fuel (125kW/170PS) (204-01 Front Suspension, Removal and
Installation).
2. Use the General Equipment: Electric Drill
Installation
1. Torque: 70 Nm
1/2
139/2430
10/30/2018 Print
2/2
140/2430
10/30/2018 Print
Front Suspension - Front Stabilizer Bar Link

Print
Removal
1. Torque: 62 Nm
2. Torque: 48 Nm
Installation
1/1
141/2430
10/30/2018 Print
Front Suspension - Front Strut and Spring Assembly

Print
Disassembly and Assembly
Special Tool(s)
204-167
Compressor, Coil Spring
204-167-01
Adapter for 204-167
Disassembly
WARNING: Take extra care when handling the compressed spring.
1. Install Special Service Tools: 204-167, 204-167-01.
2. NOTE: Note the position of each component before removal.
1/3
142/2430
10/30/2018 Print
Assembly
WARNING: Take extra care when handling the compressed spring.

3. To assemble, reverse the disassembly procedure.
4. NOTE: Only tighten the nut finger tight at this stage.
5. NOTE: Make sure that these components are installed to the noted removal position.
NOTE: Make sure that the spring is correctly located in the lower spring seat.
NOTE: Make sure that the installation marks are aligned.
2/3
143/2430
10/30/2018 Print
6. NOTICE: Use an Allen key to prevent the piston rod from rotating.
Torque: 55 Nm
7. Remove Special Service Tools: 204-167, 204-167-01.
3/3
144/2430
10/30/2018 Print
Rear Suspension - Rear Suspension - Component Location

Print
4-door and 5-door
Item Description
1 Wheel bearing and wheel hub
2 Control arm
3 Anti-roll bar connecting rod
4 Stabilizer bar
5 Upper arm
6 Front lower arm
7 Rear lower arm
8 Shock absorbers
9 Spring
Wagon
1/3
145/2430
10/30/2018 Print
Item Description
2 Control arm
4 Stabilizer bar
5 Upper arm
6 Front lower arm
7 Rear lower arm
8 Shock absorbers
9 Spring
Focus RS
Item Description
2 Control arm
2/3
146/2430
10/30/2018 Print

4 Stabilizer bar
5 Upper arm
6 Front lower arm
7 Rear lower arm
8 Shock absorbers
9 Spring
10 Spindle carrier
3/3
147/2430
10/30/2018 Print
Rear Suspension - Rear Suspension - Overview

Print
General information
The 4 and 5-door models have the same rear suspension as the 2011 C-MAX Compact. However,
the rear axle springs, shock absorbers, stabilizer bar and suspension arm bushes have been
individually adapted to the vehicle. The rear suspension features upright shock absorbers.
Due to the wider load area, the shock absorbers on the rear suspension of the combi version are
positioned at an angle. Essentially, this rear suspension is based on that of the previous model, but
has similar modifications to the rear suspension on the 4 and 5-door models. As a result, the rear
axle is now substantially stiffer.
1/1
148/2430
10/30/2018 Print
Rear Suspension - Rear Suspension

Print
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and
Testing).
1/1
149/2430
10/30/2018 Print
Rear Suspension - Trailing Arm

Print
General Equipment
Transmission Jack
Removal
1. Refer to: Spring (204-02 Rear Suspension, Removal and Installation).
Vehicles with rear drum brakes

2.
3.
Vehicles with rear disc brakes

4.
1/8
150/2430
10/30/2018 Print
All vehicles
5. Refer to: Wheel Bearing and Wheel Hub - Vehicles With: Rear Disc Brakes (204-02 Rear
Suspension, Removal and Installation).
Refer to: Wheel Bearing and Wheel Hub - Vehicles With: Rear Drum Brakes (204-02 Rear
6.
8.
2/8
151/2430
10/30/2018 Print
9.
10.
11.
12.
3/8
152/2430
10/30/2018 Print
Installation
1. Fabricate a spacer.
2.
3.
1. Torque: 175 Nm
2. NOTE: Only tighten the bolt finger tight at this stage.
4/8
153/2430
10/30/2018 Print
4. Torque: 115 Nm
5. Torque: 115 Nm
6.
7. Torque: 2 Nm
5/8
154/2430
10/30/2018 Print
8. Torque: 115 Nm
9. Remove the equipment.
10.
All vehicles
11. Refer to: Wheel Bearing and Wheel Hub - Vehicles With: Rear Disc Brakes (204-02 Rear
Refer to: Wheel Bearing and Wheel Hub - Vehicles With: Rear Drum Brakes (204-02 Rear
Vehicles with rear drum brakes

12.
6/8
155/2430
10/30/2018 Print
13.
Vehicles with rear disc brakes

14.
All vehicles
16. Refer to: Rear Toe Adjustment (204-00 Suspension System - General Information, General
Procedures).
7/8
156/2430
10/30/2018 Print
8/8
157/2430
10/30/2018 Print
Rear Suspension - Trailing Arm Bushing

Print

204-351
Installer, Pivot Bushing
303-433
Remover/Installer, Crankshaft Bearing
Hydraulic Press
Removal
1. Refer to: Trailing Arm (204-02, Removal and Installation).
1/3
158/2430
10/30/2018 Print
4. Use the General Equipment: Hydraulic Press
Installation
2/3
159/2430
10/30/2018 Print
2. NOTE: Make sure that the installation marks are aligned.
3. Refer to: Trailing Arm (204-02, Removal and Installation).
3/3
160/2430
10/30/2018 Print
Rear Suspension - Wheel Bearing and Wheel Hub—Vehicles With: Rear

Disc Brakes
Print
Removal
2.
3.
4. WARNING: Make sure that no load is placed on the brake hose.

Torque: 70 Nm
1/4
161/2430
10/30/2018 Print
5.
NOTE: This step is only necessary when installing a new component.

NOTE: Make sure that the sensor is installed in the same location as when removed.

7. NOTE: The O-ring seals are to be reused unless damaged.
NOTE: Make sure that the sensor housing is clean and free of foreign material.
8.
2/4
162/2430
10/30/2018 Print
Installation
3. Torque: 110 Nm
3/4
163/2430
10/30/2018 Print
4/4
164/2430
10/30/2018 Print
Rear Suspension - Wheel Bearing and Wheel Hub—Vehicles With: Rear

Drum Brakes
Print
Removal
1. Refer to: Brake Drum (206-02 Drum Brake, Removal and Installation).
2.


4. NOTE: The O-ring seals are to be reused unless damaged.
NOTE: Make sure that the sensor housing is clean and free of foreign material.
5.
1/3
165/2430
10/30/2018 Print
Installation

Remove the equipment.
3. Torque: 110 Nm
2/3
166/2430
10/30/2018 Print
3/3
167/2430
10/30/2018 Print
Rear Suspension - Rear Stabilizer Bar—Vehicles With: Ball Joint Stabilizer

Bar Link
Print
General Equipment
Hydraulic Press
Removal
2.
1. Torque: 120 Nm
2. Torque: 60 Nm
Installation
NOTE: Make sure that these components are installed to the noted removal position.
1/2
168/2430
10/30/2018 Print
2. On both sides.
3. NOTE: Make sure that the clamp is installed to the same orientation as when removed.
2/2
169/2430
10/30/2018 Print
Rear Suspension - Rear Stabilizer Bar—Vehicles With: Solid Stabilizer Bar

Link
Print
General Equipment
Hydraulic Press
Removal
2. On both sides.
Refer to: Rear Stabilizer Bar Link - Vehicles With: Solid Stabilizer Bar Link (204-02 Rear
3. Torque: 60 Nm
Installation
NOTE: Make sure that these components are installed to the noted removal position.
1/2
170/2430
10/30/2018 Print
2. On both sides.
3. NOTE: Make sure that the clamp is installed to the same orientation as when removed.
2/2
171/2430
10/30/2018 Print
Rear Suspension - Rear Stabilizer Bar Bushing

—Vehicles With: Ball Joint Stabilizer Bar Link
Print
Removal
1. Refer to: Rear Stabilizer Bar - Vehicles With: Ball Joint Stabilizer Bar Link (204-02 Rear
Installation
1. To install, reverse the removal procedure
1/1
172/2430
10/30/2018 Print
Rear Suspension - Rear Stabilizer Bar Bushing

—Vehicles With: Solid Stabilizer Bar Link
Print
Removal
1. Refer to: Rear Stabilizer Bar - Vehicles With: Solid Stabilizer Bar Link (204-02 Rear Suspension,
Removal and Installation).
Installation
1/1
173/2430
10/30/2018 Print
Rear Suspension - Rear Stabilizer Bar Link—

Vehicles With: Ball Joint Stabilizer Bar Link
Print
Removal
1. Torque: 48 Nm
2. Torque: 120 Nm
Installation
1/1
174/2430
10/30/2018 Print
Rear Suspension - Rear Stabilizer Bar Link—

Vehicles With: Solid Stabilizer Bar Link
Print
Removal
2. Torque: 30 Nm
Installation
1/1
175/2430
10/30/2018 Print
Rear Suspension - Upper Arm

Print
General Equipment
Transmission Jack
Removal
3.
1/5
176/2430
10/30/2018 Print
6.
2/5
177/2430
10/30/2018 Print
7.
Installation
1.
3/5
178/2430
10/30/2018 Print
2. Torque: 115 Nm
3. Torque: 115 Nm
4/5
179/2430
10/30/2018 Print
4. Torque: 115 Nm
Procedures).
5/5
180/2430
10/30/2018 Print
Rear Suspension - Front Lower Arm

Print
General Equipment
Transmission Jack
Removal
2.

1/4
181/2430
10/30/2018 Print
5.
Installation
2/4
182/2430
10/30/2018 Print
2. Torque: 115 Nm
3. Torque: 115 Nm
3/4
183/2430
10/30/2018 Print
Procedures).
4/4
184/2430
10/30/2018 Print
Rear Suspension - Rear Lower Arm

Print
General Equipment
Transmission Jack
Removal
1. Refer to: Rear Stabilizer Bar Link - Vehicles With: Ball Joint Stabilizer Bar Link (204-02 Rear
3.
4.
1/5
185/2430
10/30/2018 Print
5.
Installation
2/5
186/2430
10/30/2018 Print
2. NOTE: Only tighten the nuts finger tight at this stage.
3/5
187/2430
10/30/2018 Print
4.
1. Torque: 115 Nm
2. Torque: 17 Nm
6. Torque: 115 Nm
4/5
188/2430
10/30/2018 Print
7. Torque: 47 Nm
9. Refer to: Rear Stabilizer Bar Link - Vehicles With: Ball Joint Stabilizer Bar Link (204-02 Rear
Procedures).
5/5
189/2430
10/30/2018 Print
Rear Suspension - Spring

Print
Special Tool(s)
204-167
Compressor, Coil Spring
204-215
Adapter for 204-167
Removal
1. Refer to: Wheels and Tires (204-04A Wheels and Tires, Description and Operation).
2. Install Special Service Tools: 204-167, 204-215.
Installation
1/1
190/2430
10/30/2018 Print
Rear Suspension - Rear Shock Absorber—4-Door/5-Door

Print
General Equipment
Transmission Jack
Removal
All vehicles
2.
2. Torque: 115 Nm
3. Torque: 25 Nm
Installation
1/1
191/2430
10/30/2018 Print
Rear Suspension - Rear Shock Absorber—1.6L Duratec-16V Ti-VCT

(63kW/85PS) - Sigma/1.6L Duratec-16V Ti-VCT (77kW/105PS) -
Sigma/1.6L Duratec-16V Ti-VCT (92kW/125PS) - Sigma/1.6L Duratec-
16V Ti-VCT Flex Fuel (88kW/120PS) - Sigma/1.6L Duratorq-TDCi
(77kW/105PS)/1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi
(70kW/95PS) (T3)/1.6L EcoBoost (110kW/150PS) - Sigma/1.6L
EcoBoost (132kW/180PS) - Sigma/1.6L EcoBoost Flex Fuel
(110kW/150PS)/2.0L Duratec-HE (110kW/150PS) - MI4/2.0L Duratec-
HE (125kW/170PS) - MI4/2.0L Duratec-HE Flex Fuel
(125kW/170PS)/2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW/2.0L
EcoBoost (184kW/250PS) - MI4
Print
General Equipment
Transmission Jack
Removal
1.
2. Torque: 23 Nm
3.
4.
1/2
192/2430
10/30/2018 Print
2. Torque: 115 Nm
Installation
2/2
193/2430
10/30/2018 Print
Wheels and Tires - Specifications

Print
TYRE PRESSURES (COLD TYRES) - ALL EXCEPT 2.0L ECOBOOST - MI4 - UP TO 80 KM/H (50 MPH)
Variant Tyre size Normal load Full load
Front Rear Front Rear
bar (psi) bar (psi) bar (psi) bar (psi)
All T125/85 R 16 4.2 (61) 4.2 (61) 4.2 (61) 4.2 (61)
TYRE PRESSURES (COLD TYRES) - ALL EXCEPT 2.0L ECOBOOST - MI4 - UP TO 160 KM/H (100 MPH)
NORMAL LOAD FULL LOAD
VARIANT TYRE SIZE FRONT REAR FRONT REAR
BAR (PSI) BAR (PSI) BAR (PSI) BAR (PSI)
All 205/55 R 16* 2.1 (31) 2.1 (31) 2.4 (35) 2.8 (41)
Vehicles with a petrol engine 215/55 R 16* 2.1 (31) 2.1 (31) 2.4 (35) 2.8 (41)
and 1.6L Duratorq-TDCi (DV)
Diesel
2.0L Duratorq-TDCi (DW) 215/55 R 16* 2.3 (33) 2.1 (31) 2.4 (35) 2.8 (41)
Diesel
Vehicles with a petrol engine 215/50 R 17 2.1 (31) 2.1 (31) 2.4 (35) 2.8 (41)
Diesel
2.0L Duratorq-TDCi (DW) 215/50 R 17 2.3 (33) 2.1 (31) 2.4 (35) 2.8 (41)
Diesel
Diesel
Diesel
*Only fit snow chains to specified tyres.
TYRE PRESSURES (COLD TYRES) - ALL EXCEPT 2.0L ECOBOOST - MI4 - CONTINUOUS SPEED IN EXCESS OF 160 KM/H (100 MPH)
1.6L Duratec-Ti-VCT (Sigma) 205/55 R 16 2.1 (31) 2.1 (31) 2.4 (35) 2.8 (41)
Diesel
1.6L EcoBoost SCTi (Sigma) 205/55 R 16 2.2 (32) 2.1 (31) 2.4 (35) 2.8 (41)
Diesel
1/3
194/2430
10/30/2018 Print
Diesel
Diesel
Diesel
Diesel
Diesel
TYRE PRESSURES (COLD TYRES) - 2.0L ECOBOOST - MI4 - UP TO 80 KM/H (50 MPH)
WARNING: Do not switch stability control off if you have fitted a temporary spare wheel to your vehicle.
TYRE SIZE FRONT REAR FRONT REAR
T125/80 R 16 4.2 (61) 4.2 (61) 4.2 (61) 4.2 (61)
T125/90 R 16 4.2 (61) 4.2 (61) 4.2 (61) 4.2 (61)
WARNING: Do not switch stability control off if you have fitted a temporary spare wheel to your vehicle.
205/55 R 16 3 (44) 3 (44) 3 (44) 3 (44)
215/55 R 16* 2.4 (35) 2.4 (35) 2.4 (35) 2.8 (41)
215/50 R 17* 2.4 (35) 2.4 (35) 2.4 (35) 2.8 (41)
235/40 R 18 2.4 (35) 2.4 (35) 2.4 (35) 2.4 (35)
*Only fit snow chains to specified tyres.
2/3
195/2430
10/30/2018 Print
TYRE PRESSURES (COLD TYRES) - 2.0L ECOBOOST - MI4 - CONTINUOUS SPEED IN EXCESS OF 220 KM/H (137 MPH)
215/55 R 16 2.4 (35) 2.4 (35) 2.6 (38) 2.8 (41)
215/50 R 17 2.5 (36) 2.4 (35) 2.8 (41) 2.8 (41)
235/40 R 18 2.4 (35) 2.4 (35) 2.5 (36) 2.5 (36)
3/3
196/2430
10/30/2018 Print
Wheels and Tires - Wheels and Tires -

Overview
Print
Tyre/Wheel Rim Combinations
The following tyre/wheel rim combinations are available:

6.5J x 16 steel wheel rim and structured steel wheel rim, also 7J x 16 light alloy wheel
rim:
- 205/55 R 16 91V 1)
- 215/55 R 16 93H
- 215/55 R 16 93V
- 215/55 R 16 97W (XL 2))
7J x 17 light alloy wheel rim:
- 215/50 R 17 95W
8J x 18 light alloy wheel rim:
- 235/40 R 18 95W
1) This size of tire may only be fitted on the standard steel rim.
2) XL = Xtra Load; tire is suitable for markets with poor roads
WARNING: Only the tire/rim combinations which are envisaged for the vehicle may be fitted.
Tyre repair kit
The vehicle comes with a tire repair kit as standard.

The tire repair kit is stowed in the spare wheel well.
The tyre repair kit consists of:

- a compressor with a pressure gauge,
- a power supply cable which plugs into the cigarette lighter,
- an air hose,
- tyre sealant.
A tire filled with sealant must be replaced with a new tire after 200 km (approx. 125 miles) at the
latest.
Instructions on using the tire repair kit can be found in a separate manual that is enclosed with the
tire repair kit.
Spare wheel/emergency spare wheel
A full-size 16" spare wheel is available as an option but initially only for 16" wheels.
For all other wheels, only an emergency spare wheel is available as an option.
Wheel nuts/locking wheel nuts
The wheels are fastened with wheel nuts/locking wheel nuts of size M12, socket size 19 mm.
1/2
197/2430
10/30/2018 Print
WARNINGS:
The wheel nuts used for fastening the textured steel wheels are the same as the ones used
for fitting alloy wheels.
The wheel nuts/locking wheel nuts for alloy wheels may only be used as a temporary
measure to fasten standard steel wheels or the emergency spare wheel. This even applies
when an alloy wheel has to be replaced with an emergency spare wheel or a full-size spare wheel in
an emergency. Under no circumstances must wheel nuts/locking wheel nuts for alloy wheels be
fitted to standard steel wheels as a long-term measure.
Under no circumstances must wheel nuts for standard steel wheels be used for alloy
wheels.
Global standardization of wheel attachment
With the launch of the 2011 C-MAX and now the 2011.25 Focus, the diameter of the wheel nut
holes has been reduced from 21 mm to 14.75 mm.
The reason for this is that Ford is standardizing its wheel nuts and plans to implement this globally
at a later date. The global standardization process will reduce the multitude of wheel nuts available
worldwide to a minimum.
At present, however, the conventional wheel nuts are still being fitted for steel and alloy wheels. At
the time of going to print, the globally standardized wheel nuts were scheduled for introduction in
mid-2012. Further information on using the globally standardized wheel nuts will be available at the
stated time.
Wheel nuts/locking wheel nuts for alloy wheels
Item Description
1 M12 1-piece locking wheel nut for alloy wheel (03/2008-)
2 M12 1-piece wheel nut for alloy wheel, for alloy wheels and textured steel wheels (08/2006-)
3 M12 2-piece wheel nut for alloy wheel with conical washer
4 M12 2-piece locking wheel nut for alloy wheel with conical washer
WARNING: Do not use 2-piece wheel nuts or locking wheel nuts on the wheels of the 2011.25
Focus/2011 C-MAX! This wheel nut/locking wheel nut will not lie against the cone of the wheel nut
hole. In the worst case scenario, this may result in the wheel becoming loose.
2/2
198/2430
10/30/2018 Print
Wheels and Tires - Wheels and Tires

Print
General Equipment
Ford diagnostic equipment
Mechanical
Wheel(s)
Tire(s)
Tire pressure(s) *
Valve stem(s)
Wheel nuts
Wheel studs
* Vehicles equipped with a tire pressure monitoring system must be inspected for correct operation using
the Ford diagnostic equipment.
Tires should be checked for correct:
tire pressure(s)
tire sizes
speed rating
load range.
tire construction type
The use of any other tire/wheel size, load range or type can seriously affect:
ride
handling
speedometer/odometer calibration
vehicle ground clearance
tire clearance between the body and chassis
wheel bearing life.
braking performance
New wheels need to be installed when the vehicle wheels:
are bent
are cracked
are dented
are heavily corroded
are leaking
have elongated wheel hub bolt holes
have excessive lateral or radial runout
It is mandatory to use only the tire sizes recommended on the tire label located on the door pillar
attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability and require
changing the speedometer calibration. Make sure wheel size and offsets match those recommended
for the tire in use.
Inspect the tires for signs of uneven wear. the following descriptions to identify the type of wear.
Check the tires for:
cuts
stone bruises
1/4
199/2430
10/30/2018 Print
abrasions
blisters
embedded objects
Check the valve stems for:
cracks
cuts
Install a new valve stem when damage is found or when a new tire is installed.
Normal Tire Wear
Normal tire wear is identified as even wear around and across the tread. Because there are many
factors (driving style, road surfaces, type of vehicle, type of tire) that can affect tire wear, there is no
absolute mileage expectation for a normal wear condition. A tire is considered worn-out when the
tread has worn to the level of the tread-wear indicators.
Abnormal/Incorrect Tire Wear
Abnormal/incorrect tire wear is identified as tire wear that is not even around or across the tread and
that creates performance-related issues.
Abnormal/incorrect wear can be caused by numerous factors, some of which include driving style
(aggressive, passive), climate (hot, cold), road conditions, vehicle loading and maintenance (correct
tire pressure, rotation intervals and balance). It is important to determine the root cause of wear on a
vehicle before carrying out repair. Tires exhibiting abnormal/incorrect tire wear may still be
serviceable provided that the minimum tread depth is greater than and the tire is not causing a
vehicle performance (noise/vibration) concern.
Inner Edge/Shoulder Wear
Inner edge (or shoulder) wear occurs on the inside edge of the tire and is usually caused by excessive
toe out and/or excessive negative camber. If the tread depth of the outer shoulder is at least 50%
greater than the tread depth of the inner shoulder, the tire is experiencing inner edge/shoulder wear.
To determine whether tires have this type of wear, visually inspect the tires. In some instances, it
may be necessary to measure the tread depth of each rib and compare it to that of the shoulder.
NOTE: Right-Front tire shown, others similar.
Outer Edge/Shoulder Wear

Outer edge (or shoulder) wear occurs on the outside edge of the tire and is usually caused by
excessive toe in and/or excessive positive camber. If the tread depth of the inner shoulder is at least
50% greater than the tread depth of the outer shoulder, the tire is experiencing outer edge/shoulder
wear. To determine whether tires have this type of wear, visually inspect the tires. In some instances,
it may be necessary to measure the tread depth of each rib and compare it to that of the shoulder.
NOTE: Right-Front tire shown, others similar.
2/4
200/2430
10/30/2018 Print
Heel/Toe Wear
Heel/toe wear (also known as feathering) occurs along the outside or inside edge/shoulder of the tire.
To determine whether tires have this type of wear, visually inspect the tires in both the inside and
outside shoulder ribs. In some instances, it may be necessary to measure the difference in tread
depth of leading versus trailing edge of each lug in the inside and outside shoulder rib.
Diagonal Wear
Diagonal wear occurs diagonally across the tread area and around the circumference of the tire. To
determine whether tires have this type of wear, visually inspect the tires to determine if the wear
pattern runs diagonally across the tread and around the circumference of the tire. In some instances,
the difference in tread depth along the diagonal wear pattern may need to be measured.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure should begin with a road test. The road test and customer
interview (if available) will provide much of the information needed to find the source of a vibration.
During the road test, drive the vehicle on a road that is smooth and free of undulations. If vibration is
apparent, note and record the following:
the speed at which the vibration occurs

what type of vibration occurs in each speed range.
mechanical or audible
how the vibration is affected by changes in the following:
engine torque
vehicle speed
engine speed
type of vibration - sensitivity:
torque sensitive
vehicle speed sensitive
engine speed sensitive
The following explanations help isolate the source of the vibration.

3/4
201/2430
10/30/2018 Print
Torque Sensitive
This means that the condition can be improved or made worse by accelerating, decelerating, coasting,
maintaining a steady vehicle speed or applying engine torque.
Vehicle Speed Sensitive
This means that the vibration always occurs at the same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear selected.
Engine Speed Sensitive
This means that the vibration occurs at varying vehicle speeds when a different transmission gear is
selected. It can sometimes be isolated by increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related to the tires.
If the road test indicates that there is tire whine, but no shake or vibration, the noise originates with
the contact between the tire and the road surface.
A thumping noise usually means that the tire is flat or has soft spots making a noise as they slap the
roadway. Tire whine can be distinguished from axle noise. Tire whine remains the same over a range
of speeds.
Symptom Chart
The table provides all possible Wheels ans Tires symptoms. For a detailed diagnostics, proceed to the
Ford diagnostic equipment.

Tire(s) show excess wear on edge of tread Tire(s) under-inflated
Vehicle overloaded
Tire(s) show excess wear in center of tread Tire(s) over-inflated
Other excessive tire wear concerns Incorrect tire pressure(s)
Wheel and tire assemblies need rotating
Vehicle overloaded
Loose or leaking front strut and spring assembly
Wheel bearings worn
Suspension components, bushings and ball joints
Excessive lateral or radial runout of wheel or tire
Wobble or shimmy affecting wheel runout Damaged wheel
Front wheel bearing
Excessive vehicle vibration, rough steering Suspension components
Incorrect tire pressure(s)
Wheel or tire imbalance
Uneven tire wear
Brake disc imbalance
Water in tire(s) / Damaged wheel
Incorrectly seated tire bead
Excessive lateral or radial runout of wheel or tire
Foreign material between wheel mounting face and hub
mounting surface
Front wheel bearing
Rust streaks from the wheel stud holes in Wheel nuts
the wheel
Seized wheel nuts Corrosion
Vehicle overloaded
4/4
202/2430
10/30/2018 Print
Wheels and Tires - Wheel and Tire

Print
Removal
NOTICE:
Do not use heat to loosen a seized wheel nut.
Do not use power tools on locking wheel nuts.
1. Loosen: 360°
3. NOTICE: If equipped with full wheel cover with exposed wheel nuts, the wheel nuts must
be removed prior to removing the wheel cover or damage to the wheel cover will occur.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign
material present on the mounting surface of the wheel and the mounting surface of the
wheel hub, brake drum or brake disc. Make sure that any fasteners that attach the rotor to
the hub are secured so they do not interfere with the mounting surfaces of the wheel. Failure
to follow these instructions when installing wheels may result in the wheel nuts loosening
and the wheel coming off while the vehicle is in motion, which could result in loss of control,
leading to serious injury or death to vehicle occupant(s).
NOTICE: Make sure to apply a thin coat of anti-seize lubrication only to the interface
between the wheel pilot bore and the hub pilot. Do not allow the anti-seize to make contact
with the wheel-to-brake disc/drum mounting surface, wheel studs, wheel nuts, brake pads or
brake disc friction surfaces or damage to components may occur.
NOTE: Only tighten the nuts finger tight at this stage.
1/2
203/2430
10/30/2018 Print
3. Tighten the wheel nuts in the sequence shown.
Torque: 135 Nm
2/2
204/2430
10/30/2018 Print
Wheels and Tires - Wheel and Tire

Print
General Equipment
Wooden Block
Disassembly
NOTICE:
Failure to follow the instructions below may result in damage to the TPMS (tire pressure
monitoring system).
The TPMS sensor is mounted to the valve stem. Removal of the valve stem requires
dismounting the tire from the wheel and removal of the TPMS sensor.
NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure
that accurate values are obtained.
1. WARNING: Before beginning any service procedure in this section, refer to Safety
Warnings in section 100-00 General Information. Failure to follow this instruction may result
in serious personal injury.
2. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
3. NOTICE: The valve stem is connected to the TPMS sensor. Do not pull the valve stem
from the wheel, or damage to the sensor will occur.
NOTE: If a new TPMS sensor is being installed, remove and discard the valve stem-to-sensor
screw and the sensor.
Remove the valve stem core and fully deflate all air from the tire.
4. NOTICE:
Do not allow the tire beads to move beyond the wheel mid-plane (middle of the wheel)
when separating the beads from the wheels, damage to the TPMS sensor may occur.
Tire and valve stem position is critical to prevent damage to theTPMS sensor when
using a paddle-type bead separator.
NOTE: Some machines may have a nylon roller bead separator at the 12 o'clock position
instead of the paddle-type bead separator at the 3 o'clock position.
For a paddle-type tire machine, position the valve stem at the 12 o'clock or 6 o'clock position
and the paddle at the 3 o'clock position.
For a roller-type tire machine, align the valve stem with the roller at any position.
If bead separation is difficult to achieve using the nylon roller bead separators due to high
anchoring force between the tire and the wheel; the paddle-type bead separator may be a
more effective method.
NOTE: Paddle type shown, roller type similar.
1/4
205/2430
10/30/2018 Print
5. NOTE: Index-mark the valve stem and wheel weight positions on the tire.
Place the wheel and tire assembly on the turntable of the tire machine with the valve stem at the
11:30 position and the machine arm at the 12 o'clock position and dismount the outer bead from
the wheel.
6. Reset the wheel and tire assembly on the turntable of the tire machine with the valve stem at the
11:30 position and the machine arm at the 12 o'clock position and dismount the inner bead from
the wheel.
7. NOTE: A new valve stem must be installed whenever a new tire or wheel is installed.
Discard the specified component. Follow local disposal regulations.
8. NOTICE: Use care not to damage the wheel surface when removing the valve stem.
Discard the specified component. Follow local disposal regulations.
Use the General Equipment: Wooden Block
2/4
206/2430
10/30/2018 Print
NOTE: When installing a new wheel, always install a new valve stem and sensor screw. Reuse
theTPMS sensor from the previous wheel if possible. The TPMS will not have to be trained if the
sensor is reused.
NOTE: If the TPMS sensor is being reused, inspect the TPMS sensor for damage and install a new
sensor as necessary.
9. NOTICE: To prevent TPMS sensor and valve stem damage, the valve stem must be
installed onto theTPMS sensor and then installed into the wheel as an assembly.
Torque: 1.5 Nm
Assembly
NOTICE: Damage to the TPMS sensor may result if the tire mounting is not carried out as
instructed.
10. NOTICE:
It is important to pull the valve stem and TPMS sensor assembly through the wheel rim
hole in a direction parallel to the valve stem hole axis. If the assembly is pulled through at an
angle, damage to the valve stem and sensor assembly may occur.
Use care not to damage the wheel surface when installing the valve stem and TPMS
sensor assembly.
NOTE: Lubricate the valve stem with soapy water and install the valve stem and TPMS sensor
assembly into the wheel using a block of wood and a suitable valve stem installer.
11. NOTE: Lubricate the tire beads using a suitable fast-drying, corrosion-inhibiting tire bead
lubricant.
NOTE: Do not mount the tire at this time.
Position the wheel on the turntable of the tire machine, then lubricate and position the bottom
bead of the tire on the wheel.
12. Position the wheel to align the valve stem with the machine arm, at the 6 o'clock position, and
mount the bottom bead of the tire.
3/4
207/2430
10/30/2018 Print
13. Reposition the wheel to align the valve stem with the machine arm at the 6 o'clock position, and
mount the top bead of the tire.
14. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be
sure that accurate values are obtained.
Inflate the tire to the pressure specified on the VC (vehicle certification) label located on the driver
door or door pillar.
NOTE: Proceed to the next step if the tire beads do not seat at the specified inflation pressure.
15. WARNING: If there is a need to exceed the maximum pressure indicated on the sidewall
of the tire in order to seat the beads, follow all steps listed below. Failure to follow these
steps may result in serious personal injury.
NOTICE: The following steps should only be carried out if the tire beads cannot be
seated by inflating the tire up to the maximum inflation pressure listed on the tire sidewall.
1. Relubricate the tire bead and wheel bead seat area.
2. Install a remote valve and pressure gauge.
3. Wear eye and ear protection and stand at a minimum of 3.65 m (12 ft) away from the wheel
and tire assembly.
4. Inflate the tire using the remote valve and tire gauge until the beads have seated or until the
pressure gauge is 138 kPa (20 psi) more than maximum inflation pressure on tire sidewall. If
beads have not seated, deflate the tire and proceed to the next step.
5. Place the wheel and tire assembly in an OSHA-approved tire safety cage.
6. Inflate the tire using the remote valve and pressure gauge until the beads have seated or
until the pressure gauge is 276 kPa (40 psi) more than maximum inflation pressure on the
tire sidewall. Do not exceed 276 kPa (40 psi) above the maximum pressure on tire
sidewall. Install a new tire if the beads do not seat at this pressure.
16. Install the wheel and tire.
Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
4/4
208/2430
10/30/2018 Print
Tire Pressure Monitoring System (TPMS) - Tire Pressure Monitoring

System (TPMS) - Component Location
Print
Item Description
1 BCM (body control module)
2 Sensor.
3 Valve
4 Indicator in the IPC (instrument panel cluster)
1/1
209/2430
10/30/2018 Print

System (TPMS) - Overview
Print
Overview
The BCM (body control module) monitors the tire pressure in the 4 road tires with tire pressure
sensors that communicate the tire pressure status via radio signals to the BCM. The tire pressure
sensors are battery operated and mounted to the valve stems. All of the controlling software for the
TPMS (tire pressure monitoring system) is contained in the BCM. The IPC (instrument panel cluster)
illuminates the TPMS warning indicator and the message center displays a message when a fault is
present or when the tire pressure falls below the low pressure limit.
NOTE: After changing the wheels, the sensors must be re-learned.
NOTE: The system learns automaticly the sensors between nine to twelve minutes while driving.
TPMS Sensor
General
Ford of Europe uses two different designs of TPMS sensor:

TPMS valve mounted snap-in sensors
TPMS valve mounted bolt-on sensors
TPMS Valve Mounted Snap-In Sensor
This two piece snap-in valve mounted sensor contains two separate parts (sensor and valve stem)
which are screwed together but only the valve stem can be replaced separately.
The sensor is referred to as “snap-in” because it has a traditional rubber valve stem and not a hex nut
fastener.
The sensor is mounted to the valve by using a Torx screw. When the valve needs to be replaced the
sensor can be removed and a new valve kit can be in installed. The valve kit consists of a new valve,
valve cap and Torx screw.
TPMS Valve Mounted Bolt-On Sensors
1/3
210/2430
10/30/2018 Print
The valve mounted bolt-on TPMS sensor is an assembly where the sensor and valve stem are screwed
together. The sensor is secured by a hex nut and uses a rubber grommet to prevent any leaks.
The bolt-on system uses a grommet to seal the sensor in the rim and an additional retention nut.
When the sensor is removed or a tire is replaced a new mounting kit must be installed. The mounting
kit includes a new grommet, valve core, valve cap and hex nut.
TPMS Sensor Identification
TPMS type valves have a different design compared to standard type valves. The identification is
possible without removing the tire.
TPMS Valve Mounted Snap-In Sensor
Item Description
1 TPMS sensor identification rib
TPMS Valve Mounted Bolt-On Sensors
Item Description
2/3
211/2430
10/30/2018 Print
1 Metal valve stem and nut, metal cap
3/3
212/2430
10/30/2018 Print

System (TPMS) - System Operation and Component Description
Print
System Operation
System Diagram
Item Description
1 LF TPMS (tire pressure monitoring system) Sensor
2 RF TPMS Sensor
3 LR TPMS Sensor
4 RR TPMS Sensor
5 Radio frequency signals from four sensors
6 Module –BCM (body control module) with integrated receiver
7 Module –IPC (instrument panel cluster)
8 Module – PCM (powertrain control module)
TPMS Function
TPMS is a new comfort feature function of the BCM. It checks the pressure of every single tire and
alerts the driver in case of a significant pressure loss via telltale in the IPC. In comparison to the
former Deflation Detection System (DDS, no direct pressure monitoring: calculating possible deflation
through comparison of wheel speeds) TPMS offers improved functionality. It works with 4 separate
sensors in each wheel that monitor tire pressure, tire air temperature and acceleration. This allows
the system not only to detect deflation in, 2 or 3 tires but also a consistent loss of pressure in all 4
tires. TPMS reacts to pressure losses of at least 20 % compared to the learned warm tire pressure.
The 4 sensors wirelessly transmit their data to the BCM regularly or if a pressure loss is detected
immediately. If a deflation of at least 20 % is detected the BCM sends requests to the IPC to switch
on the indicator lamp and/or to show a message in the IPC display.
The scan tool is a useful tool in diagnosing TPMS concerns and may be used to verify the accuracy of
the tire pressure data transmitted by the TPMS sensors. This is accomplished by comparing the BCM
tire pressure Parameter Identification (PID) data to the actual tire pressure using a digital tire
pressure gauge. Training the sensors is not necessary after a tire rotation on vehicles with the same
front and rear tire pressures however, the BCM cannot recognize that the sensor identifiers have been
moved to different positions and will retain the original position information for each sensor.
Resetting TPMS
1/2
213/2430
10/30/2018 Print
TPMS has to be reset after every manual change to the tires or the tire pressure (wheel change or
pressure adjustment).
Automatic learning process TPMS
After every reset TPMS has to go through an automatic learning process. In this time the system gets
to know all parameters that are necessary to work precisely and the warm tire pressure (depending
on isolation, surface temperature, ambient air temperature, tire pressure, driving situation, friction
etc.) is learned. The process lasts 10 minutes but the system already works with default parameters
before it is completed.
TPMS Warning Indicator
The TPMS warning indicator and vehicle message center occasionally displays faults that cannot be
resolved by the customer. Treat these messages as TPMS faults that must be serviced.
TPMS Warning Indicator Illuminates Continuously
The TPMS warning indicator remains on continuously and the message center displays LOW TIRE
PRESSURE when any of the tire pressures fall below the low pressure limit. When this condition
exists, adjust the tire pressure to the recommended cold tire pressure indicated on the tyre placard.
Perform system reset.
Tire Pressure Monitoring System (TAMS) Warning Indicator Flashes
The TPMS warning indicator flashes for 75 seconds and then remains on continuously when the
ignition is set to ON and the TPMS is malfunctioning. The Parameter Identification (PID) TP_STAT can
be used to determine why the TPMS warning indicator is flashing.
Tire Pressure Sensor Fault — The message center displays TIRE PRESSURE SENSOR FAULT when a
TPMS sensor is malfunctioning.
No communication with the BCM — The TPMS warning indicator illuminates when the IPC has not
received any signals from the BCM for more than 5 seconds. The message center displays TIRE
PRESSURE MONITOR FAULT.
Tire Pressure Monitor Fault — The message center displays TIRE PRESSURE MONITOR FAULT when
the TPMS is malfunctioning.
2/2
214/2430
10/30/2018 Print
Tire Pressure Monitoring System (TPMS) - Tire

Pressure Monitoring System (TPMS)
Print
A number of reasons can cause the TPMS warning light to illuminate or flash. Before proceeding with
the actual diagnostic method using the FordETIS IDS Diagnostics, perform these basic checks:
Verify all tires are inflated to its recommended pressure, as mentioned in the Owner’s Manual.
Inspect all the tires and wheels for any visual damage.
Check that all the wheels have a TPMS sensor appropriately installed.
If these above conditions are verified as fine, then proceed for further diagnosis.
The TPMS warning indicator alerts the customer of faulty conditions in 2 different ways.
TPMS indicator illuminates continuously
The TPMS warning indicator remains on continuously and the message center displays LOW TIRE
PRESSURE when any of the tire pressures fall below the low pressure limit. When this condition
exists, check that all tires are correctly inflated to the recommended cold tire pressure indicated on
the placat pressure label. Perform system reset.
TPMS indicator flashes
When the TPMS warning indicator flashes for 75 seconds and remains continuously on when the
ignition is set to ON, it means the TPMS is malfunctioning. The Parameter Identification (PID)
TP_STAT can be used to determine why the TPMS warning indicator is flashing.
The message center displays TIRE PRESSURE SENSOR FAULT when a TPMS sensor is
malfunctioning.
The TPMS warning indicator illuminates when the IPC has not received any signals from the BCM for
more than 5 seconds. The message center displays TIRE PRESSURE MONITOR FAULT.
The message center displays TIRE PRESSURE MONITOR FAULT when the TPMS is malfunctioning.
TPMS replacement is called for when the TPMS fails due to mechanical or electrical failure, broken
accelerometer, low TPMS battery power or blocked pressure port. One of the most common causes of
failure is inappropriate handling during wheel or tire removal or servicing. The TPMS is an electronic
component fitted as part of a heavyweight mechanical process.
Resetting TPMS
TPMS must be reset after every manual change to the tires or the tire pressure (wheel change or
pressure adjustment).
Automatic learning process TPMS
After every reset, TPMS must go through an automatic learning process. During this time, the system
knows all parameters that are required to work precisely and the warm tire pressure (depending on
isolation, surface temperature, ambient air temperature, tire pressure, driving situation and friction)
is learned. The process lasts 10 minutes but the system already works with default parameters before
it is completed.
For all TPMS malfunctioning issues, proceed to the FordETIS IDS Diagnostics for a detailed diagnosis.
FordETIS provides only supporting information to the FordETIS IDS Diagnostics.
DTC Chart: BCM (body control module)
A certain skill level and knowledge of Ford-specific diagnostic practices is assumed to perform this
diagnostics.
DTC DESCRIPTION
B1182:00 TIRE PRESSURE MONITORING SYSTEM: NO SUB TYPE INFORMATION
B1182:55 TIRE PRESSURE MONITORING SYSTEM: NOT CONFIGURED
B124D:02 TIRE PRESSURE SENSOR: GENERAL SIGNAL FAILURE
B1251:00 TIRE PRESSURE SENSOR LOW BATTERY: NO SUB TYPE INFORMATION
B1254:51 RIGHT REAR (OUTSIDE ON DUAL WHEEL) TIRE PRESSURE SENSOR AND TRANSMITTER
ASSEMBLY: NOT PROGRAMMED
1/2
215/2430
10/30/2018 Print
DTC DESCRIPTION
B1255:51 LEFT REAR (OUTSIDE ON DUAL WHEEL) TIRE PRESSURE SENSOR AND TRANSMITTER
ASSEMBLY: NOT PROGRAMMED
C1A56:51 LEFT FRONT TIRE PRESSURE SENSOR AND TRANSMITTER ASSEMBLY: NOT PROGRAMMED
C1A58:51 RIGHT FRONT TIRE PRESSURE SENSOR AND TRANSMITTER ASSEMBLY: NOT PROGRAMMED
For all DTC code diagnosis, proceed to the FordEtis IDS Diagnostics.
2/2
216/2430
10/30/2018 Print

Pressure Monitoring System (TPMS) Sensor
Activation
Print
General Procedures
Special Tool(s)
204-D081A
Tire Pressure Monitor (TPMS)
Activation
1. NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to
conserve battery power. The sensors do not transmit information while in sleep mode. It will
be necessary to wake them up so they will transmit the latest tire pressure information.
NOTE: The tire pressure data in the BCM (body control module) can be cleared when the
module performs a reset. When this occurs the air pressure DIDs will be reset to the factory
default of 1033 kPa (149.96 psi) and the cluster will display dashes.
Turn the ignition switch to the ON position.
2. Position the special tool against the Left Front (LF) tire sidewall at the tire valve stem.
Use Special Service Tool: 204-D081A.
3. NOTE: The special tool should provide feedback in the form of a flashing green light and a
beep sound for each successful response from a tire pressure sensor. This feedback may not
always be present, do not rely on it as a confirmation that the module heard a particular
sensor.
NOTE: If a sensor does not respond to the special tool move the vehicle to rotate the wheels
at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor
still does not respond, attempt to activate the same sensor again using the customer
activation tool (if available). If the sensor still fails to train, attempt to train the sensor with
the vehicle doors open.
Press the test button on the special tool to activate the sensor. Activate the sensor at least 2 times.
4. Repeat Steps 2 and 3 for the remaining tires.
5. If the TPMS (tire pressure monitoring system) indicator remains illuminated after adjusting and
activating each sensor,
Refer to: Tire Pressure Monitoring System (TPMS) (204-04 Tire Pressure Monitoring System
(TPMS), Diagnosis and Testing).
1/1
217/2430
10/30/2018 Print

Location Calibration
Print
General Procedures
Special Tool(s)
204-D081A
Tire Pressure Monitor (TPMS)
Activation
1. NOTE: Before performing the TPMS sensor location calibration, have the vehicle parked at
least 2 meter away from any other vehicle equipped with TPMS to avoid activating other
TPMS sensors.
With the ignition OFF, press and release the brake pedal.
2. Using the start/stop switch, position the ignition from OFF to RUN 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Position the ignition to OFF position.
5. Using the start/stop switch, position the ignition from OFF to RUN 3 times, ending in the RUN
position.
6. The horn will sound once and the TPMS (tire pressure monitoring system) indicator will flash if the
training mode has been entered successfully. If equipped, the message center will display TRAIN
Left Front (LF) TIRE.
7. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the
special tool must remain in place at the valve stem.
Place the special tool on the Left Front (LF) tire sidewall at the valve stem. Press and release the
test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor
has been recognized by the BCM (body control module).
8. Within 2 minutes of the horn sounding, place the special tool on the Right Front (RF) tire sidewall
at the valve stem and press and release the test button to train the Right Front (RF) tire pressure
sensor.
9. NOTE: Do not wait more than 2 minutes between training each sensor or the BCM will time
out and the entire procedure must be repeated and the already trainedTPMSsensors have to
be activated again.
Repeat Step 7 for the Right Rear (RR) and Left Rear (LR) tires. The procedure is completed after
the last tire has been trained. When the training procedure is complete, the message center (if
equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message
center, successful completion of the training procedure will be verified by positioning the ignition to
OFF without the horn sounding. If the horn sounds twice when the ignition is positioned to OFF, the
training procedure was not successful.
10. Using the scan tool, locate the updated TPMS sensor identifiers trained to the BCM and document
1/2
218/2430
10/30/2018 Print
them on the applicable warranty claim.
11. This step is required to clear DTC (diagnostic trouble code) B1182:55, cause the BCM to exit the
manufacturing mode and to make sure there are no other concerns with a newly programmed
BCM.
12. If the sensors are being trained due to the installation of a new BCM, clear anyDTC and carry out
the BCM On-Demand Self Test.
13. NOTE: TPMS sensor identifiers are stored as long no new TPMS sensor identifiers have been
trained by either performing this procedure or performing TPMS customer reset.
2/2
219/2430
10/30/2018 Print

Print
Removal
1. WARNING: The Tire Pressure Monitoring System (TPMS) sensor battery may release
hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact
the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt
medical attention. If any part of the battery is swallowed, contact a physician immediately.
When disposing of Tire Pressure Monitoring System (TPMS) sensors, follow the correct
procedures for hazardous material disposal. Failure to follow these instructions may result in
serious personal injury.
NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be removed without
disassembly of the wheel and tire.
NOTE: The maximum shelf life of a TPMS snap in valve stem before being mounted to a
wheel is 1 year. The production date / week / year is marked on the TPMS sensor / valve
stem itself. Snap in valve stems which are older than 1 year are to be scrapped. TPMS snap
in sensors with valve stems older than one year should not be mounted but the valve stem
should be replaced.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Disassembly and Assembly).
Installation
1. NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be installed without
disassembly of the wheel and tire.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Disassembly and Assembly).
1/1
220/2430
10/30/2018 Print
Front Drive Halfshafts - Specifications

Print
LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES
SPECIFICATIONS
Constant Velocity Joint Grease WSS-M1C259-A1 /

2S6W-M1C259-AA
Constant Velocity Joint Grease WSD-M1C230-A
Constant Velocity Joint Grease 6G9N-39209-CAAGA
Constant Velocity Joint Grease 6G91-39209-LBCGA
CAPACITY
DRIVESHAFT JOINT GREASE FILL CAPACITY
DESCRIPTION
INNER OUTER
INNER GREASE OUTER GREASE
(GRAMS) (GRAMS)
Vehicles with 1.6L 100 WSS-M1C259-A1 / 105 WSS-M1C259-A1 /

Duratec Ti-VCT engine 2S6W-M1C259-AA 2S6W-M1C259-AA
and IB5 manual transaxle
Vehicles with 1.6L 155 6G91-39209-LBCGA 110 WSS-M1C259-A1 /

Duratorq TDCI engine and 2S6W-M1C259-AA
B6 manual transaxle
Vehicles with 1.6L 140 6G9N-39209-CAAGA 125 WSD-M1C230-A

EcoBoost GTDI engine
and B6 manual transaxle
Vehicles with manual 127 6G9N-39209-CAAGA 95 WSD-M1C230-A

transaxle MTX75
Vehicles with 6DCT450 180 6G9N-39209-CAAGA 120 WSD-M1C230-A

powershift transaxle
Vehicles with manual 180 6G9N-39209-CAAGA 120 WSD-M1C230-A

transaxle MMT6
Vehicles with 6DCT250 127 6G9N-39209-CAAGA 95 WSD-M1C230-A

automatic transaxle
1/1
221/2430
10/30/2018 Print
Front Drive Halfshafts - Front Drive Halfshafts - Overview

Print
Front drive halfshafts
Item Description
1 Left-hand halfshaft
2 Intermediate shaft center bearing
3 Halfshaft RH
General information
The halfshafts have constant velocity (CV) joints at both ends to provide smooth drive to the road
wheels.
The inner constant velocity joints are slip joints.
On the wheel side, constant velocity joints without longitudinal adjustment are installed.
The left-hand halfshaft CV joint is secured in the differential with a snap ring.
The intermediate shaft (right-hand side) is secured in the differential by the intermediate shaft
center bearing assembly.
The wheel-side constant velocity joints are attached to the wheel hubs.
How the halfshafts work
The halfshafts transmit the engine torque to the wheels.

In order to allow vertical movement of the wheels and engine, the halfshafts operate at varying
lengths and angles.
The tripode joints allow for changes in halfshaft length during axial movements.
Handling halfshafts
NOTE: The inner constant velocity (CV) joint must not be bent at more than 18 degrees, the outer
CV joint must not be bent at more than 45 degrees.
NOTE: Do not subject the tripode joint to tensile loads.
The following points must be observed during removal and installation of the halfshafts:
Check polished surfaces and splines for damage. Do not allow the boots and the clamps to come
into contact with sharp edges, the engine or the exhaust system.
Do not drop the halfshaft as this can damage the inside of the CV joint boots without showing any
signs of damage on the outside.
Do not use halfshafts as levering tools for the installation of other components.
Halfshafts must always hang free.
The tripode joint can be damaged by knocks outside the joint housing.
1/2
222/2430
10/30/2018 Print
During removal and installation of the right-hand halfshaft always renew the bolts and the bearing
shell of the center bearing.
Wheel balancing, front

Using a portable wheel balancing unit when the vehicle is lifted completely off the ground will result in
damage to the tripode joints or boots, as the joint is bent at a greater angle than its normal operating
range. The joints would overheat in the process.
To use a portable balancing unit position a trolley jack under the suspension arm opposite the wheel
which is being balanced. This prevents the joint from being bent too much when the vehicle is raised.
Where possible, wheels should be removed for balancing, and balanced using a stationary wheel
balancing unit.
Raising the vehicle
NOTE: Do not fasten a towing rope to the halfshafts.
Underbody protection and corrosion prevention
NOTE: The boots should be covered during application of underbody protection or corrosion
prevention.
Foreign bodies can be the cause of premature material wear. Foreign matter on the halfshafts can
cause the imbalance.
2/2
223/2430
10/30/2018 Print
Front Drive Halfshafts - Front Drive Halfshafts - Component Location

Print
Overview of front drive halfshafts
Item Description
1 Outer CV joint housing without length compensation, left side
2 Boot tightening strap – outer boot
3 Outer CV joint boot, left side
5 Front drive halfshaft, left side
6 Boot tightening strap – inner boot
7 Inner CV joint boot, left side
9 Inner CV joint housing with length compensation, left side
10 Front drive halfshaft stub
11 Intermediate shaft
12 Intermediate shaft bracket
13 Intermediate shaft center bearing
14 Inner CV joint housing with length compensation, right side
16 Inner CV joint boot, right side
18 Front drive halfshaft, right side
20 Outer CV joint boot, right side
22 Outer CV joint housing without length compensation, right side
1/1
224/2430
10/30/2018 Print
Front Drive Halfshafts - Front Drive Halfshafts - System Operation and

Component Description
Print
System Operation
The powertrain and the transmission of torque through the powertrain on vehicles with front-wheel
drive are as follows:
engine,
Transaxle input shaft
Transmission output shafts
Differential
Drive shafts
wheel hub assembly,
Wheel
Halfshafts transmit rotary motion through constant velocity joints in a uniform manner, i.e. the
angular velocities on the drive side and the output side do not vary from one another. This avoids
irregularities in the powertrain and additional stresses from neighboring components.
The outer CV joints use balls, have no length compensation and engage in the wheel hubs.
The intermediate shaft (right side) is correctly positioned and secured in the differential by the
intermediate shaft center bearing.
The left CV joint is locked in the differential by a snap-ring.
To allow the vehicle suspension to operate, the inner CV joints have tripod joints which allow changes
in the torque transmission angle and length compensation when an axial shift occurs between the
transmission and the wheel. The wheel-side constant velocity joints are attached to the wheel hubs.
CV joint with length compensation
The length compensation of the halfshaft needed due to the suspension is achieved on the axle drive
side by constant velocity joints with length compensation. In the case of front-wheel drive vehicles
these CV joints are mounted on the transmission side and in the case of rear-wheel drive vehicles on
the wheel side.
1/5
225/2430
10/30/2018 Print
A CV joint with length compensation is also called a tripod joint, because the outer cup has three
large, elongated recesses arranged at equal intervals around the periphery, in which three needle-
bearing-mounted rollers are able to move axially. The cross-section clearly shows how the left shaft
terminates inside the joint, where it supports three short shaft stubs (called a spider), on which the
needle-bearing-mounted rollers are arranged.
Item Description
1 Needle-bearing-mounted rollers
2 Halfshaft stub
3 Spider
4 Boot
The CV joint with length compensation transmits the torque uniformly from the axle drive (sprung
mass) to the driving wheel (unsprung mass). Therefore during a rotation, in contrast to universal
joints for example, there is no lead or lag of the driven elements relative to the driving elements. Due
to the uniform transmission of torque, even on deflection, constant velocity joints with length
compensation are also called homokinetic joints.
The maximum deflection angle is approx. 20° and the length compensation needed, mainly due to the
vehicle suspension, is up to approx. 30 mm. In view of the high stresses, the sliding surfaces are
hardened. Constant velocity slip joints are permanently lubricated with grease. Their protective boots
should be checked regularly for damage, to prevent grease from escaping and dirt from getting in,
thus causing rapid wear.
Constant velocity joint without length compensation
2/5
226/2430
10/30/2018 Print
In the case of large deflection angles on the driving wheels of front-wheel drive vehicles, this half
shaft joint transmits torque with minimal effect on the steering.
Ball cup
Item Description
1 Ball cup of a constant velocity joint without length compensation
2 Milled and hardened ball races
Ball races are milled inside a ball cup connected to the wheel.
3/5
227/2430
10/30/2018 Print
Item Description
1 Ball
2 Ball star
3 Half shaft stub
4 Snap ring
5 Carrier
6 Ball cup
Races are also milled in the outside of the ball star connected to the half shaft. The balls are held by a
suitable cage and allow the joint to transmit force in a uniform (homokinetic) manner up to a
deflection angle of approx. 47°. This allows full wheel deflection with front-wheel drive, despite the
half shaft.
Cross-section through front drive half shaft
Item Description
1 Outer CV joint without length compensation (ball cups shown complete)
2 Boot tightening strap – outer boot (large)
4/5
228/2430
10/30/2018 Print
3 Outer CV joint boot

4 Front axle driveshaft
5 Boot tightening strap – outer boot (small)
The illustration shows a cross-section of a front drive half shaft through the wheel suspension with a
CV joint without length compensation. The CV joint engages in the wheel hubs.
Ball joints are therefore also called constant velocity fixed joints and are permanently lubricated with
grease. Their protective boots should be checked regularly for damage, to prevent grease from
escaping and dirt from getting in. When replacing boots make sure they contain exactly the right
quantity of grease; it is also necessary to inject a certain quantity into the joint.
Gaiter
Item Description
1 Recess for large boot tightening strap
2 Recess for small boot tightening strap
The boot tightening straps ensure dustproof and waterproof seating on the half shaft.
The rubber boot protects the CV joint from moisture and dirt and the joint grease from drying out.
The rubber compound of the boot ages and becomes brittle and must be checked for cracks during
vehicle maintenance.
5/5
229/2430
10/30/2018 Print
Front Drive Halfshafts - Front Drive Halfshafts

Print

NOTE: New front wheel drive halfshafts should not be installed unless disassembly and inspection
reveals unusual wear.
NOTE: While inspecting the front wheel halfshaft CV joint boots, look for indentations (dimples) in
the boot convolutions. If an indentation is observed, it must be removed.
Mechanical
Constant velocity (CV) joints
CV joint boots
Front halfshaft(s)
Intermediate shaft
Intermediate shaft bearing
Front halfshaft(s) nut
4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
SYMPTOM POSSIBLE SOURCES ACTION

AXLE HOWLING OR WHINE * DAMAGED OR WORN * CHECK FOR ABNORMAL WHEEL HUB
WHEEL HUB BEARINGS. BEARING PLAY OR ROUGHNESS.
REFER TO: FRONT WHEEL BEARING
(204-01 FRONT SUSPENSION,
REMOVAL AND INSTALLATION).
CLICKING, POPPING OR * INADEQUATE OR * CHECK THE CV JOINT BOOTS AND
GRINDING NOISES WHILE CONTAMINATED JOINTS FOR WEAR OR DAMAGE.
TURNING LUBRICATION IN THE CV INSTALL NEW COMPONENTS AS
JOINTS. NECESSARY. REFER TO: (205-04 FRONT
DRIVE HALFSHAFTS)
FRONT HALFSHAFT LH - 6-SPEED
MANUAL TRANSMISSION - B6
(REMOVAL AND INSTALLATION),
FRONT HALFSHAFT RH - 6-SPEED
(REMOVAL AND INSTALLATION).
REFER TO: (205-04 FRONT DRIVE
HALFSHAFTS)
MANUAL TRANSMISSION - MMT6
HALFSHAFTS)
POWERSHIFT TRANSMISSION -
DPS6/6DCT250 (REMOVAL AND
INSTALLATION),
1/6
230/2430
10/30/2018 Print
MPS6/6DCT450 (REMOVAL AND

INSTALLATION).
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
* DAMAGED OR WORN CV * INSPECT THE CV JOINTS FOR WEAR OR
JOINTS. DAMAGE. INSTALL A NEW HALFSHAFT
AS NECESSARY. REFER TO: (205-04
FRONT DRIVE HALFSHAFTS)
HALFSHAFTS)
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
* ANOTHER COMPONENT * CHECK THE HALFSHAFT AND THE AREA
CONTACTING THE AROUND THE HALFSHAFT. REPAIR AS
HALFSHAFT. NECESSARY.
* WHEEL BEARINGS, BRAKES, * INSPECT AND REPAIR AS
SUSPENSION OR STEERING NECESSARY.REFER TO:
COMPONENTS. FRONT WHEEL BEARING (204-01
FRONT SUSPENSION, REMOVAL
AND INSTALLATION),
BRAKE SYSTEM (206-00 BRAKE
SYSTEM - GENERAL INFORMATION,
DIAGNOSIS AND TESTING),
2/6
231/2430
10/30/2018 Print
SUSPENSION SYSTEM (204-00

SUSPENSION SYSTEM - GENERAL
INFORMATION, DIAGNOSIS AND
TESTING),
STEERING SYSTEM (211-00
STEERING SYSTEM - GENERAL
INFORMATION, DIAGNOSIS AND
TESTING).
DRIVELINE VIBRATION - * OUT OF BALANCE FRONT * BALANCE THE WHEELS AND TIRES AS
OCCURS AT CRUISING SPEEDS WHEELS OR TIRES. NECESSARY.
* OUT-OF-ROUND WHEELS * REPAIR OR INSTALL NEW WHEELS OR
OR TIRES. TIRES AS NECESSARY.
* INCORRECTLY SEATED CV * CHECK THE OUTER CV JOINT FOR
JOINT IN THE WHEEL HUB. CORRECT SEATING INTO THE HUB.
REPAIR AS NECESSARY.REFER TO:
(205-04 FRONT DRIVE HALFSHAFTS)
HALFSHAFTS)
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
REFER TO: FRONT WHEEL BEARING

(204-01 FRONT SUSPENSION,
SHUDDER VIBRATION DURING * DAMAGED OR WORN CV * INSPECT THE CV JOINTS FOR WEAR OR
ACCELERATION. JOINTS. DAMAGE. INSTALL A NEW HALFSHAFT
AS NECESSARY. REFER TO: (205-04
FRONT DRIVE HALFSHAFTS)
3/6
232/2430
10/30/2018 Print

HALFSHAFTS)
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
* HALFSHAFT CV JOINT * CHECK THE OUTER CV JOINT FOR
BINDING. CORRECT SEATING INTO THE HUB.
REPAIR AS NECESSARY. REFER TO:
(205-04 FRONT DRIVE HALFSHAFTS)
HALFSHAFTS)
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
4/6
233/2430
10/30/2018 Print

INSTALLATION),
INSTALLATION).
HALFSHAFTS)
* EXCESSIVELY HIGH CV * CHECK RIDE HEIGHT, VERIFY CORRECT
JOINT OPERATING ANGLES SPRING RATE AND CHECK ITEMS
CAUSED BY INCORRECT UNDER HALFSHAFT JOINT PULLOUT.
RIDE HEIGHT. REPAIR OR INSTALL NEW PARTS AS
NECESSARY.
DRIVELINE CLUNK — OCCURS * LOOSE HUB NUT. * CHECK THE TORQUE ON THE HUB NUT.
DURING ACCELERATION OR AS INSTALL A NEW HUB NUT IF THE
THE VEHICLE STARTS TO MOVE TORQUE IS NOT AT SPECIFICATION.
FORWARD FOLLOWING A STOP REFER TO: (205-04 FRONT DRIVE
HALFSHAFTS)
HALFSHAFTS)
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
INSTALLATION),
INSTALLATION).
HALFSHAFTS)
HALFSHAFT JOINT PULLOUT * INBOARD HALFSHAFT * INSPECT AND REPAIR OR INSTALL NEW
BEARING RETAINER PARTS AS NECESSARY.
CIRCLIP MISSING OR NOT
CORRECTLY SEATED IN
DIFFERENTIAL SIDE GEAR.
* ENGINE/TRANSAXLE * CHECK ENGINE MOUNTS FOR DAMAGE
ASSEMBLY MIS- OR WEAR. REPAIR OR INSTALL NEW
POSITIONED. PARTS AS NECESSARY.
* FRAME RAIL OR STRUT * CHECK UNDERBODY DIMENSIONS.
TOWER OUT OF POSITION
5/6
234/2430
10/30/2018 Print
OR DAMAGED.
* FRONT SUSPENSION * CHECK FOR WORN BUSHINGS OR BENT
COMPONENTS WORN OR COMPONENTS (FRONT STABILIZER
DAMAGED. BAR, FRONT SUSPENSION LOWER
ARM). REPAIR OR INSTALL NEW PARTS
AS NECESSARY.
6/6
235/2430
10/30/2018 Print
Front Drive Halfshafts - Boot Clamp Pliers

Print
General Procedures

204-169
Clamping Tool, Boot Retaining Clamp
Boot Clamp Pliers
Connect
1. If equipped with Omega Profile Clamps.
2. NOTE: Make sure that new components are installed.

NOTE: Make sure that the component is correctly installed.
1/3
236/2430
10/30/2018 Print

Torque: 21 Nm
4. Bosch Order Number: 222 1140 029 00
Use the General Equipment: Boot Clamp Pliers
5. If equipped with Low Profile Clamps.
2/3
237/2430
10/30/2018 Print
6. Bosch Order Number: 802 1140 088 00
Use the General Equipment: Boot Clamp Pliers
3/3
238/2430
10/30/2018 Print
Front Drive Halfshafts - Front Halfshaft RH—6-Speed Manual

Transmission - B6
Print

204-161
204-821
205-775
Protector, Halfshaft Seal
308-072-01
Adapter for 308-072

Puller
Removal
1.
3. Remove Engine Undershield - If equipped.
4.
1/11
239/2430
10/30/2018 Print
5. If equipped.
6.
2/11
240/2430
10/30/2018 Print
Vehicles with petrol engine

7. If equipped.
8. 1. If equipped.
All vehicles
9.
11.
3/11
241/2430
10/30/2018 Print
12. NOTICE: Make sure that the strut is not moved more than necessary to prevent damage
to top mount.
Use Special Service Tool: 308-072-01.
13. NOTICE:
Make sure that the strut is not moved more than necessary to prevent damage to top
mount.
The inner constant velocity (CV) joint must not be bent more than 18°.
The outer constant velocity (CV) joint must not be bent more than 45°.
4/11
242/2430
10/30/2018 Print
14. WARNING: Be prepared to collect escaping fluid.
NOTICE: Make sure that the strut is not moved more than necessary to prevent damage
to top mount.
to top mount.
1. 1. NOTICE: Take extra care not to damage the seal.
Installation
All vehicles
1. NOTICE:
5/11
243/2430
10/30/2018 Print
mount.
Take extra care not to damage the seal.

Remove the special tool before completely installing the halfshaft.
to top mount.
1. NOTE: Make sure that a new component is installed.
2. 2. NOTICE: Make sure that a new nut is installed.

Torque: 6 Nm

Torque: 6 Nm
4. Torque: 25 Nm
5. Torque: 25 Nm

3. 1. If equipped.
2. Torque:
Stage 1:7 Nm
Stage 2:Loosen: 360°
3. Torque: 24 Nm
6/11
244/2430
10/30/2018 Print
All vehicles
4.
to top mount.
7/11
245/2430
10/30/2018 Print

Torque: 45 Nm
8. NOTE: Make sure that the component is correctly installed.
8/11
246/2430
10/30/2018 Print
9.
10. NOTICE:
Make sure that a new bolt is installed.
Make sure that a new nut is installed.

Torque: 83 Nm
9/11
247/2430
10/30/2018 Print
11. Torque: 10 Nm
12. If equipped.
Torque: 8 Nm
13. Refer to: Transmission Fluid Level Check (308-03C Manual Transmission, General Procedures).
10/11
248/2430
10/30/2018 Print
15. Torque:
Stage 1:80 Nm
Stage 2:90°
11/11
249/2430
10/30/2018 Print
Front Drive Halfshafts - Front Halfshaft LH—6-Speed Manual

Transmission - B6
Print

204-161
204-821
205-071-01
205-775

Puller
Tire Lever
Removal
1.
4.
1/11
250/2430
10/30/2018 Print
5. If equipped.
6.
2/11
251/2430
10/30/2018 Print
7.
9.
to top mount.
11. NOTICE:
mount.
3/11
252/2430
10/30/2018 Print
to top mount.
NOTE: Be prepared to collect escaping fluid.
1. Use the General Equipment: Tire Lever
13. NOTICE:
mount.

4/11
253/2430
10/30/2018 Print
14.
Installation
1. NOTICE: Make sure a new component is installed.
2. NOTICE:
mount.

5/11
254/2430
10/30/2018 Print
2.
3. NOTICE:
mount.

Remove Special Service Tool: 205-775.
4.
6/11
255/2430
10/30/2018 Print
5. NOTICE:
mount.

Torque: 45 Nm
7/11
256/2430
10/30/2018 Print
8/11
257/2430
10/30/2018 Print
9.
10. NOTICE:
Make sure that a new bolt is installed.
Make sure that a new nut is installed.
Torque: 83 Nm
11. Torque: 10 Nm
9/11
258/2430
10/30/2018 Print
12. If equipped.
Torque: 8 Nm
15. Torque:
Stage 1:80 Nm
Stage 2:90°
10/11
259/2430
10/30/2018 Print
11/11
260/2430
10/30/2018 Print
Front Drive Halfshafts - Intermediate Shaft—1.6L Duratorq-TDCi

(85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3), 6-Speed Manual
Transmission - B6
Print
Special Tool(s)
204-169
Removal
1. Refer to: Front Halfshaft RH - 6-Speed Manual Transmission - B6 (205-04 Front Drive Halfshafts,
2.
3.
1/5
261/2430
10/30/2018 Print
Installation
1. Refer to: Specifications (205-04 Front Drive Halfshafts, Specifications).
2/5
262/2430
10/30/2018 Print
2. 1. Release any trapped air.

2.
3.
4.
3/5
263/2430
10/30/2018 Print

Torque: 21 Nm
4/5
264/2430
10/30/2018 Print
5/5
265/2430
10/30/2018 Print
Front Drive Halfshafts - Intermediate Shaft Bearing—6-Speed Manual

Transmission - B6
Print

205-080
205-310
Remover, Bearing/Gear
303-255
Installer, Timing Cover Seal
Hydraulic Press
Removal
1. Refer to: Intermediate Shaft - 1.6L EcoBoost (110kW/150PS) - Sigma/1.6L EcoBoost

(132kW/180PS) - Sigma, 6-Speed Manual Transmission - B6 (205-04 Front Drive Halfshafts,
2.
Installation
1.
Use Special Service Tools: 205-080, 303-255.
1/2
266/2430
10/30/2018 Print
2. Refer to: Intermediate Shaft - 1.6L EcoBoost (110kW/150PS) - Sigma/1.6L EcoBoost

(132kW/180PS) - Sigma, 6-Speed Manual Transmission - B6 (205-04 Front Drive Halfshafts,
2/2
267/2430
10/30/2018 Print
Front Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot—5-Speed

Manual Transmission - MTX75/6-Speed Manual Transmission - B6/6-
Speed Manual Transmission - MMT6/6-Speed PowerShift Transmission -
DPS6/6DCT250/6-Speed PowerShift Transmission - MPS6/6DCT450
Print

204-169
204-325
Installer, Water Seal
Flat Headed Screw Driver

Puller
Materials
Name Specification
Grease -
Removal
1. Refer to: Front Halfshaft RH - 6-Speed PowerShift Transmission - MPS6/6DCT450 (205-04 Front
Drive Halfshafts, Removal and Installation).
Refer to: Front Halfshaft LH - 6-Speed PowerShift Transmission - MPS6/6DCT450 (205-04 Front
Refer to: Front Halfshaft RH - 6-Speed PowerShift Transmission - DPS6/6DCT250 (205-04 Front
Refer to: Front Halfshaft LH - 6-Speed PowerShift Transmission - DPS6/6DCT250 (205-04 Front
Refer to: Front Halfshaft RH - 5-Speed Manual Transmission - MTX75 (205-04 Front Drive
Halfshafts, Removal and Installation).
Refer to: Front Halfshaft LH - 5-Speed Manual Transmission - MTX75 (205-04 Front Drive
Refer to: Front Halfshaft RH - 6-Speed PowerShift Transmission - MPS6/6DCT450 (205-04 Front
Refer to: Front Halfshaft LH - 6-Speed Manual Transmission - MMT6 (205-04 Front Drive
Refer to: Front Halfshaft RH - 6-Speed Manual Transmission - B6 (205-04 Front Drive Halfshafts,
Refer to: Front Halfshaft LH - 6-Speed Manual Transmission - B6 (205-04 Front Drive Halfshafts,
2.
1/11
268/2430
10/30/2018 Print
3. 1. Dismountable constant velocity joint bearing.

2. Not dismountable constant velocity joint bearing.
4. Dismountable constant velocity joint bearing.
2/11
269/2430
10/30/2018 Print
3/11
270/2430
10/30/2018 Print
7. NOTICE: Take extra care not to damage the bearing.

Not dismountable constant velocity joint bearing.
8.
4/11
271/2430
10/30/2018 Print
Installation
1.
5/11
272/2430
10/30/2018 Print
2. 1. NOTE: Make sure that a new component is installed.

3.
6/11
273/2430
10/30/2018 Print

Dismountable constant velocity joint bearing.

7/11
274/2430
10/30/2018 Print

Torque: 21 Nm
8/11
275/2430
10/30/2018 Print

Material: - (Grease)
8.
1. Release any trapped air.
Use the General Equipment: Flat Headed Screw Driver

9/11
276/2430
10/30/2018 Print
2.
3.
4. Use the General Equipment: Flat Headed Screw Driver
9. Refer to: Boot Clamp Pliers (205-04 Front Drive Halfshafts, General Procedures).
10. Refer to: Front Halfshaft RH - 6-Speed PowerShift Transmission - MPS6/6DCT450 (205-04 Front
Refer to: Front Halfshaft LH - 6-Speed PowerShift Transmission - MPS6/6DCT450 (205-04 Front
Refer to: Front Halfshaft RH - 6-Speed PowerShift Transmission - DPS6/6DCT250 (205-04 Front
Refer to: Front Halfshaft LH - 6-Speed PowerShift Transmission - DPS6/6DCT250 (205-04 Front
Refer to: Front Halfshaft RH - 5-Speed Manual Transmission - MTX75 (205-04 Front Drive
Refer to: Front Halfshaft LH - 5-Speed Manual Transmission - MTX75 (205-04 Front Drive
10/11
277/2430
10/30/2018 Print
Refer to: Front Halfshaft RH - 6-Speed PowerShift Transmission - MPS6/6DCT450 (205-04 Front
Refer to: Front Halfshaft LH - 6-Speed Manual Transmission - MMT6 (205-04 Front Drive
Refer to: Front Halfshaft RH - 6-Speed Manual Transmission - B6 (205-04 Front Drive Halfshafts,
11/11
278/2430
10/30/2018 Print
Front Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot—5-Speed

Manual Transmission - MTX75/6-Speed Manual Transmission - B6/6-
Speed Manual Transmission - MMT6/6-Speed PowerShift Transmission -
DPS6/6DCT250/6-Speed PowerShift Transmission - MPS6/6DCT450
Print

204-169
Removal
1. Refer to: Inner Constant Velocity (CV) Joint Boot - 5-Speed Manual Transmission - MTX75/6-Speed
Manual Transmission - B6/6-Speed Manual Transmission - MMT6/6-Speed PowerShift Transmission
- DPS6/6DCT250/6-Speed PowerShift Transmission - MPS6/6DCT450 (205-04 Front Drive
2.
Installation
1/5
279/2430
10/30/2018 Print
2/5
280/2430
10/30/2018 Print
3/5
281/2430
10/30/2018 Print
4.

Torque: 21 Nm
4/5
282/2430
10/30/2018 Print
6. Refer to: Inner Constant Velocity (CV) Joint Boot - 5-Speed Manual Transmission - MTX75/6-Speed
Manual Transmission - B6/6-Speed Manual Transmission - MMT6/6-Speed PowerShift Transmission
- DPS6/6DCT250/6-Speed PowerShift Transmission - MPS6/6DCT450 (205-04 Front Drive
5/5
283/2430
10/30/2018 Print
Front Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot—1.6L

Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3), 6-
Speed Manual Transmission - B6
Print

204-169
204-325
Installer, Water Seal

Puller
Removal
2.
3. 1. Dismountable constant velocity joint bearing.

1/9
284/2430
10/30/2018 Print
2/9
285/2430
10/30/2018 Print

3/9
286/2430
10/30/2018 Print
8.
Installation
1.
4/9
287/2430
10/30/2018 Print

3.
5/9
288/2430
10/30/2018 Print

Dismountable constant velocity joint bearing.

6/9
289/2430
10/30/2018 Print

Torque: 21 Nm
7/9
290/2430
10/30/2018 Print
8.

2.
8/9
291/2430
10/30/2018 Print
3.
9. Refer to: Boot Clamp Pliers (205-04 Front Drive Halfshafts, General Procedures).
9/9
292/2430
10/30/2018 Print
Brake System - General Information -

Specifications
Print
SPECIFICATION
DOT 4 LV brake fluid WSS-M6C65-A2
FRONT BRAKE DISC SPECIFICATION
MM
Brake disc diameter 278/300/320
New brake disc nominal thickness 25
Worn brake disc discard thickness * 23
Maximum brake disc thickness variation 0.025
Worn brake pad discard thickness** 1.5
Maximum brake disc runout (installed) 0.07
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
REAR DISC BRAKE SPECIFICATION
DESCRIPTION MM
Brake disc diameter 271
New brake disc nominal thickness 11
Worn brake disc discard thickness * 9
Maximum brake disc thickness variation 0.025
Worn brake pad discard thickness ** 1.5
Maximum brake disc runout (installed) 0.1
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
DRUM BRAKE SPECIFICATION
DESCRIPTION MM
1/2
293/2430
10/30/2018 Print
DESCRIPTION MM
Worn brake drum discard diameter* 230,20
Worn brake shoe lining discard thickness** 1
* When the discard diameter/thickness has been reached, install a new brake drum/brake
shoes.
** When the discard diameter/thickness has been reached, install a new brake
drum/brake shoes.
2/2
294/2430
10/30/2018 Print
Brake System - General Information - Brake System - Component

Location
Print
Item Description
1 Brake master cylinder
2 Brake Fluid Reservoir
3 Brake Booster.
4 Parking brake cable
5 Parking brake handle
6 ABS (anti-lock brake system) (MK-70)/Stability Assist (MK-60) module
7 Front brake disk (internally ventilated)
8 Brake drum (version and/or market-dependent)
9 Rear brake disk with caliper (version and/or market-dependent)
10 Brake calliper
1/1
295/2430
10/30/2018 Print
Brake System - General Information - Brake

System - Overview
Print
Front brake
Three different sizes of internally ventilated brake disks are used, depending on vehicle version:
Diameter = 278 mm
Diameter = 300 mm
Diameter = 320 mm
Thickness = 25 mm
Rear brakes
Depending on the version and the market in question, either drum brakes or disk brakes may be
installed.
4 and 5-door models:

Drum brakes may be installed on these versions but only in conjunction with the 1.6L Duratec
Ti-VCT (Sigma) engine and the 1.6L Duratorq TDCi (DV) diesel engine. Depending on the
market, however, disk brakes may also be fitted.
Versions with the 1.6L EcoBoost-SCTi, 2.0L EcoBoost-SCTi and 2.0L Duratorq-TDCi (DW)
diesel are equipped with disk brakes.
Wagon:
Disk brakes are always fitted to this version.
Only one size of disk brake can be fitted to the rear:

Diameter = 271 mm
Thickness = 11 mm
1/1
296/2430
10/30/2018 Print
Brake System - General Information - Brake

System
Print
General Equipment
Pressure/vacuum gauge set
The brake system operates by transferring effort applied to the brake pedal by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel, using a hydraulic system. The system is assisted using
a vacuum brake booster that reduces pedal effort and increases hydraulic pressure.
The parking brake operates on the rear wheels and is applied using a hand operated control.
NOTE: Before carrying out any diagnosis, make sure that the brake system warning indicator is
functional.
Mechanical Electrical
Tire pressure(s) Electrical connector(s)
Wheels and tires Wiring harness(s)
Fluid leak(s) Switch(es)
3. If an obvious cause for an observed or reported concern is found, correct the case (if possible)
4. If the cause if not visually evident, verify the symptom and refer to the Symptom Chart.
Road Test
Carry out a road test to compare actual vehicle braking performance with the performance standards
expected by the driver. The ability of the test driver to make valid comparisons and detect
performance deficiencies will depend on experience.
The driver should have a thorough knowledge of the brake system operation and accepted general
performance guidelines to make good comparisons and detect performance concerns.
An experienced technician will always establish a route that will be used for all brake diagnosis road
tests. The road selected will be reasonably smooth and level. Gravel or bumpy roads are not suitable
because the surface does not allow the tires to grip the road equally. Crowned roads should be
avoided because of the large amount of weight shifted to the low set of wheels on this type of road.
Once the route is established and consistently used, the road surface variable can be eliminated from
the test results.
Before a road test, get a complete description of the customer concerns or suspected condition. From
the description, the technician will be able to match possible causes with symptoms. Certain
components will be identified as possible sources while others will be eliminated by the evidence.
More importantly, the customer description can reveal unsafe conditions which should be checked or
corrected before a road test. The description will also help form the basic approach to the road test by
narrowing the concern to specific components, vehicle speed or conditions.
Begin the road test with a general brake performance check. Using the description of the concern,
test the brakes at different vehicle speeds using both light and heavy pedal pressure. Determine if the
concern is in the front or rear braking system. First use the foot brake and then the parking brake. If
the condition (i.e. pull, vibration, pulsation) occurs only on operation of the parking brake, the
concern is in the rear brake system. If the condition occurs when the foot brake is depressed, the
concern is in the front brake system.
1/5
297/2430
10/30/2018 Print
Avoid locking the brakes and sliding the tires. This condition will not indicate brake efficiency. A
heavily braked but turning wheel will stop the vehicle in a shorter distance than locked wheels.
If the concern becomes evident during this check, make sure it fits the description given before the
road test. If the concern is not evident, attempt to duplicate the condition using the information from
the description.
If a concern exists, use the Brake System Symptom Chart in order to isolate it to a specific sub-
system and condition description. From this description, a list of possible sources can be used to
further narrow the cause to a specific component or condition.
Symptom Chart
The following table provides all the possible symptoms and sources related to the Brake System. For
the actual diagnosis, proceed to use the Ford diagnostic equipment.
Symptoms Possible Sources

Brakes pull or drift Worn or damaged brake shoes or brake pads and linings
Abnormal wear or distortion of front brake disc(s)
Incorrect rear brake adjustment
Incorrect wheel alignment adjustment
Incorrect wheel bearing preload adjustment
Grease or fluid on the brake shoes or brake pads; glazed linings
Stuck or seized wheel cylinders or brake calipers
The red brake Low brake fluid level
warning indicator is Leaking brake master cylinder primary piston cup
always on Parking brake control not fully released
Malfunctioning anti-lock braking system (ABS)
Shorted indicator circuit
Vibration when the Grease or fluid on the brake shoes or brake pads; glazed linings
brakes are applied Worn or damaged brake shoes or brake pads
Loose caliper mounting bolt(s)
Damaged brake drum contact surface
Excessive brake disc thickness variation or brake disc runout
Wheels and tires
Loose or missing wheel hub bolts
Worn or damaged brake drums or brake discs
Pedal goes down fast Low brake fluid level
Leak in the hydraulic system
Air in the system
Brake disc “brake knock back” (Brake pads push the brake caliper piston back into
the brake caliper. Caused by excessive brake disc lateral runout or loose wheel
bearings.)
Worn brake shoes or brake pads
Worn brake master cylinder piston cups or scored cylinder bore
Hydraulic control unit (HCU)
Pedal eases down Air in the system
slowly Malfunctioning brake master cylinder
Low engine vacuum (stationary)
Pedal is low or feels Worn brake shoes or brake pads
spongy Air in the system
Brake master cylinder
Brake lockup during Glazed or worn brake shoes or brake pads
light brake pedal Hydraulic control unit (HCU)
force Brake booster
Low engine vacuum
Excessive or erratic Worn brake shoes or brake pads
pedal travel Hydraulic control unit (HCU)
Wheel bearings
Brake drag Incorrectly adjusted parking brake
Brake booster
2/5
298/2430
10/30/2018 Print
Seized wheel cylinder or brake caliper

Seized brake caliper slide pins
Seized parking brake cables
Stoplamp switch
Brake master cylinder
Hydraulic control unit (HCU)
Excessive brake Worn or contaminated brake shoes or brake pads
pedal effort Malfunctioning vacuum pump (diesel)
Disconnected or damaged brake booster vacuum pipe
Brake booster
Brake noise Worn or damaged brake shoes or brake pads
Worn or damaged brake drums or brake discs
Brake booster
Slow or incomplete Brake booster
brake pedal return Seized brake pedal pivot
Component Tests
Hydraulic Leak Check
NOTE: There is a common clutch and brake fluid reservoir, therefore it is possible that a clutch leak
can lead to reduction in the reservoir level.
It is possible that all evidence of fluid leakage may have washed off if the vehicle has been operated
in rain or snow, as brake fluid is water-soluble. Refill the system, bleed then apply the brakes several
times. Examine the system to verify that the reservoir fluid level is actually dropping. Locate and
repair the external leak. If the fluid level drops and no external leak can be found, check for a brake
master cylinder bore end seal leak.
Brake System Check
Brake Pedal Reserve Check
Where a low brake pedal or the feel of a bottomed-out condition exists, check for brake pedal
reserve.
1. Operate the engine at idle with the transaxle in the NEUTRAL position.
2. Apply the brake pedal lightly three or four times.
3. Allow 15 seconds for the vacuum to replenish the brake booster.
NOTE: This increased resistance may feel like something has bottomed out.
4. Apply the brake pedal until it stops moving downward or an increased resistance to the pedal
travel occurs.
5. Hold the brake pedal in the applied position and raise the engine speed to approximately 2000
rpm.
NOTE: The additional movement of the brake pedal is the result of the increased engine manifold
vacuum which exerts more force on the brake booster during engine rundown. This means that
additional stroke is available in the brake master cylinder and the brake system is not bottoming
out.
6. Release the accelerator pedal and observe that the brake pedal moves downward as the engine
returns to idle speed.
Brake Booster Functional Test

Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and their
connections should be correctly secured and in good condition with no holes and no collapsed areas.
Inspect the check valve on the brake booster for damage.
Brake Booster Operation Check
1. Check the hydraulic brake system for leaks or low fluid.
3/5
299/2430
10/30/2018 Print
2. With the transaxle in the NEUTRAL position, stop the engine and apply the parking brake. Apply
the brake pedal several times to exhaust all the vacuum in the system.
3. With the engine turned off and the vacuum in the system exhausted, apply the brake pedal and
hold it down. Start the engine. If the vacuum system is operating, the brake pedal will tend to
move downward under constant foot pressure. If no motion is felt, the vacuum booster
system is not functioning.
4. Remove the vacuum hose from the brake booster. Manifold vacuum should be available at the
brake booster end of the hose with the engine at idle speed and the transaxle in the NEUTRAL
position. Make sure that all unused vacuum outlets are correctly capped, hose connectors are
correctly secured and vacuum hoses are in good condition. When it is established that
manifold vacuum is available to the brake booster, connect the vacuum hose to the brake
booster and repeat Step 3. If no downward movement of the brake pedal is felt, install a new
brake booster.
REFER to: Brake Booster - LHD FWD (206-07 Power Brake Actuation, Removal and
Installation).
5. Operate the the engine a minimum of 10 seconds at approximately 1200 rpm. Stop the engine
and let the vehicle stand for 10 minutes. Then, apply the brake pedal with approximately 89 N
(20 lb) force. The pedal feel (brake application) should be the same as that noted with the
engine operating. If the brake pedal feels hard (no power assist), install a new vacuum check
valve and then repeat the test. If the brake pedal still feels hard, install a new brake booster.
REFER to: Brake Booster - LHD FWD (206-07 Power Brake Actuation, Removal and
Installation).
If the brake pedal movement feels spongy, bleed the brake system. REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures).
Brake Master Cylinder
Usually, the first and strongest indicator of anything wrong with the braking system is a feeling
through the brake pedal. In diagnosing the condition of the brake master cylinder, check pedal feel as
evidence of a brake concern. Check for the red brake warning indicator illumination and the fluid level
in the master cylinder reservoir.
Normal Conditions
The following conditions are considered normal and are not indications that the brake master cylinder
is in need of service.
Modern brake systems are not designed to produce as hard a pedal effort as in the past. Complaints
of light pedal efforts should be compared to pedal efforts of another vehicle, of the same model and
year.
During normal operation of the brake pedal, the fluid level in the reservoir will rise during brake
pedal application and fall during release. The net fluid level (i.e., after brake pedal application and
release) will remain unchanged.
A trace of brake fluid will exists on the brake booster shell below the master cylinder mounting
flange. This results from the normal lubricating action of the master cylinder bore end seal.
The fluid level will fall with brake shoe and lining wear.
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make sure the brake system warning indicator is
functional.
Changes in brake pedal feel or travel are indicators that something could be wrong with the braking
system. The diagnostic procedure and techniques use brake pedal feel, warning indicator illumination
and low brake fluid level as indicators in diagnosing braking system concerns. The following conditions
are considered abnormal and indicate that the brake master cylinder is in need of service.
The brake pedal goes down fast. This could be caused by an external or internal leak.
The brake pedal eases down slowly. This could be caused by an external or internal leak.
The brake pedal is low and or feels spongy. This condition may be caused by no fluid in the brake
master cylinder reservoir, reservoir cap vent holes clogged or air in the hydraulic system.
The brake pedal effort is excessive. This may be caused by a bind or obstruction in the pedal or
linkage, clogged fluid control valve or insufficient booster vacuum.
4/5
300/2430
10/30/2018 Print
The rear brakes lock up during light pedal force. This may be caused by incorrect tire pressures,
grease or fluid on the brake shoes and linings, damaged brake shoes and linings, incorrectly
adjusted parking brake, or damaged or contaminated brake pressure control valves.
The brake pedal effort is erratic. This condition could be caused by a brake booster malfunction,
extreme caliper piston knock back or incorrectly installed brake shoes and linings.
The red brake warning indicator is ON. This may be caused by low fluid level, ignition wire routing
too close to the fluid level indicator assembly, or float assembly damage.
Brake Master Cylinder - Compensator Port Test
1. Inspect the master cylinder.
2. Raise and support the vehicle.

3. Apply and release the brakes.
4. With the brakes released, attempt to rotate each wheel and check for any brake drag.
If an excessive amount of brake drag exists at multiple wheels, continue to the next step.
If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized brake
caliper, brake wheel cylinder or parking brake component. Repair or install new components as
necessary.
5. Check the brake stoplamp switch and the brake pedal free play to verify the brake pedal is not
partially applied.
6. Loosen the brake master cylinder nuts and position the brake master cylinder away from the
brake booster.
7. With the brakes released, attempt to rotate each wheel and check for any brake drag.
If the brake drag is no longer present, install a new brake booster.

REFER to: Brake Booster - LHD FWD (206-07 Power Brake Actuation, Removal and Installation).
If the brake drag is still present, install a new master cylinder.
REFER to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation, Removal and Installation).
Brake Master Cylinder - Bypass Condition Test
1. Check the fluid in the brake master cylinder reservoir. Fill the brake master cylinder reservoir if
low or empty.
2. Observe the fluid level in the brake master cylinder reservoir. If after several brake applications,
the fluid level remains the same, measure the wheel turning torque required to rotate the
wheels with the brakes applied as follows:
Place the transaxle in the NEUTRAL position. Raise and support the vehicle.
Apply the brakes with a minimum of 445 N (100 lb) and hold for approximately 15 seconds. With the
brakes still applied, exert a torque on the front wheels of 10.1 Nm (75 lb ft). If either wheel rotates,
install a new brake master cylinder.
REFER to: Brake Booster - LHD FWD (206-07 Power Brake Actuation, Removal and Installation).
Non-Pressure Leaks
Any empty brake master cylinder reservoir condition may be caused by two types of non-pressure
external leaks.
Type 1: An external leak may occur at the brake master cylinder reservoir cap because of incorrect
positioning of the gasket and cap. Reposition the cap and gasket.
Type 2: An external leak may occur at the brake master cylinder reservoir mounting seals. Service
such a leak by installing new seals.
5/5
301/2430
10/30/2018 Print
Brake System - General Information - Brake Disc Runout Check

Print
General Procedures
Special Tool(s)
205-069
Dial Indicator Gauge (Metric)
205-070
Holding Fixture, Dial Indicator Gauge
206-003
Holding Fixture, Dial Indicator Gauge (Disc Brake)

1. Refer to: Wheels and Tires (204-04A Wheels and Tires, Description and Operation).
2. Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
2.
1. Position the dial indicator gauge so that it contacts the brake disc face approximately 10 mm
from the outer edge (inner face measurement shown).
Use Special Service Tools: 205-069, 205-070, 206-003.

2. Slowly rotate the brake disc and note the readings.
3. Repeat sub-steps 1 and 2 on the brake disc outer face.
4. If any of the measurements exceed the brake disc runout specification, a new brake disc
must be installed and the brake disc runout re-checked.
Refer to: Specifications (206-00, Specifications).
3.
1/2
302/2430
10/30/2018 Print
1. Measure the brake disc thickness at eight positions, 45 degrees apart and approximately 15
mm from the outer edge of the brake disc.
2. If any of the measurements exceed the brake disc thickness variation specification, a new
brake disc must be installed and the brake disc runout re-checked.
4. If all the brake disc runout measurements and the thickness variation are within the specifications,
check the wheel balance.
2/2
303/2430
10/30/2018 Print
Brake System - General Information - Brake System Bleeding

Print
General Procedures
General Equipment
Fluid Container
1. Refer to: Brake and Clutch Systems Health and Safety Precautions (100-00 General Information,
Vehicles with stability assist

2. Bleed the brake system using the BleedMASTER function in the diagnostic tool.
Vehicles without stability assist

3.
4. NOTICE: The brake fluid reservoir must remain full with new, clean brake fluid at all
times during bleeding.
1/5
304/2430
10/30/2018 Print
5.
6. NOTICE: Make sure that the pressure within the brake system does not exceed 1 bar.
Use the General Equipment: Fluid Container
2/5
305/2430
10/30/2018 Print
7. Loosen: 180°
8. Operate the brake pedal fully (pumping brake fluid and air into the bleed jar) and allow the brake
pedal to return to the rest position.
9. Continue operating the brake pedal until air-free fluid is being pumped into the bleed jar.
10. Refer to: Specifications (206-00, Specifications).
3/5
306/2430
10/30/2018 Print
11. With the brake pedal fully depressed tighten the bleed nipple.
Torque: 9 Nm
12.
4/5
307/2430
10/30/2018 Print
13. Repeat the procedure for the remaining brake lines.
14.
5/5
308/2430
10/30/2018 Print
Brake System - General Information - Brake System Draining and Filling

Print
General Procedures
General Equipment
Fluid Container
Draining
2.
4. On both sides.
1/4
309/2430
10/30/2018 Print
5. On both sides.
6. On both sides.
Loosen: 180°
2/4
310/2430
10/30/2018 Print
7.
8. On both sides.
Torque: 9 Nm
3/4
311/2430
10/30/2018 Print
Filling
1. Refer to: Brake System Bleeding (206-00 Brake System - General Information, General
Procedures).
Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General
Procedures).
Refer to: Component Bleeding (206-00 Brake System - General Information, General Procedures).
4/4
312/2430
10/30/2018 Print
Brake System - General Information - Brake System Pressure Bleeding

Print
General Procedures
General Equipment
Ford approved diagnostic tool
Brake/Clutch System Pressure Bleeder/Filler
2. Bleed the brake system using the BleedMASTER function in the diagnostic tool.
Use the General Equipment: Ford approved diagnostic tool

3.
1/3
313/2430
10/30/2018 Print
4. Refer to: Specifications (206-00 Brake System - General Information, Specifications).
5. NOTICE: Make sure that the pressure within the brake system does not exceed 1 bar.
Using the brake/clutch system pressure bleeder/filler, pressure bleed the system in accordance
with the manufacturer's instructions.
Use the General Equipment: Brake/Clutch System Pressure Bleeder/Filler
6.
2/3
314/2430
10/30/2018 Print
8.
3/3
315/2430
10/30/2018 Print
Brake System - General Information - Component Bleeding

Print
General Procedures
General Equipment
Fluid Container
Bleeding

2. Bleed the brake system using the BleedMASTER function in the diagnostic tool

3.
4. NOTICE: The brake fluid reservoir must remain full with new, clean brake fluid at all
times during bleeding.
Refer to: Specifications (206-00 Brake System - General Information, Specifications).
1/5
316/2430
10/30/2018 Print
5.
6. Use the General Equipment: Fluid Container
2/5
317/2430
10/30/2018 Print
7. Loosen: 180°
8. Operate the brake pedal fully (pumping brake fluid and air into the bleed jar) and allow the brake
pedal to return to the rest position.
9. Continue operating the brake pedal until air-free fluid is being pumped into the bleed jar.
3/5
318/2430
10/30/2018 Print
11. With the brake pedal fully depressed tighten the bleed nipple.
Torque: 9 Nm
12.
4/5
319/2430
10/30/2018 Print
13.
5/5
320/2430
10/30/2018 Print
Drum Brake - Drum Brake

Print
REFER to Section 206-00 Brake System - General Information.
1/1
321/2430
10/30/2018 Print
Drum Brake - Brake Backing Plate

Print
Removal
1. Refer to: Brake Shoes (206-02 Drum Brake, Removal and Installation).
2.
3. NOTE: Use suitable paper to absorb any escaping fluid.

Torque:
1 15 Nm
2 12 Nm

NOTE: Make sure that the component is clean and free of foreign material.
Torque:
1 23 Nm
2 12 Nm
1/3
322/2430
10/30/2018 Print
5.
6.
7.
2/3
323/2430
10/30/2018 Print
Installation
1. NOTE: Make sure that the component is clean and free of foreign material.
2. Torque: 110 Nm
4. Refer to: Component Bleeding (206-00 Brake System - General Information, General Procedures).
3/3
324/2430
10/30/2018 Print
Drum Brake - Brake Drum

Print

206-D002
Gauge, Brake Adjustment
501-125
Remover, Grab Handle Cover
Cable Ties
Removal
Vehicles with center armrest
3.
1/8
325/2430
10/30/2018 Print
Vehicles without center armrest

4.
5.
All vehicles
2/8
326/2430
10/30/2018 Print
7. On both sides.
Installation
1. On both sides.
Use Special Service Tool: 206-D002.
2. On both sides.

3/8
327/2430
10/30/2018 Print
3. Use the General Equipment: Cable Ties
4.
4/8
328/2430
10/30/2018 Print
5. Adjust the parking brake cable adjustment nut until the allen key falls out.
6.
7. On both sides.
5/8
329/2430
10/30/2018 Print
8. On both sides.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
10. Torque: 2 Nm
6/8
330/2430
10/30/2018 Print
11. Torque: 2 Nm
12.
All vehicles
7/8
331/2430
10/30/2018 Print
13. Start the engine.
14.
8/8
332/2430
10/30/2018 Print
Drum Brake - Brake Shoes

Print
Materials
Name Specification
Multi-Purpose Grease WSS-M12A4-A2
Removal
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
4.
5.
6.
1/3
333/2430
10/30/2018 Print
7.
8.
9.
10.
Installation
2/3
334/2430
10/30/2018 Print
1. Material: WSS-M12A4-A2 (Multi-Purpose Grease)
3/3
335/2430
10/30/2018 Print
Drum Brake - Wheel Cylinder

Print
Removal

Torque:
1 15 Nm
2 12 Nm

Torque:
1 23 Nm
2 12 Nm
1/2
336/2430
10/30/2018 Print
Installation
2/2
337/2430
10/30/2018 Print
Front Disc Brake - Front Disc Brake

Print
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
1/1
338/2430
10/30/2018 Print
Front Disc Brake - Brake Pads

Print
Special Tool(s)
206-005
Retractor, Brake Caliper Piston
Materials
Name Specification
Brake Fluid WSS-M6C65-A2
Removal
3.

NOTE: The brake caliper housing Torx bolts must not be removed.
Torque: 28 Nm
1/4
339/2430
10/30/2018 Print
5.
6.
2/4
340/2430
10/30/2018 Print
Installation
3/4
341/2430
10/30/2018 Print
4. Depress the brake pedal, check the brake fluid level in the brake fluid reservoir and top up as
necessary with brake fluid.
Material: WSS-M6C65-A2 (Brake Fluid)
4/4
342/2430
10/30/2018 Print
Front Disc Brake - Brake Caliper

Print
Materials
Name Specification
Removal
3. NOTICE: Make sure that all openings are sealed.

NOTE: Note the position of the component before removal.
4.
1/4
343/2430
10/30/2018 Print
5. Torque: 28 Nm
6.
7.
2/4
344/2430
10/30/2018 Print
Installation
3/4
345/2430
10/30/2018 Print
4.
1. 1. NOTICE: Make sure that the brake hose is not twisted and is correctly located.
Torque: 18 Nm
4/4
346/2430
10/30/2018 Print
Front Disc Brake - Front Brake Flexible Hose

Print
Removal
Installation
2. NOTICE: Make sure that the brake hose is not twisted and is correctly located.
1. Torque: 10 Nm
2. Torque: 15 Nm
3. Torque: 18 Nm
4.
1/2
347/2430
10/30/2018 Print
2/2
348/2430
10/30/2018 Print
Front Disc Brake - Brake Disc

Print
Removal
NOTE: 278 mm brakes shown, 320 mm brakes similar.
1. Remove the wheel and tire.
2. NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the
brake hose or damage to the hose can occur.
NOTE: Make sure that new bolts are installed.
Torque: 175 Nm
3.
1/2
349/2430
10/30/2018 Print
Installation
2/2
350/2430
10/30/2018 Print
Rear Disc Brake - Rear Disc Brake

Print
1/1
351/2430
10/30/2018 Print
Rear Disc Brake - Brake Pads

Print
Special Tool(s)
206-012
Retractor, Rear Brake Caliper Piston
Materials
Name Specification
Removal
2.

Torque: 35 Nm
1/3
352/2430
10/30/2018 Print

NOTE: Make sure that the mating faces are clean and free of foreign material.
2/3
353/2430
10/30/2018 Print
Installation
3. Depress the brake pedal, check the brake fluid level in the brake fluid reservoir and top up as
3/3
354/2430
10/30/2018 Print
Rear Disc Brake - Brake Caliper

Print
Materials
Name Specification
Removal
3. 1.
2. Loosen: 90°
4.
1/3
355/2430
10/30/2018 Print

Torque: 35 Nm
6. Torque: 28 Nm
2/3
356/2430
10/30/2018 Print
Installation
4. NOTICE: Make sure that the mating faces are clean and free of foreign material.
Depress the brake pedal, check the brake fluid level in the brake fluid reservoir and top up as
3/3
357/2430
10/30/2018 Print
Rear Disc Brake - Rear Brake Flexible Hose

Print
Removal
1. Remove the wheel and tire.

2. Torque: 15 Nm
3.
1. Torque: 10 Nm
2. Torque: 28 Nm
Installation
1. NOTICE: Make sure that the brake hose is not twisted and is correctly located.
To install, reverse the removal procedure.
2. Bleed the brake caliper.
Refer to: Component Bleeding (206-00 Brake System - General Information, General Procedures).
1/1
358/2430
10/30/2018 Print
Parking Brake and Actuation - Parking Brake - Overview

Print
General overview
Item Description
2 Parking brake control on vehicles equipped with center armrest
Item Description
2 Parking brake control on vehicles not equipped with center armrest
The following components may be renewed separately:

Parking brake cable
Parking brake handle
1/2
359/2430
10/30/2018 Print
Parking brake cable
The following instructions must be followed when removing, installing or renewing the parking
brake cable:
If the parking brake lever is removed, installed or renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment - Vehicles With: Rear Disc Brakes (206-05 Parking Brake
and Actuation, General Procedures).
Refer to: Parking Brake Cable Adjustment - Vehicles With: Rear Drum Brakes (206-05 Parking Brake
For further information, see: Adjusting the parking brake cable (206-05 Brake system, General
service work).
Parking brake handle
The following instructions must be followed when removing, installing or renewing the parking
brake lever:
If the parking brake lever is removed, installed or renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment - Vehicles With: Rear Disc Brakes (206-05 Parking Brake
Refer to: Parking Brake Cable Adjustment - Vehicles With: Rear Drum Brakes (206-05 Parking Brake
For further information, see: Adjusting the parking brake cable (206-05 Brake system, General
service work).
2/2
360/2430
10/30/2018 Print
Parking Brake and Actuation - Parking Brake

Print
1. Verify the customer concern by operating the parking brake system.
Parking brake control Parking brake warning circuit.
REFER to: Parking Brake Control (206-05 REFER to: Instrument Panel Cluster (IPC)
Parking Brake and Actuation, Removal and (413-01A Instrument Panel Cluster (IPC),
Installation). Diagnosis and Testing).
Cable and conduit
REFER to: Parking Brake Cable - Vehicles
With: Rear Disc Brakes (206-05 Parking Brake
and Actuation, Removal and Installation).
Symptom Chart

The parking brake will not apply Parking brake control
Cable and conduit
The parking brake will not release Parking brake control
Cable and conduit
1/1
361/2430
10/30/2018 Print
Parking Brake and Actuation - Parking Brake Cable Adjustment—Vehicles

With: Rear Disc Brakes
Print
General Procedures
Special Tool(s)
501-125
Activation
3.
1/5
362/2430
10/30/2018 Print

4.
5.
All vehicles
2/5
363/2430
10/30/2018 Print
7. NOTE: This step requires the aid of another technician.

1. Insert a 0.7 mm feeler gauge between the parking brake lever and the brake caliper
abutment, on both sides.
2. Tighten the parking brake cable adjustment nut until movement is observed on one of the
parking brake levers.
3. Remove the feeler gauges.
4. Rotate the rear wheels and tires and check for brake drag. If brake drag is felt,loosen the
parking brake cable adjustment nut to the end of the parking brake cable thread, clean the
parking brake cables and repeat the parking brake cable adjustment procedure.
9. Torque: 2 Nm
3/5
364/2430
10/30/2018 Print
11. Torque: 2 Nm
4/5
365/2430
10/30/2018 Print
12.
5/5
366/2430
10/30/2018 Print
Parking Brake and Actuation - Parking Brake Cable Adjustment—Vehicles

With: Rear Drum Brakes
Print
General Procedures

206-D002
501-125
Cable Ties
Activation
3.
1/8
367/2430
10/30/2018 Print

4.
5.
All vehicles
2/8
368/2430
10/30/2018 Print
6. On both sides.
7. On both sides.
8. On both sides.
9. On both sides.

3/8
369/2430
10/30/2018 Print
11.
4/8
370/2430
10/30/2018 Print
13.
14. On both sides.
5/8
371/2430
10/30/2018 Print
15. On both sides.
17. Torque: 2 Nm
6/8
372/2430
10/30/2018 Print
18. Torque: 2 Nm
19.
All vehicles
7/8
373/2430
10/30/2018 Print
21.
8/8
374/2430
10/30/2018 Print
Parking Brake and Actuation - Parking Brake Cable—Vehicles With: Rear

Disc Brakes
Print
Special Tool(s)
501-125
Removal
3.
1/11
375/2430
10/30/2018 Print

4.
5.
All vehicles
2/11
376/2430
10/30/2018 Print
6.
8.
9.
10. NOTE: Note the position of the components before removal.
3/11
377/2430
10/30/2018 Print
11. On both sides.
12.
NOTE: Note the position of the components before removal.
Installation
4/11
378/2430
10/30/2018 Print
1.
NOTE: Make sure that the components are installed to the position noted before removal.
1. Torque: 10 Nm
2. Torque: 2 Nm
2. On both sides.
3. NOTE: Make sure that the components are installed to the position noted before removal.
5/11
379/2430
10/30/2018 Print
4.
5.
6.
7. Torque: 2 Nm
6/11
380/2430
10/30/2018 Print
8.
9. Torque: 2 Nm
10.
7/11
381/2430
10/30/2018 Print
All vehicles
11. NOTE: This step requires the aid of another technician.
1. Insert a 0.7 mm feeler gauge between the parking brake lever and the brake caliper
abutment, on both sides.
2. Tighten the parking brake cable adjustment nut until movement is observed on one of the
parking brake levers.
3. Remove the feeler gauges.
4. Rotate the rear wheels and tires and check for brake drag. If brake drag is felt,loosen the
parking brake cable adjustment nut to the end of the parking brake cable thread, clean the
parking brake cables and repeat the parking brake cable adjustment procedure.
13. Torque: 2 Nm
8/11
382/2430
10/30/2018 Print
15. Torque: 2 Nm
9/11
383/2430
10/30/2018 Print
16.
All vehicles
18.
10/11
384/2430
10/30/2018 Print
11/11
385/2430
10/30/2018 Print
Parking Brake and Actuation - Parking Brake Cable—Vehicles With: Rear

Drum Brakes
Print

206-D002
501-125
Cable Ties
Removal
3.
1/17
386/2430
10/30/2018 Print

4.
5.
All vehicles
2/17
387/2430
10/30/2018 Print
6. On both sides.
7.
8.
9.
3/17
388/2430
10/30/2018 Print
11. On both sides.
12. On both sides.
13.
4/17
389/2430
10/30/2018 Print
Installation
1.
1. Torque: 10 Nm
2. Torque: 2 Nm
2. On both sides.
5/17
390/2430
10/30/2018 Print
3. On both sides.
5.
6/17
391/2430
10/30/2018 Print
6.
7.
8. On both sides.
9. On both sides.
7/17
392/2430
10/30/2018 Print
10. On both sides.

8/17
393/2430
10/30/2018 Print
12.
9/17
394/2430
10/30/2018 Print
14.
15. On both sides.

16.
10/17
395/2430
10/30/2018 Print
17.

18.
11/17
396/2430
10/30/2018 Print
19.
20.
12/17
397/2430
10/30/2018 Print
22.
13/17
398/2430
10/30/2018 Print
24.
25. On both sides.
26. On both sides.
27. Torque: 2 Nm
14/17
399/2430
10/30/2018 Print
29. Torque: 2 Nm
15/17
400/2430
10/30/2018 Print
30.
All vehicles
32.
16/17
401/2430
10/30/2018 Print
17/17
402/2430
10/30/2018 Print
Parking Brake and Actuation - Parking Brake Control

Print
Removal
2. Refer to: Floor Console - Vehicles With: Center Armrest (501-12 Instrument Panel and Console,
Refer to: Floor Console - Vehicles Without: Center Armrest (501-12 Instrument Panel and Console,

3.

4.
All vehicles
6.
1/4
403/2430
10/30/2018 Print
7.

9.
2/4
404/2430
10/30/2018 Print
10.
1. Torque: 35 Nm
2. NOTE: Make sure that the seal is correctly located.

11. 1.
2. Torque: 35 Nm
3/4
405/2430
10/30/2018 Print
Installation
3. Refer to: Parking Brake Cable Adjustment - Vehicles With: Rear Disc Brakes (206-05 Parking Brake
Refer to: Parking Brake Cable Adjustment - Vehicles With: Rear Drum Brakes (206-05 Parking
Brake and Actuation, General Procedures).
4/4
406/2430
10/30/2018 Print
Hydraulic Brake Actuation - Hydraulic Brake

Actuation
Print
1/1
407/2430
10/30/2018 Print
Hydraulic Brake Actuation - Brake Pedal and Bracket—LHD FWD

Print
Removal
1.
2.
3. NOTICE: Make sure that the brake pedal remains in the rest position.
1/3
408/2430
10/30/2018 Print
4. Torque: 8 Nm
5. NOTE: The brake pedal actuating rod pin will be damaged during removal.
Torque: 23 Nm
2/3
409/2430
10/30/2018 Print
Installation
1. NOTICE: Make sure that the brake booster push rod is correctly located.
3/3
410/2430
10/30/2018 Print
Hydraulic Brake Actuation - Brake Master Cylinder

Print
Removal
2.
Left-hand drive vehicles
3. Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
All vehicles
4. Refer to: Brake System Draining and Filling (206-00 Brake System - General Information, General
Procedures).

Torque: 25 Nm
2. Torque: 18 Nm
1/2
411/2430
10/30/2018 Print
Installation
2/2
412/2430
10/30/2018 Print
Power Brake Actuation - Power Brake System

Print
1/1
413/2430
10/30/2018 Print
Power Brake Actuation - Brake Booster—LHD

FWD
Print
Removal
1. Refer to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation, Removal and Installation).
2. 1. NOTE: The brake pedal actuating rod pin will be damaged during removal.
2. Torque: 24 Nm
3.
Installation
1. NOTICE: Make sure that the brake booster push rod is correctly located.
1/1
414/2430
10/30/2018 Print
Power Brake Actuation - Brake Vacuum Hose—1.6L Duratorq-TDCi

(85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3)
Print
Removal
1.
3.
4.
Right-hand drive vehicles

5.
1/2
415/2430
10/30/2018 Print
Installation
2/2
416/2430
10/30/2018 Print
Power Brake Actuation - Brake Vacuum Pump—1.6L Duratorq-TDCi

Print
Removal
1.
2.
3. Torque:
Stage 1:5 Nm
Stage 2:20 Nm
1/2
417/2430
10/30/2018 Print
4. NOTICE: Make sure that the couplings are aligned.

Installation
2/2
418/2430
10/30/2018 Print
Anti-Lock Control - Front Wheel Speed Sensor

Print
Removal
3. Torque: 5 Nm
Installation
1/1
419/2430
10/30/2018 Print
Anti-Lock Control - Rear Wheel Speed Sensor

Print
Removal
3.
4. Torque: 5 Nm
5. NOTE: The O-ring seal is to be reused unless damaged.
Installation
1. NOTE: Make sure that the sensor housing is clean and free of foreign material.
1/1
420/2430
10/30/2018 Print
Anti-Lock Control - Stability Assist - Anti-Lock Control - Stability Assist -

Component Location
Print
NOTE: The combined yaw rate sensor and lateral acceleration sensor / longitudinal acceleration
sensor is integrated into the RCM (restraints control module) module.
Item Description
1 Rear right-hand wheel speed sensor
2 Steering wheel rotation sensor
3 RCM module
4 ABS (anti-lock brake system)/ESP module
5 Front left-hand wheel speed sensor
1/1
421/2430
10/30/2018 Print
Anti-Lock Control - Stability Assist - Anti-Lock

Control - Stability Assist - Overview
Print
The vehicle is available as standard with Stability Assist. In certain markets only (initially Russia and
Turkey), the vehicle is also available with just ABS (anti-lock brake system).
ABS
NOTE: The ABS module and the HCU (hydraulic control unit) can be separated from each other in
service and can therefore be replaced individually.
The ABS fitted has the designation MK-70M and is identical in terms of function to the system on the
previous model.
NOTE: Vehicles which are fitted with just ABS do not have Brake Assist.
Stability Assist
NOTE: The Stability Assist module must not be separated from the HCU in service. If one of the two
components is faulty, the entire unit must be renewed.
In terms of components, the system is identical to that installed on the 2011 C-MAX.
However, thanks to some software extensions, the system is able to support the following
additional functions which are being introduced with the launch of the 2011.25 Focus and also
incorporated into the production of the C-MAX:
Auto start/stop
Adaptive speed control system and collision warning
Collision avoidance system
Unlike the 2011 C-MAX, the system on the 2011.25 Focus does not have roll-over prevention.
1/1
422/2430
10/30/2018 Print
Anti-Lock Control - Stability Assist - Anti-Lock

Control - Stability Assist
Print

Refer to Wiring Diagrams Section 206-09B, for schematic and connector information.
General Equipment
before proceeding to the next step
Wheel speed sensor(s) Fuse(s)
Wheel speed sensor ring(s) Electrical connector(s)
Wiring harness
Wheel speed sensor(s)
Yaw rate sensor and lateral acceleration
sensor / longitudinal acceleration sensor
Steering wheel rotation sensor
ABS/ESP module and hydraulic control unit
4. If the cause is not visually evident, verify the symptom and refer to the Ford diagnostic
equipment to diagnose the system.
1/1
423/2430
10/30/2018 Print
Anti-Lock Control - Stability Assist - Hydraulic Control Unit (HCU)

Print
Removal
2. Refer to: Brake System Draining and Filling (206-00 Brake System - General Information, General
Procedures).
4. Torque: 18 Nm

5.
6. Torque: 18 Nm
1/3
424/2430
10/30/2018 Print
All vehicles
1.
2. Torque: 18 Nm
3. Torque: 9 Nm
8. Torque: 9 Nm
2/3
425/2430
10/30/2018 Print
Installation
1. NOTICE: If accidentally dropped or knocked install a new hydraulic control unit (HCU)
and module.
The blanking caps/plugs must not be removed until the brake tubes are ready to be
connected.
3/3
426/2430
10/30/2018 Print
Steering System - General Information -

Specifications
Print
FLUID
SPECIFICATIONS
Hydraulic Fluid WSS-M2C204-A2
1/1
427/2430
10/30/2018 Print

Steering System
Print

Refer to Wiring Diagrams Cell 043-1, for schematic and connector information.
General Equipment
Ford Diagnostic Equipment
Tire pressure(s) Fuse(s)
Wheels and tires Wiring harness
Loose tie-rod end(s) Electrical connector(s)
Tie-rod(s) Relay
Steering gear housing Switch(es)
Loose front strut and spring assemblies or ball Electric assist power steering (EPAS) motor
joints warning lamp
Loose pinch bolt on the steering column shaft Battery junction box (BJB)
flexible coupling Body control module (BCM)
Steering gear boot(s) Power steering control module (PSCM)
EPAS motor
Symptom Chart
The following table provides all the possible symptoms and sources related to the Steering System.
For the actual diagnosis, proceed to use the Ford diagnostic equipment.
Symptom Chart Possible Sources

Drift left or right Wheels and tires
Vehicle attitude incorrect (front or rear is high or
low)
Damaged or worn front wheel bearing(s)
Brake system
Steering linkage
PSCM
EPAS motor
Steering wheel off center Vehicle attitude incorrect (front or rear is high or
low)
Front suspension lower arm ball joint
Steering linkage
Vibration Wheels and tires
Damaged or worn front wheel bearing(s)
Damaged front suspension lower arm(s)
Steering linkage
Steering effort is too high/low Tire pressure(s) incorrect
Incorrect Tire(s) installed
1/5
428/2430
10/30/2018 Print
Floor covering/accessory mat fouling the steering

gear pinion
Foreign material fouling the steering gear pinion
Bulkhead floor seal
Steering column shroud / Steering column
universal joint
Steering linkage / Steering gear
Circuit(s)
CAN bus malfunction
PSCM / EPAS motor
Excessive noise Steering column universal joint
Steering linkage / Steering gear
Bulkhead floor seal
Steering column shroud
Steering column/bracket incorrectly fitted
Steering column shaft
Steering gear bushings worn or perished
Loose steering gear retaining bolts
Worn tie-rod
EPAS motor
The steering does not respond correctly in relation to Worn tie-rod ends
the steering wheel rotation Worn front suspension bushings
Worn front suspension lower arm ball joints
Steering gear bushings worn or perished
Loose steering gear retaining bolts / Loose
steering column retaining bolts
Loose steering column to steering gear pinion
retaining bolt
Excessive steering gear backlash
Circuit(s)
CAN bus malfunction
PSCM / EPAS motor
EPAS motor warning lamp does not illuminate with the Circuit(s)
ignition ON CAN bus malfunction
Central car configuration
Instrument panel cluster
LED
EPAS motor warning lamp does not extinguish with Circuit(s)
the engine running Torque sensor
Instrument cluster
CAN bus malfunction
PSCM
Components Tests
Steering Column
1. Grasp the steering wheel firmly and move it up and down and to the left and right without
turning the steering wheel, to check for steering column bearing wear, steering column
universal joint free play, steering wheel or steering column looseness. The steering column
cannot be repaired. Install a new steering column.
REFER to: Steering Column (211-04 Steering Column, Removal and Installation).
Steering Linkage
1. With the road wheels in the straight ahead position, gently turn the steering wheel to the left
and the right to check free play in the steering linkage.
2. There should be no excessive free play at the steering wheel rim. If there is excessive free play,
CHECK the tie-rod inner and outer ball joints, REFER to Tie-Rod Component Test in this
procedure. CHECK the steering column universal joint, REFER to Steering Column Universal
Joint Component Test in this procedure. If there is no free play in the tie-rod and the steering
2/5
429/2430
10/30/2018 Print
column, install a new steering gear.

REFER to: Steering Gear - Vehicles With: Electronic Power Assist Steering (EPAS) (211-02
Power Steering, Removal and Installation).
Tie-Rod
NOTICE: The steering gear boots must be handled carefully to avoid damage. Use new steering
gear boot clamps when installing the steering gear boots.
NOTE: Noises such as knocks, which may appear to originate from the steering linkage, may also be
generated by front suspension components.
1. Raise and support the vehicle.
2. Firmly grasp the road wheel and apply a rocking motion to check for any free play in the wheel
bearing or suspension components.
3. NOTICE: To prevent damage to the steering linkage, turn the steering wheel to move the
steering linkage to the steering lock stop.
Turn the steering wheel to position the steering linkage against the right-hand steering lock
stop.
4. NOTE: To isolate the steering gear design clearance, check the right-hand tie-rod with the
steering held against the right-hand steering lock stop.
With the aid of another technician holding the steering against the right-hand steering lock
stop, firmly grasp the right-hand road wheel and apply a rocking motion to check for any free
play in the tie-rod.
5. Detach the steering gear boot from the steering gear body and check for free play at the tie-rod
inner ball joint.
6. If there is free play at the tie-rod inner ball joint, install a new tie-rod.
REFER to: Tie Rod (211-03 Steering Linkage, Removal and Installation).
3/5
430/2430
10/30/2018 Print
7. If there is free play at the tie-rod end, install a new tie-rod end.
REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).
8. NOTICE: To prevent damage to the steering linkage, turn the steering wheel to move the
steering linkage to the steering lock stop.
Turn the steering wheel to position the steering linkage against the left-hand steering lock stop.
9. NOTE: To isolate the steering gear design clearance, check the left-hand tie-rod with the
steering held against the left-hand steering lock stop.
With the aid of another technician holding the steering against the left-hand steering lock stop,
firmly grasp the left-hand road wheel and apply a rocking motion to check for any free play in
the tie-rod.
10. Detach the steering gear boot from the steering gear body and check for free play at the tie-rod
inner ball joint.
11. If there is free play at the tie-rod inner ball joint, install a new tie-rod.
REFER to: Tie Rod (211-03 Steering Linkage, Removal and Installation).
12. If there is free play at the tie-rod end, install a new tie-rod end.
Steering Column Shaft Universal Joint
1. WARNING: Install a new steering column shaft to steering gear pinion retaining bolt.
Failure to follow this instruction may result in personal injury.
Make sure that the road wheels are in the straight ahead position and that the steering lock is
engaged.
Detach the steering column shaft from the steering gear pinion.
Discard the steering column shaft to steering gear pinion retaining bolt.
2. Check for smooth movement of the steering column shaft universal joint.
4/5
431/2430
10/30/2018 Print
1. Hold the steering column shaft universal joint yoke.

2. Articulate the free yoke in a figure of eight movement.
If the movement is not smooth or resistance is felt, install a new steering column.
3. Hold both of the steering column shaft universal joint yokes and then twist them clockwise and
counterclockwise.
If any movement is felt, install a new steering column.
5/5
432/2430
10/30/2018 Print

Steering Gear Checks After a Collision
Print
General Equipment
Feeler gauge
Straight edge
Items to be observed when checking the steering system
The following list of steering gear conditions and the methods of testing should be taken into account
when carrying out checks to the steering system:
If the steering gear has no faults after completing the following checks, do not install a new
steering gear.
Surface corrosion and marks on the tie-rod are acceptable.
When checking for turning effort torque peaks in the steering gear, turn the steering wheel from
steering lock stop to steering lock stop in approximately 15 seconds.
A steady increase of turning effort torque from steering center to steering lock stop is acceptable.
Noises from the power steering, for example the power steering motor, are acceptable. If in doubt,
compare the noise level to a known good vehicle of similar specification.
STEERING GEAR HOUSING

Connect the Ford diagnostic equipment to the vehicle and check for any EPAS DTC(s). If DTC
U3000-49, U3000-53 or U3000-96 is present, install a new steering gear.
REFER to: Steering Gear - Vehicles With: Electronic Power Assist Steering (EPAS) (211-02 Power
Steering, Removal and Installation).
Visually inspect the steering gear housing (especially along the split lines), power steering motor,
electrical connectors, rubber bushes, and wiring harness for cracks, cuts and damage. If the
steering gear housing, power steering motor/electrical connector or bushes of the steering gear are
cracked or damaged, install a new steering gear.
If the vehicle-side wiring harness or electrical connectors are cut or damaged, install a new wiring
harness.
STEERING GEAR BOOTS

Visually inspect the steering gear boot(s) for splits, damage and correct fitment. If the steering gear
boot(s) is split, damaged or incorrectly fitted, install a new steering gear boot(s) as necessary.
REFER to: Steering Gear Boot (211-03 Steering Linkage, Removal and Installation).
TIE RODS AND TIE-ROD ENDS

Using a straight edge and feeler gauge, check the tie-rods to see if they are straight. If the distance
between the tie-rod and straight edge is greater than 0.5 mm, install a new steering gear.
Check the tightening torque of the tie-rod end to wheel knuckle nut.
Check the tightening torque of the tie-rod end locking nut.
CHECK FOR TURNING EFFORT TORQUE PEAKS IN THE STEERING GEAR

Lower and support the vehicle making sure that the road wheels are just clear of the floor.
With the ignition switch in position I (engine off), slowly turn the steering wheel from steering lock
stop to steering lock stop.
Only continue to the step 4, if a turning effort torque peak or judder is felt while turning the
steering wheel.
Detach the tie-rods from the wheel knuckles.
Slowly turn the steering wheel from steering lock stop to steering lock stop.
1/2
433/2430
10/30/2018 Print
- If no torque peak or judder can be felt now, investigate the front suspension for damage.
- If a turning effort torque peak or judder is felt while turning the steering wheel, install a new
steering gear.
Lower the vehicle and drive it onto a four-post hoist or inspection pit.
Run the engine at idle and slowly turn the steering wheel to the left-hand steering lock stop. Hold
the steering wheel in this position for 5 seconds with a turning effort torque of 15 Nm at the
steering wheel rim and check for steering gear movements and touch conditions to surrounding
components.
Turn the steering wheel away from the left-hand steering lock stop for 30 seconds.
Run the engine at idle and slowly turn the steering wheel to the right-hand steering lock stop. Hold
the steering wheel in this position for 5 seconds with a turning effort torque of 15 Nm at the
steering wheel rim and check for steering gear movements and touch conditions to surrounding
components.
Turn the steering wheel away from the right-hand steering lock stop.
Rectify any touch conditions found.
Install new steering gear retaining bolts and tighten to the correct torque if steering gear movement
was found.
Drive the vehicle on roads at different vehicle speeds while executing different steering
manoeuvres. In an appropriate location, drive several figures of 8. Carry out a parking manoeuvre
and steer to full lock during this manoeuvre. Check for torque peaks, judder noise and any warning
messages in the message center.
If available, use Active Park Assist to carry out a parking manoeuvre.
If available, drive on straight roads with clearly visible side limitation bars at speeds above 60 km/h
and check the Lane Departure Warning and Lane Keeping Aid for correct function.
Rectify any faults found.
2/2
434/2430
10/30/2018 Print
Steering System - General Information - Power

Steering System Filling
Print
General Procedures
Special Tool(s)
211-189
Adapter, Power Steering Bleeding
416-D001
Hand Vacuum Pump/Pressure Pump
Materials
Name Specification
Hydraulic Fluid WSS-M2C204-A2
1. Fill the power steering fluid reservoir to the MAX mark.
Material: WSS-M2C204-A2 (Hydraulic Fluid)
2. Raise the vehicle until the road wheels are clear of the floor. Support the vehicle.
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
3. Slowly turn the steering wheel from lock to lock and add power steering fluid until the power
steering fluid in the power steering fluid reservoir stops dropping.
4. Start the engine and slowly turn the steering wheel from lock to lock and add power steering fluid
until the power steering fluid in the power steering fluid reservoir stops dropping.
5. Switch the engine OFF and using the special tools, create a vacuum of 62cm-Hg - 75cm-Hg for 30
seconds.
Use Special Service Tools: 211-189, 416-D001.
6. 1. Observe the vacuum gauge reading.

2. If the vacuum decreases by more than 5cm-Hg in 5 minutes, the system should be checked
for leaks.
7. Remove the special tools. Fill the power steering fluid reservoir to the MAX mark as necessary.
Material: WSS-M2C204-A2 (Hydraulic Fluid)
1/2
435/2430
10/30/2018 Print
2/2
436/2430
10/30/2018 Print
Steering System - General Information - Power Steering System Vacuum

Bleeding
Print
General Procedures
Special Tool(s)
211-189
Adapter, Power Steering Bleeding
416-D001
Hand Vacuum Pump/Pressure Pump
Bleeding
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information, Description
and Operation).
2.
3. Refer to: Specifications (211-00 Steering System - General Information, Specifications).
4. NOTE: Make sure the fluid in the reservoir does not fall below the MIN mark, as air could
enter the system.
1/5
437/2430
10/30/2018 Print
6. When bleeding the power steering system the vacuum will decrease. Using the special tools,
maintain a sufficient vacuum of 38cm-Hg. If the vacuum decreases by more than 5cm-Hg in 5
minutes, the system should be checked for leaks.
Install Special Service Tools: 416-D001, 211-189.
7. Remove Special Service Tools: 211-189, 416-D001.
2/5
438/2430
10/30/2018 Print
enter the system.
10. 1. Using the special tools, create a vacuum of 38cm-Hg. Maintain the vacuum until the air is
evacuated from the system (minimum of five minutes).
2. Release the vacuum.
3/5
439/2430
10/30/2018 Print
11. Remove Special Service Tools: 211-189, 416-D001.
enter the system.
4/5
440/2430
10/30/2018 Print
14.
5/5
441/2430
10/30/2018 Print
Steering System - General Information - Power

Steering System Flushing
Print
General Procedures
Flushing
NOTE: This procedure is only valid for vehicles with remote reservoir.
1. Refer to: Power Steering Fluid Reservoir (211-02 Power Steering, Removal and Installation).
1/1
442/2430
10/30/2018 Print
Power Steering - Power Steering - Component Location

Print
NOTE: The {Acronym.EPS} ({Acronym.EPS}) must not be dismantled! If a malfunction occurs, the
complete steering gear must be replaced, together with the components of the {Acronym.EPS}.
NOTE: The steering gear rubber boots, the track rods and the ball joints can be changed separately
in service.
Item Description
1 {Acronym.EPS} module
2 {Acronym.EPS} motor
3 Housing, steering assistance drive
4 Steering gear
5 Torsional shaft with steering torque sensor
6 Securing bolts, steering gear
1/2
443/2430
10/30/2018 Print
Item Description
1 Cover, steering torque sensor
2 O-ring
3 Protective cap
4 Ball joint, track rod end
5 Track rod
6 Steering stop limiter
7 Steering gear stop
8 Guide sleeve
9 O-ring
11 Output pinion, toothed belt drive
12 Recirculating ball nut
13 Motor with integrated {Acronym.EPS} module
14 Securing ring, toothed belt pulley
15 Toothed belt
16 Gasket
17 Bearing bush, steering gear
18 Wiring harness, steering torque sensor
19 Identification plate, steering gear
20 Needle bearing
21 Torsional shaft with steering torque sensor and steering gear pinion
22 Retaining ring, steering torque sensor
2/2
444/2430
10/30/2018 Print
Power Steering - Power Steering - Overview

Print
This vehicle employs electric power steering (EPS).

The components of the {Acronym.EPS} ({Acronym.EPS}) are integrated in the steering gear.
Layout
The {Acronym.EPS} consists of the following main components:

{Acronym.EPS} motor,
{Acronym.EPS} module,
steering torque sensor,
toothed belt drive.
Functionality overview
As soon as the steering wheel is moved, an electric motor assists the steering movement.
When a steering movement occurs, it is detected by the steering torque sensor. The signal from the
steering torque sensor is used by the module to calculate the power of the steering
assistance.
The {Acronym.EPS} module drives the {Acronym.EPS} motor with the corresponding current.
Advantages of electric power steering
{Acronym.EPS} is only active when a steering movement occurs. This decreases the load on the
engine and therefore reduces the fuel consumption.
The system adjusts the power of the steering assistance specifically for every speed.
Not sensitive to disturbances from the running gear which lead to vibrations at the steering wheel.
This may include:
- imbalance at the wheels or brake discs,
- the vehicle drifting to one side.
Fewer components compared with hydraulic power steering. The hydraulic pump, hoses and
reservoir are dispensed with.
Environmentally friendly:
- no need to dispose of hydraulic fluid,
- escape of hydraulic fluid caused by leaks in the hydraulic system cannot occur.
Improved diagnostic facilities via IDS (Integrated Diagnostic System) or FordEtis-IDS.
Steering assistance power transfer
1/2
445/2430
10/30/2018 Print
Item Description
2 Drive pinion, toothed belt drive
3 Toothed belt
5 Steering rack
6 Steering gear rubber boot
NOTE: Repairs or adjustments are not permitted at the toothed belt drive!
A toothed belt is used to transfer the rotational movement of the motor via a recirculating ball nut
to the steering rack of the steering gear.
Recirculating ball nut
Item Description
1 Inner ring, ball bearing
2 Outer ring, ball bearing
3 Balls
4 Ball return
5 Steering rack with ball track
The recirculating ball nut produces a linear movement of the steering rack from the rotational
movement of the output pinion.
Operation
A ball track (thread-like grooves) is machined into the steering rack. The balls of the recirculating ball
nut run close together in a row in part of the ball track.
The toothed belt causes the toothed belt drive output pinion to rotate. Because of the rotation of the
output pinion, the balls build up an axial force and push the steering rack to the right or left.
The front and rear ends of the chain of balls are connected via the ball return. The balls therefore run
in an infinite loop.
The toothed belt drive output pinion runs on a ball bearing.
Advantage compared to toothed rack drive:
A larger transmission ratio is generated. This is necessary because the {Acronym.EPS} motor is
more efficient at higher rotational speeds.
In addition, no bending force is generated on the steering rack.
WARNING: The ball bearing is sensitive to axial impact load. When working on the front axle or
on the front brakes, harsh impacts must be absolutely avoided (such as those caused by hammer
blows on the brake disk or wheel hub).
2/2
446/2430
10/30/2018 Print
Power Steering - Power Steering - System Operation and Component

Description
Print
System Diagram
Item Description
1 Steering torque sensor
2 {Acronym.EPS} ({Acronym.EPS}) module
3 Module, electronic stability program (ESP)
4 PCM (powertrain control module)
6 Parking Aid Module
7 GEM (generic electronic module)
8 Instrument Cluster
System Operation
The steering force applied by the driver is transmitted via the steering column to the steering gear
and on to the front wheels of the vehicle.
The steering shaft is composed of an input shaft and an output shaft. The two parts of the steering
shaft are connected to one another via a torsion bar.
When the driver turns the steering wheel, torsion occurs in the steering shaft.
The amount of torsion depends on the frictional force between the tires and the road surface.
The torsion is increased by the use of the torsion bar, causing relative movement between the input
and output shafts. This relative movement is detected by a steering torque sensor and transmitted
to the {Acronym.EPS} module.
The relative movement is the main parameter for calculating the control current for the
{Acronym.EPS} motor and thus for the power assistance.
Other input parameters for calculating the steering power assistance are the vehicle speed and the
engine status.
HS-CAN (controller area network) input and output signals
EPS module input signals:
1/7
447/2430
10/30/2018 Print
Vehicle Speed
Signals from the rear wheel speed sensors
Engine status (is the ignition switched off or on, or is the engine running):
- The information about the status of the engine is received by the {Acronym.EPS} module from the
GEM. If the GEM does not provide any meaningful engine status, the engine status query occurs
from the PCM.
Absolute steering angle from the steering column steering wheel rotation sensor
Steering request for active parking from the active parking assistant module
EPS module output signals:

Warning messages to the instrument cluster:
- The warning messages are sent via the HS-CAN to the GEM (gateway). The GEM converts the HS-
CAN message into an MS-CAN message and then forwards this to the instrument cluster.
Steering angle to the active parking assistant module
Diagnostics
The {Acronym.EPS} module is connected to the HS-CAN. A diagnostic routine can be performed with
IDS (Integrated Diagnostic System).
{Acronym.EPS} motor
Item Description
NOTE: The {Acronym.EPS} motor cannot be replaced separately during service repairs. Under no
circumstances may the securing bolts of the motor be loosened, as this would change the tension
of the toothed belt. The result would be breakage or slipping of the toothed belt.
The electric motor is bolted directly to the steering assistance drive housing.
Design/function
The {Acronym.EPS} motor is brushless, with a stator and three phases connected in star-delta.
The rotor is a permanent magnet. The angular position of the rotor is detected by a total of three
Hall sensors and transmitted to the {Acronym.EPS} module.
The module uses this angular position to calculate the control current for each fixed coil winding.
The required assistance torque is therefore applied evenly and without any jolting.
Steering torque sensor
2/7
448/2430
10/30/2018 Print
Item Description
1 Input shaft
Comments:
with integrated torsion bar
2 Steering torque sensor unit
3 Steering torque sensor housing
4 Output shaft
5 Cover.
6 Electronic printed circuit board, steering torque sensor
7 Steering torque sensor clock spring
8 Support for steering torque sensor stator
9 Steering torque sensor stator
10 Steering torque sensor rotor
NOTE: The steering torque sensor cannot be replaced separately during service repairs. In the
event of a fault, the complete steering gear with the {Acronym.EPS} must be replaced.
The input shaft of the steering torque sensor is connected to the universal joint of the intermediate
shaft.
The splines at the lower end of the output shaft engage directly with the steering rack of the
steering gear.
The steering torque sensor operates according to the induction principle.
The following components of the steering torque sensor rotate with the input/output shaft:
Support for steering torque sensor stator,
Steering torque sensor stator,
Steering torque sensor rotor.
For this reason, power is supplied to the steering torque sensor via a clock spring.
Purpose and function
Upon a steering movement, a relative movement is generated between the input and output shafts.
3/7
449/2430
10/30/2018 Print
The size of the relative movement depends on how strongly the torsion bar between the input and
output shafts is twisted. The amount of torsion in turn depends on the frictional resistance between
the road surface and the tires.
Example:
When the vehicle is traveling at approx. 100 km/h, the steering torque is low. Therefore when a
steering movement is made, there is little relative movement between the input and output shafts.
Only a small relative movement is detected by the steering torque sensor.
With the vehicle standing still, the steering torque is high. Therefore when a steering movement
is made, the relative movement between the input and output shafts is correspondingly higher. A
large relative movement is detected by the steering torque sensor.
{Acronym.EPS} module
Item Description
1 Connector 1
2 Connector 2
3 Connector 3
NOTE: The {Acronym.EPS} module must not be separately replaced during service repairs.
Electrical connectors
The module has three connectors in total. The connectors are occupied as follows:
Connector 1:
- HS-CAN and ignition status
Connector 2:
- Input signals from steering torque sensor
- Caution:This connector must not be detached under any circumstances. Detaching the
connector may result in damage to the plug and socket connections. Damage to the plug and socket
connections cannot be repaired in service and will therefore require complete replacement of the
{Acronym.EPS}.
Connector 3:
- Power supply
Purpose and function
The {Acronym.EPS} module uses the main input parameters from the steering torque sensor and
the vehicle speed to calculate the required steering assistance.
The steering torque sensor is directly wired to the {Acronym.EPS} module.
The engine status is a further input variable. This information is decisive in determining
whether steering assistance is provided or not. There are the following possibilities:
Vehicle stationary and ignition OFF:
- no steering assistance
Vehicle stationary and ignition ON:
- no steering assistance
Vehicle is being driven, ignition is turned off:
4/7
450/2430
10/30/2018 Print
- Steering assistance continues to be provided until the vehicle speed has decreased to below three
km/h.
Vehicle being driven, engine stops (ignition continues to be switched on):
- Steering assistance continues to be provided until the vehicle speed has decreased to below three
km/h.
Straight-ahead travel correction function
The straight-ahead travel correction function equalizes sideways drift of the vehicle via the
{Acronym.EPS} system.
Operation:
When traveling straight ahead, vehicle drift is initially corrected by the driver steering the other
way.
The system recognizes corrective steering by the driver above a speed of 60 km/h. Beyond that
speed the corrective steering torque is detected by the steering torque sensor and a teach-in
process begins.
The {Acronym.EPS} module calculates the control current for the {Acronym.EPS} motor from the
steering torque sensor signal. The {Acronym.EPS} module thereby specifically controls the
{Acronym.EPS} motor. The straight-ahead travel correction is now taken over by the
{Acronym.EPS}.
The complete learning process lasts for about 20 to 40 minutes. However, vehicle drift is already
corrected to a certain extent during this period.
Requirements for activating the teach-in process:

Vehicle speed greater than 60 km/h,
steering torque sensor functioning within the operating limits,
Center position of the steering was detected.
The teach-in process is stopped, or does not take place, if any of the above conditions is not met. It is
continued when the conditions are met again.
After the learning process has been completed, vehicle drift is corrected almost entirely by the
{Acronym.EPS} system. Drift correction then takes place at vehicle speeds above 30 km/h. Even if
the driver lets go of the steering wheel, the vehicle remains exactly on track. At vehicle speeds from
about 30 km/h down to 6 km/h the power assistance which counters the drift is continuously reduced.
NOTE: The straight-ahead travel correction function is limited to a certain range. If the system has
to apply too much steering torque for the straight-ahead travel correction, an error code is set and
the straight-ahead travel correction function is limited to the maximum permitted value.
Vehicle speed and wheel speed sensors
The vehicle speed (determined from the front wheel speed sensor signals) is received by the
{Acronym.EPS} module from the electronic stability program via the HS-CAN.
In addition, the {Acronym.EPS} module picks up the wheel speed signals of the rear wheels from
the HS-CAN. The {Acronym.EPS} module can use these signals to check the incoming signal from the
steering column steering wheel rotation sensor for plausibility.
Example:
A steering wheel rotation sensor which has been installed incorrectly orientated by 360° will be
detected in this way by the {Acronym.EPS} module and a DTC (diagnostic trouble code) set. In this
case, some functions will be disabled, such as:
- assistance in steering return,
- straight-ahead travel correction function,
- active parking assistant
Furthermore, the end stops of the steering will be approached hard. This means that no targeted
reduction in the control current will take place before the end stops.
System malfunction
In the event of certain system malfunctions, an appropriate message text is shown in the
instrument cluster display.
Depending on the malfunction, the steering assistance

is to a large extent maintained or
5/7
451/2430
10/30/2018 Print
is limited to a fixed and defined power assistance (about the same value as for a vehicle speed of
100 km/hr) or
is completely prohibited.
EPS module receiving no vehicle speed signal:

In this case, the module assumes a constant vehicle speed of 100 km/h. This is particularly
noticeable when the vehicle is stationary or moving slowly, in that the steering forces are increased.
NOTE: If the steering becomes overheated, steering assistance will also be reduced or prohibited.
This is indicated with the DTC U3000-4B. For more information, please refer to the section
"Overheating protection".
Damage/corrosion in the steering
A damaged or corroded recirculating ball nut can cause increased friction in the steering.
Because of the electric steering assistance, this is at first not noticeable to the driver of the vehicle.
After a certain limiting value however, a DTC will be set and an appropriate message text displayed in
the instrument cluster. Steering assistance continues to be provided for this driving cycle.
In the next driving cycle, i.e. after the next engine start, no steering assistance will be provided.
NOTE: Absence of steering assistance together with a corroded/damaged recirculating ball nut can
lead to heavy steering! This corrosion/damage leads to unacceptable steering noises at an early
stage, before the steering assistance is finally prohibited.
Reason for the heaviness:

In order to be able to optimally use the efficiency of the {Acronym.EPS} motor, the recirculating
ball nut has only a small pitch on its ball track.
In addition, the tolerances in the recirculating ball nut are approximately 5µ. This makes the
recirculating ball nut extremely sensitive to dirt and corrosion.
Dirt and moisture could enter the recirculating ball nut through a defective steering boot for
example.
For this reason, it is particularly important to check the condition of the steering boots
during routine vehicle servicing.
The system recognizes a heavy steering through the normal steering corrections made by the driver.
In the process, an increased steering torque is measured by the steering torque sensor.
NOTE: Before changing the {Acronym.EPS}, all the other possible causes which could have caused
the steering to become heavy must first be eliminated. These could for instance be stiff supporting
joints on the suspension arms or stiff constant velocity joints on the driveshaft.
NOTE: During diagnosis, the instructions of the symptom-based diagnosis must always be followed.
Service instructions
WARNING: In extreme cases, the {Acronym.EPS} motor may reach very high temperatures.
Before service work, wait a suitable time before starting repairs to the {Acronym.EPS}.
Overheating protection
A temperature sensor and an algorithm for calculating the temperature are located in the
{Acronym.EPS} module.
From a certain temperature, steering assistance via the {Acronym.EPS} motor is continuously
reduced. Overheating is indicated with the DTC U3000-4B.
Overheating may occur if, for example, the steering is constantly moved from full lock to full lock
when the vehicle is not moving. Under these operating conditions, the {Acronym.EPS} motor is
actuated with maximum power. Here the peak current can be up to 80 A to 90 A.
The {Acronym.EPS} operates normally again when the {Acronym.EPS} module has cooled down.
Capture of the steering center position
Each time the ignition is switched on, the {Acronym.EPS} module receives the absolute steering
angle from the steering column steering wheel rotation sensor. This input variable signals the
absolute steering center position to the {Acronym.EPS} module.
Because of tolerances in the components (for instance the steering column, steering gear, front axle
components), there is an offset between the given absolute steering center position from the sensor
6/7
452/2430
10/30/2018 Print
and the actual steering center position.

The {Acronym.EPS} module makes a compensation to the absolute steering center position.
The compensation occurs during straight ahead driving. The learned parameters are stored in the
module.
Because of this fine tuning, the compensation values for the steering center position must be
reset by the IDS after various service operations which affect the steering center position. The
various service operations are for example:
Changing the steering column, the steering wheel angle sensor, the rear axle or
adjusting the toe.
NOTE: The last saved fine adjustment (the learned offset) of the steering center position corrects
the required value of the steering center position each time the ignition is switched on. It does not
matter how many degrees the steering has been turned with the ignition switched off. The learned
offset is also retained in the {Acronym.EPS} module after the battery has been disconnected. The
reference mark is always the raw input signal of the steering wheel angle sensor. Learning of the
steering center position after the battery has been disconnected is therefore not necessary.
Minimum voltage
For the {Acronym.EPS} to operate, a minimum voltage of 10.8 V is required. Below this voltage the
{Acronym.EPS} will not be activated.
Straight-ahead travel correction function
After any repair work on the front axle which may have an effect on the straight line stability of
the vehicle, the following activities must be performed using IDS:
clear DTCs from fault memory (if set) and
reset the compensation values for the straight ahead travel correction function.
reset the compensation values for the steering center position.
WARNING: Resetting the compensation values is extremely important! Correction values which
have not been reset would cause the system to continue to attempt to correct a drift of the vehicle.
7/7
453/2430
10/30/2018 Print
Power Steering - Power Steering Fluid Cooler

Print
General Equipment
Hose Clamp Remover/Installer
Removal
1. Refer to: Steering System Health and Safety Precautions (100-00 General Information, Description
and Operation).
2. Torque: 10 Nm

Use the General Equipment: Hose Clamp Remover/Installer
1/5
454/2430
10/30/2018 Print
5.

2/5
455/2430
10/30/2018 Print
7. Torque: 9 Nm
Installation

Refer to: Power Steering Fluid Reservoir (211-02 Power Steering, Removal and Installation).
3/5
456/2430
10/30/2018 Print

Refer to: Specifications (211-00 Steering System - General Information, Specifications).

NOTE: Make sure the fluid in the reservoir does not fall below the MIN mark, as air could
enter the system.
Slowly turn the steering wheel from lock to lock five times.

4/5
457/2430
10/30/2018 Print
5/5
458/2430
10/30/2018 Print
Power Steering - Power Steering Fluid Reservoir

Print
General Equipment
Hose Clamp(s)
Removal
1.
2.
3. Use the General Equipments: Hose Clamp(s), Flat Headed Screw Driver
1/5
459/2430
10/30/2018 Print
4. Use the General Equipment: Hose Clamp Remover/Installer
Installation
1. NOTICE: Take extra care when handling the component.

NOTE: Make sure that a new component is installed.
2. Remove the General Equipment: Hose Clamp(s)
2/5
460/2430
10/30/2018 Print
3.
5.
3/5
461/2430
10/30/2018 Print
6.
8. Slowly turn the steering wheel from lock to lock and add power steering fluid until the fluid level
remains constant at the MAX mark.
4/5
462/2430
10/30/2018 Print
10.
5/5
463/2430
10/30/2018 Print
Power Steering - Power Steering Pressure Line and Return Line Assembly
Print
General Equipment
Removal
2.
3.
4. Torque: 7 Nm
5.
2. Torque: 11 Nm
3. Torque: 23 Nm
1/5
464/2430
10/30/2018 Print
6.
1. Torque: 4 Nm
2. 2. NOTICE: Make sure that all openings are sealed.

Torque: 18 Nm
7.
2/5
465/2430
10/30/2018 Print
Installation

Refer to: Power Steering Fluid Reservoir (211-02 Power Steering, Removal and Installation).
3/5
466/2430
10/30/2018 Print


NOTE: Make sure the fluid in the reservoir does not fall below the MIN mark, as air could
enter the system.
Slowly turn the steering wheel from lock to lock five times.

4/5
467/2430
10/30/2018 Print
5/5
468/2430
10/30/2018 Print
Power Steering - Steering Gear—Vehicles With: Electronic Power Assist

Steering (EPAS)
Print

205-880
211-020
Transmission Jack
Removal

2. NOTICE: Make sure a new bolt is installed.

Torque: 28 Nm
1/13
469/2430
10/30/2018 Print
4. If equipped.
Torque: 11 Nm
2/13
470/2430
10/30/2018 Print
On both sides.
Torque: 62 Nm

On both sides.
Make sure that the tie rod thread is clean and free of foreign material.
Torque: 90 Nm
3/13
471/2430
10/30/2018 Print
On both sides.
Loosen:
5 turn(s)
4/13
472/2430
10/30/2018 Print
On both sides.
Torque: 48 Nm
NOTE: Make sure that the tie rod end is installed with the same number of turns as when
removed.
5/13
473/2430
10/30/2018 Print
12. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent.
13. Torque: 24 Nm
6/13
474/2430
10/30/2018 Print
14. Torque: 125 Nm
Torque: 25 Nm
7/13
475/2430
10/30/2018 Print
2.0L
16.
1. Torque: 25 Nm
All vehicles
8/13
476/2430
10/30/2018 Print

1. Torque: 48 Nm
2. Torque: 63 Nm
3. Torque:
Stage 1:140 Nm
Stage 2:180°
4. Torque: 115 Nm
19.
9/13
477/2430
10/30/2018 Print
20.
21. Torque: 7 Nm
22. 1.
10/13
478/2430
10/30/2018 Print
Installation
11/13
479/2430
10/30/2018 Print
3.
1. Torque: 110 Nm
2. Loosen: 360°
3. Torque: 55 Nm
4. Torque: 180°
4.
1. Torque: 110 Nm
2. Loosen: 360°
3. Torque: 55 Nm
4. Torque: 180°
5.
1. Torque: 110 Nm
2. Loosen: 360°
3. Torque: 55 Nm
4. Torque: 180°
6. 1.
12/13
480/2430
10/30/2018 Print
2. Torque:
Stage 1:115 Nm
Stage 2:90°
3. Torque:
Stage 1:115 Nm
Stage 2:90°
7. On both sides.
Procedures).
13/13
481/2430
10/30/2018 Print
Steering Linkage - Tie Rod End

Print
Special Tool(s)
211-020
Removal
1. Make sure that the tie rod thread is clean and free of foreign material.
Torque: 90 Nm
2. Torque: 48 Nm
4. NOTE: Make sure that the tie rod end is installed with the same number of turns as when
removed.
1/2
482/2430
10/30/2018 Print
Installation
Procedures).
2/2
483/2430
10/30/2018 Print
Steering Linkage - Tie Rod

Print
General Equipment
Vise
Vise Jaw Protectors
Materials
Name Specification
Grease - Silicone ESE-M1C171-A
Removal
1. Refer to: Steering Gear - Vehicles With: Electronic Power Assist Steering (EPAS) (211-02 Power
Refer to: Steering Gear - Vehicles With: Hydraulic Power Assist Steering (HPAS) (211-02 Power
2. NOTE: Make sure that the tie rod end is installed with the same number of turns as when
removed.
Torque: 90 Nm
3. NOTICE: Note the position of the components before removal.
4.
1/4
484/2430
10/30/2018 Print
5.
1. Use the General Equipment: Vise
2. Use the General Equipment: Vise Jaw Protectors
6.
Installation
2. Torque: 90 Nm
2/4
485/2430
10/30/2018 Print
3. Material: ESE-M1C171-A (Grease - Silicone)
Torque: 2 Nm
3/4
486/2430
10/30/2018 Print
Procedures).
4/4
487/2430
10/30/2018 Print
Steering Linkage - Steering Gear Boot

Print
Materials
Name Specification
Removal
1. Refer to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).
2. NOTICE: Note the position of the components before removal.
Installation
3. NOTICE: Make sure that the components are installed to the position noted before
removal.
Torque: 2 Nm
1/2
488/2430
10/30/2018 Print
2/2
489/2430
10/30/2018 Print
Steering Column - Steering Column - Overview

Print
Steering Column
Item Description
1 Steering Column
1/1
490/2430
10/30/2018 Print
Steering Column - Steering Wheel

Print
General Equipment
Adhesive Tape
Removal
1. Refer to: Driver Airbag (501-20B Supplemental Restraint System, Removal and Installation).
2. NOTE: Make sure that the road wheels are in the straight ahead position.
Torque: 48 Nm
3. NOTICE:
Make sure that the clockspring rotor does not rotate.
Make sure that the clockspring pins are not bent or damaged.
Use the General Equipment: Adhesive Tape

Torque: 3 Nm
1/2
491/2430
10/30/2018 Print
Installation
2/2
492/2430
10/30/2018 Print
Steering Column - Steering Column

Print
General Equipment
Adhesive Tape
Center Punch
Removal
WARNING: The following procedure prescribes critical repair steps required for correct restraint
system operation during a crash. Follow all notes and steps carefully. Failure to follow step
instructions may result in incorrect operation of the restraint system and increases the risk of
serious personal injury or death in a crash.
1. Refer to: Pyrotechnic Device Health and Safety Precautions (100-00 General Information,
2.
3.
4.
1/6
493/2430
10/30/2018 Print
5.
6. Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint
System, General Procedures).
7. Refer to: Driver Airbag (501-20B Supplemental Restraint System, Removal and Installation).

8. NOTE: Make sure that the road wheels are in the straight ahead position.
Torque: 48 Nm
2/6
494/2430
10/30/2018 Print
9. NOTICE: Make sure that the clockspring rotor does not rotate.
10.
NOTE: Make sure a new bolt is installed.
Torque: 28 Nm
Vehicles with keyless entry

12.
3/6
495/2430
10/30/2018 Print

13.
1. On both sides.
Use the General Equipment: Center Punch

14. On both sides.
Vehicles without keyless entry

15.

16. If equipped.
4/6
496/2430
10/30/2018 Print

17.

18.

19.
All vehicles
20. Torque: 3 Nm
5/6
497/2430
10/30/2018 Print
21. NOTE: Make sure that new bolts are installed.

Torque: 25 Nm
Installation
WARNING: Incorrect repair techniques or actions can cause an accidental Supplemental

Restraint System deployment. Make sure the restraint system is depowered before reconnecting the
component. Refer to the Supplemental Restraint System depowering General Procedure in section
501-20B. Failure to precisely follow depowering instructions could result in serious personal injury
from an accidental deployment.
2. Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint
6/6
498/2430
10/30/2018 Print
Steering Wheel and Column Electrical Components - Steering Wheel and

Column Electrical Components - Component Location
Print
Item Description
A Steering column switches (vehicles without Lane Departure Warning System)
B Steering column switches (vehicles with Lane Departure Warning System)
1 Switch unit carrier, steering column
2 Clock spring and steering wheel rotation sensor unit
4 Clockspring unit
1/1
499/2430
10/30/2018 Print
Steering Wheel and Column Electrical Components - Steering Wheel and

Column Electrical Components - Overview
Print
Depending on the equipment level of the vehicle, two different steering column switches are used.
Which version of the switch is fitted depends on whether or not the vehicle is equipped with the Lane
Departure Warning System.
On vehicles without the Lane Keeping Aid, the clockspring and the steering wheel rotation
sensorform a single unit.
On vehicles with the Lane Keeping Aid, the clockspring and the steering wheel rotation sensor are
housed in two separate units.
Clock spring
The following signals are transmitted via the clock spring:

Signals from the operating buttons for the cruise control system,
Signals from the operating buttons for the audio and driver information system (multifunction
display),
Signals to/from the driver's airbag,
Signal from the horn switch.
Steering wheel rotation sensor

The steering wheel rotation sensor is a magneto-resistive sensor.
The sensor is used to detect the absolute steering angle.
The absolute steering angle information is also used by the following modules:
Module, electronic stability program (ESP)
{Acronym.EPS} ({Acronym.EPS}) module
Adaptive headlamps/headlamp range control module
Parking aid camera module
Vehicles without Lane Departure Warning System
NOTE: If the clockspring or the steering wheel rotation sensor are defective then the complete
clockspring unit and the steering wheel rotation sensor will need to be replaced. The steering
column switches can be transferred from the old unit to the new one.
NOTE: For removal and installation, the detailed instructions in the current workshop literature,
section 501-20B – Supplemental Restraint System, Clockspring - Vehicles not equipped
with Lane Departure Warning System, must be followed.
Vehicles with Lane Departure Warning System
NOTE: On this variant, the clockspring and the steering wheel rotation sensor can be separated
from each other in service.
1/3
500/2430
10/30/2018 Print
Item Description
1 Clockspring hub (steering wheel drive)
2 Clockspring housing (fixed)
3 Outer ring, steering wheel rotation sensor (rotatable)
4 Inner ring, steering wheel rotation sensor (fixed)
NOTE: The wheels must be moved to the straight-ahead position before the steering wheel is
removed. Furthermore, the clockspring hub must be secured with suitable adhesive tape so that
it cannot be rotated.
The clockspring hub is connected via a claw coupling (see arrows). The grooves and lugs on the claw
coupling have different shapes. This makes it impossible to accidentally put the parts together the
wrong way round.
When the clockspring unit is taken off, the steering wheel rotation sensor is automatically
prevented from rotating. Consequently, it is then no longer possible for the steering wheel rotation
sensor to be rotated out of position. However, this locking action is only possible if the front wheels
are in the straight-ahead position.
NOTE: The steering wheel rotation sensor cannot be removed from the steering column switch unit
carrier. In the event of a defect the entire carrier must be replaced. The steering column switches
can be transferred from the old carrier to the new one.
On a new steering column switch unit carrier the steering wheel rotation sensor is in the locked
position.
During assembly of the clockspring unit, the outer ring of the steering wheel rotation sensor is
automatically released.
NOTICE: During assembly, make sure that the lugs/grooves of the claw coupling engage
exactly in each other.
2/3
501/2430
10/30/2018 Print
NOTICE: During installation of the clockspring, make sure that the U-shaped part of the
cable is visible in the window.
NOTE: For removal and installation, the detailed instructions in the current workshop literature,
section 501-20B – Supplemental Restraint System, Clockspring - Vehicles equipped with
Lane Departure Warning System, must be followed.
3/3
502/2430
10/30/2018 Print
Steering Wheel and Column Electrical Components - Ignition Switch

Print
Removal
2.
3.
4.
1/3
503/2430
10/30/2018 Print
5.
6. NOTICE: The ignition switch lock cylinder must not be turned while the ignition switch is
removed.
2/3
504/2430
10/30/2018 Print
Installation
3/3
505/2430
10/30/2018 Print
Steering Wheel and Column Electrical Components - Steering Column

Multifunction Switch LH
Print
Removal
1.
2. If equipped.
3. NOTE: Turn the steering wheel to access the slots.
1/3
506/2430
10/30/2018 Print
4.
5. Torque: 2 Nm
2/3
507/2430
10/30/2018 Print
6. NOTE: Make sure that the component terminals are not bent or damaged.
Installation
3/3
508/2430
10/30/2018 Print

Multifunction Switch RH
Print
Removal
1.
2. If equipped.
3. NOTE: Turn the steering wheel to access the slots.
1/3
509/2430
10/30/2018 Print
4.
5. Torque: 2 Nm
2/3
510/2430
10/30/2018 Print
Installation
3/3
511/2430
10/30/2018 Print
Steering Wheel and Column Electrical

Components - Steering Column Control Module
(SCCM)—Vehicles With: Lane Departure
Warning
Print
Removal
1. Refer to: Clockspring - Vehicles With: Lane Departure Warning (501-20B Supplemental Restraint
System, Removal and Installation).
4. Torque: 3 Nm
5. Torque: 3 Nm
1/2
512/2430
10/30/2018 Print
Installation
2/2
513/2430
10/30/2018 Print

Components - Steering Column Control Module
(SCCM)—Vehicles Without: Lane Departure
Warning
Print
Removal
1. Refer to: Clockspring - Vehicles Without: Lane Departure Warning (501-20B Supplemental
Restraint System, Removal and Installation).
4. Torque: 3 Nm
5. Torque: 3 Nm
1/2
514/2430
10/30/2018 Print
Installation
2/2
515/2430
10/30/2018 Print

Lock Module
Print
General Equipment
Center Punch
Removal
1.
2.
3.
1/3
516/2430
10/30/2018 Print
4.
5.
1. On both sides.
Use the General Equipment: Center Punch
2/3
517/2430
10/30/2018 Print
6. On both sides.
Installation
3/3
518/2430
10/30/2018 Print

Components - Steering Column Lock and
Ignition Switch Housing
Print
General Equipment
2 mm Punch
Removal
1. Refer to: Steering Column Control Module (SCCM) - Vehicles Without: Lane Departure Warning
(211-05 Steering Wheel and Column Electrical Components, Removal and Installation).
Refer to: Steering Column Control Module (SCCM) - Vehicles With: Lane Departure Warning (211-
05 Steering Wheel and Column Electrical Components, Removal and Installation).
2. If equipped.
3.
4.
5.
1/2
519/2430
10/30/2018 Print

Use the General Equipment: 2 mm Punch
Installation
2/2
520/2430
10/30/2018 Print
Engine System - General Information - Specifications

Print
OIL DRAIN PLUG
NOTE: The oil drain plug O-ring seal is to be reused or replaced in accordance with the table below.
NOTE: If the seal is damaged it must always be replaced.
VEHICLE DISPLACEMENT ENGINE TYP OIL DRAIN PLUG
Ka 2009 (07/08 - ) 1.2 Duratec-8V reuse
1.3 Duratorq-TDCi reuse
Ka+ 2016.50 (01/16 - ) 1.2 Duratec 16V Ti-VCT reuse
Fiesta 2008.75 (06/08 - )/ Fiesta 2013 1.0 Duratec replace

(05/12 - )
1.0 Duratec replace
1.0 EcoBoost replace
1.25 Duratec-16V reuse
1.6 Duratec-16V Ti-VCT reuse
1.6 EcoBoost reuse
Fiesta 2017.75 (01/2017 - ) 1.0 EcoBoost replace
1.1 Duratec replace
1.5 EcoBoost - I3 reuse
B-MAX 2012.75 (01/12 - ) 1.0 EcoBoost replace
Fusion 2002.75 (06/02 - ) 1.25 Duratec-16V reuse
1.3 Duratec 8V reuse
1/6
521/2430
10/30/2018 Print
Mondeo 2007.5 (02/07 - ) 1.6 Duratec-16V Ti-VCT reuse
1.6 EcoBoost reuse
2.0 Duratec-HE reuse
2.0 EcoBoost reuse
2.5 Duratec-ST reuse
1.6 Duratorq-TDCI reuse
1.8 Duratorq-TDCi replace
Mondeo 2014.75 (10/14 - ) 1.0 EcoBoost replace
2.0 EcoBoost reuse
2.0 Duratec-HE HEV reuse
Focus 2004.75 (07/04 - ) 1.4 Duratec-16V reuse
2/6
522/2430
10/30/2018 Print
Focus 2011.25 (07/10 - ) 1.0 EcoBoost replace
1.5 EcoBoost reuse
2.0 EcoBoost reuse
Focus 2015 (05/14 - ) 1.0 EcoBoost replace
1.5 EcoBoost reuse
2.0 EcoBoost reuse
2.3 EcoBoost reuse
Focus 2019 (01/18 - ) 1.0 EcoBoost replace
1.5 Duratec I3 reuse
1.5 EcoBoost I3 reuse
1.5 EcoBlue reuse
2.0 EcoBlue replace
C-MAX 2003.75 (06/03 - ) 1.6 Duratec-16V reuse
3/6
523/2430
10/30/2018 Print
C-MAX 2011.0 (04/10 -) 1.0 EcoBoost replace
C-MAX Hybrid (10/14 - ) 2.0 Duratec-HE HEV reuse
C-MAX 2015.5 (03/15 - ) 1.0 EcoBoost replace
1.5 EcoBoost reuse
1.6 EcoBoost reuse
Kuga 2008.5 (02/08 - ) 2.0 Duratorq-TDCi reuse
Kuga 2013.25 (05/12 - ) 1.5 EcoBoost reuse
1.6 EcoBoost reuse
2.0 Duratec reuse
EcoSport 2013 (05/12 - ) 1.0 EcoBoost replace
EcoSport 2018.25 1.0 EcoBoost replace
1.5 Duratec I3 reuse
4/6
524/2430
10/30/2018 Print
1.5 EcoBlue reuse
Ranger 2006.5 (05/06 - ) 2.5 Duratorq-TDCi replace
Ranger 2012 (04/11 - ) 2.2 Duratorq-TDCi replace
Edge 2016 (08/15 - ) 2.0 Duratorq-TDCi reuse
2.0 EcoBlue replace
Mustang 2015 (02/14 - ) 2.3 EcoBoost reuse
5.0 Ti-VCT reuse
S-MAX/Galaxy 2006.5 (02/06 - ) 1.6 EcoBoost reuse
2.0 EcoBoost reuse
S-MAX/Galaxy 2015.5 (01/15 - ) 1.5 EcoBoost reuse
2.0 EcoBoost reuse
2.0 EcoBlue replace
Transit 2006.5 (04/06 - ) RWD 2.3 Duratec-HE reuse
Transit 2006.5 (04/06 - ) FWD 2.2 Duratorq-TDCi replace
5/6
525/2430
10/30/2018 Print
Transit 2014.5 (08/13 - ) FWD 2.0 EcoBlue reuse
Transit 2014.5 (08/13 - ) AWD 2.0 EcoBlue reuse
Transit Custom 2012.75 (04/12 - ) 2.0 EcoBlue reuse
Transit/Tourneo Connect 2002.5 (06/02 1.8 Duratec replace

-)
Transit/Tourneo Connect 2014 (02/13 - ) 1.0 EcoBoost replace
1.6 EcoBoost reuse
1.5 EcoBlue reuse
Transit Courier/Tourneo Courier 2014.50 1.0 EcoBoost replace

(10/2013-)
6/6
526/2430
10/30/2018 Print
Engine - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-

TDCi (70kW/95PS) (T3) - Specifications
Print
ENGINE DATA
DESCRIPTION
Engine code T3DA T3DB T1DA T1DB
Emission level Stage V Stage V Stage V Stage V
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Bore 75 mm 75 mm 75 mm 75 mm
Stroke 88.3 mm 88.3 mm 88.3 mm 88.3 mm
Engine capacity 1,560 cm³ 1,560 cm³ 1,560 cm³ 1,560 cm³
Compression 16:1 16:1 16:1 16:1

ratio
Power output 70 kW (95 PS) 70 kW (95 PS) 85 kW (115 PS) 85 kW (115 PS)
Torque 230 Nm 230 Nm 270 Nm 270 Nm
Idle speed 750 rpm 750 rpm 750 rpm 750 rpm
Maximum oil 0.1 l / 1000 km 0.1 l / 1000 km 0.1 l / 1000 km 0.1 l / 1000 km
consumption
ENGINE OIL
DESCRIPTION SPECIFICATION
SAE 5W-30 Material: WSS-M2C913-D (Engine Oil -

SAE 5W-30)
OIL PRESSURE
DESCRIPTION UNIT
Oil pressure at idle speed 1–2 bar
Minimum oil pressure at an oil temperature of 80°C and 2.3–3.7 bar

an engine speed of 2000 rpm
ENGINE OIL CAPACITY
1/3
527/2430
10/30/2018 Print
DESCRIPTION UNIT
Initial fill including oil filter 4.25 L
Service fill including oil filter 3.85 L
Service fill without oil filter 3.45 L
VALVE CLEARANCES
DESCRIPTION UNIT
Valve clearance (engine cold), intake 0.103–0.118 mm
Valve clearance (engine cold), exhaust 0.113–0.128 mm
CYLINDER HEAD
DESCRIPTION UNIT
Thickness of cylinder head gasket with piston protrusion of 0.533 - 0.634 1.25 (two notches)
Thickness of cylinder head gasket with piston protrusion of 0.634 - 0.684 1.30 (three notches)
Thickness of cylinder head gasket with piston protrusion of 0.684 - 0.734 1.35 (one notch)
Thickness of cylinder head gasket with piston protrusion of 0.734 - 0.784 1.40 (four notches)
Thickness of cylinder head gasket with piston protrusion of 0.784 - 0.886 1.45 (five notches)
Maximum distortion - measured longitudinally and diagonally 0.025 mm
CAMSHAFT DIMENSIONS
DESCRIPTION UNIT
Camshaft end float 0.195–0.3 mm
Camshaft bearing journal diameter 23.959–23.98 mm
CRANKSHAFT DIMENSIONS
DESCRIPTION UNIT
Main bearing journal end float 0.1–0.3 mm
Main bearing journal diameter 49.962–49.981 mm
PISTON DIMENSIONS
2/3
528/2430
10/30/2018 Print
DESCRIPTION UNIT
Piston diameter 74.104–74.128 mm
Piston clearance in cylinder 0.164–0.196 mm
- upper compression ring 0.2–0.35 mm
- lower compression ring 0.2–0.4 mm
- oil control ring 0.2–0.4 mm
Piston ring gap position: The piston ring gaps must be distributed evenly around the
circumference of the piston. This also applies to the oil control ring elements. Align the
piston ring gaps at 120 degrees to each other.
PISTON PIN DIMENSIONS
DESCRIPTION UNIT
Piston pin length 59.7–60 mm
Piston pin diameter 24.995–25 mm
ITEM SPECIFICATION
Sealant, oil pan contact surface to oil seal carrier, oil pan to cylinder block, Material: WSE-
oil pan to oil pump M4G323-A4 (Silicone
Sealant)
Coolant Material: WSS-

M97B44-D
(Antifreeze)
Torque Specifications
Description Nm lb.ft lb.in
Oil filter 25 18 221
3/3
529/2430
10/30/2018 Print
Engine - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L

Duratorq-TDCi (70kW/95PS) (T3) - Engine
Print

Compression Test Adapter
303-1520

Ultraviolet (UV) leak tester
Compression tester
1. Verify the customer concern by operating the system.
Coolant leaks Fuse(s)
Oil leaks Loose or corroded connector(s)
Fuel system leaks Powertrain control module (PCM)
Visibly damaged or worn parts Damaged or worn switch(es)
Loose or missing nuts or bolts

LOSS OF OIL * OIL LEAKS ON COMPONENTS * CHECK FOR EVIDENCE OF OIL LEAKS ON
THAT ARE EITHER COATED IN COMPONENTS. USE AN ULTRAVIOLET (UV) LEAK
OIL THEMSELVES OR ON TESTER IF AN OIL LEAK IS NOT EVIDENT. INSTALL
COMPONENTS LOCAL TO THEM. NEW GASKETS OR COMPONENTS AS REQUIRED.
* INTERNAL OR EXTERNAL LEAK * CHECK THE COOLANT EXPANSION TANK FOR A
AT THE ENGINE OIL COOLER. FILM OF OIL ON THE COOLANT SURFACE. INSTALL
A NEW ENGINE OIL COOLER OR ENGINE OIL
COOLER GASKET.
* CRANKSHAFT FRONT SEAL. * INSTALL A NEW CRANKSHAFT FRONT SEAL.
REFER TO: CRANKSHAFT FRONT SEAL (303-01F
ENGINE, REMOVAL AND INSTALLATION).
* LEAKS FROM OIL CARRYING * CHECK FOR CRACKS IN OIL CARRYING
COMPONENTS OR BASIC COMPONENTS OF THE BASIC ENGINE BY MEANS
ENGINE. OF AN ULTRAVIOLET UV LEAK TESTER. INSTALL
NEW COMPONENTS OR SEALS AS NECESSARY.
OIL * USE OF THE WRONG TYPE OF * INSTALL A NEW ENGINE OIL FILTER AND THE
CONSUMPTION ENGINE OIL. CORRECT ENGINE OIL.
* FAULTY POSITIVE CRANKCASE * CHECK IF THE PCV SYSTEM IS OPERATING
VENTILATION (PCV) SYSTEM. CORRECTLY AND REPAIR AS NECESSARY.
- HOSES OR VENTILATION OR REFER TO: ENGINE EMISSION CONTROL (303-08E
BREATHER VALVES ARE ENGINE EMISSION CONTROL, DIAGNOSIS AND
BLOCKED. THIS CAUSES TESTING).
EXCESSIVE PRESSURE IN THE
CRANKCASE WHICH CAUSES
MORE OIL TO ENTER THE
COMBUSTION CHAMBER.
-
1/6
530/2430
10/30/2018 Print
PCV OIL SEPARATOR IS FAULTY

AND ENGINE OIL CAN ENTER
THE COMBUSTION CHAMBER
THROUGH THE INTAKE
MANIFOLD.
* TURBOCHARGER SEALS. * INSTALL A NEW TURBOCHARGER.
REFER TO: TURBOCHARGER (303-04K FUEL
CHARGING AND CONTROLS - TURBOCHARGER,
* DAMAGED GASKETS OR * REMOVE THE CYLINDER HEAD.
MATING SURFACES. REFER TO: CYLINDER HEAD (303-01F ENGINE,
- CYLINDER HEAD GASKET IS REMOVAL AND INSTALLATION).
DAMAGED OR MATING FACE CHECK THE MATING FACES, CYLINDER HEAD
ARE WARPED. GASKET AND THE EVENNESS OF THE CYLINDER
HEAD AND ENGINE BLOCK MATING FACES.
* VALVE STEM SEALS. * INSTALL NEW VALVE STEM SEALS.
- ENGINE OIL CAN ENTER THE REFER TO: VALVE STEM SEALS (303-01F ENGINE,
COMBUSTION CHAMBER REMOVAL AND INSTALLATION).
BETWEEN THE VALVE STEM
AND THE VALVE STEM GUIDE.
* PISTON RING OR CYLINDER * INSTALL NEW COMPONENTS AS NECESSARY.
LINER WEAR.
* DAMAGED CYLINDER LINERS * CHECK THE RUNNING SURFACES AND
OR EXCESSIVE CLEARANCE OF CLEARANCES OF THE INDIVIDUAL ENGINE
ENGINE COMPONENTS. COMPONENTS. CHECK THE PISTONS FOR WEAR
- PISTONS OR DAMAGE. CHECK THE PISTON RINGS FOR
- PISTON RINGS (CLEARANCE IN WEAR OR DAMAGE. INSTALL NEW COMPONENTS
GROOVE AND END GAP) AS NECESSARY. INSTALL A NEW CYLINDER BLOCK
- CYLINDER LINERS IF NECESSARY.
COOLANT * COOLING SYSTEM * CHECK THE COOOLING SYSTEM.
CONSUMPTION COMPONENTS. REFER TO: ENGINE COOLING (303-03F ENGINE
COOLING, DIAGNOSIS AND TESTING).
* ENGINE OIL COOLER. * INSTALL A NEW ENGINE OIL COOLER.
* DAMAGED GASKETS OR * REMOVE THE CYLINDER HEAD.
WARPED MATING FACES. REFER TO: CYLINDER HEAD (303-01F ENGINE,
CHECK THE MATING FACES, CYLINDER HEAD
GASKET AND THE EVENNESS OF THE CYLINDER
HEAD AND ENGINE BLOCK MATING FACES.
* CRACKS OR FRACTURES IN * DETERMINE THE DAMAGED ENGINE
ENGINE COMPONENTS COMPONENT(S) AND INSTALL NEW
SURROUNDED BY COOLANT, COMPONENT(S) AS NECESSARY.
SUCH AS CYLINDER LINERS
AND CYLINDER HEAD
COMBUSTION CHAMBER.
ENGINE DOES * PASSIVE ANTI-THEFT SYSTEM * CHECK THE PATS LED EXTINGUISHES WITHIN 3
NOT CRANK (PATS). SECONDS WHEN THE IGNITION IS TURNED ON.
REFER TO: PASSIVE ANTI-THEFT SYSTEM (PATS)
(419-01B PASSIVE ANTI-THEFT SYSTEM (PATS),
DIAGNOSIS AND TESTING).
* STARTING SYSTEM. * CHECK THE STARTING SYSTEM.
REFER TO: STARTING SYSTEM (303-06D
STARTING SYSTEM, DIAGNOSIS AND TESTING).
* IGNITION SWITCH. * REFER TO THE WIRING DIAGRAMS.
* POWERTRAIN CONTROL * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
MODULE (PCM).
ENGINE CRANKS * FUEL TANK FUEL LEVEL LOW. * CHECK THE FUEL LEVEL.
BUT DOES NOT * WATER IN FUEL (DIESEL * DRAIN THE WATER FROM THE FUEL SYSTEM.
START ENGINE ONLY). REFER TO: FUEL SYSTEM (310-00G FUEL SYSTEM
- GENERAL INFORMATION, DIAGNOSIS AND
TESTING).
* FUEL FILTER BLOCKED. * INSTALL A NEW FUEL FILTER.
* ENGINE INTAKE AIR SYSTEM. * CHECK THE INTAKE AIR SYSTEM.
2/6
531/2430
10/30/2018 Print
REFER TO: INTAKE AIR DISTRIBUTION AND

FILTERING (303-12F INTAKE AIR DISTRIBUTION
AND FILTERING, DIAGNOSIS AND TESTING).
* GLOW PLUG FAULTY (DIESEL * CHECK THE GLOW PLUGS. INSTALL NEW GLOW
ENGINE ONLY). PLUGS AS NECESSARY.
REFER TO: GLOW PLUGS (303-07H GLOW PLUG
SYSTEM, REMOVAL AND INSTALLATION).
* ENGINE MANAGEMENT SYSTEM. * CHECK THE ENGINE MANAGEMENT SYSTEM.
REFER TO: ELECTRONIC ENGINE CONTROLS (303-
14F ELECTRONIC ENGINE CONTROLS, DIAGNOSIS
AND TESTING).
* INCORRECT VALVE TIMING. * CHECK AND ADJUST THE VALVE TIMING.
REFER TO: TIMING BELT (303-01F ENGINE,
* BROKEN OR DAMAGED TIMING * CHECK THE TIMING BELT AND
BELT OR PULLEY/SPROCKET. SPROCKETS/PULLEYS. INSTALL NEW
COMPONENTS AS NECESSARY.
VERY POOR * FUEL SYSTEM. * CHECK THE FUEL SYSTEM.
POWER OUTPUT REFER TO: FUEL CHARGING AND CONTROLS (303-
OR FUEL 04C FUEL CHARGING AND CONTROLS,
CONSUMPTION DIAGNOSIS AND TESTING).
TOO HIGH OR * ENGINE INTAKE AIR SYSTEM. * CHECK THE INTAKE AIR SYSTEM.
ENGINE REFER TO: INTAKE AIR DISTRIBUTION AND
RUNNING FILTERING (303-12F INTAKE AIR DISTRIBUTION
ROUGH AND FILTERING, DIAGNOSIS AND TESTING).
* EXHAUST SYSTEM BLOCKED. * CHECK THE EXHAUST SYSTEM.
* ENGINE MANAGEMENT SYSTEM. * CHECK THE ENGINE MANAGEMENT SYSTEM.
REFER TO: ELECTRONIC ENGINE CONTROLS (303-
AND TESTING).
* TURBOCHARGER. * CHECK THE TURBOCHARGER. REFER TO:
TURBOCHARGER (303-04N FUEL CHARGING AND
CONTROLS - TURBOCHARGER, DIAGNOSIS AND
TESTING).
* INCORRECT VALVE TIMING. * CHECK AND ADJUST THE VALVE TIMING.
TIMING BELT/TIMING REFER TO: TIMING BELT (303-01F ENGINE,
SPROCKET OR REMOVAL AND INSTALLATION).
PULLEY/SPROCKET DAMAGED.
* IGNITION TIMING INCORRECT * CHECK THE ELECTRONIC ENGINE CONTROLS.
(PETROL ENGINES ONLY). REFER TO: ELECTRONIC ENGINE CONTROLS (303-
AND TESTING).
NOISY RUNNING * ENGINE AUXILIARY * CHECK ENGINE AUXILIARY COMPONENTS FOR
COMPONENTS LOOSE OR DAMAGE OR LOOSENESS.
DAMAGED.
NOISY * INCORRECT FUEL * DETERMINE WHICH TYPE OF FUEL WAS LAST PUT
RUNNING, IN THE TANK (NOTE THE COUNTRY SPECIFIC FUEL
MISFIRING, SPECIFICATIONS).
BACKFIRING OR * WATER IN FUEL OR FUEL * CHECK THE FUEL SYSTEM FOR WATER OR OTHER
KNOCKING CONTAMINATED. CONTAMINATION.
* VALVE TIMING INCORRECT, * CHECK AND ADJUST THE VALVE TIMING.
TIMING BELT OR REFER TO: TIMING BELT (303-01F ENGINE,
PULLEY/SPROCKET DAMAGED. REMOVAL AND INSTALLATION).
NOISY RUNNING * VALVE CLEARANCE TOO LARGE * INSTALL NEW HYDRAULIC LASH ADJUSTERS OR
OR VALVE TRAIN DUE TO FAULTY VALVE TAPPETS ADJUST THE VALVE CLEARANCE.
NOISE OR WORN VALVE TRAIN
COMPONENTS.
* TIMING BELT DAMAGED. * INSTALL A NEW TIMING BELT.
* TIMING BELT INCORRECTLY * CHECK THE TIMING BELT TENSION. INSTALL A
3/6
532/2430
10/30/2018 Print
TENSIONED. NEW TIMING BELT AS NECESSARY.

NOISY RUNNING * ENGINE COMPONENTS * CHECK THE ENGINE COMPONENTS FOR WEAR OR
OR ENGINE - PISTONS DAMAGE. MAKE SURE ALL COMPONENTS ARE
NOISE - PISTON RINGS WITHIN SPECIFICATION. INSTALL NEW
- CONNECTING ROD BIG END, COMPONENTS AS NECESSARY.
MAIN BEARING OR THRUST
BEARING JOURNALS
- CONNECTING RODS BENT OR
DAMAGED.
Engine - Oil Leaks

NOTE: Before installing new gaskets or seals, make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual inspection, carry out an ultraviolet (UV) test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the quantity specified by the manufacturer through
the oil filler neck into the engine and install the oil filler cap.
WARNING: Vehicles with manual transaxle, shift the transaxle into Neutral. Failure to follow this
3. Start the engine and let it run for about five minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the vehicle under various loads and check the engine for
leaks again.
5. Check the engine for oil leaks using a suitable UV lamp.
6. Rectify any leaks found and check the engine for oil leaks.
Measure the compression pressure

WARNINGS:
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related components. Highly flammable mixtures are always present and can ignite. Failure to
follow these instructions may result in personal injury.
Do not carry out any repairs to the fuel injection system without checking that the fuel
pressure has dropped to zero and that the fuel temperature has either reached ambient
temperature or is below 30° C, whichever is the greater. Failure to follow these instructions may
result in personal injury.
NOTE: The powertrain control module (PCM) receives an error message when the fuel pump relay is
removed or electrical components are disconnected. This error message must be deleted from the
fault memory using the Ford diagnostic equipment after completing the compression test.
NOTE: Valve clearance must be set correctly before performing a compression test. Make sure the
engine is at the normal operating temperature.
NOTE: The varying design of compression checking devices and fluctuating starter motor speeds
normally only allows for a comparison to be made of the compression pressures in all cylinders.
NOTE: The readings from the compression pressure check should be used as an indication of
cylinder balance. If one or more of the readings is significantly lower than the others, investigate
that particular cylinder for concerns.
1. Using datalogger in the Ford diagnostic equipment, check that the fuel pressure has dropped to
zero and that the fuel temperature has either reached ambient temperature or is below 30°C,
whichever is the greater.
2. Disconnect the glow plug module C1E513.
4/6
533/2430
10/30/2018 Print
3. Remove the glow plugs.

REFER to: Glow Plugs (303-07H Glow Plug System, Removal and Installation).
4. NOTE: Operate the starter motor until the pointer on the compression tester stops rising.
Using Special Tool 303-1520, carry out the measurement on each cylinder according to the
instructions provided by the manufacturer of the Compression tester.
5. Detach the compression tester and the special tool.
6. Install the glow plugs,

REFER to: Glow Plugs (303-07H Glow Plug System, Removal and Installation).
7. Connect the glow plug module C1E513.
8. Using the Ford diagnostic equipment, reset the PCM fault memory.
Measure the oil pressure

NOTE: The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity,
extent of oil filter contamination).
NOTE: The graphics used are for illustration purposes only.
1. Disconnect the oil pressure switch electrical connector from the oil pressure switch.
2. Remove the oil pressure switch.
3. Attach the oil pressure gauge with the oil pressure gauge connector.
4. NOTE: Measure the oil pressure at the specified engine speed. Measure the oil pressure at an
oil temperature of 125°C.
NOTE: Measure the oil pressure at idle speed and at 2000 rpm.
Check the oil pressure.
5/6
534/2430
10/30/2018 Print
5. Detach the oil pressure gauge and the oil pressure gauge connector.
6. Coat the oil pressure switch with adhesive.
7. Install the oil pressure switch.
8. Connect the oil pressure switch electrical connector to the oil pressure switch.
Valve train analysis - static (engine off)

Remove the valve cover.
Check all valve train components for damage and wear. Make sure that only original components are
installed and that all bolts and nuts have been tightened to the correct tightening torque.
6/6
535/2430
10/30/2018 Print
Engine - 1.6L Duratorq-TDCi

(85kW/115PS)/1.6L Duratorq-TDCi
(70kW/95PS) (T3) - Intake Manifold
Print
Removal
1. Refer to: Cylinder Head (303-01F Engine, Removal and Installation).
Installation
1. Refer to: Cylinder Head (303-01F Engine, Removal and Installation).
1/1
536/2430
10/30/2018 Print

(70kW/95PS) (T3) - Crankshaft Front Seal
Print

303-293
Remover, Crankshaft Seal
303-733
Installer, Crankshaft Front Seal
Trolley Jack
Wooden Block
Removal
1. Disconnect the following items:

1. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

1. Refer to: Timing Belt (303-01F Engine, Removal and Installation).
3. Install the following items:

NOTE: Only tighten the bolts finger tight at this stage.

NOTE: Only tighten the nuts and bolts finger tight at this stage.
1/3
537/2430
10/30/2018 Print
Installation

2. Assemble the following items:

Use the General Equipment: Trolley Jack
2/3
538/2430
10/30/2018 Print

Refer to: Timing Belt (303-01F Engine, Removal and Installation).
6. Connect the following items:

3/3
539/2430
10/30/2018 Print
Engine - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Valve Stem Seals
Print
Special Tool(s)
205-047
Slide Hammer
303-060
Compressor, Valve Spring
303-060-07
Adapter for 303-060
303-060-09A
Adapter for 303-060
303-292
Remover, Valve Stem Seal
303-362
Installer, Valve Stem Collets
Removal

1. Refer to: Camshaft (303-01F Engine, Removal and Installation).

NOTE: Use a new seal.
1/3
540/2430
10/30/2018 Print
3. Use Special Service Tools: 303-060, 303-060-09A, 303-060-07, 303-362.
4.
2/3
541/2430
10/30/2018 Print
Installation

Use a suitable socket.
3/3
542/2430
10/30/2018 Print

(70kW/95PS) (T3) - Camshaft
Print

205-072
Universal Flange Holding Wrench
303-245
Alignment Pins, Cylinder Head
303-684

Plastic Scraper
Materials
Name Specification
Primer -
Silicone Sealant WSE-M4G323-A4
Engine Oil - SAE 5W-20 WSS-M2C948-B
Removal
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General
Procedures).
2. Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling - 1.6L Duratorq-
TDCi (85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3), General Procedures).
4. Torque: 8 Nm
1/8
543/2430
10/30/2018 Print
5.
6. Torque: 10 Nm
7. Torque: 8 Nm
2/8
544/2430
10/30/2018 Print
8. Torque: 10 Nm
9. Torque: 10 Nm
10. NOTICE: The tip of the sensor must touch the component.
Torque: 10 Nm
3/8
545/2430
10/30/2018 Print
11. Torque:
Stage 1:13 Nm
Stage 2:8 Nm

Torque: 7 Nm
13. Refer to: Quick Release Coupling (310-00F Fuel System - General Information, General
Procedures).
Torque: 20 Nm
4/8
546/2430
10/30/2018 Print

Torque:
Stage 1:20 Nm
Stage 2:50°
15.
5/8
547/2430
10/30/2018 Print
Installation
2. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper
2. Material: - (Primer)
NOTE: The component must be installed within 10 minutes of applying the sealant.
Material: WSE-M4G323-A4 (Silicone Sealant)
Material: WSS-M2C948-B (Engine Oil - SAE 5W-20)
6/8
548/2430
10/30/2018 Print
4. Tighten each bolt 1 turn at a time.

Torque: 10 Nm

7/8
549/2430
10/30/2018 Print
8/8
550/2430
10/30/2018 Print

(70kW/95PS) (T3) - Camshaft Seal
Print
Special Tool(s)
303-293
303-684
Removal

Installation
1/2
551/2430
10/30/2018 Print

2/2
552/2430
10/30/2018 Print

(70kW/95PS) (T3) - Timing Belt
Print

303-393
Locking Tool, Flywheel
303-732
Alignment Peg, Crankshaft
303-735
Alignment Peg, Camshaft
Dowel with a Diameter of 6 mm

Trolley Jack
Wooden Block
Removal
NOTICE: The crankshaft or camshafts must not be rotated while the timing belt is removed.
1. Disconnect the following items:
Procedures).
2.
3.
1/13
553/2430
10/30/2018 Print

1. Refer to: Accessory Drive Belt (303-05F Accessory Drive, Removal and Installation).
5.

1. Refer to: Starter Motor (303-06F Starting System, Removal and Installation).
7. NOTICE: Make sure that the crankshaft is not rotated while the special tool is installed.
8.
2/13
554/2430
10/30/2018 Print
10.
11. NOTICE: Take extra care when handling the crankshaft position (CKP) sensor ring.
NOTE: This step is not necessary when installing a new component.
Torque: 20 Nm
3/13
555/2430
10/30/2018 Print
13. NOTICE: Only rotate the camshaft clockwise.

NOTE: The special tool can only be installed if the valve timing is correct.
14.
15.
1. NOTICE: Use a wooden block to protect the oil pan when supporting the engine.
Use the General Equipments: Trolley Jack, Wooden Block
4/13
556/2430
10/30/2018 Print
17.
18.
19.
20.
5/13
557/2430
10/30/2018 Print
Installation
1. Torque: 37 Nm

NOTE: Only tighten the bolt finger tight at this stage.
6/13
558/2430
10/30/2018 Print
4. Torque: 30 Nm
5. Torque: 55 Nm
7/13
559/2430
10/30/2018 Print
6. Torque:
1: 48 Nm
2: 48 Nm

1. Use the General Equipments: Trolley Jack, Wooden Block
9. Torque: 10 Nm
10. Torque: 10 Nm
8/13
560/2430
10/30/2018 Print
12. NOTICE: Only rotate the crankshaft clockwise.

Rotate the crankshaft 10 revolutions.


15. Use the General Equipment: Dowel with a Diameter of 6 mm
9/13
561/2430
10/30/2018 Print
19. Discard the bolt.
10/13
562/2430
10/30/2018 Print
20. Torque: 4 Nm

Torque:
Stage 1:35 Nm
Stage 2:190°
11/13
563/2430
10/30/2018 Print

1. Refer to: Starter Motor (303-06F Starting System, Removal and Installation).
25.

27. Torque: 4 Nm
12/13
564/2430
10/30/2018 Print
28.
29. Connect the following items:

Procedures).
13/13
565/2430
10/30/2018 Print

(70kW/95PS) (T3) - Exhaust Manifold
Print
Removal
Procedures).
2. Refer to: Turbocharger (303-04K Fuel Charging and Controls - Turbocharger, Removal and
Installation).
3. Torque: 8 Nm
4. Torque: 25 Nm
Installation
1/1
566/2430
10/30/2018 Print

(70kW/95PS) (T3) - Cylinder Head
Print
General Equipment
Plastic Scraper
Trolley Jack
Wooden Block
Materials
Name Specification
Primer -
Removal
NOTE: Use the Cylinder Head Gasket Check routine in the diagnostic scan tool.
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information,
2. WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel
temperature is at ambient air temperature.
Use the General Equipment: Ford Diagnostic Equipment
Procedures).
Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
Refer to: Air Cleaner (303-12F Intake Air Distribution and Filtering, Removal and Installation).
4.
5.
1/22
567/2430
10/30/2018 Print
6.
7.
8.
2/22
568/2430
10/30/2018 Print
10.
13.
3/22
569/2430
10/30/2018 Print
14. NOTE: Be prepared to collect escaping fluid.

Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information,
Refer to: Quick Release Coupling (310-00F Fuel System - General Information, General
Procedures).
15.
16.
4/22
570/2430
10/30/2018 Print
17.
18.

5/22
571/2430
10/30/2018 Print
20. NOTICE:
Make sure that the fuel line remains in contact at both ends until both unions nuts have
been unscrewed and the area around the joints thoroughly cleaned.
Make sure that all openings are sealed with new blanking caps.
21.
22. Torque: 10 Nm
6/22
572/2430
10/30/2018 Print
23.
24.
25.
7/22
573/2430
10/30/2018 Print
Procedures).
28.
29.
8/22
574/2430
10/30/2018 Print
30. Assemble the following items:

31.
9/22
575/2430
10/30/2018 Print
33.
Installation
10/22
576/2430
10/30/2018 Print
2. NOTICE: Make sure that new bolts are installed.

Torque:
Stage 1:20 Nm
Stage 2:40 Nm
Stage 3:260°
3. Torque:
1: 48 Nm
2: 48 Nm
4. Disassemble the following items:

11/22
577/2430
10/30/2018 Print

Torque: 30 Nm
NOTE: Use new seals.
12/22
578/2430
10/30/2018 Print
9. Torque: 10 Nm
13/22
579/2430
10/30/2018 Print
Procedures).
Torque: 20 Nm
12. Torque:
Stage 1:7 Nm
Stage 2:85°
14/22
580/2430
10/30/2018 Print
13.
14. Torque:
1: 13 Nm
2: 8 Nm
Torque: 10 Nm
15/22
581/2430
10/30/2018 Print
16.
17. NOTICE: Use an open-ended wrench to prevent the component from turning.
NOTE: Make sure that new components are installed.
Torque:
1: 20 Nm
2: 20 Nm
Torque:
1: 25 Nm
2: 25 Nm
16/22
582/2430
10/30/2018 Print

Torque: 7 Nm
20. Torque: 10 Nm
21. Torque:
1: 8 Nm
2: 8 Nm
3: 8 Nm
4: 20 Nm
5: 8 Nm
17/22
583/2430
10/30/2018 Print
22.
23. Torque: 8 Nm
Procedures).
18/22
584/2430
10/30/2018 Print
25. Torque:
1: 45 Nm
2: 39 Nm
28. Torque: 25 Nm
19/22
585/2430
10/30/2018 Print
Torque: 15 Nm
30. Torque: 12 Nm
20/22
586/2430
10/30/2018 Print
31. Torque: 10 Nm
32. Torque: 10 Nm
33.
34. Torque: 12 Nm
21/22
587/2430
10/30/2018 Print
Procedures).
22/22
588/2430
10/30/2018 Print

(70kW/95PS) (T3) - Oil Pan
Print
General Equipment
Oil Drain Equipment
Plastic Scraper
Materials
Name Specification
Primer -
Removal

NOTE: Use suitable paper to absorb any escaping fluid.
Use the General Equipment: Oil Drain Equipment
Torque:
1: 35 Nm
2: 10 Nm
3: 12 Nm
Installation
1/2
589/2430
10/30/2018 Print
2/2
590/2430
10/30/2018 Print

(70kW/95PS) (T3) - Oil Pump
Print
General Equipment
Plastic Scraper
Materials
Name Specification
Primer -
Removal
1. Refer to: Crankshaft Front Seal (303-01F Engine, Removal and Installation).
Refer to: Oil Pan (303-01F Engine, Removal and Installation).
2. Torque: 10 Nm
3. Torque:
Stage 1:5 Nm
Stage 2:9 Nm
Installation
1/2
591/2430
10/30/2018 Print
3. NOTE: The component must be installed within 10 minutes of applying the sealant.
2/2
592/2430
10/30/2018 Print

(70kW/95PS) (T3) - Crankshaft Rear Seal
Print
Special Tool(s)
303-172-01
Adapter for 303-172
303-172-02A
Adapter for 303-172
303-172-05
Adapters for 303-172-02A
303-174
Gauge, Bolt Angle
303-293
303-393
303-738
Installer, Crankshaft Rear Seal
Removal

Refer to: Transmission - 1.6L Duratorq-TDCi (77kW/105PS)/1.6L Duratorq-TDCi
(85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3) (308-03C Manual Transmission,
Removal).
Refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and Installation).
1/6
593/2430
10/30/2018 Print
3.
2/6
594/2430
10/30/2018 Print
Installation
1. Use Special Service Tools: 303-172-02A, 303-172-05.
3/6
595/2430
10/30/2018 Print
2. NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which must
be removed after installation.
Use Special Service Tools: 303-172-02A, 303-172-05.
3. Use Special Service Tools: 303-172-01, 303-738.
4/6
596/2430
10/30/2018 Print

NOTE: Install all the bolts finger tight before final tightening.

Torque:
Stage 1:30 Nm
Stage 2:90°
5/6
597/2430
10/30/2018 Print

Refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and Installation).
Refer to: Transmission - 1.6L Duratorq-TDCi (77kW/105PS)/1.6L Duratorq-TDCi

Installation).
6/6
598/2430
10/30/2018 Print

(70kW/95PS) (T3) - Engine
Print
Removal
204-605
204-609
Protection Cap, Ball Joint Gaiter
205-775
303-122
Lifting Bracket, Engine
Cable Ties
Mounting Table Set
Retaining Strap
Wooden Block
TDCi (70kW/95PS) - DV/1.6L Duratorq-TDCi (85kW/115PS) - DV, General Procedures).

1. Refer to: Cooling Fan Motor and Shroud (303-03F Engine Cooling, Removal and Installation).
2. Refer to: Air Cleaner (303-12F Intake Air Distribution and Filtering, Removal and
Installation).
3.
1/11
599/2430
10/30/2018 Print
4.
5.
6.
7. On both sides.
2/11
600/2430
10/30/2018 Print
8.
9.
10.
3/11
601/2430
10/30/2018 Print
11.
12.
13. Refer to: Gearshift Cable Adjustment - 6-Speed Manual Transmission - B6 (308-00 Manual
Transmission and Clutch - General Information, General Procedures).
4/11
602/2430
10/30/2018 Print
1. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.
Use the General Equipment: Cable Ties
15. 1.
2.
4.
16.
17.
5/11
603/2430
10/30/2018 Print
19. On both sides.
20. On both sides.
21.
22.
6/11
604/2430
10/30/2018 Print
23. Remove the special tool before completely installing the halfshaft.

7/11
605/2430
10/30/2018 Print
26.
27.

29.
8/11
606/2430
10/30/2018 Print
30.
31.
32. Use the General Equipment: Mounting Table Set
9/11
607/2430
10/30/2018 Print

1. Use the General Equipments: Wooden Block, Mounting Table Set, Retaining Strap
35.
10/11
608/2430
10/30/2018 Print
36.
37.
11/11
609/2430
10/30/2018 Print

(70kW/95PS) (T3) - Engine Accessories
Print
Removal
Special Tool(s)
303-122
303-293
303-435
Mounting Stand
303-435-06
Mounting Bracket for 303-435
303-435-13C
Mounting Plate for 303-435-06
1.
2.
1/13
610/2430
10/30/2018 Print
3.
4.
5.
2/13
611/2430
10/30/2018 Print
6. Install Special Service Tools: 303-435, 303-435-06, 303-435-13C.
8.
3/13
612/2430
10/30/2018 Print
9.
10.
4/13
613/2430
10/30/2018 Print
11.
12.
5/13
614/2430
10/30/2018 Print
13.
14.
15.
6/13
615/2430
10/30/2018 Print
16. NOTICE:
17. NOTICE:
18.
7/13
616/2430
10/30/2018 Print
20.
21.
22.
8/13
617/2430
10/30/2018 Print
23.
24.
25.
9/13
618/2430
10/30/2018 Print
26.
27.
28.
29.
10/13
619/2430
10/30/2018 Print
30.
11/13
620/2430
10/30/2018 Print
33.
34.
35.
12/13
621/2430
10/30/2018 Print
36.
37.
38. Loosen: 2 turn(s)
39.
13/13
622/2430
10/30/2018 Print

Print
Disassembly
Special Tool(s)
303-293
WARNING: Avoid flames, sparks or lighted substances.

1.
1/7
623/2430
10/30/2018 Print
3.
4.
2/7
624/2430
10/30/2018 Print
8.
9.
10.
3/7
625/2430
10/30/2018 Print
11.
12.
13.
4/7
626/2430
10/30/2018 Print
14.
15.
16.
5/7
627/2430
10/30/2018 Print
6/7
628/2430
10/30/2018 Print
7/7
629/2430
10/30/2018 Print

(70kW/95PS) (T3) - Cylinder Head
Print
Disassembly and Assembly of Subassemblies
Special Tool(s)
205-047
Slide Hammer
303-060
Compressor, Valve Spring
303-060-07
Adapter for 303-060
303-060-09A
Adapter for 303-060
303-292
Remover, Valve Stem Seal
303-362
Installer, Valve Stem Collets
Disassembly
1. NOTE: Use new seals.

1/6
630/2430
10/30/2018 Print

Use Special Service Tools: 303-060, 303-060-09A, 303-060-07, 303-362.
5.
2/6
631/2430
10/30/2018 Print
6.
7.
Assembly

Torque: 25 Nm
3/6
632/2430
10/30/2018 Print
9. Torque: 8 Nm
10. Torque: 25 Nm

Use a suitable socket.
4/6
633/2430
10/30/2018 Print
Use Special Service Tools: 303-060, 303-060-09A, 303-060-07, 303-362.
14. NOTE: Use new seals.

5/6
634/2430
10/30/2018 Print
6/6
635/2430
10/30/2018 Print

Print
Assembly
303-172-01
Adapter for 303-172
303-172-02A
Adapter for 303-172
303-172-05
Adapters for 303-172-02A
303-245
Alignment Pins, Cylinder Head
303-733
303-737
Guide, Crankshaft Bearing
303-738
Installer, Crankshaft Rear Seal
Plastic Scraper
Punch
Materials
Name Specification
Primer -
Engine Oil - SAE 5W-30 WSS-M2C913-D
Torque: 20 Nm
1/13
636/2430
10/30/2018 Print
Material: WSS-M2C913-D (Engine Oil - SAE 5W-30)
Material: WSS-M2C913-D (Engine Oil - SAE 5W-30)
Torque:
Stage 1:10 Nm
Stage 3:10 Nm
Stage 4:130°
2/13
637/2430
10/30/2018 Print
6. Use the General Equipment: Punch
3/13
638/2430
10/30/2018 Print
11. Torque: 10 Nm
4/13
639/2430
10/30/2018 Print
12. Torque: 6 Nm
13. Torque: 6 Nm
14. Torque:
5/13
640/2430
10/30/2018 Print

Stage 2:30 Nm
Stage 3:140°
15. Torque: 8 Nm
16. Torque: 8 Nm
6/13
641/2430
10/30/2018 Print
17. Material: WSE-M4G323-A4 (Silicone Sealant)
7/13
642/2430
10/30/2018 Print
20. Torque:
Stage 1:5 Nm
Stage 2:9 Nm
22. Torque: 10 Nm
8/13
643/2430
10/30/2018 Print
25. 1. NOTE: Use a new seal.

Torque: 35 Nm
2. Torque: 10 Nm
3. Torque: 12 Nm
9/13
644/2430
10/30/2018 Print
26. Use Special Service Tools: 303-172-02A, 303-172-05.
27. Use Special Service Tools: 303-172-01, 303-738.
28. Torque:
Stage 1:5 Nm
Stage 2:10 Nm
10/13
645/2430
10/30/2018 Print
30. Torque:
Stage 1:20 Nm
Stage 2:40 Nm
Stage 3:260°
11/13
646/2430
10/30/2018 Print
12/13
647/2430
10/30/2018 Print
34. Torque: 10 Nm
13/13
648/2430
10/30/2018 Print

Print
Installation
204-605
204-609
205-775
303-122
Cable Ties
Mounting Table Set
Retaining Strap
Wooden Block
Materials
Name Specification
Multi-Purpose Grease SA-M1C9107-A
1. Torque: 47 Nm
2. Torque: 47 Nm
1/12
649/2430
10/30/2018 Print
3. Torque:
1 25 Nm
2 12 Nm
3 6 Nm
4. Torque:
1 47 Nm
2 25 Nm
3 25 Nm

1. Use the General Equipments: Wooden Block, Mounting Table Set, Retaining Strap
2/12
650/2430
10/30/2018 Print
7. Use the General Equipment: Mounting Table Set
8. NOTE: Only tighten the nuts and bolts finger tight at this stage.
3/12
651/2430
10/30/2018 Print
9. NOTE: Only tighten the nuts and bolts finger tight at this stage.
10. Torque:
1 80 Nm
2 90 Nm
11. Torque: 80 Nm
12. Torque: 25 Nm
4/12
652/2430
10/30/2018 Print
13.

Torque: 25 Nm

5/12
653/2430
10/30/2018 Print
18. Torque:
1 6 Nm
2 6 Nm
3 25 Nm
4 25 Nm
6/12
654/2430
10/30/2018 Print
19. Torque: 48 Nm
20. On both sides.
Torque: 48 Nm
21. On both sides.
Torque: 25 Nm
23. Torque:
1: 63 Nm
2: 70 Nm
7/12
655/2430
10/30/2018 Print
24.
1. Material: SA-M1C9107-A (Multi-Purpose Grease)

4. Torque: 48 Nm
1. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.
26.
8/12
656/2430
10/30/2018 Print
28.
29. Torque: 35 Nm
30. Torque: 35 Nm
9/12
657/2430
10/30/2018 Print
31. Torque:
1 25 Nm
2 25 Nm
32. On both sides.
33. Torque: 25 Nm
10/12
658/2430
10/30/2018 Print
34.
35.
36.
37.
11/12
659/2430
10/30/2018 Print

1. Refer to: Cooling Fan Motor and Shroud (303-03F Engine Cooling, Removal and Installation).
2. Refer to: Air Cleaner (303-12F Intake Air Distribution and Filtering, Removal and
Installation).
39. Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General
Procedures).
12/12
660/2430
10/30/2018 Print

(70kW/95PS) (T3) - Engine Accessories
Print
Installation
205-072
Universal Flange Holding Wrench
303-122
303-1557
Wrench, Generator
303-435
Mounting Stand
303-435-06
303-435-13C
Mounting Plate for 303-435-06
303-684
303-732
303-733
1/19
661/2430
10/30/2018 Print
303-734
Locking Tool, Crankshaft
303-735
Alignment Peg, Camshaft
308-204
Aligner, Clutch Disc
Dowel with a Diameter of 6 mm

2. Torque:
Stage 1:30 Nm
Stage 2:90°
3. Torque: 10 Nm
2/19
662/2430
10/30/2018 Print
4. Torque:
1 8 Nm
2 8 Nm
3 8 Nm
4 20 Nm
5. Torque: 25 Nm
6. Torque: 8 Nm
3/19
663/2430
10/30/2018 Print
7.
1. Torque: 25 Nm

Torque: 30 Nm
8. Torque: 25 Nm
9. NOTE: Make sure that a new clamp is installed.

Torque: 15 Nm
4/19
664/2430
10/30/2018 Print
10. Torque: 12 Nm
11. Torque: 12 Nm
5/19
665/2430
10/30/2018 Print

Torque:
Stage 1:20 Nm
Stage 2:50°
15.
6/19
666/2430
10/30/2018 Print


7/19
667/2430
10/30/2018 Print
20. Torque: 30 Nm
8/19
668/2430
10/30/2018 Print
23. NOTICE: Only rotate the crankshaft clockwise.

Rotate the crankshaft 10 revolutions.

9/19
669/2430
10/30/2018 Print
28. Discard the bolt.
29.
30. Torque: 10 Nm
31.
1. Torque: 55 Nm

3. Torque: 6 Nm
32. Using the special tool, lock the flywheel.

10/19
670/2430
10/30/2018 Print
33. Torque:
Stage 1:35 Nm
Stage 2:190°
35. NOTE: The seal is to be reused unless damaged.

Torque: 7 Nm
36. NOTE: Use a new seal.

Torque: 20 Nm
11/19
671/2430
10/30/2018 Print
38. Torque:
Stage 1:7 Nm
Stage 2:85°
39.
40. Torque: 13 Nm
12/19
672/2430
10/30/2018 Print
Torque: 10 Nm
42. Torque: 10 Nm
43. Torque: 10 Nm
13/19
673/2430
10/30/2018 Print
44. NOTICE:
Torque:
Stage 1:20 Nm
Stage 2:25 Nm
45. NOTICE:
Torque:
Stage 1:20 Nm
Stage 2:25 Nm
14/19
674/2430
10/30/2018 Print
46. Torque: 8 Nm
47.
48.
15/19
675/2430
10/30/2018 Print
49.
50. Torque: 8 Nm
16/19
676/2430
10/30/2018 Print
52. Remove Special Service Tools: 303-435, 303-435-13C, 303-435-06.
53. Torque: 8 Nm
17/19
677/2430
10/30/2018 Print
54. Torque:
1 20 Nm
2 15 Nm

Torque:
1 45 Nm
2 39 Nm
18/19
678/2430
10/30/2018 Print

Torque: 29 Nm
19/19
679/2430
10/30/2018 Print
Engine Cooling - 1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Specifications
Print
SPECIFICATIONS
Motorcraft Super Plus Antifreeze WSS-M97B44-D
CAPACITIES
LITERS
Cooling system and heater 7,3
ANTIFREEZE
APPROXIMATE PERCENTAGE OF ANTIFREEZE (BY VOLUME) REMAINS FLUID TO SOLIDIFIES AT
50 % -25°C (-13°F) -37°C (-35°F)
COOLING SYSTEM PRESSURE
DESCRIPTION BAR (PSI)
Radiator pressure test 1,75 (25)
Coolant expansion tank cap release pressure 1,45-1,55 (21 - 23)
1/1
680/2430
10/30/2018 Print

(85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS)
(T3) - Engine Cooling
Print

Pressure Tester, Cooling System
303-396 (24-001 A)
Adapter for 303-396

303-396-08
Coolant leak(s) Fuse(s)
Coolant level Relay(s)
Air in system Wiring harness
Gaskets/seals Electrical connector(s)
Hose(s)/hose joints Cooling fan motor
Coolant expansion tank cap and seal Engine coolant temperature (ECT) sensor
Coolant expansion tank Powertrain control module (PCM)
Radiator
Coolant pump
Thermostat
Thermostat housing
Accessory drive belt
Symptom Chart

LOSS OF COOLANT * HOSE(S)/HOSE * INSPECT THE HOSES AND HOSE JOINTS. INSTALL A NEW
JOINT(S). HOSE(S) AS NECESSARY.
* RADIATOR. * INSPECT THE RADIATOR FOR LEAKS. CARRY OUT THE
PRESSURE TEST COMPONENT TESTS IN THIS SECTION.
INSTALL A NEW RADIATOR AS NECESSARY.
REFER TO: RADIATOR (303-03F ENGINE COOLING,
* COOLANT PUMP. * INSPECT THE COOLANT PUMP FOR LEAKS. CARRY OUT THE
PRESSURE TEST COMPONENT TESTS IN THIS SECTION.
INSTALL A NEW COOLANT PUMP OR COOLANT PUMP
GASKET AS NECESSARY.
REFER TO: COOLANT PUMP (303-03F ENGINE COOLING,
1/7
681/2430
10/30/2018 Print
* THERMOSTAT * INSPECT THE THERMOSTAT HOUSING FOR LEAKS. CARRY

HOUSING. OUT THE PRESSURE TEST COMPONENT TESTS IN THIS
SECTION. INSTALL A NEW THERMOSTAT HOUSING OR
THERMOSTAT HOUSING GASKET AS NECESSARY.
REFER TO: THERMOSTAT (303-03F ENGINE COOLING,
* COOLANT * CHECK THE COOLANT EXPANSION TANK CAP FOR
EXPANSION TANK TIGHTNESS. IF OK, CARRY OUT THE COOLANT EXPANSION
CAP OR SEAL. TANK CAP PRESSURE TEST COMPONENT TEST IN THIS
SECTION.
* COOLANT * INSPECT THE SEAL FACE ON THE COOLANT EXPANSION
EXPANSION TANK. TANK FOR DAMAGE. INSTALL A NEW COOLANT EXPANSION
TANK AS NECESSARY.
* HEATER CORE. * CHECK THE HEATER CORE FOR LEAKS.
* ENGINE. * INSPECT THE ENGINE, CYLINDER HEAD, CYLINDER BLOCK
AND CYLINDER HEAD GASKET.
REFER TO: CYLINDER HEAD (303-01F ENGINE, REMOVAL
AND INSTALLATION).
THE ENGINE * COOLING SYSTEM * CARRY OUT THE PRESSURE TEST COMPONENT TESTS IN
OVERHEATS (SIGNS DOES NOT HOLD THIS SECTION.
OF COOLANT PRESSURE. * INSPECT THE COOLANT EXPANSION TANK FOR DAMAGE.
BOILING) INSTALL A NEW COOLANT EXPANSION TANK AS
NECESSARY.
* INSPECT THE COOLANT PUMP OR COOLANT PUMP GASKET
FOR DAMAGE. INSTALL A NEW COOLANT PUMP OR
COOLANT PUMP GASKET AS NECESSARY.
* INSPECT THE ENGINE, CYLINDER HEAD, CYLINDER BLOCK
AND INSTALLATION).
* RADIATOR. * INSPECT THE RADIATOR FOR BLOCKAGE OR DAMAGE.
CARRY OUT THE PRESSURE TEST COMPONENT TESTS IN
THIS SECTION. INSTALL A NEW RADIATOR AS NECESSARY.
REFER TO: RADIATOR (303-03F ENGINE COOLING,
* AIR IN SYSTEM. * BLEED THE COOLING SYSTEM. REFER TO: (303-03 ENGINE
COOLING - 1.5L DURATORQ-TDCI (55KW/75PS))
COOLING SYSTEM DRAINING, FILLING AND BLEEDING
(GENERAL PROCEDURES),
* COOLANT * CHECK THE COOLANT EXPANSION TANK CAP FOR
EXPANSION TANK TIGHTNESS. IF OK, CARRY OUT THE COOLANT EXPANSION
CAP OR SEAL. TANK CAP PRESSURE TEST COMPONENT TEST IN THIS
SECTION.
* COOLANT * INSPECT THE SEAL FACE ON THE COOLANT EXPANSION
EXPANSION TANK. TANK FOR DAMAGE. INSTALL A NEW COOLANT EXPANSION
TANK AS NECESSARY.
* COOLANT * CHECK THE COOLANT LEVEL. REFILL THE COOLING
LEVEL/CONDITION. SYSTEM AS NECESSARY. REFER TO: (303-03 ENGINE
COOLING - 1.5L DURATORQ-TDCI (55KW/75PS))
* CHECK THE COOLANT CONDITION. IF THE COOLANT IS IN
POOR CONDITION DRAIN AND REFILL WITH NEW
COOLANT. REFER TO: (303-03 ENGINE COOLING - 1.5L
DURATORQ-TDCI (55KW/75PS))
* COOLANT *
CONCENTRATION. REFER TO: SPECIFICATIONS (303-03F ENGINE COOLING,
SPECIFICATIONS).
* RADIATOR GRILLE. * INSPECT THE RADIATOR GRILLE FOR AIR RESTRICTIONS
2/7
682/2430
10/30/2018 Print
OR DAMAGE. REPAIR OR INSTALL NEW PARTS AS

NECESSARY.
* COOLANT PUMP. * CARRY OUT THE PRESSURE TEST COMPONENT TESTS IN
THIS SECTION. INSPECT THE COOLANT PUMP FOR LEAKS.
INSTALL A NEW COOLANT PUMP OR COOLANT PUMP
GASKET AS NECESSARY.
* THERMOSTAT. * CARRY OUT THE THERMOSTAT TEST COMPONENT TEST IN
THIS SECTION. INSTALL A NEW THERMOSTAT AS
NECESSARY.
* ACCESSORY DRIVE * CHECK THE ACCESSORY DRIVE BELT FOR CORRECT
BELT OPERATION.
REFER TO: ACCESSORY DRIVE (303-05F ACCESSORY
DRIVE, DIAGNOSIS AND TESTING).
* COOLING FAN * CHECK THE OPERATION OF THE COOLING FAN MOTOR.
MOTOR. REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* ENGINE. * INSPECT THE ENGINE, CYLINDER HEAD, CYLINDER BLOCK
AND INSTALLATION).
THE ENGINE DOES * ECT SENSOR. * CHECK THE ECT SENSOR. REFER TO THE FORD
NOT REACH NORMAL DIAGNOSTIC EQUIPMENT.
OPERATING * TEMPERATURE * CHECK THE INSTRUMENT CLUSTER ENGINE TEMPERATURE
TEMPERATURE. GAUGE. GAUGE.
REFER TO: INSTRUMENT PANEL CLUSTER (IPC) (413-01A
INSTRUMENT PANEL CLUSTER (IPC), DIAGNOSIS AND
TESTING).
* THERMOSTAT. * CARRY OUT THE THERMOSTAT TEST COMPONENT TEST IN
THIS SECTION. INSTALL A NEW THERMOSTAT AS
NECESSARY.
THE COOLING FAN * COOLING FAN. * CHECK THE OPERATION OF THE COOLING FAN. REFER TO
IS INOPERATIVE THE FORD APPROVED DIAGNOSTIC TOOL.
Component Tests
Static Pressure Test
NOTICE: During this procedure do not exceed a pressure of 200 kPa (29 psi) as cooling system
damage may occur.
1. WARNING: When releasing the system pressure, cover the expansion tank cap with a
thick cloth to prevent the possibility of coolant scalding, Failure to follow this instruction may
Remove the coolant expansion tank cap.
2. Install the special tools to the coolant expansion tank.
3. Pressurize the cooling system to 175 kPa (25 psi).
4. Observe the cooling system pressure tester gauge reading for approximately six minutes. The
pressure should not drop during this time. If the cooling system holds pressure, proceed to
step 6. If the cooling system does not hold pressure, check the cooling system thoroughly for
coolant leaks.
5. Check the engine for coolant leaks. Drain the cooling system, repair any coolant leaks found
and fill and bleed the cooling system as necessary. REFER to:
Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling - 1.5L Duratorq-TDCi
(55kW/75PS), General Procedures),
3/7
683/2430
10/30/2018 Print
Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling, General
Procedures).
6. Carry out the Dynamic Pressure Test
Dynamic Pressure Test
NOTICE: During this procedure do not exceed a pressure of 200 kPa (29 psi) as cooling system
damage may occur.
1. With the special tools still connected to the coolant expansion tank and pressurized to 175 kPa
(25 psi).
2. Start the engine and allow it to idle.
3. Increase the engine speed to 2000 RPM and hold at that speed
4. Observe the cooling system pressure tester gauge reading for approximately ten minutes. The
pressure should not drop during this time. If the cooling system does not hold pressure, check
the cooling system thoroughly for coolant leaks.
5. Allow the engine to return to idle.
6. Switch the ignition off.
7. WARNING: When releasing the system pressure, cover the expansion tank cap with a
thick cloth to prevent the possibility of coolant scalding, Failure to follow this instruction may
Remove the special tools.
8. Install the coolant expansion tank cap.
9. Check the engine for coolant leaks. Drain the cooling system, repair any coolant leaks found
and fill and bleed the cooling system as necessary. REFER to:
Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling - 1.5L Duratorq-TDCi
(55kW/75PS), General Procedures),
Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling, General
Procedures).
Coolant Expansion Tank Cap Pressure Test
WARNING: When releasing the system pressure, cover the expansion tank cap with a thick
cloth to prevent the possibility of coolant scalding, Failure to follow this instruction may result in
personal injury.
1. Remove the coolant expansion tank cap.
2. Use water to clean the area of the rubber seal and pressure relief valve. Install the pressure
tester and adapter and immerse the coolant expansion tank cap in water .
NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure reading will
result.
3. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing, and note the highest pressure reading obtained.
4. Release pressure by turning the pressure relief screw counterclockwise. Tighten the pressure
relief screw and repeat step 3 at least twice to make sure the pressure test reading is
repeatable and within acceptable gauge reading limits of the coolant expansion tank cap.
5. If the pressure test gauge readings are not within the acceptable gauge reading limits, INSTALL
a new coolant expansion tank cap.
Radiator Leak Test, Removed From Vehicle
4/7
684/2430
10/30/2018 Print
NOTICE: Radiator internal pressure must not exceed 200 kPa (29 psi) or damage may result.
Clean the radiator thoroughly before leak testing it, to prevent contamination of the water in the test
tank. Leak test the radiator in clean water with 175 kPa (25 psi) air pressure. Check it thoroughly for
air leaks. INSTALL a new radiator if necessary.
REFER to: Radiator (303-03B Engine Cooling, Removal and Installation).
Thermostat Test
1. Connect the Ford diagnostic equipment to the data link connector (DLC).
2. Using the Ford diagnostic equipment datalogger function, SELECT the following sensors (as
applicable to the application):
IAT - intake air temperature (IAT) sensor

ECT - engine coolant temperature (ECT) sensor
CHT - cylinder head temperature (CHT) sensor
LOAD - engine load
VSS - vehicle speed sensor (VSS)
RPM - engine speed
DSRPM - desired engine speed
The IAT sensor output is useful if the engine being tested is cold or after an over-night cold soak. The
ECT sensor or CHT sensor and the IAT sensor should either indicate the same value or be within 1 to
2 degrees Celsius of each other.
The ECT sensor output is important to display as it indicates the engine warm-up and opening
temperature for the thermostat. It will initially indicate a slightly higher reading just before the
thermostat opens and then drops back before settling to a near flat line output (see graphic below).

A - Thermostat opens
B - Thermostat settles into a cyclic open and closure pattern
NOTICE: If the ECT sensor output reaches the 120ºC default line under normal cooling system
pressure, internal damage may be caused to the engine and a diagnostic trouble code (DTC) will be
set in the PCM. The test should be stopped and the cause located and corrected. If the cooling
system does not pressurize, the coolant will boil at 100ºC which may also damage the engine.
CARRY OUT the Coolant Expansion Tank Cap Pressure Test Component Test in this section.
If the Ford diagnostic equipment only allows the ECT sensor to be displayed in volts, refer to the
following table for corresponding Celsius values:
Volts ºCelsius
1.33 60
1.02 70
0.78 80
0.60 90
0.46 100
0.35 110
0.27 120
The CHT sensor output is useful to examine the cylinder head temperature rise during the warm-up
cycle and later during the normal light throttle cruise test. This sensor output may vary between
vehicles with manual transmission and vehicles with automatic transmission and should be used for
reference only.
5/7
685/2430
10/30/2018 Print
The LOAD display is used for reference as it is necessary to maintain a stable load line during the test.
It is necessary to carry out the test under normal light throttle cruise driving conditions and average
loads, typically 40% to 70% of the load value.
The VSS output is used for reference but can help to identify misfires and sensors which fail during
the warm-up cycle.
The RPM display indicates the engine speed and can be compared with the DSRPM.
The DSRPM is the desired or calculated idle speed which the PCM commands the engine to reach. If
the thermostat opens too early (before the correct opening temperature has been reached), the
engine will not reach this value.
When using the Ford diagnostic equipment in data logger mode, the signals recorded should remain
within the DEFAULT values set by the Ford diagnostic equipment.
3.
WARNING: Make sure that the Ford diagnostic equipment is placed in the vehicle so that
it does not interfere with the safe operation of the vehicle. Do not place the Ford diagnostic
equipment in the deployment path of any air bag. Failure to follow these instructions may
NOTE: The road test is best carried out with the aid of another technician in the vehicle to
enable the vehicle to be driven safely while the sensor outputs are monitored within
datalogger. If there is only one technician available, the Ford diagnostic equipment can be set
up (using the record/capture mode camera icon) before leaving the workshop to record a 16
km (10 mile) test.
NOTE: The results from the test are more conclusive if the engine is cold when the test is
started.
Carry out a road test.
REFER to: Road/Roller Testing (100-00 General Information, Description and Operation).
4. Drive the vehicle at a constant throttle opening and set speed until the ECT value settles into a
shallow rise and fall signal, close to a straight line. This indicates that the thermostat is
functioning correctly.
NOTE: Some thermostats indicate the temperature(s) in Celsius and Fahrenheit.

The graphic below shows the location and an example of the opening temperature (88ºC) and fully
open temperature (102ºC) of a thermostat.
The graphic below shows an alternative method used to show the opening temperature (88ºC) and
fully open temperature (112ºC) of a thermostat.

A - Opening temperature
B - Fully open temperature
6/7
686/2430
10/30/2018 Print
NOTE: Generally, most thermostats maintain a coolant temperature between 88ºC (190ºF) and
92ºC (198ºF) although dual stage electric thermostats may increase the coolant temperature up to
100ºC (212ºF) under light engine load conditions.
The engine should start cleanly and the ECT value will rise quite quickly with smooth progression. If
the ECT signal appears unstable or erratic, the ECT sensor, electrical connector and wiring harness to
the PCM need to be visually inspected for damage, chafing or water ingress.
The temperature should rise to approximately 90ºC for a thermostat that has an 88ºC value. The
signal value will then fall as cooler coolant enters the engine.
If the ECT value fails to maintain a constant value and falls back to lower figures, typically between
60ºC (140ºF) and 70ºC (150ºF), the thermostat and its sealing function within the thermostat
housing must be checked.
5. INSTALL a new thermostat.

REFER to: Thermostat (303-03F Engine Cooling, Removal and Installation).
6. Carry out another road test from step 1 using the same criteria to confirm that the concern has
been rectified.
7. Using the Ford diagnostic equipment, clear the PCM keep alive memory (KAM) or electrically
erasable programmable read only memory (EEPROM) so that new drive values can be learnt.
7/7
687/2430
10/30/2018 Print
Engine Cooling - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Cooling System Draining, Vacuum Filling and
Bleeding
Print
General Procedures
General Equipment
Cooling System Vacuum Tester and Refiller
Fluid Container
Materials
Name Specification
Antifreeze WSS-M97B44-D
Draining
NOTE: Always follow the manufacturer's instructions when handling the equipment.
1. Refer to: Engine Cooling System Health and Safety Precautions (100-00, Description and
Operation).
2.
WARNING: When releasing the cooling system pressure, cover the coolant expansion
tank cap with a thick cloth.
Release the cooling system pressure by slowly turning the coolant expansion tank cap between 2
and 3 turns.
4.
5.
WARNING: Be prepared to collect escaping fluid.

Use the General Equipments: Fluid Container, Hose Clamp Remover/Installer
1/4
688/2430
10/30/2018 Print
6.
Filling
1.
If the cooling system was completely drained, fill the fluid container with the full cooling
system fill capacity plus 0.5L of additional coolant.
Material: WSS-M97B44-D (Antifreeze)

If the cooling system was partially drained, fill the fluid container with the removed and
spilled amount of coolant plus 1.0L of additional coolant. When in doubt always use the full
cooling system fill capacity plus 0.5L of additional coolant.
2. Use the General Equipment: Cooling System Vacuum Tester and Refiller
3. 1. Close the valve, install the coolant hose and place it into the fluid container.
2. Close the valve and connect the compressed air hose.
2/4
689/2430
10/30/2018 Print
4. Open the valve until the specificied vacuum is achieved.
5. 1. Open the valve until the coolant reservoir fluid level is at the MAX mark.
2. If no coolant is visible in the coolant expansion tank, add 2.0L of coolant to the fluid
container and repeat the evacuating and filling procedure.
3/4
690/2430
10/30/2018 Print
6.
4/4
691/2430
10/30/2018 Print

(70kW/95PS) (T3) - Thermostat
Print
General Equipment
Hose Clamp(s)
Removal
Procedures).
2. Torque: 10 Nm
3. Refer to: Cooling System Draining, Filling and Bleeding (303-03D, General Procedures).
4. Use the General Equipment: Hose Clamp(s)

Torque: 7 Nm
1/2
692/2430
10/30/2018 Print
Installation
2/2
693/2430
10/30/2018 Print

(70kW/95PS) (T3) - Coolant Pump
Print
Removal
2. Torque:
Stage 1:5 Nm
Stage 2:10 Nm
Installation
1/1
694/2430
10/30/2018 Print

(70kW/95PS) (T3) - Radiator
Print
General Equipment
Transmission Jack
Removal
Procedures).
3.
4.
1/5
695/2430
10/30/2018 Print
6.
2/5
696/2430
10/30/2018 Print
10. On both sides.
Torque: 25 Nm

Torque: 25 Nm
3/5
697/2430
10/30/2018 Print
12.
13. Torque: 10 Nm
4/5
698/2430
10/30/2018 Print
Installation
5/5
699/2430
10/30/2018 Print

(70kW/95PS) (T3) - Cooling Fan Motor and Shroud
Print
Removal
1. Refer to: Air Cleaner (303-12F Intake Air Distribution and Filtering, Removal and Installation).
2.
3.
Installation
1/1
700/2430
10/30/2018 Print
Fuel Charging and Controls - 1.6L Duratorq-TDCi

(T3) - Fuel Charging and Controls
Print
General Equipment

WARNINGS:
Do not smoke or carry lighted tobacco of any type when working on or near any fuel related
components. Highly flammable mixtures are always present and may ignite. Failure to follow these
instructions may result in personal injury.
This procedure involves fuel handling. Be prepared for fuel spillage at all times. Failure to
follow this instruction may result in personal injury.
NOTICE: Diesel fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute cleanliness is observed when working with these
components. Always fit blanking plugs to any open orifices or lines.
NOTE: As well as carrying out its normal function the glow plug indicator also acts as an engine
check lamp which will flash continuously when a hard diagnostic trouble code (DTC) is detected by
the powertrain control module (PCM). Soft DTCs are also stored by the PCM but will only be known
if the system is checked for DTCs using the Ford diagnostic equipment.
NOTE: If a DTC is detected, all DTCs must be cleared after the concern is rectified. Failure to clear
all DTCs may cause driveability concerns.
NOTE: If the fuel level in the fuel tank drops below approximately four liters, rough running will
occur. This is to signal to the driver that the vehicle requires refuelling in order to prevent the fuel
system from running dry.
Fuel leak(s) Fuse(s)
Fuel filter Relay(s)
Air cleaner element Wiring harness
Vacuum line(s)/vacuum connections Electrical connector(s)
Hose(s)/hose connections Passive anti-theft system (PATS) LED
Tube(s)/tube connections operation
Contaminated fuel Sensor(s)
Fuel supply line(s) Glow plug indicator
Fuel return line(s) Powertrain control module (PCM)
Diesel particulate filter (DPF)
High-pressure fuel supply line(s)
Fuel injectors
Fuel rail
Fuel pump
equipment to retrieve the diagnostic trouble codes (DTCs).
5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue
diagnostics.
Symptom Chart
1/11
701/2430
10/30/2018 Print

ENGINE DOES NOT * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
CRANK AND GLOW
PLUG INDICATOR IS
FLASHING
ENGINE DOES NOT * BATTERY * CHECK THE CONDITION OF THE BATTERY.
CRANK REFER TO: CHARGING SYSTEM (414-00 CHARGING
SYSTEM - GENERAL INFORMATION, DIAGNOSIS AND
TESTING).
* STARTER MOTOR. * CHECK THE CONDITION OF THE STARTING SYSTEM.
REFER TO: STARTING SYSTEM (303-06A STARTING
SYSTEM, DIAGNOSIS AND TESTING).
* PATS. * CHECK THE PATS LED EXTINGUISHES WITHIN 3
SECONDS WHEN THE IGNITION IS TURNED ON.
REFER TO: PASSIVE ANTI-THEFT SYSTEM (PATS) (419-
01B PASSIVE ANTI-THEFT SYSTEM (PATS), DIAGNOSIS
AND TESTING).
* STARTER INHIBIT * CARRY OUT THE RELAY COMPONENT TEST. REFER TO THE
RELAY. WIRING DIAGRAMS.
* POWER RELAY.
* PCM. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
ENGINE CRANKS * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
BUT DOES NOT
START AND GLOW
PLUG INDICATOR IS
FLASHING
ENGINE CRANKS * LOW FUEL TANK * CHECK THE FUEL TANK FUEL LEVEL IS GREATER THAN
BUT DOES NOT FUEL LEVEL. FOUR LITERS. IF THE FUEL TANK FUEL LEVEL IS LESS
START THAN FOUR LITERS, FILL WITH FUEL.
* FUEL FILTER * INSTALL A NEW FUEL FILTER.
BLOCKED.
* FUEL LINES *
DAMAGED OR REFER TO: FUEL SYSTEM (310-00G FUEL SYSTEM -
BLOCKED. GENERAL INFORMATION, DIAGNOSIS AND TESTING).
* AIR INGRESS INTO *
THE FUEL LINES. REFER TO: FUEL SYSTEM (310-00G FUEL SYSTEM -
GENERAL INFORMATION, DIAGNOSIS AND TESTING).
* GLOW PLUGS. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* CRANKSHAFT * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
POSITION (CKP)
SENSOR.
* CAMSHAFT POSITION * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
(CMP) SENSOR.
* FUEL RAIL FUEL * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
PRESSURE SENSOR.
* FUEL METERING * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
VALVE.
* FUEL PUMP. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* FUEL INJECTOR(S). * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* INCORRECT VALVE * CHECK THE VALVE TIMING.
TIMING. REFER TO: TIMING BELT (303-01F ENGINE, REMOVAL
AND INSTALLATION).
* LOW CYLINDER * CHECK THE CYLINDER COMPRESSION.
COMPRESSION. REFER TO: ENGINE (303-01F ENGINE, DIAGNOSIS AND
TESTING).
POOR STARTING * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
AND GLOW PLUG
INDICATOR IS
FLASHING
POOR STARTING * LOW FUEL TANK * CHECK THE FUEL TANK FUEL LEVEL IS GREATER THAN
FUEL LEVEL. FOUR LITERS. IF THE FUEL TANK FUEL LEVEL IS LESS
2/11
702/2430
10/30/2018 Print
THAN FOUR LITERS, FILL WITH FUEL.

BLOCKED.
* AIR CLEANER * INSTALL A NEW AIR CLEANER ELEMENT.
ELEMENT BLOCKED.
* GLOW PLUG RELAY. * CARRY OUT THE RELAY COMPONENT TEST. REFER TO
WIRING DIAGRAMS.
* GLOW PLUG(S). * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* FUEL SYSTEM * CHECK THE SYSTEM FOR FUEL LEAK(S). REPAIR THE
LEAK(S). SYSTEM AS NECESSARY.
* FUEL SYSTEM *
RESTRICTION. REFER TO: FUEL SYSTEM (310-00G FUEL SYSTEM -
* CATALYTIC * REMOVE AND VISUALLY INSPECT THE CATALYTIC
CONVERTER CONVERTER FOR DAMAGE. INSTALL A NEW CATALYTIC
BLOCKED. CONVERTER AS NECESSARY.
REFER TO: CATALYTIC CONVERTER (309-00G EXHAUST
* DPF BLOCKED. * REGENERATE THE DPF. REFER TO THE FORD DIAGNOSTIC
EQUIPMENT.
* CKP SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* ECT SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* FUEL TEMPERATURE * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
SENSOR.
* MASS AIR FLOW * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
(MAF) SENSOR.
* DPF DIFFERENTIAL * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
PRESSURE SENSOR.
* INCORRECT ENGINE * INSTALL A NEW ENGINE OIL FILTER AND DESIGNATED
OIL. ENGINE OIL.
PRESSURE SENSOR.
VALVE.
TESTING).
ENGINE STARTS * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
BUT IMMEDIATELY
STOPS AND GLOW
PLUG INDICATOR IS
FLASHING
ENGINE STARTS * AIR CLEANER * INSTALL A NEW AIR CLEANER ELEMENT.
BUT IMMEDIATELY ELEMENT BLOCKED.
STOPS * AIR INGRESS INTO *
* PCM RELAY. * CARRY OUT THE RELAY COMPONENT TEST. REFER TO
WIRING DIAGRAMS.
* CMP SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* MAF SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
VALVE.
3/11
703/2430
10/30/2018 Print

POOR IDLING AND * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
GLOW PLUG
INDICATOR IS
FLASHING
POOR IDLING * LOW FUEL TANK * CHECK THE FUEL TANK FUEL LEVEL IS GREATER THAN
ELEMENT BLOCKED.
BLOCKED.
* INCORRECT OR * CHECK FOR SIGNS OF CONTAMINATION SUCH AS
CONTAMINATED STRANGE ODORS FROM THE FUEL TANK.
FUEL. * CHECK FOR SIGNS OF WATER OR PETROL IN THE
DIESEL.
* IF CONTAMINATED FUEL IS FOUND, DRAIN THE
COMPLETE FUEL SYSTEM.
REFER TO IN THIS SECTION.
FLUSH THE FUEL SYSTEM THROUGH WITH CLEAN
DIESEL. FILL WITH CLEAN FUEL. INSTALL A NEW FUEL
FILTER. INSTALL A NEW FUEL PUMP, FUEL INJECTORS,
FUEL RAIL AND HIGH-PRESSURE FUEL SUPPLY LINES.
REFER TO: (303-04I FUEL CHARGING AND CONTROLS)
FUEL PUMP (REMOVAL AND INSTALLATION),
FUEL INJECTORS (REMOVAL AND INSTALLATION),
FUEL RAIL (REMOVAL AND INSTALLATION),
FUEL RAIL SUPPLY TUBE (REMOVAL AND
INSTALLATION).
* EGR VALVE * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
INCORRECT
OPERATION.
PRESSURE SENSOR.
* FUEL INLET * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
METERING VALVE.
ENGINE STUMBLING * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
AND GLOW PLUG
INDICATOR IS
FLASHING
ENGINE STUMBLING * LOW FUEL TANK * CHECK THE FUEL TANK FUEL LEVEL IS GREATER THAN
* ACCELERATION * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
PEDAL POSITION
(APP) SENSOR.
PRESSURE SENSOR.
ENGINE LACKS * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
POWER AND GLOW
4/11
704/2430
10/30/2018 Print
PLUG INDICATOR IS
FLASHING
ENGINE LACKS * AIR CLEANER * INSTALL A NEW AIR CLEANER ELEMENT.
POWER ELEMENT BLOCKED.
BLOCKED.
* CATALYTIC * CHECK IF THE CATALYTIC CONVERTER RATTLES IF
CONVERTER GENTLY TAPPED. IF NOISE IS PRESENT, REMOVE AND
BLOCKED. VISUALLY INSPECT THE CATALYTIC CONVERTOR FOR
DAMAGE. INSTALL A NEW CATALYTIC CONVERTER AS
NECESSARY.
* KINKED OR *
RESTRICTED FUEL REFER TO: FUEL SYSTEM (310-00G FUEL SYSTEM -
LINES. GENERAL INFORMATION, DIAGNOSIS AND TESTING).
DIESEL.
INSTALLATION).
* EXHAUST GAS * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
RECIRCULATION
(EGR) VALVE.
* TURBOCHARGER. *
* TURBOCHARGER REFER TO: TURBOCHARGER (303-04K FUEL CHARGING
WASTEGATE. AND CONTROLS - TURBOCHARGER, DIAGNOSIS AND
TESTING).
* CHARGE AIR COOLER * INSPECT FOR VISIBLE SIGNS OF DAMAGE OR
BLOCKED OR BLOCKAGE. CLEAN, REPAIR OR INSTALL NEW PARTS AS
CRACKED. NECESSARY.
* CHARGE AIR COOLER
PIPES SPLIT OR
CRACKED.
* CHARGE AIR COOLER
PIPE RETAINING
CLIPS MISSING OR
LOOSE.
* DPF BLOCKED. * REGENERATE THE DPF. REFER TO THE FORD DIAGNOSTIC
EQUIPMENT.
* APP SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* VEHICLE SPEED * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
SENSOR (VSS).
* FUEL TEMPERATURE * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
SENSOR.
5/11
705/2430
10/30/2018 Print
PRESSURE SENSOR.
* DPF DIFFERENTIAL * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
PRESSURE SENSOR.
VALVE.
AND INSTALLATION).
TESTING).
* VEHICLE * ADVISE THE CUSTOMER ABOUT THE EFFECTS OF
OVERLOADED, OR OVERLOADING THE VEHICLE AND WIND RESISTANCE ON
EXCESSIVE WIND THE FUEL CONSUMPTION.
RESISTANCE (ROOF
RACKS, TOWING
ETC).
* BRAKES BINDING. * CHECK THE BRAKING SYSTEM.
REFER TO: BRAKE SYSTEM (206-00 BRAKE SYSTEM -
BLACK SMOKE AT * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
IDLE AND GLOW
PLUG INDICATOR IS
FLASHING
BLACK SMOKE AT * AIR CLEANER * INSTALL A NEW AIR CLEANER ELEMENT.
IDLE ELEMENT BLOCKED.
PRESSURE SENSOR.
AND INSTALLATION).
EXCESSIVE BLACK * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
SMOKE DURING
ACCELERATION AND
GLOW PLUG
INDICATOR IS
FLASHING
EXCESSIVE BLACK * AIR CLEANER * INSTALL A NEW AIR CLEANER ELEMENT.
SMOKE DURING ELEMENT BLOCKED.
ACCELERATION * INCORRECT OR * CHECK FOR SIGNS OF CONTAMINATION SUCH AS
DIESEL.
6/11
706/2430
10/30/2018 Print

INSTALLATION).
* EGR VALVE. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
* APP SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
PRESSURE SENSOR.
BLACK SMOKE AT * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
CRUISING SPEEDS
AND GLOW PLUG
INDICATOR IS
FLASHING
BLACK SMOKE AT * AIR CLEANER * INSTALL A NEW AIR CLEANER ELEMENT.
CRUISING SPEEDS ELEMENT BLOCKED.
* VACUUM LINES. * CHECK ALL VACUUM LINES ARE CORRECTLY INSTALLED
AND NO SIGNS OF AIR LEAKS ARE PRESENT. REPAIR OR
INSTALL NEW VACUUM LINE(S) AS NECESSARY.
* TURBOCHARGER. *
REFER TO: TURBOCHARGER (303-04K FUEL CHARGING
AND CONTROLS - TURBOCHARGER, DIAGNOSIS AND
TESTING).
PRESSURE SENSOR.
BLUE SMOKE AND * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
GLOW PLUG
INDICATOR IS
FLASHING
BLUE SMOKE * ENGINE BURNING * CARRY OUT A CONTROLLED OIL CONSUMPTION TEST
OIL. OVER 1000 KM (600 MILES). CONFIRM THAT THE OIL
CONSUMPTION IS LESS THAN 0.1 LITERS PER 1000 KM
(600 MILES).
DIESEL.
7/11
707/2430
10/30/2018 Print

INSTALLATION).
* WORN OR DAMAGED * REMOVE THE CYLINDER HEAD.
VALVE GUIDE(S), REFER TO: CYLINDER HEAD (303-01F ENGINE, REMOVAL
PISTON RING(S), AND INSTALLATION).
CYLINDER BORE(S), INSPECT THE CYLINDER HEAD, PISTONS AND CYLINDER
CYLINDER HEAD OR BORES FOR SIGNS OF WEAR OR DAMAGE.
GASKET.
* POSITIVE * INSPECT FOR VISIBLE SIGNS OF DAMAGE OR
CRANKCASE BLOCKAGE. CLEAN, REPAIR OR INSTALL NEW PARTS AS
VENTILATION (PCV) NECESSARY.
SYSTEM.
* TURBOCHARGER OIL *
SEALS LEAKING. REFER TO: TURBOCHARGER (303-04K FUEL CHARGING
* TURBOCHARGER OIL AND CONTROLS - TURBOCHARGER, DIAGNOSIS AND
RETURN TUBE TESTING).
BLOCKED OR
DAMAGED.
WHITE SMOKE AND * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
GLOW PLUG
INDICATOR IS
FLASHING
WHITE SMOKE * DPF NOTE: DURING REGENERATION OF THE DPF IT IS
POSSIBLE THAT WHITE SMOKE MAY BE EMITTED FROM
THE EXHAUST TAILPIPE. THIS IS AN INHERENT BY-
PRODUCT OF THE REGENERATION PROCESS AND
SHOULD NOT BE CONSIDERED A CONCERN.
* NO ACTION REQUIRED
* WATER IN FUEL. * CHECK FOR SIGNS OF WATER IN THE DIESEL.
* IF CONTAMINATED FUEL IS FOUND, DRAIN THE FUEL
FILTER OF WATER UNTIL CLEAR FUEL IS PRESENT. IF
CONTAMINATED FUEL IS STILL FOUND, DRAIN THE
INSTALLATION).
* COOLANT IN THE * CARRY OUT A COOLING SYSTEM PRESSURE TEST.
COMBUSTION REFER TO: ENGINE COOLING (303-03F ENGINE
CHAMBER. COOLING, DIAGNOSIS AND TESTING).
REMOVE THE CYLINDER HEAD.
AND INSTALLATION).
INSPECT THE CYLINDER HEAD, CYLINDER HEAD GASKET
AND CYLINDER BORES FOR WEAR OR DAMAGE.
AND INSTALLATION).
ENGINE MISFIRE * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
AND GLOW PLUG
INDICATOR IS
FLASHING
8/11
708/2430
10/30/2018 Print
ENGINE MISFIRE * LOW FUEL TANK * CHECK THE FUEL TANK FUEL LEVEL IS GREATER THAN
* HIGH-PRESSURE * CHECK THE HIGH-PRESSURE FUEL SUPPLY LINES FOR
FUEL SUPPLY SIGNS OF DAMAGE. INSTALL NEW HIGH-PRESSURE FUEL
LINE(S). SUPPLY LINES AS NECESSARY.
DIESEL.
INSTALLATION).
* CMP SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
PRESSURE SENSOR.
* LOW CYLINDER * CHECK CYLINDER COMPRESSION.
TESTING).
* WORN OR DAMAGED * REMOVE THE CYLINDER HEAD.
VALVE(S), CAMSHAFT REFER TO: CYLINDER HEAD (303-01F ENGINE, REMOVAL
FOLLOWER(S) OR AND INSTALLATION).
CAMSHAFT(S). INSPECT THE CYLINDER HEAD, VALVE(S), CAMSHAFT
FOLLOWER(S) AND CAMSHAFT(S) FOR SIGNS OF WEAR
OR DAMAGE.
* DAMAGED CYLINDER * REMOVE THE CYLINDER HEAD.
HEAD GASKET OR REFER TO: CYLINDER HEAD (303-01F ENGINE, REMOVAL
CYLINDER BORE(S). AND INSTALLATION).
INSPECT THE CYLINDER HEAD GASKET AND CYLINDER
BORE(S) FOR WEAR OR DAMAGE.
* ENGINE OPERATING *
TEMPERATURE TOO REFER TO: ENGINE COOLING (303-03F ENGINE
HIGH. COOLING, DIAGNOSIS AND TESTING).
ENGINE KNOCK AT * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
IDLE AND GLOW
PLUG INDICATOR IS
FLASHING
ENGINE KNOCK AT * LOW ENGINE OIL * CHECK THE ENGINE OIL LEVEL. REFILL AS NECESSARY.
IDLE LEVEL.
DIESEL.
9/11
709/2430
10/30/2018 Print

INSTALLATION).
AND INSTALLATION).
* EXCESSIVE CARBON * REMOVE THE CYLINDER HEAD.
BUILD UP. REFER TO: CYLINDER HEAD (303-01F ENGINE, REMOVAL
AND INSTALLATION).
INSPECT THE CYLINDER HEAD AND PISTONS FOR SIGNS
OF CARBON BUILD UP.
* WORN OR DAMAGED *
OIL PUMP. REFER TO: ENGINE (303-01F ENGINE, DIAGNOSIS AND
* MAJOR MECHANICAL TESTING).
ENGINE FAILURE.
ENGINE KNOCK * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
DURING
ACCELERATION AND
GLOW PLUG
INDICATOR IS
FLASHING
ENGINE KNOCK * FUEL INJECTOR(S). * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
DURING * MAJOR MECHANICAL *
ACCELERATION ENGINE FAILURE. REFER TO: ENGINE (303-01F ENGINE, DIAGNOSIS AND
TESTING).
VALVE.
EXCESSIVE FUEL * DTC DETECTED. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
CONSUMPTION AND
GLOW PLUG
INDICATOR IS
FLASHING
EXCESSIVE FUEL * BRAKES BINDING. * CHECK THE BRAKING SYSTEM.
CONSUMPTION REFER TO: BRAKE SYSTEM (206-00 BRAKE SYSTEM -
* VEHICLE * ADVISE THE CUSTOMER ABOUT THE EFFECTS OF
OVERLOADED, OR OVERLOADING THE VEHICLE AND WIND RESISTANCE ON
EXCESSIVE WIND THE FUEL CONSUMPTION.
RESISTANCE (ROOF
RACKS, TOWING
ETC).
ELEMENT BLOCKED.
BLOCKED.
* FUEL SYSTEM * CHECK THE SYSTEM FOR FUEL LEAK(S). REPAIR OR
LEAK(S). INSTALL NEW PARTS AS NECESSARY.
* INCORRECT ENGINE * INSTALL A NEW OIL FILTER AND DESIGNATED ENGINE
OIL. OIL.
10/11
710/2430
10/30/2018 Print
* GENERATOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.

* TURBOCHARGER. *
REFER TO: TURBOCHARGER (303-04K FUEL CHARGING
AND CONTROLS - TURBOCHARGER, DIAGNOSIS AND
TESTING).
AND INSTALLATION).
* LOW CYLINDER * CHECK CYLINDER COMPRESSION.
TESTING).
* SLIPPING CLUTCH. *
REFER TO: MANUAL TRANSAXLE AND CLUTCH (308-00
MANUAL TRANSMISSION AND CLUTCH - GENERAL
INFORMATION, DIAGNOSIS AND TESTING).
ENGINE CUTS OUT * CMP SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
DURING HARD * CKP SENSOR. * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
ACCELERATION * FUEL RAIL FUEL * REFER TO THE FORD DIAGNOSTIC EQUIPMENT.
PRESSURE SENSOR.
VALVE.
11/11
711/2430
10/30/2018 Print
Fuel Charging and Controls - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L

Duratorq-TDCi (70kW/95PS) (T3) - Fuel Injectors
Print
General Equipment
Removal
2. WARNINGS:
Make sure that the engine is switched off.
Make sure that the fuel pressure has dropped to zero and that the fuel temperature is
at ambient air temperature.
Wait for a minimum of 1 minute after the engine has stopped before carrying out any
repair to the fuel injection system.
Procedures).
4. Torque:
1 5 Nm
2 10 Nm
3 24 Nm
5.
1/7
712/2430
10/30/2018 Print
6.
7. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
2/7
713/2430
10/30/2018 Print
8. Refer to: Starter Motor (303-06G Starting System, Removal and Installation).
9. NOTICE:
Extreme cleanliness must be exercised when handling the components.
Use an open-ended wrench to prevent the component from turning.
Use suitable paper to absorb any escaping fluid.

NOTE: Make sure that new components are installed.
1. Torque:
1 20 Nm
2 25 Nm
2. Torque:
1 20 Nm
2 25 Nm
3/7
714/2430
10/30/2018 Print
10.
11.
12.
4/7
715/2430
10/30/2018 Print
Installation
2. Record the injector correction factors.
5/7
716/2430
10/30/2018 Print

NOTE: Only tighten the bolts finger tight at this stage.
5. Torque:
1
Stage 1:7 Nm
Stage 2:85°
2
Stage 1:7 Nm
Stage 2:80°
6/7
717/2430
10/30/2018 Print
6. Input the new Injector Correction Factors using the following menu options:
ToolBox/Powertrain/Service Functions
7/7
718/2430
10/30/2018 Print
Fuel Charging and Controls - 1.6L Duratorq-

TDCi (85kW/115PS)/1.6L Duratorq-TDCi
(70kW/95PS) (T3) - Fuel Pump
Print

303-732

Two Leg Puller
Removal

Use the General Equipment: Two Leg Puller
4. NOTICE: Make sure that all openings are sealed with new blanking caps.
Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
Torque:
Stage 1:20 Nm
Stage 2:25 Nm
1/3
719/2430
10/30/2018 Print
5. Torque:
1: 8 Nm
2: 8 Nm
3: 20 Nm
6. Torque: 20 Nm
Installation
2. Torque: 50 Nm
2/3
720/2430
10/30/2018 Print
3. Refer to: Fuel System Bleeding - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi

(70kW/95PS) (T3), Emission Requirements: Stage V (310-00G Fuel System - General Information,
4. Carry out a reset of the High Pressure Fuel System Learned Values using the following menu
options: ToolBox/Powertrain/Service Functions/PCM
3/3
721/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Fuel Rail
Print
Removal
Procedures).
2.
3. Torque: 10 Nm
4. Torque: 10 Nm
1/5
722/2430
10/30/2018 Print

Procedures).
6. Torque: 10 Nm
7.
2/5
723/2430
10/30/2018 Print
8. Torque: 10 Nm
9.
10.
NOTICE:
3/5
724/2430
10/30/2018 Print
Make sure that the area around the component is clean and free of foreign material.
NOTE: Use suitable paper to absorb any escaping fluid.
Torque:
Stage 1:20 Nm
Stage 2:25 Nm
11.
12. NOTICE: Make sure that all openings are sealed with new blanking caps.
Torque: 20 Nm
4/5
725/2430
10/30/2018 Print
Installation
2. Torque:
1 8 Nm
2 8 Nm
3 8 Nm
4 20 Nm
5 8 Nm
5/5
726/2430
10/30/2018 Print
Fuel Charging and Controls - 1.6L Duratorq-

(70kW/95PS) (T3) - Fuel Rail Supply Tube
Print
General Equipment
Removal
WARNINGS:
Avoid flames, sparks or lighted substances.
Wait for a minimum of 1 minute after the engine has stopped before carrying out any repair to
the fuel injection system.
1. WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel
temperature is at ambient air temperature.
Procedures).
3. NOTICE:

Torque:
Stage 1:20 Nm
Stage 2:25 Nm
Installation
1/1
727/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Fuel Metering Valve
Print
General Equipment
Materials
Name Specification
Brake Cleaner -
Removal
2. WARNINGS:
Make sure that the engine is switched off.
Make sure that the fuel pressure has dropped to zero and that the fuel temperature is
at ambient air temperature.
Wait for a minimum of 1 minute after the engine has stopped before carrying out any
repair to the fuel injection system.
3.
4. NOTICE: Extreme cleanliness must be exercised when handling the components.

Material: - (Brake Cleaner)
1/4
728/2430
10/30/2018 Print
5.
6. NOTICE:
Make sure that the area around the component is clean and free of foreign material.
The component must be removed by hand, the use of tools is prohibited.

Torque: 6 Nm
2/4
729/2430
10/30/2018 Print
Installation
2. NOTICE:
Extreme cleanliness must be exercised when handling the component.
Take extra care when handling the component.

NOTE: Make sure that the seal is correctly located.
3. Carry out a reset of the High Pressure Fuel System Learned Values using the following menu
options: ToolBox/Powertrain/Service Functions/PCM
3/4
730/2430
10/30/2018 Print
4. Bleed the fuel system if necessary.
Refer to: Fuel System Bleeding - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi

(70kW/95PS) (T3), Emission Requirements: Stage V (310-00G Fuel System - General Information,
4/4
731/2430
10/30/2018 Print
Fuel Charging and Controls - Turbocharger -

1.6L Duratorq-TDCi (85kW/115PS)/1.6L
Duratorq-TDCi (70kW/95PS) (T3) -
Turbocharger
Print
General Equipment

NOTE: It is normal for a small amount of combustion gas to pass into the crankcase. This gas is
scavenged into the air intake system through the positive crankcase ventilation (PCV) system,
which incorporates an oil separator. Some engine oil, in the form of a vapor is carried into the air
intake system with the blow-by gases (this engine oil also contributes to valve seat durability). This
means that oil will collect inside the air intake components and the turbocharger. This is not an
indication that the turbocharger oil seal has failed. The turbocharger oil seal will not fail unless the
bearings fail first, which will cause the turbocharger to become noisy or seize. Do not install a new
turbocharger due to oil inside the turbocharger or the air intake components. If a leak is detected in
the oil supply or return tubes or connections, locate and rectify the source. Do not install a new
turbocharger due to an oil leak.
Mechanical
Oil leak(s)
Air cleaner element
Turbocharger intake tube
Air cleaner intake pipe
Turbocharger oil supply pipe
Turbocharger oil return tube
Wastegate control valve
Turbocharger housing
Wastegate control pipe
Catalytic converter
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
1/1
732/2430
10/30/2018 Print
Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi

(85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3) - Turbocharger
Print
Removal
Procedures).
2. Torque: 12 Nm
3.
4. Torque: 10 Nm
5. Torque: 10 Nm
1/4
733/2430
10/30/2018 Print
6. Torque: 12 Nm
2/4
734/2430
10/30/2018 Print
9. Torque: 25 Nm
10.
11.
1. Torque: 25 Nm

Torque: 30 Nm
3/4
735/2430
10/30/2018 Print
Installation
Torque: 25 Nm
4/4
736/2430
10/30/2018 Print
Accessory Drive - 1.6L Duratec-16V Ti-VCT

(63kW/85PS) - Sigma/1.6L Duratec-16V Ti-VCT
(77kW/105PS) - Sigma/1.6L Duratec-16V Ti-VCT
(92kW/125PS) - Sigma/1.6L Duratec-16V Ti-VCT Flex
Fuel (88kW/120PS) - Sigma - Accessory Drive
Print
Mechanical
Damaged or contaminated accessory drive belt
Damaged or contaminated pulley(s)
Incorrect accessory drive belt
Incorrect fitment of the accessory drive belt
Generator
Air conditioning (A/C) compressor
Pulley(s)
Loose hardware
Accessory Drive Belt Concerns
NOTICE: Do not lubricate the accessory drive belt as potential damage to the accessory drive
belt material construction may occur.
Cracking
Accessory drive belts are made from rubber which hardens with time and can develop cracks. As the
accessory drive belt runs on the back of some of the pulleys, the cracks are opened up. Small cracks
are not considered to be a failure of the accessory drive belt. Only if the crack is deep enough to
reach the bottom of the groove to expose the cord or any chunks are found to be missing from the
accessory drive belt, is the accessory drive belt condition considered to be unacceptable.
1. Check the accessory drive belt for cracks. If the damage exceeds the acceptable limit, install a
new accessory drive belt. REFER to:
Accessory Drive Belt (303-05B Accessory Drive, Removal and Installation),
Accessory Drive (303-05C Accessory Drive, Description and Operation),
Accessory Drive Belt (303-05B Accessory Drive, Removal and Installation).
Chunking
Chunking describes the condition where long lengths of rubber become detached from the ribs of the
accessory drive belt. This is considered to be a failure of the accessory drive belt.
2.
1/4
737/2430
10/30/2018 Print
Check the accessory drive belt for damage. If any chunks are found to be missing, install a new
accessory drive belt. REFER to:
Pilling
Pilling is dust that forms in between the ribs of the accessory drive belt from rubber that is worn off
the accessory drive belt when it is new. There may also be loose particles left on the accessory drive
belt during the manufacturing process. These are worn off and form into small balls of rubber that
then get trapped in the grooves of the accessory drive belt. This condition will usually clear itself
within 4800 km - 8000 km (3000 miles - 5000 miles) of normal driving.
3. Check the accessory drive belt for pilling. The condition of the accessory drive belt should be
compared against the illustration.
1. Small scattered pills. Not considered a concern. No action required.
2. Small scattered pills. Not considered a concern. No action required.
3. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new accessory
drive belt if noise is apparent. REFER to:
4. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new accessory
drive belt if noise is apparent. REFER to:
5. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new accessory
drive belt. REFER to:
6. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new accessory
drive belt. REFER to:
Incorrect fitment
Accessory drive belt noise can be generated by the accessory drive belt being incorrectly fitted on the
pulley as shown in the following illustration. Make sure that all the V grooves on the accessory drive
2/4
738/2430
10/30/2018 Print
belt contact correctly with the pulley.
Symptom Chart
SYMPTOM POSSIBLE ACTION

SOURCES
ACCESSORY DRIVE BELT * ACCESSORY * USE A STETHOSCOPE OR OTHER LISTENING DEVICE TO
NOISE DRIVE SYSTEM DETERMINE THE SOURCE OF THE NOISE. INSTALL NEW
COMPONENTS AS NECESSARY. TEST THE SYSTEM FOR
NORMAL OPERATION.
* ACCESSORY * CHECK THE ACCESSORY DRIVE BELT IS CORRECTLY
DRIVE BELT INSTALLED IN THE PULLEY GROOVES. INSTALL A NEW
INCORRECTLY ACCESSORY DRIVE BELT AS NECESSARY. REFER TO:
INSTALLED. ACCESSORY DRIVE BELT (303-05B ACCESSORY
DRIVE, REMOVAL AND INSTALLATION),
ACCESSORY DRIVE (303-05C ACCESSORY DRIVE,
DESCRIPTION AND OPERATION),
ACCESSORY DRIVE BELT (303-05B ACCESSORY
DRIVE, REMOVAL AND INSTALLATION).
TEST THE SYSTEM FOR NORMAL OPERATION.
* PULLEY(S). * CHECK THE PULLEY(S) FOR DAMAGE, FREEDOM OF
ROTATION, STONE ENTRAPMENT AND ALIGNMENT.
INSTALL NEW COMPONENTS AS NECESSARY. TEST THE
SYSTEM FOR NORMAL OPERATION.
* LUBRICANT OR * CHECK THE ACCESSORY DRIVE BELT FOR
OTHER CONTAMINATION OR DAMAGE. RECTIFY THE SOURCE OF
CONTAMINATION. THE LEAK AND INSTALL A NEW ACCESSORY DRIVE BELT.
REFER TO:
DRIVE, REMOVAL AND INSTALLATION),
ACCESSORY DRIVE (303-05C ACCESSORY DRIVE,
DESCRIPTION AND OPERATION),
DRIVE, REMOVAL AND INSTALLATION).
NOTE: CHIRP IS * PULLEY * CHECK THAT THE ACCESSORY DRIVE BELT IS RUNNING
DEFINED AS A MISALIGNMENT CENTRALLY ON THE FLAT PULLEYS. TEST THE SYSTEM
TWITTERING NOISE, (USUALLY FOR NORMAL OPERATION.
OFTEN INTERMITTENT EVIDENT AT * CHECK THE PULLEYS FOR EXCESSIVE END FLOAT AND
ACCESSORY DRIVE BELT IDLE). BENT FLANGES.
CHIRP * WITH THE ENGINE RUNNING AT IDLE, USE A
STETHOSCOPE TO IDENTIFY THE SOURCE OF THE
NOISE. INSTALL NEW COMPONENTS AS NECESSARY.
NOTE: RATTLE IS * LOOSE * CHECK THE COMPONENTS OR HARDWARE FOR CORRECT
DEFINED AS A COMPONENTS OR INSTALLATION AND TIGHTEN AS NECESSARY. TEST THE
METALLIC KNOCKING HARDWARE. SYSTEM FOR NORMAL OPERATION.
NOISE
ACCESSORY DRIVE BELT
RATTLE
Component Tests
3/4
739/2430
10/30/2018 Print
Accessory Drive Belt Tensioner - Static Check
The accessory drive belt tensioner may be checked statically as follows:
1. Inspect the area surrounding the accessory drive belt tensioner for lubricant or other
contamination. Rectify any leaks before installing a new accessory drive belt tensioner. If the
accessory drive belt tensioner is contaminated, do not attempt to clean it as the damping
mechanism inside may be damaged. INSTALL a new accessory drive belt tensioner as
necessary.
REFER to: Accessory Drive Belt Tensioner (303-05C Accessory Drive, Removal and
Installation).
TEST the system for normal operation.
2. Detach the accessory drive belt in the area of the accessory drive belt tensioner.
3. NOTE: The accessory drive belt tensioner has a damping feature, which is usually a friction
device, therefore some friction within the system is normal.
Using the correct tool, move the accessory drive belt tensioner from its relaxed position through
its full stroke and back to the relaxed position to make sure there is no excessive stick, grab
or bind, and to make sure there is tension on the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley and check for damage, freedom of rotation and
alignment. INSTALL a new accessory drive belt tensioner as necessary.
Installation).
5. If the accessory drive belt tensioner meets the above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the accessory drive belt tensioner does not meet the above
criteria, INSTALL a new accessory drive belt tensioner.
Installation).

Accessory Drive Belt Tensioner - Dynamic Check
The accessory drive belt tensioner may be checked dynamically as follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The accessory
drive belt tensioner should move (respond) when the engine is accelerated rapidly or when
the A/C clutch cycles ON and OFF (the degree of movement can be up to 4 mm). If the
accessory drive belt tensioner movement is not constant without engine acceleration or A/C
clutch cycling, a pulley or shaft is possibly bent, out of round, or the damping mechanism
inside the accessory drive belt tensioner may be damaged. INSTALL a new accessory drive
belt tensioner as necessary.
Installation).
2. Excessive accessory drive belt rideout (uneven depth of grooves in the accessory drive belt)
may cause excessive accessory drive belt tensioner movement. Check the condition by
installing a new accessory drive belt. REFER to:
4/4
740/2430
10/30/2018 Print
Accessory Drive - 1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Accessory Drive Belt
Print
Removal
2. If equipped.
3.
4.
1/2
741/2430
10/30/2018 Print
5.
Installation
2/2
742/2430
10/30/2018 Print
Starting System - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-

TDCi (70kW/95PS) (T3) - Starting System - Component Location
Print
Start/stop system
Item Description
1 Starter motor
2 Sensor - vacuum
3 Battery monitoring sensor
4 Start/stop system deactivation switch
5 Door contact switch
6 Ambient temperature sensor
7 Voltage stabilization module
8 2 switches CPP (clutch pedal position) (BOT and TOT)
9 Clutch pedal position sensor
10 Neutral position sensor
1/1
743/2430
10/30/2018 Print
Starting System - 1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Starting System -
Overview
Print
Start/stop system
The start/stop system assists drivers who spend a lot of time in jams, traffic queues and at traffic
lights by automatically stopping and restarting the engine. This benefit noticeably reduces fuel
consumption and CO2 (carbon dioxide) emissions with mixed driving styles. When compared with the
version without auto start/stop, a substantial reduction in CO2 emissions is achieved.
The auto start/stop function is integrated into the PCM (powertrain control module). It is always
enabled when starting the vehicle and can be disabled with a switch if required.
Once the switch is pressed, the function is deactivated until it is re-activated with the switch or the
driver starts the engine manually. If the switch is pressed during a stop mode, the engine is
automatically started.
When the deactivation switch is operated, a signal is sent from the switch directly to the BCM (body
control module).
On vehicles with a start/stop system, there is always a possibility that the engine will start
automatically; consequently there is an increased risk that:
the belt drive will start to turn, or

the vehicle will move.
Engine compartment notice
WARNING: Serious injury may occur if the engine is accidently started by another person
during service work. Remove the key from the vehicle to prevent unauthorized starts. Failure to
follow this instruction may result in serious personal injury.
1/1
744/2430
10/30/2018 Print
Starting System - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-

TDCi (70kW/95PS) (T3) - Starting System - System Operation and
Print
System Diagram
Start/stop system
Item Description
3 Clutch pedal position sensor
4 Clutch pedal position switch (top of travel (TOT))
6 Sensor - vacuum
1/10
745/2430
10/30/2018 Print
9 DDM (driver door module)

11 EATC (electronic automatic temperature control) operating panel
12 Door lock with door control switch
13 Start/stop system deactivation switch
14 Clutch pedal position switch (bottom of travel (BOT))
15 Ambient temperature sensor
System Operation
Start/stop system
The start/stop system is always enabled when starting the vehicle and can be disabled using a
switch. However, the PCM does not activate the function until all of the safety-related tests have
been performed by the system.
Normal driving
Ignition position II
Gear engaged
Engine running.
Vehicle moving (VSS (vehicle speed sensor) signal > 4 km/h)
Auto stop phase
In this phase, the engine is automatically stopped when the conditions listed below are met.
Vehicle stationary (VSS signal < 4 km/h)

Accelerator pedal not pressed
Neutral and clutch pedal not pressed
Ambient temperature between 0°C and 30°C
System not manually disabled
No exclusion criteria active
Consequences of automatic shut-off of the engine
EPAS (electronic power assist steering) turned off

EATC in auto mode
- The blower motor is operated at a reduced setting.
Auto start phase
In this phase, the engine is automatically started when the conditions listed below are met.
Driver presses clutch pedal

Gear lever in neutral
Vehicle stationary (VSS signal < 4 km/h)
If the driver's door has been opened during the Stop Mode, then the system will demand a driver
activity before the engine is automatically restarted. Suitable driver activities include e.g. operation of
the accelerator pedal, brake or clutch pedal.
In addition, Stop Mode is automatically interrupted (engine is started) if the driver:
actuates the deactivation switch,

the vehicle begins to roll,
this is necessary to meet the demand from the A/C system
Engine stall
After an undesired engine stall, the engine is restarted automatically if the driver fully depresses the
clutch pedal within 5 seconds.
Text messages
There are two types and display forms for text messages relating to the start/stop system.
These are the so-called "pop-up messages" on the one hand and the so-called "status messages" on
the other. However, the status messages are only displayed when the "Information" menu option is
2/10
746/2430
10/30/2018 Print
selected on the TFT display.

NOTE: For all markets in which the text messages in the instrument cluster are not translated into
the local language, we provide them in English.
Pop-up messages
Pop-up messages:
Press clutch to start engine
Switch ignition off
Select neutral
Manual start required
Status messages
Status messages:
Available
Off
Malfunction
Engine stop
Charging battery
Driver door opened
Manual engine start required
Engine stop not available
Air conditioning and heating
Warning lamp
The start/stop warning lamp is also located in the instrument cluster. This lights up or flashes
depending on the current status or action required by the driver.
The warning lamp lights up green, once the engine has been switched off. It flashes yellow if the
clutch needs to be pressed or neutral needs to be engaged.
The yellow warning lamp in the deactivation switch also lights up if:
the system has been deactivated,

there is a malfunction,
or the engine has to be started manually.
Starter motor
On vehicles with the start/stop function, an upgraded starter motor with higher power is fitted.
3/10
747/2430
10/30/2018 Print
Depending on the particular engine fitted to the vehicle, the starter motor has an output power of 1.2
kW (petrol engine) or 2 kW (diesel engine) and is designed for 150,000 engine start cycles instead of
the usual 35,000 engine starts on vehicles without the start/stop system.
The following starter motor components have been upgraded:

Drive pinion
Clutch
Solenoid coil
Engagement lever
Longer brushes are also used.

NOTE: During servicing, the starter motor must only ever be replaced with an equivalent
component.
Enhanced Flooded Battery
The battery on vehicles equipped with the stop/start system is subjected to particularly heavy loads.
The reasons for this include the large number of starting processes and the fact that the entire vehicle
electrical system has to be supplied with voltage during every stop mode.
For this reason, vehicles equipped with the start/stop system have been equipped with so-called
"Enhanced Flooded" batteries. These are basically conventional lead-acid batteries on account of the
electrolyte used, but they can be cycled significantly more frequently without degradation than
conventional batteries.
Fabric laminated onto the positive plates also helps to reduce active material loss and the resulting
lead deposits inside the battery. A considerable extra benefit of this is a significant increase in battery
life.
Item Description
1 Positive grid
2 Positive plate
3 Positive plate with laminated fabric
4 Negative grid
5 Negative plate
6 Positive plate set
7 Negative plate set
8 Fabric on the surface of the positive plate
4/10
748/2430
10/30/2018 Print
Depending on engine type and equipment levels, two battery versions are used with the
following data:
60Ah capacity and 590A cold discharge test current.
75Ah capacity and 700A cold discharge test current.
NOTE: During servicing, the battery must only ever be replaced with an equivalent component.
Voltage stabilization module
The purpose of the voltage stabilizer module is to maintain a constant voltage supply to components
which are sensitive to voltage drops. Its primary function is to supply components such as the audio
system, which may switch off or reset when the engine is restarted.
The voltage stabilizer module is a so-called "step up converter", i.e. it can only ever cause a voltage
increase. It has a power output of 200 W, is provided with one input and, depending on equipment
levels, up to two outputs.
In the event of an engine start after a stop mode, the voltage stabilizer module ensures that the
connected systems/modules continue to receive a stabilized 12.5 V supply. This is necessary, as the
high power requirement of the starter motor causes a voltage drop in the vehicle electrical system
during the engine restart.
The voltage stabilizer module requires a minimum input voltage of 4 V.
Connected systems
5/10
749/2430
10/30/2018 Print
Item Description
1 Forward alert system module
2 EATC module
4 Multi-function display level 5
5 Audio system operating unit
6 Handsfree module / Bluetooth® module / voice activation module
8 Audio system
9 Blind spot monitoring module, right-hand side
10 Blind spot monitoring module, left-hand side
11 Front camera module
12 Laser sensor
Sensor - vacuum
6/10
750/2430
10/30/2018 Print
On the variant with the start/stop system, an additional vacuum sensor is fitted on the brake servo
unit. Its task is to monitor the brake servo vacuum during a stop mode.
If the vacuum in the brake servo unit drops below a certain value, the start/stop function is disabled.
This means that - in this case - a running engine would not be turned off.
The engine is restarted immediately if the vacuum drops below this value while the vehicle is in stop
mode (engine is stopped).
Depending on the particular brake system fitted, the value at which the start/stop system is disabled
is between 280 and 380 mbar.
This strategy is intended to ensure that adequate braking performance is guaranteed at all times.
Such a situation might arise, for example, where the driver presses the brake several time in
succession while at a traffic light.
Neutral position sensor
Item Description
2 Permanent magnet
3 Selector shaft
On vehicles with the start/stop system, information is required about whether a gear is engaged or
the transmission is in neutral. The neutral position sensor is located on the gearbox housing for this
purpose.
The neutral position sensor is a Hall effect sensor which emits two PWM (pulse width modulation)
signals.
It detects the rotary motion of the selector shaft by scanning the motion of the magnet located on it.
The PWM output signal of the sensor varies depending on whether an even, odd or no gear is
engaged.
7/10
751/2430
10/30/2018 Print
Depending on the transmission, the PWM rate of the first signal is less than 30% for an odd gear,
more than 70% for an even gear and between 45 and 55% in neutral. (Refer also to the diagram.)
The second signal is used exclusively for a plausibility check and has different values to the first
signal.
Item Description
1 Odd gears
2 No gear engaged
3 Even gears
4 Rotational angle of the selector shaft
Clutch pedal monitoring
Item Description
1 Upper clutch pedal position switch (top of travel (TOT))
2 Lower clutch pedal position switch (bottom of travel (BOT))
3 CPP (clutch pedal position) sensor
The clutch pedal monitoring system in vehicles equipped with the start/stop system comprises three
components. Two of these are switches with signals that change near the top of travel (TOT) and
bottom of travel (BOT) limit stops of the clutch pedal. BOT indicates whether the clutch pedal is
depressed, while TOT indicates whether the clutch pedal is in its initial position. The third component
is a sensor that monitors the entire travel path of the clutch pedal.
The CPP sensor and upper clutch pedal position (TOT) switch signals are sent to the PCM, whereas the
lower clutch pedal position (BOT) switch signals are sent to the PCM and BCM.
CPP sensor
In addition to the usual clutch pedal switches, all vehicles equipped with the start/stop system are
now fitted with an extra sensor that monitors the entire travel path of the clutch pedal between its
8/10
752/2430
10/30/2018 Print
two limit stops.

TOT switch
BOT switch
When the clutch pedal is pressed, it initially moves away from the TOT switch, which causes this to
close. This occurs when the pedal has travelled approx. 25% along its total path.
If the pedal continues to be pressed then the BOT switch is actuated next, and it also closes as a
result. This occurs when the pedal has travelled approx. 75% along its total path.
Battery monitoring sensor
Item Description
1 Connection to negative terminal of main battery
2 Plug-in connection
The battery monitoring sensor continuously monitors the condition of the main battery. To do this, it
is bolted directly to the negative terminal of the battery. It also includes a plug-in connection with two
pins. One of the two pins is connected to the LIN (local interconnect network) via the BCM data bus.
The other pin is connected to the BJB (battery junction box). From there, the cable - protected by a
15 A fuse - runs to the positive terminal of the battery.
This guarantees that the system is constantly informed about the state of charge of the battery.
The battery monitoring sensor has to be recalibrated at regular intervals. This always happens during
a rest period, when the battery standby current is less than 100 mA. The rest period must last for at
least three hours. The timeframe in which a recalibration must take place is seven days.
Normally, the battery standby current after switching off the ignition is less than 20mA. However, if a
consumer which draws a current in excess of 100mA is permanently connected to the vehicle
electrical system, this would prevent a calibration of the battery monitoring sensor.
If the system has been unable to carry out a recalibration within this time then it is impossible to
confirm the exact state of charge of the battery. Should this be the case then the start/stop system is
9/10
753/2430
10/30/2018 Print
deactivated and a DTC (diagnostic trouble code) is set.

A DTC is also set if acid stratification is detected inside the battery, or if no definitive terminal voltage
can be measured.
After replacing the battery, the learned values for the battery monitoring sensor need to be reset with
the IDS (Integrated Diagnostic System).
10/10
754/2430
10/30/2018 Print
Starting System - 1.6L Duratec-16V Ti-VCT

(63kW/85PS) - Sigma/1.6L Duratec-16V Ti-
VCT (77kW/105PS) - Sigma/1.6L Duratec-16V
Ti-VCT (92kW/125PS) - Sigma/1.6L Duratec-
16V Ti-VCT Flex Fuel (88kW/120PS) - Sigma -
Starting System
Print

Refer to Wiring Diagrams Section 303-06, for schematic and connector information.
General Equipment
2. Visually inspect for obvious signs of electrical damage.
Electrical
Fuse(s)
Wiring harness
Electrical connector(s)
Relay
Switch(es)
Battery junction box (BJB)
Engine junction box (EJB)
Central junction box (CJB)
Transmission range sensor (automatic transaxle only)
Keyless vehicle module (KVM) (if equipped)
Battery
Starter motor
Powertrain Control Module (PCM)
1/1
755/2430
10/30/2018 Print
Starting System - 2.0L Duratec-HE (110kW/150PS) - MI4/2.0L Duratec-

HE (125kW/170PS) - MI4 - Start Control Unit
Print
Removal
1.
2.
3.
1/2
756/2430
10/30/2018 Print
Installation
2/2
757/2430
10/30/2018 Print
Starting System - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Starter Motor
Print
Removal
Procedures).
Refer to: Air Cleaner (303-12 Intake Air Distribution and Filtering - 1.5L Duratorq-TDCi
(70kW/95PS)/1.5L Duratorq-TDCi (77kW/105PS)/1.5L Duratorq-TDCi (88kW/120PS), Removal and
Installation).
2.
3. Torque: 5 Nm
1/6
758/2430
10/30/2018 Print
4. Torque: 14 Nm
5. Torque: 8 Nm
2/6
759/2430
10/30/2018 Print
6. Torque:
1 10 Nm
2 14 Nm
3 10 Nm
4 10 Nm
7.
3/6
760/2430
10/30/2018 Print
8.
9. Torque: 25 Nm
4/6
761/2430
10/30/2018 Print
10. If equipped.
11. If equipped.
5/6
762/2430
10/30/2018 Print
12. Torque:
1 25 Nm
2 12 Nm
Installation
2.
6/6
763/2430
10/30/2018 Print
Glow Plug System - 1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Glow Plug System
Print

Refer to Wiring Diagrams Cell 027-1, for schematic and connector information.
General Equipment
Electrical
Fuse(s)
Relay
Wiring harness
Glow plug(s)
Glow plug wire
Glow plug module
Powertrain control module (PCM)
1/1
764/2430
10/30/2018 Print
Glow Plug System - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-

TDCi (70kW/95PS) (T3) - Glow Plugs
Print
Removal
1. NOTE: Make sure that the ignition key is in the OFF position.
2.
3.
4. Torque: 6 Nm
1/2
765/2430
10/30/2018 Print
Installation
2.
2/2
766/2430
10/30/2018 Print
Engine Emission Control - 1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Engine Emission Control
Print
General Equipment
EGR valve Electrical connector(s)
EGR valve outlet tube Wiring harness
EGR valve tube clamp EGR valve
EGR cooler PCM (powertrain control module)
Gaskets/seals
Hose(s)/hose joints
PCV valve
PCV oil separator
before proceeding to the next step
4. If the cause is not visually evident, verify the symptom and refer to the Diagnostic Trouble Code
(DTC) Index Chart.
5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue
diagnosis.
Diagnostic Trouble Code (DTC) Index Chart
DTC Description Possible Source Action

P1412 MIL illuminated EGR valve REFER to Excessive exhaust black smoke in the Symptom Chart
P0404 MIL illuminated EGR valve REFER to Excessive exhaust black smoke in the Symptom Chart
Symptom Chart

EXCESSIVE EXHAUST * EGR VALVE INCORRECT BASE * REFER TO THE FORD DIAGNOSTIC
BLACK SMOKE SETTING. EQUIPMENT.
* EGR VALVE.
EXCESSIVE CRANKCASE * BLOCKED OR DAMAGED PCV * GO TO PINPOINT TEST A.
PRESSURE HOSE(S).
* BLOCKED PCV OIL
SEPARATOR.
* BLOCKED OR DAMAGED PCV
VALVE.
* WORN OR DAMAGED ENGINE *
COMPONENTS. REFER TO: ENGINE (303-01F ENGINE,
Pinpoint Tests
PINPOINT TEST A : EXCESSIVE CRANKCASE PRESSURE

CONDITIONS
A1: CHECK THE POSITIVE CRANKCASE VENTILATION HOSE FOR BLOCKAGE
1/2
767/2430
10/30/2018 Print
1 Remove the air cleaner.

REFER to: Air Cleaner (303-12F Intake Air Distribution and Filtering, Removal and
Installation).
2 Inspect the PCV hose for blockage.
Is the PCV hose free from blockage?
Yes
GO to A2.
No
CLEAN or INSTALL a new PCV hose as necessary. TEST the system for normal
operation. If the concern persists, GO to A2.
A2: CHECK THE POSITIVE CRANKCASE VENTILATION VALVE FOR DAMAGE.
1 Inspect the PCV valve for damage or blockage.
Is the PCV valve spring undamaged and the PCV valve free from blockage?
Yes
Test the system for normal operation. If the concern persists,
REFER to: Engine (303-01F Engine, Diagnosis and Testing).
No
CLEAN the PCV oil separator and PCV valve assembly or INSTALL a new engine valve
cover as necessary. Test the system for normal operation.
2/2
768/2430
10/30/2018 Print
Engine Emission Control - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L

Duratorq-TDCi (70kW/95PS) (T3) - Exhaust Gas Recirculation (EGR)
Valve
Print
Removal
1.
2. Torque: 8 Nm
Installation
2.
1/2
769/2430
10/30/2018 Print
2/2
770/2430
10/30/2018 Print
Engine Emission Control - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L

Duratorq-TDCi (70kW/95PS) (T3) - Exhaust Gas Recirculation (EGR)
Cooler
Print
Removal
1. Refer to: Battery and Cables (414-01, Description and Operation).

Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and Installation).
2.
3.
1/4
771/2430
10/30/2018 Print
4.
5. Torque: 8 Nm
6. Refer to: Cooling System Draining, Filling and Bleeding (303-03E, General Procedures).
Refer to: Cooling System Draining and Vacuum Filling (303-03E, General Procedures).
7. Torque: 8 Nm
2/4
772/2430
10/30/2018 Print
8. Torque:
1 8 Nm
2 8 Nm
3 8 Nm
4 20 Nm

Torque: 8 Nm
3/4
773/2430
10/30/2018 Print
Installation
2.
4/4
774/2430
10/30/2018 Print
Intake Air Distribution and Filtering - 1.6L

Duratorq-TDCi (77kW/105PS)/1.6L Duratorq-
(70kW/95PS) (T3) - Intake Air Distribution
and Filtering
Print
Air cleaner element Wiring harness
Air cleaner intake pipe Electrical connector(s)
Air cleaner outlet pipe MAF (mass air flow)
Charge air cooler (Vehicles with 1.6L IAT (intake air temperature) sensor
Duratorq-TDCi (DV) Diesel engine) PCM (powertrain control module)
Charge air cooler intake hose (Vehicles with
1.6L Duratorq-TDCi (DV) Diesel engine)
Charge air cooler outlet hose (Vehicles with
1.6L Duratorq-TDCi (DV) Diesel engine)
Symptom Chart

EXCESSIVE * DETACHED AIR CLEANER * CHECK THE PIPE(S) FOR SECURITY AND LEAKS TO
INTAKE PIPE(S). ATMOSPHERE. INSTALL NEW INTAKE AIR
AIR NOISE * DETACHED TURBOCHARGER COMPONENTS AS NECESSARY. TEST THE SYSTEM FOR
PIPE(S) NORMAL OPERATION.
* DETACHED CHARGE AIR COOLER
HOSE(S) (VEHICLES WITH 1.6L
DURATORQ-TDCI (DV) DIESEL
ENGINE).
OIL IN THE * BLOCKED OR DAMAGED *
AIR POSITIVE CRANKCASE REFER TO: ENGINE EMISSION CONTROL (303-08E
INTAKE VENTILATION (PCV) VALVE. ENGINE EMISSION CONTROL, DIAGNOSIS AND
SYSTEM * BLOCKED OR DAMAGED PCV TESTING).
PIPE(S)/HOSE(S).
* BLOCKED OR DAMAGED REFER TO: ENGINE EMISSION CONTROL (303-08E
CRANKCASE VENT OIL ENGINE EMISSION CONTROL, DIAGNOSIS AND
SEPARATOR. TESTING).
* TURBOCHARGER *

WATER IN * DETACHED AIR CLEANER INTAKE * CHECK THE AIR CLEANER INTAKE PIPE FOR SECURITY.
THE AIR PIPE. INSTALL NEW INTAKE AIR SYSTEM COMPONENTS AS
CLEANER NECESSARY. TEST THE SYSTEM FOR NORMAL
OPERATION.
* BLOCKED AIR CLEANER DRAIN. * CLEAN THE AIR CLEANER DRAIN. TEST THE SYSTEM
1/2
775/2430
10/30/2018 Print
FOR NORMAL OPERATION.

ENGINE * AIR CLEANER ELEMENT * INSPECT THE AIR CLEANER FOR SIGNS OF BLOCKAGE.
LACKS BLOCKED. INSTALL A NEW AIR CLEANER ELEMENT AS
POWER NECESSARY.
* CHARGE AIR COOLER PIPE(S) * INSPECT THE CHARGE AIR COOLER PIPES FOR
(VEHICLES WITH 1.6L DAMAGE. INSTALL A NEW CHARGE AIR COOLER
DURATORQ-TDCI (DV) DIESEL PIPE(S) AS NECESSARY.
ENGINE).
* CHARGE AIR COOLER BLOCKED * INSPECT THE CHARGE AIR COOLER FOR BLOCKAGE.
(VEHICLES WITH 1.6L INSTALL A NEW CHARGE AIR COOLER AS NECESSARY.
DURATORQ-TDCI (DV) DIESEL
ENGINE).
* FUEL CHARGING AND CONTROLS *
REFER TO: FUEL CHARGING AND CONTROLS (303-04I
FUEL CHARGING AND CONTROLS, DIAGNOSIS AND
TESTING).
REFER TO: FUEL CHARGING AND CONTROLS (303-04I

FUEL CHARGING AND CONTROLS, DIAGNOSIS AND
TESTING).
* TURBOCHARGER *

2/2
776/2430
10/30/2018 Print
Electronic Engine Controls - 1.6L Duratorq-

(70kW/95PS) (T3) - Electronic Engine Controls
Print
General Equipment
Principles of Operation
For Principles of Operation on the electronic accelerator control system
REFER to: Acceleration Control (310-02 Acceleration Control, Diagnosis and Testing).
European On-Board Diagnostics (EOBD)
EOBD is a diagnostic system integrated into the powertrain control module (PCM). This system
continuously monitors vehicle emission components. The system includes a malfunction indicator
lamp (MIL) which indicates when there is a concern that can affect emissions or the system
malfunctions. Data stored within the module DTC memory can be accessed using a generic scan tool
or the Ford diagnostic equipment.
EOBD is mandated within European Union regulations from the year 2000 for passenger vehicles with
petrol engines and from 2003 onwards for passenger vehicles with diesel engines.
EOBD Functions:
Establishes when and how emissions control faults must be indicated.
Actuates emission control malfunction indicator lamp (MIL) and fault memory.
Indicates operating conditions in which the concern occurred (freeze frame data).
Standardized output of operating data such as engine speed, engine coolant temperature etc.
Standardized names and abbreviations for components and systems.
Standardized DTCs for all manufacturers.
Standardized communication with the diagnostic equipment.
Standardized 16-pin data link connector (DLC) in area of the instrument panel.
Concern display must be possible using a generic scan tool.
EOBD consists of the following elements:

Warm-up Cycle
The warm-up cycle is an operation that consists of key on, engine start and a coolant temperature
increase of 22°C, exceeding 71°C on completion.
Drive Cycle
A drive cycle commences when the engine is started (cold or warm) and ends when the engine is
switched off.
Trip
A trip begins when the engine is started and is complete when all the EOBD monitors have completed
a self-test. This may take place over a number of drive cycles. On diesel variants, the information
gathered from one drive cycle is not carried over to a subsequent cycle or cycles.
When a concern has been rectified, particularly after electronic engine control components have been
changed, the DTC memory, which is part of the EEPROM must be cleared of all trouble codes. When
the DTC memory has been cleared, the code P1000 (known as the readiness code) is set in the PCM
memory, which indicates that since the EEPROM has been cleared, not all of the monitoring systems
have completed their tests. P1000 can only be cleared by carrying out a trip, which includes driving
the vehicle under variable conditions of speed, load and time so that all of the monitors are
completed. As P1000 will not illuminate the MIL it is not necessary to carry out the trip before
returning the vehicle to the customer.
Freeze Frame Data
When a concern is detected, various data is stored depending on application including:
Diagnostic trouble code.

Vehicle speed.
1/7
777/2430
10/30/2018 Print
Engine coolant temperature.

Engine speed.
Engine load.
Mixture formation trim value (trim value for engine wear) (All except vehicles with diesel engine).
State of oxygen sensor control (open and closed loop) (All except vehicles with diesel engine).
Distance covered since the concern was first registered.
Monitors
The purpose of the monitors is to continuously check the operation of the emission related sensors
and actuators. It then establishes if they are operating within specified tolerances. All monitors carry
out their functions in such a way as to be unnoticeable by the driver of the vehicle. Each one is
carried out under specific conditions of load, speed and engine temperature. The Comprehensive
Component Monitor, Combustion Misfire Monitor and Air/Fuel Ratio Monitor operate continuously. The
remaining monitors are only invoked under certain operating conditions. On diesel variants, all of the
monitors operate under normal driving conditions: There are no monitors which intervene and cause
special operating modes to enable the monitors to work. Some diesel monitors are non-continuous.
This means that in a drive cycle, monitoring is done as and when suitable driving conditions exist and
potential faults are accumulated and compared with acceptance criteria. Examples of this type are the
turbocharger boost pressure and exhaust gas recirculation (EGR) monitors on vehicles with common
rail fuel injection.
Comprehensive Component Monitor (CCM)
When the CCM detects a component operating out of tolerance, it sets a Diagnostic Trouble Code
(DTC), which is stored in the EEPROM. If the same concern is confirmed during the next trip the MIL
will be switched on. The CCM monitors many components, sub-systems and signals. The following is a
list of those that can effect emissions depending on application:
Electronic Ignition (EI) System.

Crankshaft Position (CKP) Sensor.
Ignition Coil.
Electronic Throttle Control Unit.
Camshaft Position (CMP) Sensor.
Air Conditioning (A/C) Clutch.
Idle Air Control (IAC) Valve.
Mass Air Flow (MAF) Sensor.
Manifold Absolute Pressure (MAP) Sensor.
Intake Air Temperature (IAT) Sensor.
Engine Coolant Temperature (ECT) Sensor.
Cylinder Head Temperature (CHT) Sensor.
Heated Oxygen Sensor (HO2S).
Catalyst Monitor Sensor.
Charge Air Temperature Sensor.
Knock Sensor (KS).
Throttle Position (TP) Sensor.
Vehicle Speed Sensor (VSS).
Boost Pressure Sensor.
Cam-Crank Phasing Sensor.
EEPROM.
High Pressure Fuel Injection Pump.
Exhaust Gas Recirculation (EGR) Valve Monitor.
Fuel Injectors.
Turbocharger.
Combustion Noise Monitor.
Barometric Pressure (BARO) Sensor.
Combustion Misfire Monitor (All except vehicles with diesel engine)

The combustion misfire monitor operates independently of the others, and can detect misfires caused
by the ignition system, fuel system or mechanical engine components. As each cylinder fires, a
characteristic crankshaft acceleration is produced. The monitor detects irregularities in the
acceleration pattern using the crankshaft position (CKP) sensor, thus detecting the misfire. It can also
detect which cylinder has misfired. Combustion misfires can be categorized as follows:
Type A: These can cause catalytic converter damage due to excessive internal temperatures. If a
certain number of misfires occur over a pre-determined number of engine revolutions, the MIL will be
2/7
778/2430
10/30/2018 Print
switched on to alert the driver of the concern.

Type B: These can lead to an increase in emissions to a point above the EOBD threshold. If the
misfire is detected during a second trip, over a pre-determined number of engine revolutions, the MIL
will be switched on. If the misfire does not occur over the next three trips, the MIL will be
extinguished
Air/Fuel Ratio (AFR) Monitor (All except vehicles with diesel engine)
The HO2S fitted before the catalytic converter (upstream) measures the oxygen content of the
exhaust gas and the variations in it. This then enables the PCM to adjust the opening times of the fuel
injectors to maintain the correct AFR. This is known as Short Term Fuel Trim (STFT). If the same
variation is registered a pre-determined number of times, a permanent correction factor is applied.
This is known as Long Term Fuel Trim (LTFT), which is stored in the EEPROM. When the correction
factors exceed pre-determined limits a DTC will be set in the EEPROM. If a concern is detected in
either the STFT or LTFT, and it is still present on a second trip, the MIL will be switched on.
Heated Oxygen Sensor (HO2S) Monitor (All except vehicles with diesel engine)
This monitors the operation of the pre (upstream) and post (downstream) catalytic converter HO2S
sensors. It will detect deviations in air/fuel ratios (AFR) and sensor faults.
The HO2S will cause emission increase when its response time increases too much. To diagnose a
sensor a period is measured and the number of lean/rich transitions are counted. The sum of valid
periods is then calculated. To avoid non-representative measurements, the period is valid only if the
HO2S has been below a low threshold and above a high threshold between 2 consecutive lean/rich
transitions. A failure is declared when the sum of the measured periods exceeds the sum of the
corresponding limit (held within the PCM) and the MIL is illuminated.
Catalytic Converter Efficiency Monitor (All except vehicles with diesel engine)
The efficiency of a catalytic converter is measured by its ability to store and later release oxygen to
convert harmful gases. The efficiency is reduced if the converter becomes contaminated as it ages,
and at high gas flow rates, because the exhaust gas does not remain in the converter long enough to
complete the conversion process.
This monitor checks for the oxygen storage capacity (OSC) of the catalytic converter. During a
controlled period, the catalyst monitor sensor signal is analyzed to evaluate the OSC of the catalyst.
It represents the quantity of oxygen that is really used for the oxidation-reduction reaction by the
catalytic converter If a fault has occurred with the catalyst monitor sensor during the catalyst
diagnosis, a sensor diagnosis is carried out. During the controlled diagnosis phase, the catalyst
monitor sensor activity is measured and is compared to the OSC of the catalyst. If this activity is high
(low OSC) the MIL will be illuminated. If throughout the controlled phase, repeated several times, the
downstream sensor output has not moved, the closed loop mode is delayed in order to test the
sensor. If the catalyst monitor sensor is set to rich, the injection time is forced to lean and conversely
if the downstream sensor is set to lean, the injection time is forced to rich until the sensor switches
over or until the end of a delay. If this delay expires or the sensor does not switch, the sensor is
treated as failed.
Combustion Noise Monitor (Vehicles with common rail fuel injection)
In diesel variants, the Combustion Noise Monitor is used to trim the fuel injection pulse lengths. Each
fuel injector has an associated set of correction data that is determined during a production end of
line test. The Combustion Noise Monitor is used to determine how the fuel injector characteristic
changes from this initial calibration over the life of the fuel injector.
EGR Monitor (Vehicles with diesel engine)
The functionality of the EGR system is checked by comparing either the MAP sensor output or EGR
valve lift potentiometer output (depending upon application) with expected values.
Diagnostic Requirements
Vehicles equipped with EOBD, can be diagnosed using the Ford diagnostic equipment. In order for the
EOBD system to be invoked, a number of criteria must be met. After any repair, which could affect
emissions, a trip must be carried out on the vehicle, to make sure that engine management system
operates correctly.
Malfunction Indicator Lamp (MIL)
3/7
779/2430
10/30/2018 Print
The MIL is located in the instrument cluster and is fitted to alert the driver to the fact that an
abnormal condition has developed in the engine management system, that is having an adverse
effect on emissions. In cases of misfires which are likely to cause catalytic converter damage, it is
switched on immediately. With all other faults it will illuminate continuously from the second trip after
the condition occurred. Under normal operation it should illuminate at key-on and go out almost as
soon as the engine is started.
Diagnostic Trouble Codes (DTCs)
The DTCs given by the PCM are standardized, which means that generic scan tools can read results
from all vehicles.
The DTC is always a 5 digit alphanumerical code, for example ”P0100".

The first digit of a code (letter) identifies the system which has set the code. Provision has been
made for a total of four systems to be identified although only the 'P' code is required for EOBD.
- 'B' for the body
- 'C' for the chassis
- 'P' for the powertrain
- 'U' for the network communications systems
All of the ”x0xxx" codes are standardized codes. However, any manufacturer can use additional
codes over and above the standardized codes. These will be labelled ”x1xxx"
The third digit of a code (numeric) identifies the sub-system which has set the code.
- 'Px1xx' for metering of fuel and air supply
- 'Px2xx' for metering of fuel and air supply
- 'Px3xx' for ignition system – combustion misfires
- 'Px4xx' for auxiliary emission control equipment
- 'Px5xx' for vehicle speed, idle setting and other related inputs
- 'Px6xx' for trip computer and other related outputs
- 'Px7xx' for transmission.
- 'Px8xx' for transmission.
- 'Px9xx' category to be determined
- 'Px0xx' category to be determined
When a concern occurs, the actions taken include storage of the relevant information and actuation
of the MIL occurs in line with the relevant legislation.
MIL Code List
MIL Code Description

P0030 Heated oxygen sensor (HO2S) heater open circuit
P0031 HO2S heater low voltage
P0032 HO2S heater high voltage
P0036 Catalyst monitor sensor heater open circuit
P0037 Catalyst monitor sensor heater low voltage
P0038 Catalyst monitor sensor heater high voltage
P0053 HO2S heater resistance out of limits
P0054 Catalyst monitor sensor heater resistance out of limits
P0106 Manifold absolute pressure (MAP) sensor plausibility malfunction
P0107 MAP sensor circuit low input
P0108 MAP sensor circuit high input
P0109 MAP sensor temporary malfunction
P0112 Intake air temperature (IAT) circuit low input
P0113 IAT circuit high input
P0114 IAT intermittent failure
P0116 Engine coolant temperature (ECT) signal stuck at low level
P0117 ECT circuit low input
P0118 ECT circuit high input
P0119 ECT intermittent failure
P0122 Throttle position (TP) sensor circuit 1 low input
P0123 TP sensor circuit 1 high input
P0130 HO2S circuit open circuit
P0131 HO2S circuit low voltage
P0132 HO2S circuit high voltage
P0133 HO2S circuit slow response
4/7
780/2430
10/30/2018 Print

P0134 HO2S low amplitude
P0136 Catalyst monitor sensor circuit open circuit
P0137 Catalyst monitor sensor circuit low voltage
P0138 Catalyst monitor sensor circuit high voltage
P0139 Catalyst monitor sensor circuit slow response
P0171 Fuel system error, lean limit
P0171 Fuel system error , NOx emissions
P0172 Fuel system error , rich limit
P0172 Fuel system error, HC/CO emissions
P0201 Cylinder No. 1 - injector circuit open circuit
P0222 TP sensor circuit 2 low input
P0223 TP sensor circuit 2 high input
P0231 Fuel pump input low voltage
P0232 Fuel pump input high voltage
P0261 Cylinder No. 1 - injector circuit low voltage
P0262 Cylinder No. 1 - injector circuit high voltage
P0300 Random misfire detected
P0301 Cylinder No. 1 misfire detected
P0315 Flywheel segment adaptation at the Limit
P0324 Knock sensor (KS) communication error or implausible signal
P0325 KS implausible signal
P0335 Crankshaft position (CKP) sensor implausible signal
P0336 CKP sensor missing teeth
P0336 CKP sensor loss of synchronization
P0336 CKP sensor no signal
P0340 Camshaft position (CMP) sensor no signal
P0341 CMP sensor implausible signal
P0351 Ignition coil A primary malfunction
P0352 Ignition coil B primary malfunction
P0420 Catalyst system efficiency below threshold
P0444 Evaporative mission canister purge valve open circuit
P0458 Evaporative mission canister purge valve low voltage
P0459 Evaporative mission canister purge valve high voltage
P0460 Fuel tank level malfunction from instrument cluster
P0500 Vehicle speed sensor (VSS) signal malfunction
P0500 Vehicle speed via CAN (VS CAN) implausible signal
P0503 VSS signal too high
P0511 Idle air control (IAC) valve circuit malfunction
P0560 Battery system voltage malfunction high voltage
P0562 Battery system voltage malfunction open circuit
P0571 Brake switch plausibility error
P0603 Powertrain control module (PCM) error NVMY or EEPROM error
P0604 PCM error RAM error
P0605 PCM error checksum error
P0610 VID block checksum not correct or not programmed
5/7
781/2430
10/30/2018 Print

P0617 Starter relay malfunction
P0620 Generator circuit malfunction
P0625 Generator low voltage
P0626 Generator high voltage
P0628 Fuel pump primary circuit low voltage
P0629 Fuel pump primary circuit high voltage
P0641 Transmission sensor power supply 1 noisy signal
P0642 Transmission sensor power supply 1 low voltage
P0643 Transmission sensor power supply 1 high voltage
P0646 Air conditioning (A/C) clutch relay circuit low voltage
P0647 A/C clutch relay circuit high voltage
P0651 Transmission sensor power supply 2 noisy signal
P0652 Transmission sensor power supply 2 low voltage
P0653 Transmission sensor power supply 2 high voltage
P0654 Engine run output circuit malfunction
P0686 Main relay malfunction low voltage
P0687 Main relay malfunction high voltage
P0691 Cooling fan 1 control circuit low voltage
P0692 Cooling fan 1 control circuit high voltage
P0693 Cooling fan 2 control circuit low voltage
P0694 Cooling fan 2 control circuit high voltage
P0704 Clutch switch implausible signal
P1000 EOBD system readiness test not complete
P1500 Vehicle speed sensor (VSS) output circuit malfunction
P1632 Generator command malfunction
P1794 Battery voltage malfunction too high or too low
P2100 Engine throttle body H-bridge malfunction
P2107 Safety failure level 3
P2108 Safety failure level 2 error
P2119 Engine throttle body throttle flap malfunction
P2122 Accelerator pedal position (APP) sensor circuit 1 low input
P2123 APP sensor circuit 1 high input
P2127 APP sensor circuit 2 low input
P2128 APP sensor circuit 2 high input
P2128 APP sensor circuits 1 and 2 plausibility error
P2135 TP sensor circuits 1 and 2 plausibility error
P2176 Engine throttle body adaptive algorithm failed
P2280 Air cleaner obstruction or leakage
P2282 Air leakage between throttle and inlet valves
U0001 Control Area Network (CAN) bus-off or mute
U0101 CAN missing frame from TCU
U0121 CAN missing frame from ABS
U0122 CAN missing frame from ESP
U0155 CAN missing frame from HEC
B1213 Number of Passive Anti-Theft System (PATS) programmed keys is below minimum
B1600 PATS ignition key transponder signal is not received
B1601 PATS received incorrect key-code from ignition key transponder
B1602 PATS received invalid format of key-code from ignition key transponder
B1681 PATS transceiver module signal is not received
B2103 PATS immobilizer antenna not connected
B2139 PATS immobilizer challenge response doesn't match
B2141 PATS immobilizer no PCM-ID transferred
B2431 PATS immobilizer transponder programming failure
U2510 PATS immobilizer problem with messages on data link

6/7
782/2430
10/30/2018 Print
Sensors Fuse(s)
Actuators Wiring harness
7/7
783/2430
10/30/2018 Print
Electronic Engine Controls - 1.6L Duratec-16V

16V Ti-VCT (77kW/105PS) - Sigma/1.6L
Duratec-16V Ti-VCT (92kW/125PS) -
Sigma/1.6L Duratec-16V Ti-VCT Flex Fuel
(88kW/120PS) - Sigma - Clutch Pedal Position
(CPP) Switch
Print
Removal
1. NOTICE: Make sure that the clutch pedal remains in the rest position.
Installation
1. NOTICE: Make sure that the clutch pedal remains in the rest position.
1/1
784/2430
10/30/2018 Print
Electronic Engine Controls - 1.6L Duratec-16V

16V Ti-VCT (77kW/105PS) - Sigma/1.6L
Duratec-16V Ti-VCT (92kW/125PS) -
Sigma/1.6L Duratec-16V Ti-VCT Flex Fuel
(88kW/120PS) - Sigma - Clutch Pedal Position
(CPP) Sensor—Vehicles With: Auto-Start-Stop
Print
Special Tool(s)
308-651
Installer, Clutch Master Cylinder Sensor
Removal
All vehicles
1.
Installation
1/1
785/2430
10/30/2018 Print
Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (63kW/85PS) -

Sigma/1.6L Duratec-16V Ti-VCT (77kW/105PS) - Sigma/1.6L Duratec-
16V Ti-VCT (92kW/125PS) - Sigma/1.6L Duratec-16V Ti-VCT Flex Fuel
(88kW/120PS) - Sigma - Clutch Pedal Position (CPP) Switch—Vehicles
With: Auto-Start-Stop
Print
Removal
1.
2.
3.
1/2
786/2430
10/30/2018 Print
Installation
2/2
787/2430
10/30/2018 Print
Electronic Engine Controls - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L

Duratorq-TDCi (70kW/95PS) (T3) - Camshaft Position (CMP) Sensor
Print
General Equipment
Feeler Gauge
Removal
1.
2. Torque:
1 25 Nm
2 10 Nm
3 10 Nm
1/4
788/2430
10/30/2018 Print
3.
4. NOTE: This step is only necessary if the original component is to be reused.

Torque: 4 Nm
2/4
789/2430
10/30/2018 Print
Installation

Use the General Equipment: Feeler Gauge
Torque: 8 Nm

Torque: 8 Nm
3/4
790/2430
10/30/2018 Print
4/4
791/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Crankshaft Position (CKP) Sensor
Print
Removal
1. Refer to: Jacking and Lifting (100-02, Description and Operation).
2. If equipped.
3. If equipped.
4. Loosen: 1,5 turn(s)
1/3
792/2430
10/30/2018 Print
5. Torque: 8 Nm
6.
2/3
793/2430
10/30/2018 Print
Installation
2. Torque: 5 Nm
3/3
794/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Diesel Particulate Filter (DPF)
Differential Pressure Sensor
Print
General Equipment
Removal
1.
Installation
2. Carry out the powertrain control module (PCM) Reset the Diesel Particulate Filter Differential
Pressure Sensor Learned Values service function.
1/1
795/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Diesel Particulate Filter (DPF)
Temperature Sensor
Print
Removal
1. Torque: 15 Nm
Installation
1/1
796/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Engine Coolant Temperature (ECT)
Sensor
Print
Materials
Name Specification
Removal
1. Refer to: Engine Cooling System Health and Safety Precautions (100-00, Description and
Operation).
2.
3. WARNING: When releasing the cooling system pressure, cover the coolant expansion
tank cap with a thick cloth to prevent the possibility of scalding. Failure to follow this
Loosen: 2 turn(s)
4. Close the coolant expansion tank cap.
1/3
797/2430
10/30/2018 Print
Installation
2. Material: WSS-M97B44-D (Antifreeze)
3.
2/3
798/2430
10/30/2018 Print
3/3
799/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Heated Oxygen Sensor (HO2S)
Print
Removal
1. Torque: 48 Nm
Installation
1/1
800/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Heated Oxygen Sensor (HO2S) LH
Print
Removal
2. If equipped.
3. If equipped.
4. Torque: 48 Nm
1/2
801/2430
10/30/2018 Print
Installation
2/2
802/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Intake Air Temperature (IAT) Sensor
Print
Removal
1.
2. Torque: 8 Nm
Installation
2.
1/2
803/2430
10/30/2018 Print
2/2
804/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Manifold Absolute Pressure (MAP)
Sensor
Print
Removal
1.
2. Torque: 8 Nm
Installation
2.
1/2
805/2430
10/30/2018 Print
2/2
806/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Mass Air Flow (MAF) Sensor
Print
Removal
1. Torque: 5 Nm
2. Torque: 5 Nm
Installation
1/1
807/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Post Catalytic Converter Temperature
Sensor
Print
Removal
1. Torque: 15 Nm
Installation
1/1
808/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Powertrain Control Module (PCM)
Print
General Equipment
3.5 mm Drill Bit
Center Punch
Removal

Download the module information to the diagnostic tool using the Programmable Modules
Installation routine.
2. Refer to: Battery Disconnect and Connect (414-01, General Procedures).
3. Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
Vehicles without PCM security shield

4.
Vehicles with PCM security shield
5. Use the General Equipments: Center Punch, 3.5 mm Drill Bit
1/3
809/2430
10/30/2018 Print
All vehicles
6.
Installation
Vehicles with PCM security shield

2. Tighten the shear bolt until the head is sheared off.
2/3
810/2430
10/30/2018 Print
All vehicles
Upload the module information from the diagnostic tool to the module using the Programmable
Modules Installation routine.
3/3
811/2430
10/30/2018 Print

Duratorq-TDCi (70kW/95PS) (T3) - Manifold Absolute Pressure and
Temperature (MAPT) Sensor
Print
Removal
1.
2. Torque: 8 Nm
Installation
2.
1/2
812/2430
10/30/2018 Print
2/2
813/2430
10/30/2018 Print
Manual Transmission and Clutch - General Information - 5-Speed

Manual Transmission - B5A/5-Speed Manual Transmission -
B5/IB5/5-Speed Manual Transmission - MTX75/6-Speed Manual
Transmission - B6/6-Speed Manual Transmission - MMT6 - Manual
Transaxle and Clutch
Print

303-393
Mechanical
Oil leaks.
Visibly damaged or worn components.
Loose or missing nuts or bolts.
4. If the cause is not evident, verify the symptom and REFER to the Symptom Chart.
The following checks should be carried out before repairing or installing a new transmission.
The inspection and verification of manual transmission concerns can be considered in three main
areas.
Gear Shifting Concerns
Clutch does not operate correctly.

External gearshift mechanism REFER to:
Transmission noise concerns
Check the engine and transmission mountings for sufficient clearance to the transmission and the
body.
Any other noise excluding shift noises.
Road test the vehicle. Carry out the checks in the following table and record the results.
NOTE: If the answer is "Yes" to one or more of the tests, the transmission must be removed and
the dual mass flywheel tested, for additional information GO to Pinpoint Test E.
Item No. Situation, test / diagnosis Yes No
1 Driving situation: 0 0
Road test the vehicle. Select 5th or 6th gear and fully depress the accelerator
pedal to obtain maximum engine torque.
Diagnosis:
Are there extremely harsh vibrations from the powertrain? Vibrations
disappear when the accelerator pedal is released briefly.
1a Driving situation: 0 0
Road test the vehicle. Drive the vehicle in simulated "stop and go" mode (1st
gear). Check for transmission rattle during gentle acceleration and
deceleration.
1/22
814/2430
10/30/2018 Print
Item No. Situation, test / diagnosis Yes No

Diagnosis:
Are there noises from the powertrain in driving situations between idling speed
and a maximum of 2000 rev/min which occur at a specific, vehicle-dependent
vehicle/engine speed?
REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and
Operation).
Check all engine/transmission and exhaust mountings with the engine not
running, while starting the engine and when it is idling.
Diagnosis:
Does the engine/transmission shake severely or make rattling noises during
starting? Longer time before engine reaches idle speed. Install new
components as necessary (engine/transmission or exhaust mountings) and
repeat the test.
Check the front axle driveshafts and the manual transmission. Lock the wheels
and apply the parking brake. Start the engine, engage 1st gear and slowly
release the clutch pedal while the engine idles.
Diagnosis:
Engine speed does not drop, power not transferred, vehicle does not move.
Start the engine, place the gear lever in the neutral position and slowly release
the clutch pedal. Stop the engine.
Diagnosis:
Hard metallic noise as the engine stops, coming from the manual transmission
during the last engine revolution before the engine finally stops, is NOT caused
by the dual mass flywheel. On vehicles with a diesel engine and without an
intake manifold flap solenoid valve, the concern (harsh, metallic noise) cannot
be resolved by installing a new dual mass flywheel. In diesel engines with an
intake manifold flap solenoid valve, check the operation of the solenoid valve.
If a clattering noise is detected as the engine is switched off with the clutch
pedal depressed, check the transmission housing for grease residues (more
than 2 grams) from the dual mass flywheel (remove the starter motor and
check the bell housing).
Fluid Leakage Concerns
Check that the leaking fluid is actually transmission fluid and not hydraulic fluid (from the
hydraulically operated clutch) or engine oil.
Check the transmission fluid level. If necessary, drain off any excess fluid.
Locate the oil leak with the aid of a fluorescent test fluid and an ultraviolet inspection lamp.
Clean the transaxle and the adjacent areas carefully before road testing.
Symptom Chart – General Concerns

HIGH-EFFORT * SYNCHRONIZER RING * INSTALL A NEW SYNCHRONIZER HUB WITH SYNCHRONIZER
GEAR OR SYNCHRONIZATION RING SET AND INSTALL A NEW GEAR WHEEL BELONGING
SHIFTING IN DAMAGED TO THE SYNCHRONIZER UNIT AS NECESSARY.
ONE OR MORE - BECAUSE OF VARIOUS CHANGES AND THE DIFFICULTY IN
GEARS ESTIMATING THE LEVEL OF WEAR, A COMPLETE NEW
INSTALLATION (AS DESCRIBED ABOVE) IS RECOMMENDED.
* CLUTCH DOES NOT * CHECK THE CLUTCH FUNCTION AND THE BRAKE FLUID
OPERATE CORRECTLY. LEVEL.
* INTERNAL GEARSHIFT * REMOVE THE INTERNAL GEARSHIFT MECHANISM AND
MECHANISM CHECK THE COMPONENTS. - INSTALL NEW COMPONENTS
AS NECESSARY.
CLASHING OR * SYNCHRONIZER HUB * INSTALL A NEW SYNCHRONIZER HUB WITH SYNCHRONIZER
SCRATCHING OR SYNCHRONIZER RING SET AND INSTALL A NEW GEAR WHEEL BELONGING
NOISE DURING RING DAMAGED TO THE SYNCHRONIZER UNIT AS NECESSARY.
-
2/22
815/2430
10/30/2018 Print
GEAR BECAUSE OF VARIOUS CHANGES AND THE DIFFICULTY IN

SHIFTING ESTIMATING THE LEVEL OF WEAR, A COMPLETE NEW
INSTALLATION (AS DESCRIBED ABOVE) IS RECOMMENDED.
* CLUTCH DOES NOT * CHECK THE CLUTCH FUNCTION AND THE BRAKE FLUID
OPERATE CORRECTLY. LEVEL.
GEAR * EXTERNAL GEARSHIFT * CHECK THE EXTERNAL GEARSHIFT MECHANISM FOR
ENGAGEMENT MECHANISM DAMAGED DAMAGE. IF NO CONCERN IS DETERMINED, REMOVE THE
NOT TRANSMISSION. REFER TO:
FUNCTIONING TRANSMISSION - 1.6L DURATEC-16V TI-VCT
CORRECTLY (77KW/105PS) - SIGMA/1.6L DURATEC-16V TI-VCT
(92KW/125PS) - SIGMA (308-03A MANUAL
TRANSMISSION, REMOVAL),
TRANSMISSION - 2.0L DURATEC-HE (107KW/145PS) -
MI4/2.0L DURATEC-HE FLEX FUEL (107KW/145PS) -
MI4 (308-03 MANUAL TRANSMISSION/TRANSAXLE -
VEHICLES WITH: 5-SPEED MANUAL TRANSAXLE -
MTX75, REMOVAL),
TRANSMISSION (308-03B MANUAL TRANSMISSION,
REMOVAL),
TRANSMISSION (308-03D MANUAL TRANSMISSION,
REMOVAL),
TRANSMISSION (308-03D MANUAL TRANSMISSION,
REMOVAL),
GEAR JUMPS * MISSING SNAP RINGS; * INSTALL A NEW GEAR SET, SYNCHRONIZER UNIT AND
OUT OF SYNCHRONIZATION SELECTOR FORK AS NECESSARY. CHECK THE
ENGAGEMENT COMPONENTS TRANSMISSION FOR DAMAGE, PARTICULARLY TO THE
WHILE DAMAGED OR WORN SLIDING SLEEVE.
DRIVING CLUTCH SPLINES
* INCORRECT SLIDING * INSTALL A NEW GEAR SET, SYNCHRONIZER UNIT AND
SLEEVE; WORN SELECTOR FORK AS NECESSARY. CHECK THE
CLUTCH SPLINES TRANSMISSION FOR DAMAGE, PARTICULARLY TO THE
SLIDING SLEEVE.
* SELECTOR FORKS * INSTALL NEW GEAR WHEELS, SLIDING SLEEVES AND
SELECTOR FORKS AS NECESSARY. CHECK THE
TRANSMISSION FOR DAMAGE, PARTICULARLY TO THE
SLIDING SLEEVE.
GEARSHIFT * GEARSHIFT LEVER * CHECK THE EXTERNAL GEARSHIFT MECHANISM; REPLACE
LEVER FEELS FIXING. IF NECESSARY. CHECK GEAR LEVER MOUNTING, EXTERNAL
LOOSE GEARSHIFT MECHANISM AND SHIFT CABLES; TIGHTEN IF
NECESSARY. REFER TO:
* INTERNAL GEARSHIFT * CHECK THE INTERNAL GEARSHIFT MECHANISM FOR PLAY
MECHANISM AT THE TRANSMISSION.
Symptom Chart - Transmission Noises

GEAR WHEELS BANGING WHEN * CLUTCH WORN * CHECK THE CLUTCH
SHIFTING * REFER TO:
CLUTCH DISC AND PRESSURE
PLATE (308-01 CLUTCH -
VEHICLES WITH: 5-SPEED
MANUAL TRANSAXLE - B5/IB5,
REMOVAL AND INSTALLATION),
* AIR IN THE CLUTCH * CHECK THE CLUTCH SYSTEM FOR
SYSTEM; FLUID LOSS LEAKS. CHECK THE CLUTCH
MASTER CYLINDER BLEED SCREW
FOR BLOCKAGE. REMOVE ANY
BLOCKAGE FROM THE CLUTCH
MASTER CYLINDER BLEED SCREW
AND BLEED THE CLUTCH SYSTEM
AS NECESSARY.
REFER TO: CLUTCH SYSTEM
BLEEDING (308-00, GENERAL
PROCEDURES).
3/22
816/2430
10/30/2018 Print
SLIGHT BUZZING, RATTLING OR *ROTATIONAL * THESE NOISES DO NOT AFFECT THE

METALLIC SCRAPING NOISE FROM THE VIBRATION FROM THE OPERATION AND DURABILITY OF
TRANSMISSION AT 2500 TO 3500 RPM ENGINE NOT THE TRANSAXLE.
WHEN ON OVERRUN OR DRIVING SUFFICIENTLY DAMPED
WITHOUT LOAD (PARTICULARLY IN BY THE CLUTCH.
2ND AND 3RD GEAR) *ENGINE SPEED- * CHECK TRANSMISSION INPUT
DEPENDENT SHAFT BEARINGS. REMOVE THE
TRANSMISSION NOISE TRANSMISSION. REFER TO:
TRANSMISSION - 1.6L
DURATEC-16V TI-VCT
(77KW/105PS) - SIGMA/1.6L
DURATEC-16V TI-VCT
(92KW/125PS) - SIGMA (308-
03A MANUAL TRANSMISSION,
REMOVAL),
TRANSMISSION - 2.0L
DURATEC-HE (107KW/145PS) -
MI4/2.0L DURATEC-HE FLEX
FUEL (107KW/145PS) - MI4
(308-03 MANUAL
TRANSMISSION/TRANSAXLE -
MANUAL TRANSAXLE - MTX75,
REMOVAL),
TRANSMISSION (308-03B
MANUAL TRANSMISSION,
REMOVAL),
TRANSMISSION (308-03D
REMOVAL),
REMOVAL),
* VEHICLE SPEED- * CHECK DRIVESHAFT TRIPOD
DEPENDENT JOINTS. REFER TO: (205-04 FRONT
TRANSMISSION NOISE DRIVE HALFSHAFTS)
FRONT HALFSHAFT LH - 5-
SPEED MANUAL
TRANSMISSION - B5/IB5
(REMOVAL AND
INSTALLATION),
FRONT HALFSHAFT RH - 5-
SPEED MANUAL
TRANSMISSION - B5/IB5
(REMOVAL AND
INSTALLATION).
* STEERING ANGLE- * CHECK DIFFERENTIAL SPLINES FOR
DEPENDENT DAMAGE. TURN THE DIFFERENTIAL
TRANSMISSION NOISE BEVEL GEARS AGAINST ONE
ANOTHER. FOR THIS PURPOSE,
REMOVE THE DIFFERENTIAL.
REFER TO: FRONT HALFSHAFT LH -
5-SPEED MANUAL TRANSMISSION -
B5/IB5 (205-04 FRONT DRIVE
HALFSHAFTS, REMOVAL AND
INSTALLATION).
REFER TO: FRONT HALFSHAFT RH -

5-SPEED MANUAL TRANSMISSION -
B5/IB5 (205-04 FRONT DRIVE
HALFSHAFTS, REMOVAL AND
INSTALLATION).
* THE ENGINE AND * VISUALLY INSPECT FOR EVIDENCE
TRANSAXLE ASSEMBLY OF CONTACT AND REPAIR AS
4/22
817/2430
10/30/2018 Print
IS IN CONTACT WITH NECESSARY.

THE BODY.
* ENGINE/TRANSMISSION * TIGHTEN THE TRANSMISSION
WASHER-HEAD BOLTS BOLTS.
REFER TO: TRANSMISSION - 1.6L
DURATEC-16V TI-VCT
DURATEC-16V TI-VCT
(92KW/125PS) - SIGMA (308-03A
INSTALLATION).
REFER TO: TRANSMISSION (308-

03B MANUAL TRANSMISSION,
REMOVAL).
REFER TO: TRANSMISSION (308-

03D MANUAL TRANSMISSION,
REMOVAL).

* TRANSMISSION FLUID * CHECK THE TRANSMISSION FLUID
LEVEL TOO LOW. LEVEL. REFER TO:
TRANSMISSION FLUID LEVEL
CHECK (308-03A MANUAL
TRANSMISSION, GENERAL
PROCEDURES),
CHECK (308-03B, GENERAL
PROCEDURES),
CHECK (308-03B MANUAL
TRANSMISSION, GENERAL
PROCEDURES),
CHECK (308-03D, GENERAL
PROCEDURES).
* TRANSAXLE BEARINGS * REMOVE THE TRANSAXLE. CHECK
AND GEAR WHEELS THE BEARINGS AND GEAR WHEELS
(USUALLY ON HIGH- AND INSTALL NEW COMPONENTS
MILEAGE VEHICLES). AS NECESSARY. REFER TO:
TRANSMISSION - 1.6L
DURATEC-16V TI-VCT
DURATEC-16V TI-VCT
(92KW/125PS) - SIGMA (308-
03A MANUAL TRANSMISSION,
REMOVAL),
TRANSMISSION - 2.0L
DURATEC-HE (107KW/145PS) -
MI4/2.0L DURATEC-HE FLEX
FUEL (107KW/145PS) - MI4
(308-03 MANUAL
TRANSMISSION/TRANSAXLE -
MANUAL TRANSAXLE - MTX75,
REMOVAL),
5/22
818/2430
10/30/2018 Print
TRANSMISSION (308-03B
REMOVAL),
REMOVAL),
REMOVAL),
RATTLING OR VIBRATION NOISES. * EXTERNAL GEARSHIFT * CHECK THE EXTERNAL GEARSHIFT
MECHANISM MECHANISM.
* FRONT OR REAR * CHECK FRONT OR REAR ENGINE
ENGINE MOUNTING MOUNTING; INSTALL A NEW
DEFECTIVE MOUNTING, IF NECESSARY.
Symptom Chart - Fluid Leakage

FLUID * OIL SEALS OR O-RING * CHECK THE MATING SURFACES AND INSTALL A NEW SEAL
LEAKAGE SEALS AS NECESSARY.
* FLUID LEAK BETWEEN THE * DISASSEMBLE THE TRANSMISSION AND CLEAN THE MATING
CLUTCH-SIDE AND FACES. CHECK THE SURFACES FOR DAMAGE. SEAL THE
TRANSMISSION-SIDE TRANSMISSION USING WSK-M2G348-A5 SEALER.
HOUSING HALVES.
* FLUID LEAK AT * TIGHTEN THE TRANSMISSION HOUSING BOLTS TO THE
TRANSMISSION HOUSING SPECIFIED TIGHTENING TORQUE.
BOLT. REFER TO: TRANSMISSION - 1.6L DURATEC-16V TI-VCT
(77KW/105PS) - SIGMA/1.6L DURATEC-16V TI-VCT
(92KW/125PS) - SIGMA (308-03A MANUAL TRANSMISSION,
INSTALLATION).
REFER TO: TRANSMISSION (308-03B MANUAL

TRANSMISSION, REMOVAL).
REFER TO: TRANSMISSION (308-03D MANUAL

TRANSMISSION, REMOVAL).
Symptom Chart - Clutch

CLUTCH SLIPPING * NO CLUTCH PEDAL FREE PLAY * GO TO
* CLUTCH DIAPHRAGM SPRINGS BROKEN PINPOINT
* CLUTCH DISC FACING BROKEN TEST A.
* HARDENED OR OILED CLUTCH DISC FACING
SURFACE
CLUTCH CHATTER OR SHUDDER * ENGINE MOUNTING DEFECTIVE * GO TO
* TILTED CLUTCH DISC PINPOINT
TEST B.
CLUTCH DISENGAGES TOO LATE OR * INSUFFICIENT FLUID. * GO TO
NOT AT ALL; HIGH-EFFORT GEAR * AIR IN HYDRAULIC SYSTEM. PINPOINT
SHIFTING * EXCESSIVE CLUTCH PEDAL FREE PLAY TEST C.
* CLUTCH DIAPHRAGM SPRINGS BROKEN
* CLUTCH DISC DEFORMED OR BROKEN
* CORROSION ON CLUTCH DISC SPLINES
6/22
819/2430
10/30/2018 Print
* INSUFFICIENT OR NO GREASE ON THE

TRANSMISSION INPUT SHAFT AND CLUTCH
DISC SPLINES
CLUTCH PEDAL PULSATING * UNEVEN DIAPHRAGM SPRING FINGERS * GO TO
* FREQUENCY MODULATOR DEFECTIVE (IF PINPOINT
PRESENT) TEST D.
EXCESSIVE NOISE * RELEASE BEARING DEFECTIVE * GO TO
* INPUT SHAFT PILOT BEARING PINPOINT
* EXCESSIVE CRANKSHAFT END PLAY TEST E.
* DUAL MASS FLYWHEEL
FLUID LEAKAGE * CLUTCH MASTER CYLINDER * GO TO
* CLUTCH SLAVE CYLINDER PINPOINT
* HYDRAULIC LINES IN AREA OF ENGINE AND TEST F.
TRANSMISSION
Pinpoint Tests
PINPOINT TEST A : CLUTCH SLIPPING

CONDITIONS
A1: TEST CLUTCH SLIPPAGE
1 Lock the wheels and apply the parking brake.
2 Start the engine.
3 Start the engine, depress the clutch pedal and engage fourth gear.
4 Run the engine at approx. 2000 rpm.
5 Release the clutch pedal slowly.
Does the engine stall when the clutch pedal is fully released?
Yes
Clutch OK.
No
GO to A2.
A2: CHECK THE CLUTCH PEDAL FREE PLAY
1 Measure the clutch pedal free play.
2 Depress the clutch pedal manually to the point of resistance and release, record clutch
pedal travel.
Is the clutch pedal travel approx. 10 mm?
Yes
Clutch pedal free play OK.
No
GO to A3.
A3: CHECK THE CLUTCH DIAPHRAGM SPRING
1 Remove the transmission. CHECK the clutch diaphragm spring. REFER to:
Transmission - 2.0L Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4 (308-03 Manual Transmission/Transaxle - Vehicles With: 5-
Speed Manual Transaxle - MTX75, Removal),
Transmission (308-03D Manual Transmission, Removal),
Is the clutch diaphragm spring broken?
Yes
INSTALL a new clutch disc and pressure plate. TEST the system for normal operation.
No
GO to A4.
A4: CHECK THE CLUTCH DISC
1 Remove the clutch disc and clutch pressure plate. REFER to:
Clutch Disc and Pressure Plate (308-01A, Removal and Installation),
Is the clutch disc or the clutch pressure plate broken or contaminated with oil?
Yes
CHECK the engine and transmission for leaks.INSTALL a new clutch disc and pressure
plate. TEST the system for normal operation.
No
CHECK the operation of the system.
7/22
820/2430
10/30/2018 Print
PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER

CONDITIONS
B1: CHECK FOR CLUTCH CHATTER OR SHUDDER
1 Start the engine.
2 Start the engine, depress the clutch pedal and engage 1st gear.
3 Run the engine at between 1200 rpm and 1500 rpm.
4 Release the clutch pedal slowly.
Does the vehicle shudder when it starts off?
Yes
GO to B2.
No
Clutch OK.
B2: CHECK ENGINE/TRANSMISSION MOUNTINGS AND ROLL RESISTOR
1 Check the engine/transaxle mountings isolator and roll resistor for damage or loose
bolts.
Is the engine/transaxle isolator or roll restrictor loose or damaged?
Yes
TIGHTEN the bolts or INSTALL new bolts as necessary. TEST the system for normal
operation.
No
GO to B3.
B3: CHECK THE CLUTCH PRESSURE PLATE
1 Remove the clutch pressure plate. REFER to:
Is the clutch pressure plate damaged?
Yes
INSTALL a new clutch disc and pressure plate. TEST the system for normal
operation.
No
GO to B4.
B4: CHECK THE CLUTCH DISC
1 CHECK the clutch disc.
Is the clutch disc broken, contaminated with oil or bent?
Yes
INSTALL a new clutch disc and pressure plate. TEST the system for normal
operation.
No
CHECK the dual mass flywheel. GO to Pinpoint Test E.
PINPOINT TEST C : CLUTCH DISENGAGES TOO LATE OR NOT AT ALL

CONDITIONS
C1: CHECK FLUID LEVEL
1 Check the brake fluid level.
Is the brake fluid level between the MAX and MIN marks on the brake fluid reservoir?
Yes
GO to C2.
No
Top up the brake fluid, CHECK the brake and clutch systems for leaks.
C2: BLEED THE CLUTCH SYSTEM
1 Bleed the clutch system.
REFER to: Clutch System Bleeding (308-00, General Procedures).
Does the clutch show improved disengaging characteristics following bleeding of the
system?
Yes
Clutch OK.
No
GO to C3.
C3: CHECK THE CLUTCH PEDAL FREE PLAY
8/22
821/2430
10/30/2018 Print
1 Measure the clutch pedal free play.

2 Depress the clutch pedal manually to the point of resistance and release, record clutch
pedal travel.
Is the clutch pedal travel approx. 10 mm?
Yes
GO to C4.
No
CHECK that the clutch pedal moves freely; remove if necessary.
C4: CHECK THE CLUTCH DIAPHRAGM SPRING
1 Remove the transmission and CHECK the clutch diaphragm spring.REFER to:
Transmission (308-03B Manual Transmission, Removal),
Is the clutch diaphragm spring broken?
Yes
INSTALL a new clutch disc and pressure plate. REFER to:
No
GO to C5.
C5: CHECK THE CLUTCH DISC
1 Remove the clutch disc. REFER to:
Is the clutch disc bent, contaminated with oil or broken?
Yes
INSTALL a new clutch disc and pressure plate. TEST the system for normal operation.
No
GO to C6.
C6: CHECK THE SPLINES ON THE CLUTCH DISC FOR INSUFFICIENT LUBRICATION AND/OR
SIGNS OF CORROSION
NOTICE: Do not use solvent cleaners to clean the inside of the clutch housing or the
transmission input shaft. A lint-free damp cloth should be used for cleaning. Failure to follow this
instruction may result in incorrect clutch operation.
1 CHECK the splines on the clutch disc for insufficient or no grease and/or signs of
corrosion.
Is there insufficient or no grease and/or signs of corrosion on the splines of the clutch disc?
Yes
CLEAN the splines of the clutch disc. GO to C7.
No
CHECK the splines of the transmission input shaft for damage or insufficient or no
grease and signs of corrosion. CLEAN and lubricate the splines on the clutch disc with
the specified lubricant as required. CLEAN the splines of the transmission input shaft. If
the transmission input shaft is damaged, REPLACE the components as required. TEST
the system for normal operation.
C7: CHECK THE SPLINES ON THE CLUTCH DISC FOR SIGNS OF DAMAGE OR SIGNIFICANT
FRICTION
NOTICE: Do not use solvent cleaners to clean the inside of the clutch housing or the
transmission input shaft. A lint-free damp cloth should be used for cleaning. Failure to follow this
instruction may result in incorrect clutch operation.
1 CHECK the splines on the clutch disc for damage or signs of significant friction.
Are there signs of damage or significant friction on the splines of the clutch disc?
Yes
Lubricate the splines of the clutch disc with the specified lubricant as required. TEST
the system for normal operation.
No
CHECK the splines of the transmission input shaft for damage or insufficient or no
grease and/or signs of corrosion. CLEAN and lubricate the splines on the clutch disc
9/22
822/2430
10/30/2018 Print
with the specified lubricant as required. CLEAN the splines of the transmission input
shaft. If the transmission input shaft is damaged, INSTALL new components as
required. TEST the system for normal operation.
PINPOINT TEST D : CLUTCH PEDAL PULSATING

CONDITIONS
D1: CHECK THE DIAPHRAGM SPRING FINGERS FOR UNIFORMITY
1 Remove the transmission. REFER to:
Transmission (308-03B Manual Transmission, Removal),
CHECK the diaphragm spring fingers for uniformity.
Are the diaphragm spring fingers all at the same height?
Yes
Check the frequency modulator and INSTALL a new if necessary (if present)
No
PINPOINT TEST E : EXCESSIVE NOISE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK THE TRANSMISSION AT IDLE (A)
1 Start the engine.
2 Start the engine.
3 Depress the clutch pedal fully.
Is the noise apparent when the clutch is operated?
Yes
GO to E2.
No
There is a problem with the transmission. REFER to the
Symptom Chart - Transmission Noises.
E2: CHECK THE TRANSMISSION AT IDLE (B)
1 Run the engine at idle.
Are the noises coming from the pedal box?
Yes
CHECK the clutch pedal and bushes.
No
GO to E3.
E3: CHECK THE CLUTCH RELEASE BEARING
1 Remove the clutch slave cylinder/release bearing assembly.
REFER to:
Clutch Slave Cylinder - 5-Speed Manual Transmission -
B5/IB5 (308-02 Clutch Controls, Removal and
Installation),
Clutch Slave Cylinder (308-02C, Removal and
Installation),
Clutch Slave Cylinder - 5-Speed Manual Transmission -
MTX75 (308-02 Clutch Controls, Removal and
Installation).
2 Check the release bearing for wear and corrosion.
Are there signs of wear or corrosion?
Yes
INSTALL a new clutch release bearing.
No
CHECK the crankshaft for excessive end float. Are there still
noises?GO to E4.
E4: ENGINE SELECTION – DIESEL ENGINES
10/22
823/2430
10/30/2018 Print
1 Determine the size of engine installed.

Does the vehicle have a 1.8L diesel engine or a 2.0L diesel
engine?
Yes
Vehicles with a 1.8L diesel engineGO to E5. Vehicles with a
2.0L diesel engineGO to E19.
No
GO to E28.
E5: DETERMINE THE ENGINE BUILD DATE
NOTE: A bar code sticker is located on the valve cover. The number below the bar code identifies
the exact build date of the engine.
1 Determine the build date of the engine (see example below).
ELD = Dagenham Engine Plant

0 = Not used
M = Assembly line
121201 = DDMMYY
101133 = Running number
65 = Statec code
Was the engine built before 11/07/2007?

Yes
Vehicles with a 1.8L diesel engine built up to 11/07/2007GO
to E6.
No
Vehicles with a 1.8L diesel engine built 11/07/2007
onwardsGO to E11.
E6: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS FLYWHEEL
NOTICE:
Do not rework or machine the dual mass flywheel if it is

distorted.
Do not clean the dual mass flywheel with any kind of

liquid. Use only a dry cloth to clean the flywheel.
Do not clean the gap between the primary and

secondary mass of the dual mass flywheel. Only clean the
bolt connection surface and the clutch surface.
NOTE: Discoloration is not a reason in itself to install a new
dual mass flywheel.
1 Remove the clutch disc and clutch pressure plate.
2 Secure the primary side of the dual mass flywheel.
3 Move the secondary side of the dual mass flywheel by hand
left and right several times prior to moving on.
4 Twist the secondary side of the dual mass flywheel by hand in
a clockwise direction until spring resistance is felt and release.
5 Mark the rest position on the primary and secondary sides of
the dual mass flywheel.
a counterclockwise direction until spring resistance is felt and
release.
7 Mark the new rest position on the primary side of the dual
mass flywheel.
8 Count the number of teeth between the marks for both
directions on the flywheel ring gear.
Are between 0.5 teeth and 3 teeth counted?
Yes
GO to E7.
No
11/22
824/2430
10/30/2018 Print
INSTALL a new dual mass flywheel.

E7: CHECK THE DUAL MASS FLYWHEEL
1 Carry out a visual inspection of the dual mass flywheel. For
example, but not limited to, severe scratches on the dual
mass flywheel face, grease/oil/fuel contamination & cracks or
fractures on the secondary side.
Is the dual mass flywheel free of faults?

Yes
GO to E8.
No
E8: CHECK THE FLYWHEEL RING GEAR AND CKP SENSOR RING
1 Carry out a visual inspection of the flywheel ring gear and CKP
sensor ring on the dual mass flywheel.
Is the flywheel ring gear and the CKP sensor ring OK?
Yes
GO to E9.
No
E9: CHECK THE TRANSMISSION BELL HOUSING FOR GREASE LEAKAGE
1 Visually inspect the transmission bell housing for traces of
grease.
Are there traces of circulated grease greater than 10 grams, 50

mm backwards from the front edge of the bell housing?
Yes
No
GO to E10.
12/22
825/2430
10/30/2018 Print
E10: CHECK THE GUIDE PINS OF THE DUAL MASS FLYWHEEL

NOTE: The guide pins should protrude by 11.5 mm +/- 0.5
mm.
1 CHECK the installation of the guide pins of the dual mass
flywheel.
Are the guide pins present and are they all the same length?
Yes
The dual mass flywheel is OK.
No
NOTICE:

distorted.


dual mass flywheel.
Can the secondary mass of the dual mass flywheel be turned
freely by more than 15 teeth?
Yes
No
GO to E12.
E12: CHECK THE SPRING RESISTANCE
1 Move the secondary mass of the dual mass flywheel in both
directions.
Can spring resistance be felt in both directions?
Yes
GO to E13.
No

13/22
826/2430
10/30/2018 Print

release.
mass flywheel.
Are more than 5 teeth counted?
Yes
No
GO to E14.
E14: CHECK THE DUAL-MASS FLYWHEEL
1 Carry out a visual inspection of the dual mass flywheel.
Is the dual mass flywheel free of damage?

Yes
GO to E15.
No
E15: CHECK THE FLYWHEEL RING GEAR
1 Carry out a visual inspection of the flywheel ring gear.
Is the flywheel ring gear OK?

Yes
GO to E16.
No
E16: CHECK THE TRANSMISSION BELL HOUSING FOR GREASE LEAKAGE
1 Visually inspect the transmission bell housing for traces of
grease.
14/22
827/2430
10/30/2018 Print
Are there traces of circulated grease greater than 10 grams, 41

mm backwards from the front edge of the bell housing?
Yes
No
GO to E17.
1 Check the installation of the guide pins of the dual-mass
flywheel.
Yes
GO to E18.
No
E18: CHECK FOR DISCOLORATION OF THE DUAL MASS FLYWHEEL DUE TO OVERHEATING
1 Check the dual mass flywheel for discoloration due to
overheating.
Is any discoloration evident in the marked area?

Yes
No
NOTICE:
15/22
828/2430
10/30/2018 Print

distorted.


dual mass flywheel.
Yes
No
GO to E20.
E20: CHECK THE SPRING RESISTANCE
1 Move the secondary mass of the dual mass flywheel in both
directions.
Can spring resistance be felt in both directions?
Yes
GO to E23.
No
GO to E21.
E21: CENTER THE FRICTION CONTROL DISC
1 Using Special Tool 303-254. secure the primary side of the
dual mass flywheel. Gradually turn the secondary side of the
dual mass flywheel in one direction against the resistance until
spring resistance to the force applied by hand is felt on both
sides. If it is not possible to reach the spring resistance on
both sides, gradually turn the secondary side of the dual mass
flywheel in the opposite direction in the way described above.
Is it possible to find a middle position with spring resistance on
either side?
Yes
GO to E22.
No
E22: CHECK THE ROTATION OF THE DUAL-MASS FLYWHEEL

release.
mass flywheel.
16/22
829/2430
10/30/2018 Print

Yes
No
GO to E23.

Yes
GO to E24.
No

Yes
GO to E25.
No
E25: CHECK THE WELD SEAM OF THE DUAL-MASS FLYWHEEL
1 Visually inspect the weld seam of the dual mass flywheel to
check for loss of grease.
Is a clear loss of grease visible at the weld seam of the dual mass
flywheel?
Yes
No
GO to E26.
flywheel.
17/22
830/2430
10/30/2018 Print
Yes
GO to E27.
No
E27: CHECK FOR DISCOLORATION OF THE DUAL MASS FLYWHEEL DUE TO OVERHEATING
1 Check the dual mass flywheel for discoloration due to
overheating.
Is any discoloration evident in the marked area?

Yes
No
E28: ENGINE SELECTION – PETROL ENGINES
1 Determine the size of engine installed.
Does the vehicle have a 2.0L petrol engine or a 2.5L petrol
engine?
Yes
Vehicles with a 2.0L petrol engineGO to E29. Vehicles with a
2.5L petrol engineGO to E35.
NOTICE:

distorted.


dual mass flywheel.
Yes
No
GO to E30.
18/22
831/2430
10/30/2018 Print

release.
mass flywheel.
Are between 1 and 3.5 teeth counted?
Yes
GO to E31.
No

Yes
GO to E32.
No

Yes
GO to E33.
No
E33: CHECK THE DUAL MASS FLYWHEEL FOR GREASE LEAKAGE
19/22
832/2430
10/30/2018 Print

flywheel?
Yes
No
GO to E34.
flywheel.
Yes
No
NOTICE:

distorted.


dual mass flywheel.
Can the secondary mass be turned freely by more than 15 teeth?
Yes
No
20/22
833/2430
10/30/2018 Print
GO to E36.

release.
mass flywheel.
Yes
No
GO to E37.

Yes
GO to E38.
No

Yes
GO to E39.
No
E39: CHECK THE WELD SEAM OF THE DUAL-MASS FLYWHEEL
21/22
834/2430
10/30/2018 Print

flywheel?
Yes
No
GO to E40.
flywheel.
Yes
No
PINPOINT TEST F : FLUID LEAKAGE

CONDITIONS
F1: CHECK THE CLUTCH SLAVE CYLINDER
1 Check the clutch master cylinder for leaks.
Is the clutch master cylinder OK?
Yes
GO to F2.
No
INSTALL a new clutch master cylinder.
F2: CHECK THE CLUTCH SLAVE CYLINDER
1 Check the clutch slave cylinder for leaks.
Is the clutch slave cylinder OK?
Yes
GO to F3.
No
INSTALL a new clutch slave cylinder.
F3: INSPECT SYSTEM HYDRAULIC LINES
1 Check the hydraulic lines in area of engine and transmission for loose or damaged
unions.
Are the clutch hydraulic lines OK?
Yes
CARRY OUT a road test to verify the customer concern.
No
REPAIR or INSTALL new components as necessary. CARRY OUT a road test.
22/22
835/2430
10/30/2018 Print
Manual Transmission and Clutch - General

Information - 5-Speed Manual Transmission -
B5A/5-Speed Manual Transmission -
B5/IB5/5-Speed Manual Transmission -
MTX75/6-Speed Manual Transmission - B6/6-
Speed Manual Transmission - MMT6 - Clutch
System Bleeding
Print
General Procedures
General Equipment
Brake/Clutch System Pressure Bleeder/Filler
Materials
Name Specification
Bleeding
Refer to: Brake and Clutch Systems Health and Safety Precautions (100-00 General Information,
2. NOTE: Make sure that the brake fluid level does not drop below the MIN mark.
3. If equipped.
1/4
836/2430
10/30/2018 Print
5. 1. If equipped.

6. 1. If equipped.
2/4
837/2430
10/30/2018 Print
8. If equipped.
9. In order to remove any small amounts of trapped air remaining in the system, operate the clutch
pedal 5 times, using the full clutch pedal travel.
10. NOTICE: Make sure that fluid level is to the MAX mark.
3/4
838/2430
10/30/2018 Print
12. Check the operation of the clutch. If reverse gear engagement is excessively noisy, operate the
clutch pedal 5 times, using the full clutch pedal travel.
13. After waiting approx. 30 sec., check the operation of the clutch again. If reverse gear engagement
is still excessively noisy, repeat the bleeding procedure.
4/4
839/2430
10/30/2018 Print
Manual Transmission and Clutch - General

Information - 5-Speed Manual Transmission -
Speed Manual Transmission - MMT6 - Gearshift
Cable Adjustment—6-Speed Manual
Transmission - B6
Print
General Procedures
General Equipment
4 mm Drill Bit
Adhesive Tape
Adjustment
1.
2. Refer to: Air Cleaner (303-12C Intake Air Distribution and Filtering, Removal and Installation).
3. NOTICE: Gearshift cables must not be kinked or bent.
4. 1. NOTE: Make sure that the selector lever is in the neutral (N) position.
2. NOTE: Make sure that the 4th gear is engaged.
1/3
840/2430
10/30/2018 Print
5. NOTE: Make sure that the 4th gear is engaged.

Install the following items:
Use the General Equipments: 4 mm Drill Bit, Adhesive Tape
6.
2/3
841/2430
10/30/2018 Print
Use the General Equipment: 4 mm Drill Bit
9.
3/3
842/2430
10/30/2018 Print
Clutch - 5-Speed Manual Transmission -

Speed Manual Transmission - MMT6 -
Specifications
Print
TECHNICAL DATA AND SPECIFICATIONS
NOMINAL THICKNESS MINIMUM THICKNESS **

CLAMPED THICKNESS - CLUTCH PLATE *
MM INCH MM INCH
1.6L Engine (EcoBoost SCTi) 7.30 0.29 5.10 0.20
1.6L Engine (Duratec-16V Ti-VCT) 7.30 0.29 5.60 0.22
1.6L Diesel engine (Duratorq-TDCi) 7.30 0.29 5.10 0.20
2.0L Diesel engine (Duratorq-TDCi) 8.20 0.32 5.70 0.22
* Clamp the clutch disc hand-tight in the area of the friction linings.
** If the minimum thickness has been reached, the clutch disc must be renewed.
1/1
843/2430
10/30/2018 Print
Clutch - 5-Speed Manual Transmission - B5A/5-Speed Manual

Transmission - B5/IB5/5-Speed Manual Transmission - MTX75/6-Speed
Manual Transmission - B6/6-Speed Manual Transmission - MMT6 -
Clutch - Overview
Print
Components of a clutch
Item Description
1 Flywheel
2 Clutch disc with friction lining
3 Clutch pressure plate
A Sectional plane A
The clutch consists of:
Flywheel
Clutch disc
Clutch pressure plate
When the clutch pedal is depressed, the clutch slave cylinder moves the release bearing which
presses the center of the diaphragm spring on to the compression ring towards the flywheel. The
diaphragm spring fingers rest on diaphragm spring rings and lift the compression ring from the clutch
disc. The compression spring is relieved, allowing the flow of force to the transmission to be
interrupted for gear-changing.
If the clutch pedal is not depressed, force flows to the transmission due to the compressive force of
the diaphragm spring on the compression ring.
Self-adjusting clutches
The clutch size has also been increased with the introduction of more powerful engines. The self-
adjusting clutch eliminates the increase in operating force which occurs as wear increases.
The advantages of the self-adjusting clutch are as follows:

Constant operating force throughout the whole service life of the clutch.
Increased service life of the clutch friction disc.
Shorter release bearing travel.
Self-adjusting clutches cannot be reset after the clutch friction disk has been renewed and must also
be renewed.
1/2
844/2430
10/30/2018 Print
2/2
845/2430
10/30/2018 Print

Manual Transmission - B6/6-Speed Manual Transmission - MMT6 -
Clutch - System Operation and Component Description
Print
System Operation
How the clutch works
Cross-sectional view of a single-disc dry clutch
Item Description
A Clutch disengaged
B Clutch engaged
1 Flywheel
3 Pressing ring
4 Diaphragm spring
5 Transmission input shaft
6 Clutch cover
7 Crankshaft Dimensions
The clutch transmits the torque from the engine to the transaxle; when the clutch pedal is depressed
the power transmission from the engine to the transaxle is interrupted.
When the clutch pedal is not depressed the clutch is engaged. Pressing down the pedal disengages
the clutch.
A dry clutch usually only has one clutch disc, the coatings of which are specially designed for dry
friction with a higher coefficient of friction. The torque which can be transmitted also depends on the
size and number of friction surfaces and the pressing force.
The flywheel and pressing ring are connected to the crankshaft in a rotationally fixed way and
transmit the torque via the friction linings of the clutch disc to the input shaft of the transaxle. The
clutch disc is clamped between the flywheel and the pressing ring. The force from the diaphragm
spring provides the necessary contact pressure.
The clutch cover, pressing ring and diaphragm spring are also referred to jointly as the cover
assembly.
1/12
846/2430
10/30/2018 Print
The wear on the clutch disc is greatest at the pressure point during engagement of the clutch. If the
pressing ring is moved away from the flywheel then there is no longer any friction to the clutch disc,
and the connection is disengaged.
The most frequent damage observed on the clutch is too low friction (sliding) between the clutch disc
and the pressing ring or flywheel. This can be caused by oil leaks, friction lining wear or a weakening
diaphragm spring.
Torque Path
Torque path in a single-disc dry clutch
Item Description
Torque Path
Ground
1 Crankshaft Dimensions
2 Flywheel
3 Clutch cover
4 Diaphragm spring
5 Pressing ring
6 Clutch disc with friction linings
7 Transmission input shaft
The torque path in a single-disc dry clutch as shown in the diagram above is as follows:
Crankshaft Dimensions
Flywheel
Clutch cover
Diaphragm spring
Pressing ring
Clutch disc
Transmission input shaft
Components of a clutch
2/12
847/2430
10/30/2018 Print
Item Description
1 Flywheel
3 Cover assembly
A Sectional plane A
Self-adjusting clutch
Construction and operation of a self-adjusting clutch
Item Description
A Cross-section through a self-adjusting clutch
B Schematic representation of the diaphragm spring forces
3/12
848/2430
10/30/2018 Print
a Forces in equilibrium
b Operating force of the clutch is higher than the sensing diaphragm spring
c Forces in equilibrium after the outward turn
1 Pressure spring
2 Ramp ring
3 Clutch housing
4 Sensing diaphragm spring
5 Clutch disc
6 Disk spring
7 Studs
8 Force of the sensing diaphragm spring
9 Operating force
10 Increased operating force because of wear
Part A of the illustration shows a cross-section through a self-adjusting clutch.
A key difference to conventional clutches is that the diaphragm spring is not riveted to the clutch
housing, but is supported through a sensing diaphragm spring.
The diaphragm spring is a floating fit on the studs. The ramp ring and pressure spring are shown
vertically in part A for clarity. The ramp ring and pressure spring are actually installed in the engine
running direction.
As long as the operating force is less than or equal to the force of the sensing diaphragm spring, the
diaphragm spring remains in its original position (illustration part B, diagram a). When outward
turning of the diaphragm spring tongues becomes necessary because of wear, higher operating force
must be applied.
The operating force and the sensing diaphragm spring force are no longer in equilibrium. The
diaphragm spring pushes the sensing diaphragm spring back (illustration part B, diagram b). There is
a gap between the diaphragm spring and the ramp ring.
The pressure spring displaces the ramp ring, and the gap is closed again. The diaphragm spring and
the sensing diaphragm spring take up a new position on the studs. The diaphragm spring tongues
move from their outward angle back into their original position (illustration part B, diagram c).
Construction of the ramp ring
4/12
849/2430
10/30/2018 Print
Item Description
1 Compression springs
2 Ramp ring
3 Ramp
4 Clutch housing
The illustration shows the layout of the ramp ring.
The compression springs turn the ramp ring anti-clockwise. The ramp ring is shown raised from its
normal position for clarity.
Clutch disc
Components of the clutch disc
Item Description
1 Friction lining
2 Rivet
3 Multi-spline
4 Torsion spring
5 Carrier plate
The function of the clutch disc
The clutch disc ensures judder-free engagement of the clutch, compensates for tolerances between
the surfaces of the pressure plate and the flywheel, and reduces vibrations in the transmission.
Wear and generation of heat
Normal wear increases the actuation travel, and this can be compensated for via an automatic
adjustment mechanism.
Overheating of the surface of the clutch disc will cause it to glaze. Here, glazing means a hardening
and embrittlement of the friction lining surface. The friction lining surface may display cracks and
start to become brittle. It is not a rare occurrence for individual segments of the friction lining surface
to become detached. The coefficient of friction - and therefore the amount of torque which can be
transmitted - is reduced as a result of glazing.
This damage is not undone by normal wear.
If the friction lining is connected to the carrier plate with adhesive, the latter can become soft if the
components overheat, and as a result the friction lining can be displaced or detached over large
areas. If this happens the clutch will no longer function as intended.
5/12
850/2430
10/30/2018 Print
On wet clutches, the coolant can be chemically changed as a result of continuously high
temperatures. If oil is used as the coolant, this can lead e.g. to increased oxidation or to the 'cracking'
of oil molecules. 'Cracking' means that the structure of the oil molecule chain is changed in
comparison to the original structure. Changes to the oil molecule chain can have a detrimental effect
on the function of the clutch.
If there is a local build-up of heat between the friction lining and the pressing ring as a result of a
localized concentration of heat, this is referred to as a 'hot spot'. The 'thermal peaks' created in the
process occur as a result of uneven accumulation of material in the friction lining and in the pressing
ring.
Function of the clutch disc
On the inside, the multi-splines on the clutch disc allow it to be moved axially in relation to the
transmission input shaft whilst not permitting any relative rotation.
The splines allow the clutch disc to be detached from the flywheel after the pressing ring has been
lifted off. If this axial freedom of movement is no longer given - e.g. due to rust - or the clutch disc
has too much runout, then the clutch will no longer fully disengage. Torque is then still transmitted
from the engine to the transaxle. This places correspondingly higher loads on the synchronizer
assembly. This can result in difficult and noisy gearshifts.
During engagement of the clutch, the clutch disc is clamped between the pressing ring and the
flywheel. If no dual-mass flywheel is fitted, coil springs which are arranged tangentially in the
intermediate layers and which permit limited radial twisting provide damping for noises from the
transaxle (rattling) and other vibrations.
WARNING: Older friction linings may contain asbestos - dust from the friction linings must not
be breathed in.
Apart from the size, there are a number of other differences between the clutch disc of a car and that
of a truck or commercial vehicle.
In the case of a truck or commercial vehicle, the ratio between the friction surface and the overall
area is greater in order to allow the clutch to transmit very high torques. The lining itself also contains
more stabilizing fibers, and the internal splines to the transmission input shaft are bigger.
Cover assembly
Item Description
1 Pressing ring
2 Diaphragm spring
3 Clutch cover
Role of the cover assembly
6/12
851/2430
10/30/2018 Print
The cover assembly comprises the pressing ring, diaphragm spring and clutch cover; it ensures that
sufficient contact pressure is applied. In addition, the cover assembly transmits the torque from the
flywheel to the pressing ring and then onto the clutch disc.
Function of the cover assembly
If the clutch pedal is depressed as far as it will go, the actuating force for a diaphragm spring does
not increase any further when the pressure point is exceeded. This avoids excessive axial loads being
applied to the transmission synchronization.
Diaphragm spring
Item Description
1 Clutch release bearing
2 Diaphragm spring tongues
Role of the diaphragm spring
The diaphragm spring acts as a transfer element between the clutch cover and the pressing ring.
Function of the diaphragm spring
A spring steel disc which has multiple slots and is slightly tapered towards the middle connects the
clutch cover to the pressing ring. As a result of the preload of the spring steel disc, the pressing ring
is pressed against the clutch disc when the clutch is engaged. To disengage, the release bearing
presses against the tongues of the diaphragm spring and thereby pulls the pressing ring back.
This design produces the greatest contact forces at the pressure point. If the clutch pedal is
depressed beyond this point, the pressing forces are reduced by a diaphragm spring rather than coil
springs.
Dual Clutch
General information about the dual clutch
The dual clutch operates without any interruption of driving power, and two different gears can be
selected at the same time. One of the clutches operates the uneven gears, the other clutch the even
gears.
Driving torque path in a dual clutch
7/12
852/2430
10/30/2018 Print
Item Description
1 Driving torque
2 First gear
3 Second gear
In the case of the gear change shown here, the power transmission is only slightly restricted under
load, and constant drive is maintained.
Item Description
1 Driving torque
2 First gear
3 Second gear
The illustration shows that, in conventional manual transaxles, there is a customary interruption of
driving torque during gearshifts.
Dual clutches are available either as a wet clutch or as a dry clutch.
Wet clutch
Cross-section through a wet clutch
8/12
853/2430
10/30/2018 Print
Item Description
1 Torsion damper
2 Clutch 2 for gears 2, 4, 6
3 Spiral spring, clutch 2
4 Input shaft (hollow shaft)
5 Dog teeth
6 Input shaft (core shaft)
7 Fluid pump drive gear
8 Spiral spring, clutch 1
9 Clutch 1 for gears 1, 3, 5 and reverse gear
'Wet' does not mean that the clutch is completely immersed in fluid. This would have a detrimental
impact on its efficiency.
Instead, it means that the clutch system is actively cooled via the flow of fluid whenever frictional
heat builds up, i.e. during start-up and during gearshifts. However, during constant driving the clutch
is engaged, the flow of cooling fluid is switched off, and all that there is in the clutch chamber is fluid
mist.
Every clutch has its own fluid supply and is cooled via its own flow of fluid.
9/12
854/2430
10/30/2018 Print
Operation
The wet clutch utilizes the hydraulic pressure to perform the gearshifts. The fluid performs the work
inside a clutch piston. When the clutch mechanism is actuated, the hydraulic pressure acts against a
piston on spiral springs, which then presses the clutch disc against a fixed pressing ring.
During declutching, the pressure in the piston is reduced, as a result of which the pressure acting on
the clutch disc and the pressing ring is reduced.
Dry clutch
Cross-section through a dry clutch
Item Description
1 Flywheel
2 Pressing ring
3 Pressing ring
4 Clutch discs
5 Pressing ring
6 Torsion damper
Electro-mechanical clutch servo motors shift the dry clutches independently of each other via clutch
actuators. The clutch actuators are independent systems in the clutch housing and transmit an axial
force which acts on the diaphragm spring of the corresponding clutch.
Cross-sectional view through the case of a dry clutch
10/12
855/2430
10/30/2018 Print
Item Description
1 Clutch servo motor
2 Clutch actuator
3 Wedge-shaped guide pathways
4 Dual Clutch
7 Flywheel
When a clutch is fully engaged, the clutch servo motor makes a holding torque available in a clutch
actuator. During declutching, the clutch servo motor is actuated in this clutch actuator until it reaches
a rest position.
Layout of a dry clutch
Item Description
1 Dual Clutch
2 Clutch actuator 1
11/12
856/2430
10/30/2018 Print
3 Guide tube
4 Clutch actuator 2
5 Clutch release bearing
6 Snap ring
The gear selection and the actuation of the corresponding clutch are controlled by the TCM
(transmission control module) on the basis of the evaluation of the signals from the transmission
sensors and the CAN (controller area network) data. In conjunction with a dry clutch, this control
setup enables stepless gearshifts.
The system software defines the correct calibration of the clutch via a learning algorithm. Various
parameters are taken into account in the process.
Parameters:
Torque capacity at a particular time
Contact point of the clutch discs
Contact pressure of the pressing rings
Vehicle speed
engine revs.
Load
Driving uphill/downhill
The clutches are then actuated via the TCM.
12/12
857/2430
10/30/2018 Print
Clutch - 5-Speed Manual Transmission -

Print
REFER to: Manual Transaxle and Clutch (308-00 Manual Transmission and Clutch - General
1/1
858/2430
10/30/2018 Print

Manual Transmission - B6/6-Speed Manual Transmission - MMT6 - Clutch
Disc and Pressure Plate
Print
Special Tool(s)
308-204
Aligner, Clutch Disc
Removal
1. Refer to: Transmission (308-03, Removal)

Loosen each bolt 2 turns at a time until all bolts are removed.
Installation
If equipped, the visible colour code indicate the position of the clutch disc ( Transmission Side).
1. Colour code / Transmission Side
1/2
859/2430
10/30/2018 Print
2. Install Suggested Tool: 308-204. Tool shown or a commercially available equivalent can be used.

1. Tighten each bolt 2 turns at a time.
2. Torque:
Stage 1:10 Nm
Stage 2:20 Nm
Stage 3:29 Nm
4. Remove Suggested Tool: 308-204.
5. Refer to: Transmission (308-03, Installation)
2/2
860/2430
10/30/2018 Print
Clutch Controls - 5-Speed Manual Transmission

- B5A/5-Speed Manual Transmission -
Controls
Print
1/1
861/2430
10/30/2018 Print
Clutch Controls - 5-Speed Manual Transmission - B5A/5-Speed Manual

Pedal—LHD
Print

308-554
Remover/Installer, Clutch Master Cylinder
308-651

Vise
Vise Jaw Protectors
Removal
2. Extract brake fluid from the brake fluid reservoir until the level reaches the MIN mark.
4.
1/6
862/2430
10/30/2018 Print
5. If equipped.
6. If equipped.
7.
NOTICE: Make sure that all openings are sealed.
8.
2/6
863/2430
10/30/2018 Print
9.
10. Torque: 28 Nm
11.
3/6
864/2430
10/30/2018 Print
12. Torque: 23 Nm
13.
4/6
865/2430
10/30/2018 Print
15. Use the General Equipments: Vise, Vise Jaw Protectors, Flat Headed Screw Driver
5/6
866/2430
10/30/2018 Print
Installation
2. Refer to: Clutch System Bleeding (308-00 Manual Transmission and Clutch - General Information,
6/6
867/2430
10/30/2018 Print
Clutch Controls - 5-Speed Manual Transmission - B5A/5-Speed Manual

Pedal—RHD
Print
Special Tool(s)
308-554
Remover/Installer, Clutch Master Cylinder
308-651
Removal
2. Extract brake fluid from the brake fluid reservoir until the level reaches the MIN mark.
3. If equipped.
1/6
868/2430
10/30/2018 Print
4. If equipped.
5.
6.
2/6
869/2430
10/30/2018 Print
7.
8. Torque: 28 Nm
3/6
870/2430
10/30/2018 Print
9.
10. Torque: 23 Nm
4/6
871/2430
10/30/2018 Print
12.
5/6
872/2430
10/30/2018 Print
Installation
6/6
873/2430
10/30/2018 Print

Master Cylinder
Print
Removal
1. Refer to: Clutch Pedal - LHD (308-02 Clutch Controls, Removal and Installation).
Refer to: Clutch Pedal - RHD (308-02 Clutch Controls, Removal and Installation).
Installation
1/1
874/2430
10/30/2018 Print

Slave Cylinder—6-Speed Manual Transmission
- B6
Print
Removal
1. Torque: 10 Nm
Installation
1/1
875/2430
10/30/2018 Print
Manual Transmission - 6-Speed Manual

Transmission - B6 - Specifications
Print
FILLING CAPACITIES
SPECIFICATIONS LITRES
6-Speed Manual Transaxle - B6 WSS-M2C200-D2 1.67
FLUID LEVEL CHECK
SPECIFICATIONS LITRES
For additional information, refer to: Transmission Fluid

Level Check (308-03C Manual Transmission, General
Procedures).
Fill up transmission fluid to the filler hole and then remove Remove:
transmission fluid as shown in table.
1.6L Duratorq-TDCi - DV WSS-M2C200-D2 - 0.5
1.6L EcoBoost - Sigma WSS-M2C200-D2
1.0L EcoBoost - Fox WSS-M2C200-D2
TRANSMISSION RATIOS
1.6L DURATORQ-
GEARS 1.6L ECOBOOST - SIGMA 1.0L ECOBOOST - FOX
TDCI - DV
1st gear 3.727 3.727 3.727
2nd gear 2.048 2.048 2.048
3rd gear 1.258 1.357 1.357
4th gear 0.919 1.032 1.032
5th gear 0.738 0.821 0.821
6th gear 0.622 0.690 0.690
Reverse gear 3.818 3.818 3.818
Final drive 3.611 3.824 4.067
TRANSMISSION BUILT DATE
1/2
876/2430
10/30/2018 Print
For instance: 050613 is 05.06.2013
SHIM THICKNESS REQUIRED
DIFFERENTIAL WITH TRANSMISSION DIFFERENTIAL WITH TRANSMISSION

TYPE
BUILT UP TO 10.07.2012 BUILT 11.07.2012 ONWARDS
Measured end float (mm) + 0.29 + 0.58

(for instance)
Pre-load figure (mm) + 0.28 + 0.14
Calculated shim thickness = 0.59 = 0.72

(mm) (for instance)
Required shim thickness 0.60 0.70

(mm) (for instance)
Available shims (mm) 0.10 - 1.10 (in 0.10 mm steps)
TORQUE SPECIFICATIONS
ITEM NM LB-FT LB-IN
Clutch slave cylinder retaining bolts 10 - 87
2/2
877/2430
10/30/2018 Print

Transmission - MTX75 - Manual Transaxle
Print
1/1
878/2430
10/30/2018 Print

Transmission - B6 - Transmission Fluid Level
Check
Print
General Procedures
Materials
Name Specification
Manual Transmission Fluid - SAE 75W WSS-M2C200-D2
Check
2. Remove engine undershield - If equipped.
3.
4. Material: WSS-M2C200-D2 (Manual Transmission Fluid - SAE 75W)
5. Refer to: Specifications (308-03C Manual Transmission, Specifications).
1/2
879/2430
10/30/2018 Print
6. Torque: 40 Nm
7. Install engine undershield - If equipped.
2/2
880/2430
10/30/2018 Print

Transmission - B6 - Transmission Draining and
Filling
Print
General Procedures
Materials
Name Specification
Filling
2. Remove engine undershield - If equipped.
4. Torque: 40 Nm
5.
6. Refer to: Specifications (308-03C Manual Transmission, Specifications).

Material: WSS-M2C200-D2 (Manual Transmission Fluid - SAE 75W)
1/2
881/2430
10/30/2018 Print
7. Torque: 40 Nm
8. Install engine undershield - If equipped.
9. Lower the Vehicle.
2/2
882/2430
10/30/2018 Print

Transmission - B6 - Selector Mechanism
Print
Materials
Name Specification
Removal
Vehicles with diesel engine
1. If equipped.
2. Refer to: Air Cleaner (303-12F Intake Air Distribution and Filtering, Removal and Installation).
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
3. 1.
2.

4. If equipped.
1/9
883/2430
10/30/2018 Print
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
6.
7.
All vehicles
8.
2/9
884/2430
10/30/2018 Print
9.
10. 1.
2.

11.
3/9
885/2430
10/30/2018 Print
12. 1.
3. NOTE: Make sure that no components catch.

4/9
886/2430
10/30/2018 Print
Installation
All vehicles

2. 1. NOTE: Make sure that the component is installed to the position noted before removal.
3.
5/9
887/2430
10/30/2018 Print

6/9
888/2430
10/30/2018 Print
All vehicles
5. Torque: 24 Nm
7. Torque: 48 Nm
7/9
889/2430
10/30/2018 Print

8. 1.
2. Torque: 10 Nm
10. If equipped.
8/9
890/2430
10/30/2018 Print
11. Torque: 10 Nm
12.
Refer to: Air Cleaner (303-12C Intake Air Distribution and Filtering, Removal and Installation).
14. If equipped.
9/9
891/2430
10/30/2018 Print

Transmission - B6 - Input Shaft Seal
Print

303-336
Remover, Crankshaft Rear Seal
308-847
Installer, Inputshaft Seal
Adhesive Tape
Removal
2.
4. 1. 2.5 x 15 mm self-tapping screw

2.
1/2
892/2430
10/30/2018 Print
Installation
1.
1. 1. NOTICE: Use adhesive tape to cover the input shaft splines to prevent damage
to the input shaft seal.


4.
2. Torque: 10 Nm
2/2
893/2430
10/30/2018 Print
Manual Transmission - 6-Speed Manual Transmission - B6 - Halfshaft Seal

LH—1.0L EcoBoost (90kW/120PS)/1.6L Duratorq-TDCi
(70kW/95PS) (T3)
Print

204-609
205-115A
Installer, Drive Pinion Seal
205-775
308-208
Remover, Halfshaft Seal

Tire Lever
Removal
2. If equipped.
1/9
894/2430
10/30/2018 Print
3. If equipped.
4.
2/9
895/2430
10/30/2018 Print
5.
to top mount.
Use the General Equipment: Lower Arm Down Force Lever
7.
9.
3/9
896/2430
10/30/2018 Print

Use the General Equipment: Tire Lever
11. NOTICE:
mount.
12.
4/9
897/2430
10/30/2018 Print
Installation
1. NOTICE: Make sure a new component is installed.
2. Use Special Service Tool: 205-115A.
5/9
898/2430
10/30/2018 Print
3. NOTICE:
mount.

2.
4. NOTICE: Take extra care not to damage the seal.

6/9
899/2430
10/30/2018 Print
6.
7/9
900/2430
10/30/2018 Print

NOTE: Make sure a new nut is installed.
Torque: 83 Nm
9. Torque: 10 Nm
10. If equipped.
Torque: 8 Nm
8/9
901/2430
10/30/2018 Print
9/9
902/2430
10/30/2018 Print
Manual Transmission - 6-Speed Manual Transmission - B6 - Halfshaft Seal

RH—1.0L EcoBoost (90kW/120PS)/1.6L Duratorq-TDCi
(70kW/95PS) (T3)
Print

204-609
205-115A
205-775
308-208
Removal
2. If equipped.
1/9
903/2430
10/30/2018 Print
3. If equipped.
4.
2/9
904/2430
10/30/2018 Print
5. If equipped.
6. 1. If equipped.
7.
3/9
905/2430
10/30/2018 Print
9.
11.
to top mount.
4/9
906/2430
10/30/2018 Print
13. NOTICE:
mount.
Installation
5/9
907/2430
10/30/2018 Print
3. NOTICE:
mount.

6/9
908/2430
10/30/2018 Print
5.

Torque: 83 Nm

2. NOTE: Make sure that new nuts are installed.
Torque:
2-3 6 Nm
7/9
909/2430
10/30/2018 Print
3. Torque:
4-5 25 Nm
9. 1. If equipped.
2. Torque:
Stage 1:7 Nm
3. Torque: 24 Nm
10. If equipped.
11. Torque: 10 Nm
8/9
910/2430
10/30/2018 Print
12. If equipped.
Torque: 8 Nm
9/9
911/2430
10/30/2018 Print
Manual Transmission - 6-Speed Manual Transmission - B6 - 3rd-4th Gear

Synchronizer—1.0L EcoBoost (90kW/120PS)/1.6L Duratorq-TDCi
(70kW/95PS) (T3)
Print

205-070
205-071-01
205-115A
205-310
206-003
211-014
Remover, Steering Wheel
303-336
Remover, Crankshaft Rear Seal
308-208
308-413
Remover/Installer, Transmission Front Housing
308-847
1/19
912/2430
10/30/2018 Print
Adhesive Tape
Hot Air Gun
Hydraulic Press
Vise
Vise Jaw Protectors
Materials
Name Specification
Sealant WSK-M2G348-A5
Removal
1. Refer to: Transmission Draining and Filling (308-03C Manual Transmission, General Procedures).
2. Refer to: Transmission - 1.6L Duratorq-TDCi (77kW/105PS)/1.6L Duratorq-TDCi

(85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3) (308-03C Manual Transmission, Removal).
Refer to: Transmission - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost
(92kW/125PS) (308-03C Manual Transmission, Removal).
3. 1.
2.
3.

2/19
913/2430
10/30/2018 Print
5. 1. 2.5 x 15 mm self-tapping screw
6.
7. NOTE: Make sure that the selector lever is in the neutral (N) position.
3/19
914/2430
10/30/2018 Print
9.
10.
11.
4/19
915/2430
10/30/2018 Print
12. NOTICE: Use vise jaw protectors.
13. Use the General Equipment: Hot Air Gun
14. Use a suitable socket.
5/19
916/2430
10/30/2018 Print
15.
16.

6/19
917/2430
10/30/2018 Print
19.

7/19
918/2430
10/30/2018 Print
21.
Installation
8/19
919/2430
10/30/2018 Print
4. 1.
9/19
920/2430
10/30/2018 Print
6. 1. NOTE: Make sure that the components are installed to the position noted before
removal.

10/19
921/2430
10/30/2018 Print
8. 1.
11/19
922/2430
10/30/2018 Print

12. WARNING: Make sure that a new bolt is installed.
Torque: 110 Nm
12/19
923/2430
10/30/2018 Print
15.
16. NOTICE: Take extra care not to damage the bearings.

2.
13/19
924/2430
10/30/2018 Print
3. 3. NOTICE: Take extra care when handling the component.

4.
17. 1.
18.
Material: WSK-M2G348-A5 (Sealant)
14/19
925/2430
10/30/2018 Print
19.
1. 1. NOTICE: Make sure that new bolts are installed.
Torque:
Stage 1:18 Nm
Stage 2:90°
2. Remove Special Service Tools: 205-070, 206-003.
20.
Torque:
Stage 1:18 Nm
Stage 2:90°
3. Torque: 20 Nm
15/19
926/2430
10/30/2018 Print
21.
16/19
927/2430
10/30/2018 Print
2. 2. NOTICE: Make sure that no components catch.
3. Torque: 24 Nm
24. Torque: 24 Nm
25.
17/19
928/2430
10/30/2018 Print


4.
26.
Torque:
Stage 1:18 Nm
Stage 2:90°
2. Torque: 10 Nm
27. Refer to: Transmission - 1.6L Duratorq-TDCi (77kW/105PS)/1.6L Duratorq-TDCi

18/19
929/2430
10/30/2018 Print
Installation).
Refer to: Transmission - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost
(92kW/125PS) (308-03C Manual Transmission, Installation).
19/19
930/2430
10/30/2018 Print
Manual Transmission - 6-Speed Manual Transmission - B6 - Input and

Output Shaft Bearing
Print

205-070
205-071-01
206-003
211-014
308-847
Adhesive Tape
Hot Air Gun
Hydraulic Press
Plastic Scraper
Punch
Vise
Vise Jaw Protectors
Materials
Name Specification
Brake Cleaner -
Removal
2. Refer to: Transmission - (308-03, Removal)
3.
1/14
931/2430
10/30/2018 Print
4.
6.
2/14
932/2430
10/30/2018 Print
7.
8.

Use the General Equipment: Punch
3/14
933/2430
10/30/2018 Print
4/14
934/2430
10/30/2018 Print

Use the General Equipments: Vise, Vise Jaw Protectors
14. NOTE: The component has a left-hand thread.

Use the General Equipment: Hot Air Gun

5/14
935/2430
10/30/2018 Print
Installation


6/14
936/2430
10/30/2018 Print

NOTE: The component has a left-hand thread.
Torque: 110 Nm

7/14
937/2430
10/30/2018 Print
Torque: 110 Nm

Material: - (Brake Cleaner)
8/14
938/2430
10/30/2018 Print
9.
10.
NOTICE: Take extra care not to damage the bearings.

2.

4.
9/14
939/2430
10/30/2018 Print
12.
10/14
940/2430
10/30/2018 Print
13.
Torque:
Stage 1:18 Nm
Stage 2:90°
14.
2. Torque: 20 Nm
15.
11/14
941/2430
10/30/2018 Print
3. Torque: 24 Nm
12/14
942/2430
10/30/2018 Print
18. Torque: 24 Nm
19.


4.
20.
Torque:
Stage 1:18 Nm
Stage 2:90°
2. Torque: 10 Nm
13/14
943/2430
10/30/2018 Print
21. Refer to: Transmission - (308-03, Installation)
14/14
944/2430
10/30/2018 Print
Manual Transmission - 6-Speed Manual Transmission - B6 - Transmission

—1.6L Duratorq-TDCi (77kW/105PS)/1.6L Duratorq-TDCi
Print
Removal
205-775
303-1554
Engine Support Bar
303-290A-15
Adapter for 303-290A
308-940
Wrench, Gearbox Housing Bolt
Retaining Strap
Tire Lever
Transmission Jack
Wooden Block
2.
1/15
945/2430
10/30/2018 Print
3.
4.
5.
8. If equipped.
2/15
946/2430
10/30/2018 Print
9.
10.
12.
3/15
947/2430
10/30/2018 Print
to top mount.
1. Use the General Equipment: Tire Lever
to top mount.

4/15
948/2430
10/30/2018 Print
15. NOTICE:
mount.
16.
17. If equipped.
5/15
949/2430
10/30/2018 Print
18.
19. If equipped.
20. 1. If equipped.
6/15
950/2430
10/30/2018 Print
21.
23.
7/15
951/2430
10/30/2018 Print
to top mount.
to top mount.

26. NOTICE:
mount.
27.
8/15
952/2430
10/30/2018 Print
28.
29.
30.
31.
9/15
953/2430
10/30/2018 Print
32.

Torque: 36 Nm
10/15
954/2430
10/30/2018 Print
35. Install Special Service Tools: 303-290A-15, 303-1554.
37.
11/15
955/2430
10/30/2018 Print
38.
39. Use Special Service Tool: 303-290A-15.
40.
12/15
956/2430
10/30/2018 Print
41.
Use the General Equipments: Transmission Jack, Wooden Block, Retaining Strap
43.
13/15
957/2430
10/30/2018 Print
45.
2.
4.
6.
14/15
958/2430
10/30/2018 Print
46.
15/15
959/2430
10/30/2018 Print

Print
Disassembly
205-329
Mounting Bracket, Engine/Differential
303-435
Mounting Stand
303-435-06
308-208
Puller
Punch
1. If equipped.

2.
1. Install Special Service Tools: 205-329, 303-435, 303-435-06.
2. 2. WARNING: Be prepared to collect escaping fluid.

3.
4.
1/8
960/2430
10/30/2018 Print

3.
1. Install Special Service Tools: 205-329, 303-435, 303-435-06.
2. 2. WARNING: Be prepared to collect escaping fluid.

3.
4.
All vehicles
4.
2/8
961/2430
10/30/2018 Print
5. If equipped.
3/8
962/2430
10/30/2018 Print
8.
9.
10.
4/8
963/2430
10/30/2018 Print
11.
12. 1.
2.
13.
5/8
964/2430
10/30/2018 Print
6/8
965/2430
10/30/2018 Print
17. Use the General Equipment: Puller
7/8
966/2430
10/30/2018 Print
8/8
967/2430
10/30/2018 Print

Transmission - B6 - Input Shaft
Print

205-071-01
205-310
211-014
308-045
Installer, Transmission Extension Housing Bushing/Seal
308-413
Bearing Separator
Hot Air Gun
Hydraulic Press
Vise
Vise Jaw Protectors
Materials
Name Specification
Disassembly
1. Use the General Equipments: Hydraulic Press, Bearing Separator
1/10
968/2430
10/30/2018 Print
2/10
969/2430
10/30/2018 Print
5.
6.

3/10
970/2430
10/30/2018 Print
9.

4/10
971/2430
10/30/2018 Print
11.
Assembly
5/10
972/2430
10/30/2018 Print
15. 1.
6/10
973/2430
10/30/2018 Print
17. 1. NOTE: Make sure that the components are installed to the position noted before
removal.

7/10
974/2430
10/30/2018 Print
19. 1.
8/10
975/2430
10/30/2018 Print

Torque: 110 Nm

9/10
976/2430
10/30/2018 Print
10/10
977/2430
10/30/2018 Print
Manual Transmission - 6-Speed Manual Transmission - B6 - Output Shaft

Print

205-071-01
211-014
308-045
308-072-01
Adapter for 308-072
308-413
308-605
Installer, Input Shaft Seal
308-643
Installer, Input Shaft Seal
308-850
Support Plates, Output Shaft Gear Pinions
Bearing Separator
Hot Air Gun
Hydraulic Press
Vise
Vise Jaw Protectors
1/11
978/2430
10/30/2018 Print
Materials
Name Specification
Disassembly
1. 1.

Use the General Equipments: Hydraulic Press, Bearing Separator
3. NOTE: The component has a left-hand thread.
2/11
979/2430
10/30/2018 Print
Use Special Service Tools: 308-072-01, 308-850.

3/11
980/2430
10/30/2018 Print

7. 1.
2. Use the General Equipments: Hydraulic Press, Bearing Separator
4/11
981/2430
10/30/2018 Print
8.

1.
2.
5/11
982/2430
10/30/2018 Print
10. Use the General Equipment: Hydraulic Press
11.
Assembly
6/11
983/2430
10/30/2018 Print

1.
7/11
984/2430
10/30/2018 Print


8/11
985/2430
10/30/2018 Print




9/11
986/2430
10/30/2018 Print

NOTE: The component has a left-hand thread.
Torque: 110 Nm

10/11
987/2430
10/30/2018 Print
11/11
988/2430
10/30/2018 Print

Transmission - B6 - Differential
Print

205-062
205-071-01
Bearing Separator
Puller
Disassembly
NOTICE: Use vise jaw protectors.

1. Clamp the differential in a vise.

Use the General Equipments: Bearing Separator, Puller

Use the General Equipments: Bearing Separator, Puller
1/4
989/2430
10/30/2018 Print
1. Loosen: Four turn(s)

2.
3. Save four bolts for reassembly the ring gear.
5.
Assembly
NOTICE: Use vise jaw protectors.

6. Clamp the differential in a vise.
Install the four bolts saved during disassembly.
2/4
990/2430
10/30/2018 Print
Tighten each bolt 1 turn at a time.
Torque: 50 Nm
8.

Tighten each bolt 1 turn at a time.
Torque:
Stage 1:50 Nm
Stage 2:90°

The roller bearing must not be lubricated.
3/4
991/2430
10/30/2018 Print

The roller bearing must not be lubricated.
4/4
992/2430
10/30/2018 Print

Transmission - B6 - Reverse Gear Output Shaft
Print

205-071-01
308-045
308-072-01
Adapter for 308-072
308-710
Installer, Bearing Cup
Bearing Separator
Hydraulic Press
Puller
Materials
Name Specification
Disassembly
1. Use the General Equipments: Bearing Separator, Puller
1/5
993/2430
10/30/2018 Print
2. Use the General Equipments: Bearing Separator, Puller

2/5
994/2430
10/30/2018 Print
4.
Assembly
3/5
995/2430
10/30/2018 Print

4/5
996/2430
10/30/2018 Print
Use Special Service Tools: 205-071-01, 308-045.

5/5
997/2430
10/30/2018 Print

Print
Assembly
205-044-01
Adapter for 205-044
205-069
Dial Indicator Gauge (Metric)
205-070
205-075
Installer, Rear Wheel Hub Seal
205-081
205-115A
205-329
Mounting Bracket, Engine/Differential
206-003
303-435
Mounting Stand
303-435-06
1/19
998/2430
10/30/2018 Print
308-237
Remover, Halfshaft
308-790
Installer, Driveshaft Seal
308-847
308-849
Installer Shift Shaft Bushing
308-880
Installer, Driveshaft Seal
Adhesive Tape
Hot Air Gun
Punch
Materials
Name Specification
1. In order to avoid incorrect readings, do not oil the taper roller bearings.
2.

2/19
999/2430
10/30/2018 Print
4.
3/19
1000/2430
10/30/2018 Print
6. NOTICE: Extreme cleanliness must be exercised when handling the component.

Tighten the bolts in a crisscross sequence.
Torque: 18 Nm
Clean the end face of the differential assembly and mark it at one place.
Install Special Service Tools: 205-044-01, 205-070.
4/19
1001/2430
10/30/2018 Print
8. Repeat this and the following three steps three times and determine the average values.
9. Turn the differential until the measuring pin is on the marked spot.
Pre-load the dial gauge to 1 mm and zero it.
10.
5/19
1002/2430
10/30/2018 Print
11.
2. Turn the differential until the measuring pin is on the marked spot.
3. Measure the differential end float: Make a note of the measurement, e.g. 0.265 mm.
Example: 0.265 mm + 0.255 mm + 0.260 mm, divided by 3 = 0.260 mm.
Vehicles Built Up To: 10-07-2012

12. Determine the thickness of the differential adjusting shim:
Determined differential end float 0.26 mm.
Differential bearing pre-load 0.28 mm.
Required adjusting shim thickness: 0.26 mm + 0.28 mm = 0.54 mm.
Determined adjusting shim thickness: 0.54 mm.
If the determined adjusting shim thickness is unequal, then use the next closest thickness of
adjusting shim.
Vehicles Built From: 11-07-2012

13. Determine the thickness of the differential adjusting shim:
Determined differential end float 0.26 mm.
Differential bearing pre-load 0.14 mm.
Required adjusting shim thickness: 0.26 mm + 0.14 mm = 0.40 mm.
Determined adjusting shim thickness: 0.40 mm.
If the determined adjusting shim thickness is unequal, then use the next closest thickness of
adjusting shim.
6/19
1003/2430
10/30/2018 Print
All vehicles
14. Remove Special Service Tools: 205-044-01, 205-070.
15.
7/19
1004/2430
10/30/2018 Print
18.
3. Determined adjusting shim.
4.
8/19
1005/2430
10/30/2018 Print
20. Use Special Service Tools: 205-075, 205-115A.

9/19
1006/2430
10/30/2018 Print
10/19
1007/2430
10/30/2018 Print
26. 1.
2. 2. NOTICE: Take extra care not to damage the bearing.
27.
28. NOTICE: Take extra care not to damage the bearings.

11/19
1008/2430
10/30/2018 Print

2.

4.
29. 1.
30.
2. Material: WSK-M2G348-A5 (Sealant)
12/19
1009/2430
10/30/2018 Print
31.
1. Torque:
Stage 1:18 Nm
Stage 2:90°
Vehicles built up to 13/08/2012

32.
1. Torque:
Stage 1:18 Nm
Stage 2:90°
3. Torque: 20 Nm
13/19
1010/2430
10/30/2018 Print
Vehicles built 14/08/2012 onwards

33.
1. Torque:
Stage 1:18 Nm
Stage 2:90°
3. Torque: 20 Nm
All vehicles
14/19
1011/2430
10/30/2018 Print
34.
3. Torque: 24 Nm
15/19
1012/2430
10/30/2018 Print
37. If equipped.
Torque: 10 Nm
38. Torque: 24 Nm
39.

16/19
1013/2430
10/30/2018 Print
4.
40. Transmission Built Date. For instance: 050613 is June 5th 2013
41.
1. Torque:
Stage 1:18 Nm
Stage 2:90°
2. Torque: 10 Nm
4. Transmission built up to August 12th 2012
5. Remove Special Service Tools: 205-329, 303-435, 303-435-06.
17/19
1014/2430
10/30/2018 Print
42.
1. Torque:
Stage 1:18 Nm
Stage 2:90°
2. Torque: 10 Nm
4. Transmission built August 13th 2012 onwards
Use Special Service Tool: 205-115A.
5. Remove Special Service Tools: 205-329, 303-435, 303-435-06.
43. If equipped.
Torque: 63 Nm
18/19
1015/2430
10/30/2018 Print
19/19
1016/2430
10/30/2018 Print

—1.6L Duratorq-TDCi (77kW/105PS)/1.6L Duratorq-TDCi
Print
Installation
204-821
205-775
303-1554
Engine Support Bar
303-290A-15
Adapter for 303-290A
308-940
Wrench, Gearbox Housing Bolt

Retaining Strap
Transmission Jack
Wooden Block
Materials
Name Specification
Multi-Purpose Grease SA-M1C9107-A
Grease - High Temperature WSS-M1C273-A
1. Apply a thin coating.
Material: WSS-M1C273-A (Grease - High Temperature)
1/16
1017/2430
10/30/2018 Print
2.
3. 1.
Tighten on both sides simultaneously.
3.
5.

Torque: 48 Nm
2/16
1018/2430
10/30/2018 Print
5. Torque: 48 Nm
6. Torque: 25 Nm
Use the General Equipments: Transmission Jack, Wooden Block, Retaining Strap
8. Torque: 82 Nm
3/16
1019/2430
10/30/2018 Print
9. Use Special Service Tool: 303-290A-15.
10.
Torque: 148 Nm
4/16
1020/2430
10/30/2018 Print
12. Torque: 48 Nm
13.
15. Remove Special Service Tools: 303-290A-15, 303-1554.
16. Torque: 48 Nm
5/16
1021/2430
10/30/2018 Print
17.
18.
1. Torque: 63 Nm
2. Torque:
Stage 1:30 Nm
Stage 2:270°
19.
1. Apply a thin coating.
Material: SA-M1C9107-A (Multi-Purpose Grease)
2. 2. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.
Torque: 48 Nm
6/16
1022/2430
10/30/2018 Print
20.
21. Torque: 35 Nm
22.
7/16
1023/2430
10/30/2018 Print
23. NOTICE:
mount.

25.
8/16
1024/2430
10/30/2018 Print

Torque: 83 Nm
to top mount.

Torque: 6 Nm

Torque: 6 Nm
4. Torque: 25 Nm
5. Torque: 25 Nm
9/16
1025/2430
10/30/2018 Print
28. 1. If equipped.
2. Torque:
Stage 1:7 Nm
3. Torque: 24 Nm
29. If equipped.
30. Torque: 10 Nm
10/16
1026/2430
10/30/2018 Print
31. If equipped.
Torque: 8 Nm
32.
11/16
1027/2430
10/30/2018 Print
to top mount.

to top mount.
12/16
1028/2430
10/30/2018 Print
36.
13/16
1029/2430
10/30/2018 Print

Torque: 83 Nm
38. Torque: 10 Nm
14/16
1030/2430
10/30/2018 Print
39. If equipped.
Torque: 8 Nm
42. Torque: 35 Nm
43. Torque: 48 Nm
15/16
1031/2430
10/30/2018 Print
44.
46. Torque: 48 Nm
16/16
1032/2430
10/30/2018 Print
Manual Transmission External Controls - 5-

Speed Manual Transmission - B5A/5-Speed
Manual Transmission - B5/IB5/5-Speed
Manual Transmission - MTX75/6-Speed Manual
Transmission - B6/6-Speed Manual
Transmission - MMT6 - External Controls
Print
3. Make sure that the gearshift cables are correctly routed and not under any tension from other
components.
Symptom Chart

SOURCES
EXTERNAL CONTROLS DO NOT * GEARSHIFT * ADJUST THE GEARSHIFT CABLES. VEHICLES
OPERATE FREELY OR ONE OF THE CABLES EQUIPPED WITH A MTX75,
GEARS CANNOT BE SELECTED. INCORRECTLY REFER TO: GEARSHIFT CABLE ADJUSTMENT -
ADJUSTED. 5-SPEED MANUAL TRANSMISSION - MTX75
(308-06E, GENERAL PROCEDURES).
VEHICLES EQUIPPED WITH A MMT6,
REFER TO: GEARSHIFT CABLE ADJUSTMENT -
6-SPEED MANUAL TRANSMISSION - MMT6
(308-06E, GENERAL PROCEDURES).
VEHICLES EQUIPPED WITH A B6,
REFER TO: GEARSHIFT CABLE ADJUSTMENT -
6-SPEED MANUAL TRANSMISSION - B6 (308-
06E, GENERAL PROCEDURES).
* GEARSHIFT * GO TO PINPOINT TEST A.
LEVER
DAMAGED.
* GEARSHIFT
CABLES
DAMAGED.
Pinpoint Tests
PINPOINT TEST A : STIFF GEARSHIFT

CONDITIONS
A1: CHECK THE GEARSHIFT LEVER
1 Detach the gearshift cables from the gearshift lever.
Is the gearshift lever difficult to operate?
Yes
Install a new gearshift lever. Vehicles equipped with a MTX75,
REFER to: Gearshift Lever - 5-Speed Manual Transmission - B5/IB5/5-Speed Manual
Transmission - MTX75 (308-06E, Removal and Installation).
Vehicles equipped with a MMT6,
REFER to: Gearshift Lever - 6-Speed Manual Transmission - B6/6-Speed Manual
Transmission - MMT6 (308-06E, Removal and Installation).
Vehicles equipped with a B6,
1/2
1033/2430
10/30/2018 Print
REFER to: Gearshift Lever - 6-Speed Manual Transmission - B6/6-Speed Manual

Transmission - MMT6 (308-06E, Removal and Installation).
No
GO to A2.
A2: CHECK THE GEARSHIFT CABLES
1 Attach the gearshift cables to the gearshift lever.
2 Detach the gearshift cables from the transmission.
Is the gearshift lever difficult to operate?
Yes
Install new gearshift cables. Vehicles equipped with a MTX75,
REFER to: Gearshift Cables - 5-Speed Manual Transmission - MTX75 (308-06E,
REFER to: Gearshift Cables - 6-Speed Manual Transmission - MMT6 (308-06E, Removal
and Installation).
REFER to: Gearshift Cables - 6-Speed Manual Transmission - B6 (308-06E, Removal
and Installation).
No
Vehicles equipped with a MTX75,
REFER to: Manual Transmission (308-03B, Diagnosis and Testing).
REFER to: Manual Transmission (308-03D, Diagnosis and Testing).
REFER to: Manual Transmission (308-03C, Diagnosis and Testing).
2/2
1034/2430
10/30/2018 Print

Transmission - MMT6 - Gearshift Cables—6-
Speed Manual Transmission - B6
Print
General Equipment
Draw Cord
Removal
2.
3. Attach a suitable draw cord to the gearshift cables.
Use the General Equipment: Draw Cord
5.
1/5
1035/2430
10/30/2018 Print
6.
7. Lower the Vehicle.
8. Refer to: Gearshift Lever - 6-Speed Manual Transmission - B6/6-Speed Manual Transmission -
MMT6 (308-06 Manual Transmission External Controls, Removal and Installation).
9.
1. Torque: 10 Nm
2. Torque: 25 Nm
10.
2/5
1036/2430
10/30/2018 Print
11.
12. Torque: 25 Nm
3/5
1037/2430
10/30/2018 Print
13.
Installation
NOTICE: Gearshift cables must not be kinked or bent.
1. Attach a suitable draw cord to the gearshift cables.
Use the General Equipment: Draw Cord
2. Torque: 9 Nm
4/5
1038/2430
10/30/2018 Print
5/5
1039/2430
10/30/2018 Print

Transmission - MMT6 - Gearshift Lever—6-
Speed Manual Transmission - B6/6-Speed
Manual Transmission - MMT6
Print
Removal
NOTICE: Gearshift cables must not be kinked or bent.

2. Torque: 9 Nm
3.
Installation
1/1
1040/2430
10/30/2018 Print
Exhaust System - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Catalytic Converter
Print
Removal
Procedures).
2. Torque: 12 Nm
3.
5.
1/4
1041/2430
10/30/2018 Print
6. 1. NOTE: This step is only necessary when installing a new component.

Torque: 45 Nm

Torque: 35 Nm
3. Torque: 12 Nm
7. Torque: 50 Nm
2/4
1042/2430
10/30/2018 Print

Torque: 25 Nm
3/4
1043/2430
10/30/2018 Print
Installation

NOTE: Make sure that the component is installed to the position noted before removal.
Torque: 25 Nm
4/4
1044/2430
10/30/2018 Print
Exhaust System - 1.6L Duratorq-TDCi

(70kW/95PS) (T3) - Diesel Particulate Filter
(DPF)
Print
Removal

1. Refer to: Catalytic Converter (309-00G Exhaust System, Removal and Installation).
Installation

1. Refer to: Catalytic Converter (309-00G Exhaust System, Removal and Installation).
1/1
1045/2430
10/30/2018 Print
Fuel System - General Information - 1.6L Duratorq-TDCi

(T3)/2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS)
- DW - Fuel System
Print

Hand Pressure Pump with Adapter Kit
310-110

WARNINGS:
This procedure involves fuel handling. Be prepared for fuel spillage at all times. Failure to
Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances.
It is therefore essential that absolute cleanliness is observed when working with these components.
Always fit blanking plugs to any open orifices or lines.
NOTICE: Always carry out the cleaning process before carrying out any repairs to the fuel
injection system components to prevent foreign matter ingress to the components.
Fuel level Electrical connector(s)
Fuel leak(s) Wiring harness
Fuel line(s) Fuel level sensor
Fuel filter (if equipped)
Fuel tank
Fuel tank ventilation pipe
Fuel tank filler pipe
Symptom Chart

ENGINE CRANKS * FUEL CHARGING AND *
BUT DOES NOT CONTROLS. REFER TO: FUEL CHARGING AND CONTROLS (303-
START 04I FUEL CHARGING AND CONTROLS, DIAGNOSIS
AND TESTING).
* AIR INGRESS INTO THE * GO TO PINPOINT TEST A.
FUEL LINES.
1/5
1046/2430
10/30/2018 Print
* CONTAMINATED FUEL. * INSTALL A NEW FUEL FILTER. DRAIN THE

DIESEL. FILL WITH CLEAN FUEL.
POOR STARTING * FUEL CHARGING AND *
CONTROLS. REFER TO: FUEL CHARGING AND CONTROLS (303-
04I FUEL CHARGING AND CONTROLS, DIAGNOSIS
AND TESTING).
FUEL LINES.
ENGINE STARTS BUT * FUEL CHARGING AND *
IMMEDIATELY STOPS CONTROLS. REFER TO: FUEL CHARGING AND CONTROLS (303-
AND TESTING).
FUEL LINES.
POOR IDLING * FUEL CHARGING AND *
AND TESTING).
FUEL LINES.
ENGINE LACKS * FUEL TANK TO FUEL * CHECK THE FUEL SUPPLY LINES FOR DAMAGE.
POWER FILTER FUEL SUPPLY LINE INSTALL A NEW FUEL FILTER FUEL SUPPLY LINE.
BLOCKED. * CHECK THE FUEL SUPPLY LINE FOR BLOCKAGE. GO
TO PINPOINT TEST B.
* FUEL FILTER BLOCKED. * INSTALL A NEW FUEL FILTER.
* FUEL CHARGING AND *
AND TESTING).
FUEL LINES.
ENGINE MISFIRE * FUEL CHARGING AND *
AND TESTING).
FUEL LINES.
EXCESSIVE FUEL * FUEL CHARGING AND *
CONSUMPTION CONTROLS. REFER TO: FUEL CHARGING AND CONTROLS (303-
AND TESTING).
FUEL LINES.
2/5
1047/2430
10/30/2018 Print

FUEL FILLER * FUEL TANK VENTILATION * CHECK THE FUEL TANK VENTILATION PIPE FOR
NOZZLE SHUTS OFF PIPE BLOCKED. OBSTRUCTION OR DAMAGE. INSTALL A NEW FUEL
PREMATURELY * FUEL TANK VENTILATION TANK VENTILATION PIPE.
PIPE COLLAPSED.
* FUEL TANK FILLER PIPE * CHECK THE FUEL TANK FILLER PIPE FOR
BLOCKED. OBSTRUCTION OR DAMAGE. INSTALL A NEW FUEL
* FUEL TANK FILLER PIPE TANK FILLER PIPE.
COLLAPSED.
* FUEL GAUGE INDICATION. * CHECK THE FUEL LEVEL IN THE FUEL TANK. CHECK
THE FUEL INDICATION SYSTEM.
* FUEL FILLER NOZZLE AT * VERIFY THE CONDITION BY USING A KNOWN GOOD
FUEL FILLING STATION FUEL FILLER NOZZLE.
NOT FUNCTIONING
CORRECTLY.
FUEL LOSS AFTER * FUEL TANK FILLER PIPE * CHECK THE FUEL TANK FILLER PIPE FOR EVIDENCE
NOZZLE SHUTOFF LEAKING. OF A FUEL LEAK. IF A FUEL LEAK IS EVIDENT,
OR DURING INSTALL A NEW FUEL TANK FILLER PIPE.
REFILLING * FUEL TANK LEAKING. * CHECK THE FUEL TANK FOR EVIDENCE OF A FUEL
LEAK. IF A FUEL LEAK IS EVIDENT, INSTALL A NEW
FUEL TANK.
* FUEL TANK VENTILATION * CHECK THE FUEL TANK VENTILATION PIPE FOR
PIPE LEAKING. EVIDENCE OF A FUEL LEAK. IF A FUEL LEAK IS
EVIDENT, INSTALL A NEW FUEL TANK VENTILATION
PIPE.
Pinpoint Tests
PINPOINT TEST A : ENGINE CRANKS BUT DOES NOT START

A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNINGS:
This procedure involves fuel handling. Be prepared for fuel spillage at all times and always
observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
NOTICE:
it is therefore essential that absolute cleanliness is observed when working with these components.
Always carry out the cleaning process before carrying out any repairs to the fuel injection
system components. Failure to follow this instruction may result in foreign matter ingress to the
fuel injection system.
1 Remove the air cleaner.
REFER to: Air Cleaner (303-12G Intake Air Distribution and
Filtering, Removal and Installation).
2 Crank the engine, wait a few minutes and then observe the
clear plastic fuel pipe in the fuel pump fuel return line for signs
of air ingress.
3/5
1048/2430
10/30/2018 Print
Are any signs of air present in the clear plastic fuel pipe?
Yes
GO to A2.
No
For additional diagnostics go to Fuel Charging and Controls,
REFER to: Fuel Charging and Controls (303-04I Fuel Charging
and Controls, Diagnosis and Testing).
A2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1 Using suitable clean engine oil, apply the oil to each of the fuel
supply line and fuel return line connections, unions and joints in
turn and observe the clear plastic pipe for visible signs of air
after each oil application.
Did the amount of air in the clear plastic fuel pipe decrease when
any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel pipe(s) as necessary. Test the system for
normal operation.
No
GO to A3.
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1 Drain the fuel tank.
REFER to in this section.
2 Fill the fuel tank with 10 liters of diesel.
3 Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00F Fuel System -
General Information, General Procedures).
4 Using a suitable piece of clear plastic pipe, manufacture and

install a pipe between the fuel filter and the fuel tank to fuel
filter supply line.
NOTE: Make sure that the engine is at normal operating

temperature.
5 Start the engine, wait a few minutes and then observe the clear
plastic pipe for signs of air ingress.
Are any signs of air present in the clear plastic pipe?
Yes
INSTALL a new fuel level sensor or fuel tank to fuel filter supply
pipe as necessary.
4/5
1049/2430
10/30/2018 Print
No
INSTALL a new fuel filter.
PINPOINT TEST B : ENGINE LACKS POWER

B1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE
WARNINGS:
This procedure involves fuel handling. Be prepared for fuel spillage at all times and always
observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
NOTICE:
It is therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or lines.
Always carry out the cleaning process before carrying out any repairs to the fuel injection
system components to prevent foreign matter ingress to the components.
1 Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00F Fuel System -
2 Install the special tool between the fuel filter fuel supply line
quick release coupling and the fuel filter union.
3 Operate the hand pressure pump.

4 Observe the flow of fuel in the clear plastic fuel pipe in the fuel
pump fuel return line.
Does the fuel from the fuel tank flow freely with no restrictions?
Yes
GO to Pinpoint Test A.
No
REPAIR or INSTALL a new fuel filter fuel supply line.
5/5
1050/2430
10/30/2018 Print
Fuel System - General Information - 1.6L

TDCi (70kW/95PS) (T3)/2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(120kW/163PS) - DW - Fuel System Bleeding—
1.6L Duratorq-TDCi (85kW/115PS)/1.6L
Duratorq-TDCi (70kW/95PS) (T3), Emission
Requirements: Stage V
Print
General Procedures
Special Tool(s)
310-110A
Hand Pressure Pump with Adapter Kit
Activation
2.

Procedures).
4. Install Special Service Tool: 310-110A.
1/3
1051/2430
10/30/2018 Print
5. Using the special tool, prime the fuel system.

Operate the hand pump until it becomes firm when squeezed.
Squeeze and hold the hand pump for 10 seconds.
Release the hand pump.
Squeeze and hold the hand pump for a further 10 seconds.
Release the hand pump.
6. CAUTION: Do not operate the starter motor for longer than 10 seconds at a time. After 10
seconds, turn the ignition key to position 0 and allow the starter motor to cool for 30
seconds before attempting to start the engine again.
Start the engine and allow it to idle until it reaches normal operating temperature.
Stop the engine.

Remove Special Service Tool: 310-110A.
Procedures).
2/3
1052/2430
10/30/2018 Print
9. Torque: 10 Nm
3/3
1053/2430
10/30/2018 Print
Fuel System - General Information - 1.6L

TDCi (70kW/95PS) (T3)/2.0L Duratorq-TDCi
(120kW/163PS) - DW - Quick Release
Coupling
Print
General Procedures
Disconnect
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00, Description and Operation).
2.
3.
4.
5.
1/2
1054/2430
10/30/2018 Print
6.
Connect
1. To connect, reverse the disconnect procedure.
2/2
1055/2430
10/30/2018 Print
Fuel Tank and Lines - 1.6L Duratorq-TDCi

(70kW/95PS) (T3)/2.0L Duratorq-TDCi
(120kW/163PS) - DW - Fuel Tank and Lines
Print
REFER to: Fuel System (310-00E Fuel System - General Information, Diagnosis and Testing).
1/1
1056/2430
10/30/2018 Print
Fuel Tank and Lines - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-

TDCi (70kW/95PS) (T3)/2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW - Fuel
Tank
Print

310-069
Wrench, Fuel Tank Sender Unit
Cable Ties
Fluid Container
Fuel Tank Draining Equipment
Hose Clamp(s)
Retaining Strap
Transmission Jack
Removal
Procedures).

Torque: 48 Nm
5.
1/12
1057/2430
10/30/2018 Print
6.
7.
8. Torque: 5 Nm
2/12
1058/2430
10/30/2018 Print
Vehicles with fuel fired booster heater

9.

Procedures).
3/12
1059/2430
10/30/2018 Print
All vehicles
Procedures).
12. NOTICE: Only use the specified general equipment.

NOTE: Make sure that the clamp is installed to the same orientation as when removed.
Use the General Equipments: Hose Clamp(s), Hose Clamp Remover/Installer
4/12
1060/2430
10/30/2018 Print

Torque: 25 Nm
14. NOTICE: Make sure that no strain is placed on the fuel lines and wiring harnesses.
NOTE: Make sure that no components catch.
Use the General Equipments: Transmission Jack, Retaining Strap
5/12
1061/2430
10/30/2018 Print
15.
1. 1. NOTICE:
Make sure the open end of the hose is secured above the fluid level in the
reservoir.

Remove the equipment.
Use the General Equipment: Hose Clamp(s)
3. 3. WARNING: Fuel may still be present in the fuel tank after draining.
Drain the reservoir.
Use the General Equipment: Fuel Tank Draining Equipment
16.
6/12
1062/2430
10/30/2018 Print
Use the General Equipment: Hose Clamp(s)
19.
7/12
1063/2430
10/30/2018 Print
20. NOTE: This step is only necessary when installing a new fuel tank.
NOTE: Make sure that the clamp is installed to the same orientation as when removed.
Procedures).
8/12
1064/2430
10/30/2018 Print
Vehicles with fuel fired booster heater

Procedures).
All vehicles
9/12
1065/2430
10/30/2018 Print
24. NOTICE: Take extra care not to damage the fuel tank level sensor float and arm.
NOTE: This step is only necessary when installing a new fuel tank.
25. NOTICE: Use suitable paper to absorb any escaping fluid.

NOTE: This step is only necessary when installing a new fuel tank.
Drain the reservoir.
10/12
1066/2430
10/30/2018 Print
Installation
2. NOTICE: Take extra care not to damage the fuel tank level sensor float and arm.
NOTE: Make sure that the seal is correctly located.
3. NOTICE: Make sure that the installation marks are aligned.
11/12
1067/2430
10/30/2018 Print

Torque: 100 Nm
12/12
1068/2430
10/30/2018 Print
Fuel Tank and Lines - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS) - Fuel Filler Nozzle Inhibitor
Print
General Equipment
Removal
2. 1. Type 1
2. Type 2
Type 1
3.
1/10
1069/2430
10/30/2018 Print
5.
2/10
1070/2430
10/30/2018 Print
6. Install the special tool(s) (supplied in the parts kit).
7. 1. Turn until resistance is felt.

2.
3/10
1071/2430
10/30/2018 Print
Type 2
8.
4/10
1072/2430
10/30/2018 Print
11.
5/10
1073/2430
10/30/2018 Print
12.
Installation
Type 1
1.
6/10
1074/2430
10/30/2018 Print

2. Turn until resistance is felt.
Type 2
3.
7/10
1075/2430
10/30/2018 Print

NOTE: The component can only be installed in 1 position.
5.
8/10
1076/2430
10/30/2018 Print
6. NOTE: The component can only be installed in 1 position.

7.
9/10
1077/2430
10/30/2018 Print
10/10
1078/2430
10/30/2018 Print
Fuel Tank and Lines - 1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-

TDCi (70kW/95PS) (T3)/2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW - Fuel
Filter—1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi
(70kW/95PS) (T3)
Print
Removal
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00, Description and Operation).
2.
3. Torque: 10 Nm
4. Refer to: Quick Release Coupling (310-00G Fuel System - General Information, General
1/2
1079/2430
10/30/2018 Print
Procedures).
5. Torque: 10 Nm
Installation
2.
2/2
1080/2430
10/30/2018 Print
Acceleration Control - Acceleration Control

Print
General Equipment
Accelerator pedal Wiring harness(s)
Throttle body Wiring harness retaining clips
Accelerator pedal
Electronic throttle body
1/1
1081/2430
10/30/2018 Print
Acceleration Control - Accelerator Pedal

Print
Removal
1. Torque: 8 Nm
Installation
1/1
1082/2430
10/30/2018 Print
Speed Control - Speed Control - Component Location

Print
Active City Stop
Item Description
1 Laser sensor
4 ABS (anti-lock brake system) module
1/1
1083/2430
10/30/2018 Print
Speed Control - Speed Control - Overview

Print
Active City Stop

This is an active safety system to prevent rear-end collisions.
The system is laser-based and has a built-in automatic braking function.
It is activated when the vehicle starts to approach a moving or stationary vehicle in front and the
driver does not respond.
It is particularly intended to help prevent accidents when driving in towns or in queues of traffic.
A laser in the upper area of the windshield detects a vehicle in front which is a maximum of ten
meters away.
If the system registers that a collision with the vehicle in front is unavoidable, the brake assist
function is activated and/or an emergency braking operation is initiated.
If the driver now intervenes, valuable time has been gained because brake pressure has already been
built up. If the driver does not intervene, the emergency braking operation is able either to reduce the
impact speed or prevent the collision entirely.
1/1
1084/2430
10/30/2018 Print
Speed Control - Speed Control - System Operation and Component

Description
Print
System Diagram
Active City Stop
Item Description
2 Laser sensor
System Operation
Operation
The laser sensor is continually communicating with the ABS module, the PCM, the instrument cluster
and the steering wheel rotation sensor. The control units receive information as to whether there is a
risk of a collision with the vehicle ahead.
The system's task is to prevent a collision or reduce the impact speed.
The safety system is active up to a speed of 30 km/h. If the difference in speed between two vehicles
is less than 15 km/h, the system is able to prevent the collision. If the difference is up to 30 km/h,
the emphasis is on reducing the speed as much as possible.
If full braking power has been applied and the vehicle comes to a standstill, a message telling the
driver that the system has braked autonomously is displayed in the instrument cluster. The engine is
switched off and the hazard warning lamps are activated.
If the driver has operated the clutch during the full-braking operation, the engine will remain on and
the hazard warning lamps will not be switched on.
The system is configured so that it brakes in response to reflecting objects such as a license plate and
rear lamps.
1/3
1085/2430
10/30/2018 Print
The driver can switch off the function from the instrument cluster menu.
The steering wheel rotation sensor is required for detecting avoidance maneuvers since a braking
action would not be desirable in these situations. Depending on the steering angle, the respective
channel of the sensor undergoes closer analysis and is assigned a higher weighting.
The laser sensor can request various functions, depending on the situation:
preparatory build-up of brake pressure in the braking system
automatic braking
engine torque limiting
The following engines support this system:

1.6L Duratorq-TDCi (DV6) diesel
2.0L Duratorq-TDCi (DW10) diesel
1.6L Duratec 16V Ti-VCT (Sigma)
1.6L Duratec-GDTi
Laser sensor
The exact designation of the sensor from Continental is SRL 165.

The laser sensor is attached in a mounting to the upper area of the windshield in the center. This area
is kept free of rain by the wiper blades.
The laser sensor and module form one unit.
The sensor's measuring range is between 0.5 m and 10 m. Its operating temperature range is –40°C
to 95° C.
The sensor's supply voltage is between 7.5 and 16 V and power consumption is < 1.8 W.
The sensor's dimensions are 150 x 73 x 36 mm and it weighs < 100 g.
The laser sensor has been classified as a 1M laser.
If there is a fault in the laser sensor, it can be read out with IDS (Integrated Diagnostic System). An
error message is also displayed in the instrument cluster.
2/3
1086/2430
10/30/2018 Print
Item Description
1 Windshield
2 Receiver lenses
3 Connector
4 Electronic printed circuit board
5 Body
6 Transmitter lens
3/3
1087/2430
10/30/2018 Print
Speed Control - Speed Control

Print
General Equipment
Speed Control and Proximity Warning Systems

For a description and operation of the speed control and proximity warning systems, refer to Section
413-09.
Accelerator pedal Fuse(s)
Brake pedal Wiring harness(es)
Clutch pedal (if equipped) Electrical connector(s)
Clockspring
Adaptive speed control steering wheel
switches
Accelerator pedal position (APP) sensor
Brake pedal position (BPP) deactivation switch
Clutch pedal position (CPP) deactivation
switch (if equipped)
Proximity warning radar unit
Proximity warning module
Instrument cluster
Stability assist module
Transmission control module (if equipped)
If there are no signs of obvious mechanical or electrical damage, REFER to the Ford approved
diagnostic tool to continue diagnosis.
1/1
1088/2430
10/30/2018 Print
Speed Control - Speed Control - Component Location

Print
Active City Stop
Item Description
1 Laser sensor
1/1
1089/2430
10/30/2018 Print
Speed Control - Speed Control - Overview

Print
Active City Stop

This is an active safety system to prevent rear-end collisions.
The system is laser-based and has a built-in automatic braking function.
It is activated when the vehicle starts to approach a moving or stationary vehicle in front and the
driver does not respond.
It is particularly intended to help prevent accidents when driving in towns or in queues of traffic.
A laser in the upper area of the windshield detects a vehicle in front which is a maximum of ten
meters away.
If the system registers that a collision with the vehicle in front is unavoidable, the brake assist
function is activated and/or an emergency braking operation is initiated.
If the driver now intervenes, valuable time has been gained because brake pressure has already been
built up. If the driver does not intervene, the emergency braking operation is able either to reduce the
impact speed or prevent the collision entirely.
1/1
1090/2430
10/30/2018 Print
Speed Control - Speed Control - System Operation and Component

Description
Print
System Diagram
Active City Stop
Item Description
2 Laser sensor
System Operation
Operation
The laser sensor is continually communicating with the ABS module, the PCM, the instrument cluster
and the steering wheel rotation sensor. The control units receive information as to whether there is a
risk of a collision with the vehicle ahead.
The system's task is to prevent a collision or reduce the impact speed.
The safety system is active up to a speed of 30 km/h. If the difference in speed between two vehicles
is less than 15 km/h, the system is able to prevent the collision. If the difference is up to 30 km/h,
the emphasis is on reducing the speed as much as possible.
If full braking power has been applied and the vehicle comes to a standstill, a message telling the
driver that the system has braked autonomously is displayed in the instrument cluster. The engine is
switched off and the hazard warning lamps are activated.
If the driver has operated the clutch during the full-braking operation, the engine will remain on and
the hazard warning lamps will not be switched on.
The system is configured so that it brakes in response to reflecting objects such as a license plate and
rear lamps.
1/3
1091/2430
10/30/2018 Print
The driver can switch off the function from the instrument cluster menu.
The steering wheel rotation sensor is required for detecting avoidance maneuvers since a braking
action would not be desirable in these situations. Depending on the steering angle, the respective
channel of the sensor undergoes closer analysis and is assigned a higher weighting.
The laser sensor can request various functions, depending on the situation:
preparatory build-up of brake pressure in the braking system
automatic braking
engine torque limiting
The following engines support this system:

1.6L Duratorq-TDCi (DV6) diesel
2.0L Duratorq-TDCi (DW10) diesel
1.6L Duratec 16V Ti-VCT (Sigma)
1.6L Duratec-GDTi
Laser sensor
The exact designation of the sensor from Continental is SRL 165.

The laser sensor is attached in a mounting to the upper area of the windshield in the center. This area
is kept free of rain by the wiper blades.
The laser sensor and module form one unit.
The sensor's measuring range is between 0.5 m and 10 m. Its operating temperature range is –40°C
to 95° C.
The sensor's supply voltage is between 7.5 and 16 V and power consumption is < 1.8 W.
The sensor's dimensions are 150 x 73 x 36 mm and it weighs < 100 g.
The laser sensor has been classified as a 1M laser.
If there is a fault in the laser sensor, it can be read out with IDS (Integrated Diagnostic System). An
error message is also displayed in the instrument cluster.
2/3
1092/2430
10/30/2018 Print
Item Description
1 Windshield
2 Receiver lenses
3 Connector
4 Electronic printed circuit board
5 Body
6 Transmitter lens
3/3
1093/2430
10/30/2018 Print
Climate Control System - General Information - Specifications

Print
SPECIFICATIONS
Refrigerant R134a (vehicles up to 16.08.2016) WSH-M17B19-A
Refrigerant R1234yf (vehicles from 16.08.2016) WSS-M17B21-A
Refrigerant oil (vehicles up to 16.08.2016 with Visteon / Sanden A/C WSH-M1C231-B

compressor)
Refrigerant oil (vehicles up to 16.08.2016 with Denso A/C compressor) Denso ND8
Refrigerant oil (vehicles from 16.08.2016) WSS-M2C300-A2
REFRIGERANT CAPACITIES (TOTAL REQUIRED REFRIGERANT CHARGE)
GRAMS
Air Conditioning (vehicles with 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost 540 ± 15

(90kW/120PS) engine)
Air Conditioning (vehicles with DV/1.6L Duratorq-TDCi engine up to 460 ± 15

10.07.2012)
Air Conditioning (vehicles with DV/1.6L Duratorq-TDCi engine from 530 ± 15

10.07.2012 onwards)
Air Conditioning (vehicles with DW/2.0L Duratorq-TDCi engine, 1.6L 530 ± 15

Duratec-16V Ti-VCT engine, 1.6L EcoBoost engine, 2.0L Duratec DI TIVCT
(154PS), 2.0L Duratec-HE (110kW/150PS) - MI4/2.0L Duratec-HE
(125kW/170PS) - MI4)
Air Conditioning (vehicles with 2.0L EcoBoost (184kW/250PS) 600 ± 15
REFRIGERANT OIL CAPACITIES (TOTAL REQUIRED REFRIGERANT OIL CHARGE)
ML
Air Conditioning (vehicles with 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost 130

(90kW/120PS) engine)
Air Conditioning (vehicles with DV/1.6L Duratorq-TDCi engine up to 110

10.07.2012)
Air Conditioning (vehicles with DV/1.6L Duratorq-TDCi engine from 150

10.07.2012 onwards)
1/3
1094/2430
10/30/2018 Print
ML
Air Conditioning (vehicles with DW/2.0L Duratorq-TDCi engine, 1.6L 150

Duratec-16V Ti-VCT engine, 1.5L EcoBoost engine, 1.6L EcoBoost engine,
2.0L Duratec DI TIVCT (154PS), 2.0L Duratec-HE (110kW/150PS) - MI4/2.0L
Duratec-HE (125kW/170PS) - MI4 )
Air Conditioning (vehicles with 2.0L EcoBoost (184kW/250PS) 160
ADDITION OF REFRIGERANT OIL (WHEN NEW COMPONENTS ARE INSTALLED)
ML
After renewal of all lines and components, or if system gets flushed add the total required
oil charge (new
compressor as
delivered).
After renewal of A/C compressor without system flush add the same drained
quantity
Air conditioning compressor (if the amount of refrigerant oil drained from the add the total required
faulty compressor is more than 110 ml) oil charge (new
compressor as
delivered).
A/C condenser add 30.
A/C evaporator add 30.
A/C receiver drier add 90.
Always, if refrigerant was drained. Add the same quantity

as the quantity that
was collected.
CLUTCH AIR GAP
MM
Compressor clutch air gap (Sanden A/C compressor) 0,35 - 0,70
Compressor clutch air gap (Visteon A/C compressor) 0,35 - 0,70
Compressor clutch air gap (Denso A/C compressor) 0,35 - 0,60
TORQUE SPECIFICATIONS
ITEM NM LB-FT LB-IN
2/3
1095/2430
10/30/2018 Print
ITEM NM LB-FT LB-IN
Compressor drive plate retaining bolt (vehicles 28 21 -

with Sanden compressor)
Compressor drive plate retaining bolt (vehicles 18 13

with Denso A/C compressor)
Compressor drive plate retaining bolt (vehicles 14 10 -

with Visteon compressor)
3/3
1096/2430
10/30/2018 Print
Climate Control System - General Information

- Climate Control System
Print

Refer to Wiring Diagrams Section 412-02A, for schematic and connector information.
General Equipment
Digital Multimeter (compatible with K-type thermocouple)
Refrigerant center
Thermometer - Fluke 80 PK-8 (FSE number 260 4102 001 07)
1. VERIFY customer concern.
2. Visually CHECK for any obvious mechanical or electrical damage.
VISUAL INSPECTION
Coolant level Fuses
Refrigerant lines Wiring harness
Drive belt Connectors
Condenser
Refrigerant compressor
4. If the cause is not visually evident, verify the symptom and refer to the Diagnostic tab within
Refrigerant Circuit - Quick Check
WARNING: The air conditioning system is filled with refrigerant R134a. Observe "Health and
Safety Precautions". For further information
REFER to: Health and Safety Precautions (100-00 General Information, Description and Operation).
Refrigerant circuit check
WARNING: Under certain circumstances, refrigerant lines and A/C components may be
extremely hot or cold. Exercising care, touch the refrigerant lines or A/C components in order to
check this. Failure to observe this instruction can lead to injury.
The refrigerant line from the refrigerant compressor to the condenser must be hot.
The refrigerant line from the A/C condenser to the fixed orifice tube must be warm, but not so hot
as the refrigerant line mentioned above.
Determine the difference in temperature upstream and downstream of the A/C condenser by
measuring the temperatures at the refrigerant lines. The temperature difference should be more
than 20° C, depending on the ambient temperature. If the temperature difference is less, check the
condenser for contamination or damage to the fins as well as operation of the radiator fan.
The refrigerant line between the fixed orifice tube and the evaporator must be cold from the point
where the fixed orifice tube is installed. Depending on the weather, the line may also be iced up on
the outside.
The refrigerant line between the evaporator and the A/C compressor including the accumulator
must be cold.
Evaporator outlet temperature test

To test the power of the A/C system, the temperature of the evaporator outlet line must be
measured. To do this, the following preconditions must be met:
Open all windows.

1/3
1097/2430
10/30/2018 Print
Set the air distribution to the defrost/dashboard position and open all the ventilation nozzles.
Deactivate recirculated air function.
Select lowest blower switch setting.
Select lowest temperature setting.
NOTE: The temperature measurement cannot be done with a thermometer which makes no contact.
Incorrect readings could be made because of reflections from surfaces.
Connect temperature sensor (Fluke 80 PK-8) to the refrigerant line from the evaporator to the
accumulator in the area of the accumulator (metal line). Connect the temperature sensor to the
multimeter.
Start the engine and allow it to run at idle speed for several minutes.
Switch on the air-conditioning system.
After three minutes, measure the surface temperature of the evaporator outlet line.
If the temperature measured is 2° C or lower (vehicles with automatic transmission: 5° C or lower)
the A/C system is OK. If the temperature is higher, the A/C system may be under-filled.
Frequent faults and their causes
Should a customer express concern about poor cooling performance of the A/C system it must be
ensured that the temperature control valve actuation is OK.
No or poor cooling performance:

- Blockage or narrowing in a refrigerant line or in the accumulator: The location of the blockage or
narrowing can easily be found by comparing temperatures at the refrigerant lines and at the
accumulator. The blockage or restriction is located at the point where the temperature difference is
identified. Note: A temperature difference in the area of the fixed orifice tube is normal.
Once the location of the blockage or restriction has been detected, check the relevant component
and renew if necessary.
Cooling power suddenly deteriorates (returns to normal after the compressor has been switched off
for about 5 minutes):
- The cause is an iced-up fixed orifice tube because of moisture in the refrigerant circuit. In order to
ensure that moisture is completely removed from the refrigerant circuit, evacuation time must be
extended to 2-3 hours and the dehydrator must be renewed. For further information
REFER to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate
Control System - General Information, General Procedures).
Component Tests
Air conditioning clutch relay
1. Check the normally open contact in the unswitched state:
Measure the resistance at the air conditioning clutch relay, between pin 3 and pin 5,
component side.
Is a resistance of more than 10,000 Ohm measured?
1. If yes, go to 2.
2. If no, RENEW the air conditioning clutch relay.
2. Check the normally open contact in the switched state:
Use a fused test cable (1 A) to connect pin 1 of the air conditioning clutch relay, component
side, to the battery positive terminal.
Use a test cable to connect pin 2 of the air conditioning clutch relay, component side, to the
battery negative terminal.
2/3
1098/2430
10/30/2018 Print
Measure the resistance at the air conditioning clutch relay, between pin 3 and pin 5,
component side.
Is a resistance of less than 2 Ohm registered?
1. If yes, then the air conditioning clutch relay is OK.
2. If no, RENEW the air conditioning clutch relay.
3/3
1099/2430
10/30/2018 Print

- Air Conditioning (A/C) Clutch Air Gap
Adjustment
Print
General Procedures
Special Tool(s)
412-103
Holding Fixture, Compressor Clutch
412-134
Holding Tool, Compressor Clutch
412-154
Activation
1. Operate the air conditioning clutch several times with the aid of a 5 A fused cable. Refer to the
relevant wiring diagram for the correct electrical connection. Check the gap A at 60° intervals
around the circumference of the pulley.
Refer to: Specifications (412-00 Climate Control System - General Information, Specifications).
Vehicles with 1.0L or 1.6L engine
1/5
1100/2430
10/30/2018 Print
Vehicles with 1.6L diesel or 2.0L diesel engine
Vehicles with 1.6L diesel engine built 07/2012 onwards
2/5
1101/2430
10/30/2018 Print
All vehicles
5. If necessary correct the gap A using only one spacer washers.
6. Check the gap A as described in step 1. If necessary, repeat the following steps again.
Vehicles with 1.0L or 1.6L engine
7. Refer to: Specifications (412-00 Climate Control System - General Information, Specifications).
3/5
1102/2430
10/30/2018 Print
Vehicles with 1.6L diesel engine built 07/2012 onwards
4/5
1103/2430
10/30/2018 Print
5/5
1104/2430
10/30/2018 Print
Climate Control System - General Information - Air Conditioning (A/C)

System Flushing
Print
General Procedures

412-151
Adapters, Air Conditioning
Air Conditioning Service Unit
Activation
Vehicles with petrol or 2.0L diesel engine
1. 1. Air conditioning (A/C) compressor
2. Condenser
3. Receiver drier
4. Thermostatic expansion valve
5. Evaporator
6. Adapter clamp
7. Thermostatic expansion valve adapter
8. AC service unit
9. Flushing kit
1/8
1105/2430
10/30/2018 Print
Vehicles with 1.6L diesel engine

2. 1. Air conditioning (A/C) compressor
2. Condenser
3. Receiver drier
4. Thermostatic expansion valve
5. Evaporator
6. Adapter clamps
7. Thermostatic expansion valve adapter
8. Receiver drier adapter
9. AC service unit
10. Flushing kit
All vehicles
3. Refer to: Thermostatic Expansion Valve (412-01 Climate Control, Removal and Installation).
4. Install the expansion valve adapter.

Torque: 4 Nm
2/8
1106/2430
10/30/2018 Print
5. Install the refrigerant lines to the expansion valve adapter.
Torque: 10 Nm
6. Refer to: Air Conditioning (A/C) Compressor - 1.6L EcoBoost (110kW/150PS) - Sigma/1.6L
EcoBoost (132kW/180PS) - Sigma (412-01 Climate Control, Removal and Installation).
Refer to: Air Conditioning (A/C) Compressor - 1.6L Duratec-16V Ti-VCT (77kW/105PS) -
Sigma/1.6L Duratec-16V Ti-VCT (92kW/125PS) - Sigma/1.6L Duratorq-TDCi (85kW/115PS)/1.6L
Duratorq-TDCi (70kW/95PS) (T3)/2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW (412-01 Climate Control, Removal
and Installation).
Refer to: Air Conditioning (A/C) Compressor - 2.0L Duratec-HE (110kW/150PS) - MI4/2.0L
Duratec-HE (125kW/170PS) - MI4 (412-01 Climate Control, Removal and Installation).
Refer to: Air Conditioning (A/C) Compressor - 1.6L Duratec-16V Ti-VCT (92kW/125PS) - Sigma, 6-
Speed PowerShift Transmission - DPS6/6DCT250 (412-01 Climate Control, Removal and
Installation).
Vehicles with 1.6L or diesel engine
7. Install the high-pressure compressor line adapter.
8. Install the low-pressure compressor line adapter.
3/8
1107/2430
10/30/2018 Print
Vehicles with 6-speed automatic transmission (6DCT250)
Vehicles with 2.0L engine

4/8
1108/2430
10/30/2018 Print
All vehicles
13. Refer to: Receiver Drier - 1.6L Duratec-16V Ti-VCT (77kW/105PS) - Sigma/1.6L Duratec-16V Ti-
VCT (92kW/125PS) - Sigma/1.6L EcoBoost (110kW/150PS) - Sigma/1.6L EcoBoost
(132kW/180PS) - Sigma/2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW/2.0L EcoBoost (184kW/250PS) -
MI4 (412-01 Climate Control, Removal and Installation).
Refer to: Receiver Drier - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.6L
Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS) (T3) (412-01 Climate Control,
Refer to: Receiver Drier - 2.0L Duratec-HE (110kW/150PS) - MI4/2.0L Duratec-HE (125kW/170PS)
- MI4 (412-01 Climate Control, Removal and Installation).
Refer to: Receiver Drier - 2.0L Duratec-HE (110kW/150PS) - MI4/2.0L Duratec-HE (125kW/170PS)
- MI4 (412-01 Climate Control, Removal and Installation).
14. Install the receiver drier adapter.

Torque: 5 Nm
Vehicles with 2.0L diesel or 1.6L engine

15.
16. Install the receiver drier plug.
5/8
1109/2430
10/30/2018 Print
Vehicles with 2.0L engine

Vehicles with 6-speed automatic transmission (6DCT250)

All vehicles
19. Install the flushing kit to the air conditioning service unit in accordance with the service unit
manufacturer instructions.
Use the General Equipment: Air Conditioning Service Unit
20. Connect the low-pressure service unit line to the filter line adapter.
6/8
1110/2430
10/30/2018 Print
21. Connect the high-pressure connection line (red) to the air conditioning compressor low-
pressure line adapter.
Connect the low-pressure connection line (blue) to the air conditioning compressor high-
pressure line adapter.
22. Flush the air conditioning system in accordance with the service unit manufacturer instructions.
Vehicles with 2.0L diesel or 1.6L engine

23. Install a new receiver drier with filter plug.
7/8
1111/2430
10/30/2018 Print
All vehicles
24. NOTICE: The following step is mandatory if the air conditioning compressor is damaged
due to metal abrasion.
Install a new air conditioning compressor, thermostatic expansion valve and receiver drier.
25. Install all components in reverse order.
8/8
1112/2430
10/30/2018 Print

System Leak Test Using Forming Gas
Print
General Procedures
General Equipment
Forming Gas Pressure Gauge and Leak Detector
Forming Gas Pressure Gauge and Leak Detector Set
Hydrogen Leak Detector
Refrigerant Identification Equipment
Materials
Name Specification
Forming Gas -
Activation
1. Refer to: Climate Control System Health and Safety Precautions (100-00 General Information,
2. Unscrew and remove the protective caps from the A/C charging connections.
Use the General Equipments: Air Conditioning Service Unit, Refrigerant Identification Equipment
3. 1. Low-pressure connection
2. High-pressure connection
4. Use the refrigerant analyzer before recovery, otherwise the refrigerant center may become
contaminated. Dispose of contaminated refrigerant as hazardous waste. Always follow the
manufacturer's instructions when using the refrigerant center and the refrigerant analyzer.
5. Connect the service unit lines to the filling connections of the air conditioning system.
6. Drain the air conditioning system in accordance with the service unit manufacturer instructions.
7. Evacuate the air conditioning system in accordance with the service unit manufacturer instructions.
1/4
1113/2430
10/30/2018 Print
8. Perform the vacuum leak test in accordance with the service unit manufacturer instructions.
9. Disconnect the service unit from the air conditioning system in accordance with the manufacturer
instructions.
NOTE: The following steps are only necessary when using the forming gas pressure gauge and leak
detector.
10. Connect the forming gas pressure gauge and leak detector service hose to the low-pressure port of
the air conditioning system in accordance with the manufacturer instructions.
Use the General Equipment: Forming Gas Pressure Gauge and Leak Detector
Material: - (Forming Gas)
11.
1. 1. NOTICE: Make sure that the pressure reducer (2) is closed.
Open the bottle valve.
2. Slowly turn the pressure reducer until a pressure of 10 bar is reached.
3. Close the bottle valve.
2/4
1114/2430
10/30/2018 Print
NOTE: The following steps are only necessary when using the forming gas pressure gauge and leak
detector set.
12. Connect the forming gas pressure gauge and leak detector set service hoses to the high-pressure
and low-pressure port of the air conditioning system in accordance with the service unit
Use the General Equipment: Forming Gas Pressure Gauge and Leak Detector Set
Material: - (Forming Gas)
13.
1. 1. NOTICE: Make sure that the cut-off valve (2) is closed.
Turn the pressure reducer until a pressure of 8 bar is reached.
2. Slowly open the cut-off valve.
3. Close the cut-off valve.
All vehicles
3/4
1115/2430
10/30/2018 Print
14. Locate and rectify any leaks in the A/C refrigerant circuit in accordance with the hydrogen leak
detector manufacturer instructions.
Use the General Equipment: Hydrogen Leak Detector
15. Disconnect the forming gas pressure gauge and leak detector from the air conditioning system in
accordance with the manufacturer instructions.
17. NOTICE:
Make sure that the specified amount of refrigerant oil is added.
Make sure that tracer dye is added.

NOTE: After adding tracer dye into the air conditioning (A/C) system, the decal supplied with
the tracer dye must be positioned.
Fill the air conditioning system in accordance with the service unit manufacturer instructions.
Refer to: Refrigerant Oil Adding (412-00 Climate Control System - General Information, General
Procedures).
18. Disconnect the service unit in from the air conditioning system in accordance with the
19. Screw the protective caps onto the charging connections.
4/4
1116/2430
10/30/2018 Print

System Leak Test Using Nitrogen Gas
Print
General Procedures
General Equipment
Nitrogen Pressure Gauge and Leak Detector
Materials
Name Specification
Nitrogen -
Leak Detection Spray -
Activation
6. Drain the air conditioning system in accordance with the service unit manufacturer instructions.
8. Perform the vacuum leak test in accordance with the service unit manufacturer instructions.
1/3
1117/2430
10/30/2018 Print
instructions.
10. Connect the nitrogen gas pressure gauge and leak detector service hose to the low-pressure port
of the air conditioning system in accordance with the manufacturer instructions.
Use the General Equipment: Nitrogen Pressure Gauge and Leak Detector
Material: - (Nitrogen)
11.
1. 1. NOTICE: Make sure that the pressure reducer (2) is closed.
Open the bottle valve.
2. Slowly turn the pressure reducer until a pressure of 10 bar is reached.
3. Close the bottle valve.
12. Locate and rectify any leaks in the A/C refrigerant circuit.
2/3
1118/2430
10/30/2018 Print
Material: - (Leak Detection Spray)
13. Disconnect the nitrogen gas pressure gauge and leak detector from the air conditioning system in
accordance with the manufacturer instructions.
15. NOTICE:
Make sure that the specified amount of refrigerant oil is added.
Make sure that tracer dye is added.

NOTE: After adding tracer dye into the air conditioning (A/C) system, the decal supplied with
the tracer dye must be positioned.
Fill the air conditioning system in accordance with the service unit manufacturer instructions.
Procedures).
instructions.
3/3
1119/2430
10/30/2018 Print

- Air Conditioning (A/C) System Recovery,
Evacuation and Charging
Print
General Procedures
General Equipment
Activation
5. Connect the service unit lines to the filling connection of the air conditioning system.
6. Drain the air conditioning system via the low-pressure port in accordance with the service unit
7. NOTICE: Make sure that the specified amount of refrigerant oil is added.
Fill up with refrigerant oil.
Procedures).
1/2
1120/2430
10/30/2018 Print
9. NOTE: The system is leak-free, provided that the pressure increase does not exceed 20
mbar.
Perform the leak test, by closing the hand valves on the gauge set, switching off the service unit
vacuum pump and observing the low pressure gauge.
10. NOTE: This step is only necessary if the pressure increase exceeds 20 mbar.
Locate and rectify any leaks in the A/C refrigerant circuit.
11. Add refrigerant oil to the air conditioning system.
Procedures).
12. Fill the air conditioning system with liquid through the high-pressure connection.
13. 1. Open the shut-off valve on the high-pressure side.

2. Switch the service unit to "Fill" mode and fill the system with the specified quantity of liquid
refrigerant (R134a).
14. Fill the air conditioning system with gas through the low-pressure connection.
15. 1. Open the shut-off valve on the low-pressure side.

2. Switch the service unit to "Fill" mode and fill the system with the specified quantity of
gaseous refrigerant.
3. Add the remaining amount of refrigerant with the air conditioning switched on. To do so run
the engine at about 1200-1500 rev/min. Set the air conditioning system to full cooling power
and fresh air mode. Set the blower motor to the highest setting. Fill with the remainder of
the specified fill capacity.
16. Disconnect the service unit.
17. 1. Close the shut-off valve.

2. Switch off the service unit.
3. Disconnect the service unit lines from the filling connections of the air conditioning system.
18. Install all components in reverse order.
2/2
1121/2430
10/30/2018 Print

- Contaminated Refrigerant Handling
Print
General Procedures
General Equipment
Activation
1. Use the refrigerant identification equipment to check that there is contaminated refrigerant in the
air conditioning system.
Use the General Equipment: Refrigerant Identification Equipment
2. 2. Inform the customer about the additional costs involved to repair the system because of the
contamination.
3. 3.Use a suitable A/C service unit designed for the purpose of collecting and storing contaminated
refrigerant and dispose of the contaminated refrigerant as hazardous waste. Follow the
manufacturer's instructions when working with the A/C service unit.
1/1
1122/2430
10/30/2018 Print

- Fluorescent Dye Leak Detection
Print
General Procedures
General Equipment
UV Leak Detector
Activation
2. Locate the leaks. Check all components, fittings and lines of the A/C system for leaks.
Use the General Equipment: UV Leak Detector
3. 3. After the leak is found and rectified, remove any traces of dye with a general purpose solvent.
4. 4. Check the repair by operating the system for some minutes and inspecting with the UV lamp
again.
1/1
1123/2430
10/30/2018 Print

- Refrigerant Oil Adding
Print
General Procedures
Activation
1. NOTICE: Make sure that the equipment is clean and free of foreign material.
Collect the refrigerant oil in a clean measuring cylinder.
2. NOTE: This step only needs to be carried out when removing the A/C compressor.
Rotate the compressor shaft at least 6 to 8 turns when draining the refrigerant oil.
3. NOTE: This step only needs to be carried out when removing the A/C compressor.
Drain the refrigerant oil from the defective A/C compressor and dispose of it.
4. Top up with the calculated quantity of new refrigerant oil in accordance with the A/C service unit
1/1
1124/2430
10/30/2018 Print

- Vacuum Leak Detection
Print
General Procedures
Activation
1. 1. Carry out the air conditioning (A/C) system recovery procedure.
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate
1/1
1125/2430
10/30/2018 Print
Climate Control - Specifications

Print
A/C COMPRESSOR
DESCRIPTION
Vehicles with DW/2.0L Duratorq-TDCi engine, 2.0L Duratec-HE engine, 1.6L Visteon VS16
Duratec-16V Ti-VCT engine , 1.0L EcoBoost engine, 1.6L EcoBoost SCTi
engine or 2.0L EcoBoost engine
Vehicles with DV/1.6L Duratorq-TDCi engine up to 10.07.2012 Sanden PXV16
Vehicles with DV/1.6L Duratorq-TDCi engine from 10.07.2012 onwards Denso 7SBH17
1/1
1126/2430
10/30/2018 Print
Climate Control - Air Conditioning (A/C) - Overview

Print
EATC (electronic automatic temperature control) module
Item Description
1 Maximum A/C
2 ON/OFF switch
Two buttons have been changed on the control panel of the EATC module.
‘OFF’ – ‘Symbol OFF’
‘MONO’ – ‘MAX A/C’
The manual air conditioning system and the EATC have been adapted to the auto start/stop
function.
The auto start/stop function is active between 0°C and 30°C .
At present, this function is only available on the 1.6L Duratorq-TDCi (DV) diesel and the 1.6L
EcoBoost-SCTi.
Revised EATC calibration
The following functions are active with auto stop:

Blower speed reduction
Regulation of discharge temperature
Use of air recirculation function
The engine is prevented from switching off if

the vehicle is not yet up to temperature (temperature of interior, discharge temperature and
coolant)
max. A/C is selected
max. DEFROST is selected (to prevent misting)
The humidity in the vehicle is too high (to prevent misting - humidity sensor will be available at a
later date)
The "Low" or "High" temperature setting is selected
The start request is assured if

the discharge temperature and the interior temperature can no longer ensure comfort
The humidity in the vehicle is too high (to prevent misting - humidity sensor will be available at a
later date)
the set value of the evaporator temperature sensor (approx. 13°C) has been exceeded
max. DEFROST is selected (to prevent misting)
the "Low" or "High" temperature setting is selected
1/3
1127/2430
10/30/2018 Print
If air conditioning has not been selected (A/C off), no commands to start the engine or prevent the
engine from stopping on account of discharge temperature and interior temperature will be sent. This
only applies in cooling mode, at higher ambient temperatures.
Revised operation of the manual air conditioning system
The engine is prevented from switching off if

the coolant temperature is too low (engine is still cold)
the rotary switch is set to DEFROST
the temperature is set to max.
A/C is switched on at low temperatures (to prevent misting)
The start request is assured if

the evaporator temperature sensor exceeds a threshold value
A/C is switched on at low temperatures
DEFROST is selected (to prevent misting)
the temperature is set to max.
If no air conditioning has been selected (A/C off), no command to start the engine will be sent via the
evaporator temperature sensor.
Replacing the EATC module
The ignition must be switched on for approximately 30 seconds after the module is replaced. During
this time, the module calibrates itself with the stepper motors via the central vehicle configuration.
Interior temperature and humidity sensor
The sensor measures the temperature and humidity of the passenger compartment. It is used to
regulate the pre-selected interior temperature.
For optimum measurement results, an integrated fan draws air from the passenger compartment into
the sensor.
Compressor clutch switching points
Via the refrigerant pressure:

The A/C compressor clutch is switched off when the refrigerant pressure reaches 31 ± 2 bar.
It is switched on again when the pressure has dropped to 26 ± 2 bar.
Via the evaporator temperature sensor:

The A/C compressor clutch is switched off when the evaporator temperature is 0 °C.
It is switched on if the evaporator temperature exceeds 3 °C.
Via the ambient air temperature sensor:

The A/C compressor clutch is not switched on below +5 °C.
2/3
1128/2430
10/30/2018 Print
Fault memory interrogation without diagnostic unit – vehicles with automatic temperature
control
The climate control and heating system features a on-board diagnosis function which can detect and
store both current permanent faults as well as intermittent faults which have occurred during normal
operation of the vehicle. These faults can also be read out via the display of the climate control panel.
To read out the fault memory, the ignition key must be turned to the "ON" position and the battery
voltage must be between 9 V and 14 V.
To activate on-board diagnosis on the climate control panel, press the "OFF" and "FOOTWELL"
buttons simultaneously for exactly 2 seconds, then press the "AUTO" button within 1.5 seconds. The
on-board diagnosis which then starts lasts a few seconds. During this time, a moving pattern is shown
on the display of the climate control panel. Any faults found are shown on both displays of the climate
control panel in the form of diagnostic trouble codes.
To read out stored faults on the climate control panel, press the "OFF" and "FOOTWELL" buttons
simultaneously for exactly 2 seconds, then press the "HEAD" button within 1.5 seconds. Any stored
faults are shown on the display of the climate control panel and should be noted for safety reasons.
Pressing the "DEFROST" button clears the fault memory and terminates diagnostic mode. Pressing
any button on the climate control panel terminates diagnostic mode without clearing the diagnostic
trouble codes.
To read out the software version on the climate control panel, press the "OFF" and "FOOTWELL"
buttons simultaneously for exactly 2 seconds, then press the "A/C" button within 1.5 seconds. The
software version is shown on the display of the climate control panel. Pressing any button on the
climate control panel terminates output mode.
Fill quantities of the air conditioning system:

540 grams for 1.6L Duratorq-TDCi (DV) diesel
600 grams for 1.6L Duratec-16V Ti-VCT
600 grams for 1.6L EcoBoost-SCTi
600 grams for 2.0L Duratorq-TDCi (DW) diesel
150 grams of oil in the Visteon compressor
110 grams of oil in the Sanden compressor
A/C compressors:
Sanden BMX 16 for 1.6L Duratorq-TDCi (DV) diesel
Visteon VS 16 for 1.6L Duratec-16V Ti-VCT
Visteon VS 16 for 1.6L EcoBoost-SCTi
Visteon VS 16 for 2.0L Duratorq-TDCi (DW) diesel
All the A/C compressors are designed as variable, internally regulated swash plate compressors with a
maximum volume of 160 cc.
3/3
1129/2430
10/30/2018 Print
Climate Control - Climate Control Housing

Print
Special Tool(s)
303-435
Mounting Stand
501-203
Holding Tool, Instrument Panel
Materials
Name Specification
Refrigerant Oil WSH-M1C231-B
Removal
1. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate
2. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
3.

1/13
1130/2430
10/30/2018 Print
Torque: 8 Nm
5.
6. Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
7.
2/13
1131/2430
10/30/2018 Print
8.
9.
10.
3/13
1132/2430
10/30/2018 Print
11. On both sides.
12.
Vehicles with manual transmission
13. Torque: 9 Nm
4/13
1133/2430
10/30/2018 Print
Vehicles with automatic transmission
14. Torque: 9 Nm
15.
16. Torque: 9 Nm
17. Torque: 9 Nm
5/13
1134/2430
10/30/2018 Print
All vehicles
18.
19.
6/13
1135/2430
10/30/2018 Print
20.
21.
7/13
1136/2430
10/30/2018 Print
22.
23.
8/13
1137/2430
10/30/2018 Print
24. On both sides.
Refer to: Front Door (501-03 Body Closures, Removal and Installation).
25. On both sides.
Torque: 25 Nm
26.
1. Torque: 25 Nm
9/13
1138/2430
10/30/2018 Print
27.
28. Torque: 25 Nm
10/13
1139/2430
10/30/2018 Print
29. Torque: 25 Nm
30. Torque: 25 Nm
11/13
1140/2430
10/30/2018 Print
31. 1. Remove the tolerance absorber.

32.
12/13
1141/2430
10/30/2018 Print
Installation
2. Coat the O-rings on the refrigerant lines.
Material: WSH-M1C231-B (Refrigerant Oil)
3. NOTE: Make sure that fluid level is to the MAX mark.

13/13
1142/2430
10/30/2018 Print
Climate Control - Blower Motor—LHD FWD

Print
Special Tool(s)
412-131
Remover/Installer, Blower Engine
Removal
1. Refer to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Removal and
Installation).
2.
3.
1/3
1143/2430
10/30/2018 Print
4. NOTICE: Make sure that the blower motor and fan assembly is placed on the bench with
the fan pointing upwards.
Installation
1. NOTE: The component can only be installed in 1 position.

2/3
1144/2430
10/30/2018 Print
3/3
1145/2430
10/30/2018 Print
Climate Control - Heater Core—LHD FWD

Print
Removal
1. Refer to: Climate Control Housing (412-01 Climate Control, Removal and Installation).
2.
3.
4.
1/3
1146/2430
10/30/2018 Print
5.
6.
2/3
1147/2430
10/30/2018 Print
7.
Installation
3/3
1148/2430
10/30/2018 Print
Climate Control - Climate Control Assembly—Vehicles Without: Center

Armrest
Print
Removal
1.
2.

3.
1/5
1149/2430
10/30/2018 Print

4.
All vehicles
5.
2/5
1150/2430
10/30/2018 Print
6.
7.
3/5
1151/2430
10/30/2018 Print
8.
9.
10.
4/5
1152/2430
10/30/2018 Print
Installation
5/5
1153/2430
10/30/2018 Print
Climate Control - Climate Control Assembly—Vehicles With: Center

Armrest
Print
Removal
1.
2.

3.
1/4
1154/2430
10/30/2018 Print

4.
All vehicles
5.
2/4
1155/2430
10/30/2018 Print
6.
3/4
1156/2430
10/30/2018 Print
Installation
4/4
1157/2430
10/30/2018 Print
Climate Control - Blower Motor Resistor—LHD FWD

Print
Removal
1.
2.
3.
1/2
1158/2430
10/30/2018 Print
4.
Installation
2/2
1159/2430
10/30/2018 Print
Climate Control - Air Inlet Door Actuator—Vehicles With: Manual

Temperature Control
Print
Removal
1.
2.
3.
1/3
1160/2430
10/30/2018 Print
4.
5.
6.
2/3
1161/2430
10/30/2018 Print
7.
Installation
3/3
1162/2430
10/30/2018 Print
Climate Control - Air Inlet Door Actuator—Vehicles With: Automatic

Temperature Control
Print
Removal
1.
2.
3.
1/2
1163/2430
10/30/2018 Print
4.
Installation
2/2
1164/2430
10/30/2018 Print
Climate Control - Defrost Vent/Register Door Actuator—LHD FWD

Print
Removal
1.
2.
3.
1/2
1165/2430
10/30/2018 Print
4.
Installation
2/2
1166/2430
10/30/2018 Print
Climate Control - Footwell Vent Door Actuator—LHD FWD

Print
Removal
1.
2.
3.
1/2
1167/2430
10/30/2018 Print
4.
Installation
2/2
1168/2430
10/30/2018 Print
Climate Control - Driver Side Temperature Door Actuator

Print
Removal
1.
2.
3.
1/2
1169/2430
10/30/2018 Print
4.
Installation
2/2
1170/2430
10/30/2018 Print
Climate Control - Passenger Side Temperature Door Actuator

Print
Removal
1.
2.
3.
1/2
1171/2430
10/30/2018 Print
4.
5.
Installation
2/2
1172/2430
10/30/2018 Print
Climate Control - Air Conditioning (A/C) Compressor—1.6L Duratec-16V

Ti-VCT (77kW/105PS) - Sigma/1.6L Duratec-16V Ti-VCT (92kW/125PS) -
Sigma/1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi
(70kW/95PS) (T3)/2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
(120kW/163PS) - DW
Print
Materials
Name Specification
Removal
2. Refer to: Accessory Drive Belt (303-05B Accessory Drive, Removal and Installation).
Refer to: Accessory Drive Belt (303-05F Accessory Drive, Removal and Installation).
Refer to: Accessory Drive Belt (303-05G Accessory Drive, Removal and Installation).
3. If equipped.

Torque: 20 Nm
5. Torque: 25 Nm
1/2
1173/2430
10/30/2018 Print
Installation
1. NOTICE: Only use the specified material to lubricate the seals.

2/2
1174/2430
10/30/2018 Print
Climate Control - Pollen Filter—LHD FWD

Print
Removal
1.
2.
3.
Installation
1/1
1175/2430
10/30/2018 Print
Climate Control - Pollen Filter—RHD

Print
Removal
1.
2.
3.
1/2
1176/2430
10/30/2018 Print
Installation
2/2
1177/2430
10/30/2018 Print
Climate Control - Air Conditioning (A/C) Compressor to Condenser Line—

1.6L Duratorq-TDCi (85kW/115PS)/1.6L Duratorq-TDCi (70kW/95PS)
(T3)
Print
Materials
Name Specification
Removal
2. Refer to: Active Grille Shutter (501-02 Front End Body Panels, Removal and Installation).

Torque: 15 Nm

Torque: 20 Nm
1/2
1178/2430
10/30/2018 Print
Installation

2/2
1179/2430
10/30/2018 Print
Climate Control - Connector Block to Air Conditioning (A/C) Compressor

Line—1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.6L
Duratec-16V Ti-VCT (77kW/105PS) - Sigma/1.6L Duratec-16V Ti-VCT
(92kW/125PS) - Sigma/1.6L Duratorq-TDCi (85kW/115PS)/1.6L
Duratorq-TDCi (70kW/95PS) (T3)/1.6L EcoBoost (110kW/150PS) -
Sigma/1.6L EcoBoost (132kW/180PS) - Sigma/2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L
(120kW/163PS) - DW
Print
Materials
Name Specification
Removal
2.
3.
4. Torque: 15 Nm
1/3
1180/2430
10/30/2018 Print
6.
7.
8. If equipped.
Torque: 25 Nm
2/3
1181/2430
10/30/2018 Print

Torque: 20 Nm
Installation

3/3
1182/2430
10/30/2018 Print
Climate Control - Condenser to Evaporator Line

Print
Materials
Name Specification
Removal
3. If equipped.
All vehicles
4.
5. If equipped.
1/3
1183/2430
10/30/2018 Print
6.

Torque: 11 Nm

Torque: 15 Nm
2/3
1184/2430
10/30/2018 Print
9. Torque: 15 Nm
Installation

3/3
1185/2430
10/30/2018 Print
Climate Control - Evaporator Outlet Line

Print
Materials
Name Specification
Removal
3. If equipped.
All vehicles
4. If equipped.

Torque: 11 Nm
1/3
1186/2430
10/30/2018 Print
6. Torque: 15 Nm
8.
9.
2/3
1187/2430
10/30/2018 Print

Torque: 20 Nm
Installation

3/3
1188/2430
10/30/2018 Print
Climate Control - Evaporator—LHD FWD

Print
Materials
Name Specification
Removal
1. Refer to: Climate Control Housing (412-01 Climate Control, Removal and Installation).
2.
3.
1/3
1189/2430
10/30/2018 Print
4.
5.
6. Torque: 4 Nm
2/3
1190/2430
10/30/2018 Print
Installation
1. Coat the O-rings on the refrigerant lines.
3/3
1191/2430
10/30/2018 Print
Climate Control - Condenser—1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.6L Duratorq-TDCi (85kW/115PS)
Print
General Equipment
Cable Ties
Materials
Name Specification
Removal
3. NOTICE: Make sure that no strain is placed on the refrigerant lines.

4.
1/3
1192/2430
10/30/2018 Print
5.

1. Torque: 15 Nm
2.
3.
4.
Installation


2/3
1193/2430
10/30/2018 Print
3/3
1194/2430
10/30/2018 Print
Climate Control - Thermostatic Expansion Valve Manifold and Tube

Assembly
Print
Materials
Name Specification
Removal
3. If equipped.
All vehicles
4.
5. If equipped.
1/3
1195/2430
10/30/2018 Print
6.

Torque: 11 Nm
8. Torque: 15 Nm
2/3
1196/2430
10/30/2018 Print
Installation

3/3
1197/2430
10/30/2018 Print
Climate Control - Receiver Drier—1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.6L Duratorq-TDCi (85kW/115PS)/1.6L
Duratorq-TDCi (70kW/95PS) (T3)
Print
General Equipment
Cable Ties
Materials
Name Specification
Removal
3.

Torque: 25 Nm
1/2
1198/2430
10/30/2018 Print
5.

Torque: 5 Nm
Installation

2/2
1199/2430
10/30/2018 Print
Climate Control - Thermostatic Expansion Valve

Print
Materials
Name Specification
Removal
3. If equipped.
All vehicles
4.
5. If equipped.
1/3
1200/2430
10/30/2018 Print

Torque: 11 Nm
7. Torque: 15 Nm

Torque: 4 Nm
2/3
1201/2430
10/30/2018 Print
Installation

3/3
1202/2430
10/30/2018 Print
Climate Control - Air Conditioning (A/C) Clutch

and Air Conditioning (A/C) Clutch Field Coil—
1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(70kW/95PS) (T3)/2.0L Duratec-HE
(110kW/150PS) - MI4/2.0L Duratec-HE
(118kW/160PS) - MI4/2.0L Duratec-HE
(125kW/170PS) - MI4/2.0L Duratec-HE Flex
Fuel (125kW/170PS)/2.0L Duratorq-TDCi
(120kW/163PS) - DW/2.0L EcoBoost
(184kW/250PS) - MI4
Print

412-103
412-134
Puller
Removal
1. Refer to: Air Conditioning (A/C) Compressor - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost
(90kW/120PS) (412-01 Climate Control, Removal and Installation).
Refer to: Air Conditioning (A/C) Compressor - 1.6L EcoBoost (110kW/150PS) - Sigma/1.6L
EcoBoost (132kW/180PS) - Sigma (412-01 Climate Control, Removal and Installation).
Refer to: Air Conditioning (A/C) Compressor - 2.0L Duratec-HE (110kW/150PS) - MI4/2.0L
Duratec-HE (125kW/170PS) - MI4 (412-01 Climate Control, Removal and Installation).
Refer to: Air Conditioning (A/C) Compressor - 1.6L Duratec-16V Ti-VCT (77kW/105PS) -
Sigma/1.6L Duratec-16V Ti-VCT (92kW/125PS) - Sigma/1.6L Duratorq-TDCi (85kW/115PS)/1.6L
Duratorq-TDCi (70kW/95PS) (T3)/2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW (412-01 Climate Control, Removal
and Installation).
Refer to: Air Conditioning (A/C) Compressor - 2.0L EcoBoost (184kW/250PS) - MI4 (412-01
Climate Control, Removal and Installation).
Vehicles with 1.0L, 1.6L or 2.0L engine
1/3
1203/2430
10/30/2018 Print
All vehicles
2/3
1204/2430
10/30/2018 Print
Installation
2. Refer to: Air Conditioning (A/C) Clutch Air Gap Adjustment (412-00 Climate Control System -
3/3
1205/2430
10/30/2018 Print
Climate Control - Air Conditioning (A/C) Clutch and Air Conditioning

(A/C) Clutch Field Coil—1.6L Duratec-16V Flex Fuel (85kW/115PS)/1.6L
Duratec-16V Ti-VCT (63kW/85PS) - Sigma/1.6L Duratec-16V Ti-VCT
(77kW/105PS) - Sigma/1.6L Duratec-16V Ti-VCT (92kW/125PS) -
Sigma/1.6L Duratec-16V Ti-VCT Flex Fuel (88kW/120PS) - Sigma/1.6L
EcoBoost (110kW/150PS) - Sigma/1.6L EcoBoost (132kW/180PS) -
Sigma/1.6L EcoBoost Flex Fuel (110kW/150PS)
Print

412-134
Puller
Removal
2.
3.
1/5
1206/2430
10/30/2018 Print
4.
5.
2/5
1207/2430
10/30/2018 Print
6. Torque: 25 Nm
3/5
1208/2430
10/30/2018 Print
Installation
2. Refer to: Air Conditioning (A/C) Clutch Air Gap Adjustment (412-00 Climate Control System -
3.
4/5
1209/2430
10/30/2018 Print
5/5
1210/2430
10/30/2018 Print
Climate Control - Ambient Air Temperature

Sensor
Print
Removal
1. Remove the exterior mirror on passenger side.
Refer to: Exterior Mirror (501-09, Removal and Installation).
Installation
1/1
1211/2430
10/30/2018 Print
Climate Control - Center Register Air Discharge Temperature Sensor

Print
Removal
1. Refer to: Front Control/Display Interface Module (FCDIM) - Vehicles Without: Sony Audio System
(415-01 Information and Entertainment System, Removal and Installation).
Refer to: Front Control/Display Interface Module (FCDIM) - Vehicles With: Sony Audio System
2.
Installation
1/1
1212/2430
10/30/2018 Print
Climate Control - Footwell Air Discharge Temperature Sensor

Print
Removal
1. Refer to: Audio Unit (415-01 Information and Entertainment System, Removal and Installation).
2.
Installation
1/1
1213/2430
10/30/2018 Print
Climate Control - Evaporator Temperature

Sensor
Print
Removal
1.
Installation
1/1
1214/2430
10/30/2018 Print
Climate Control - Sunload Sensor

Print
Removal
1. NOTICE: Use suitable packing material to prevent damage to the component.
Installation
1/1
1215/2430
10/30/2018 Print
Climate Control - High-Pressure Cutoff Switch

Print
Materials
Name Specification
Removal
3. If equipped.
All vehicles
4. If equipped.
5. Torque: 8 Nm
1/2
1216/2430
10/30/2018 Print
Installation

2/2
1217/2430
10/30/2018 Print
Climate Control - In-Vehicle Temperature Sensor

Print
Removal
1.
2.
3.
1/2
1218/2430
10/30/2018 Print
Installation
2/2
1219/2430
10/30/2018 Print
Auxiliary Climate Control - Fuel Fired Booster Heater—Diesel

Print
General Equipment
Hose Clamp(s)
Removal
1. Refer to: Engine Cooling System Health and Safety Precautions (100-00 General Information,
3.
4.
6.
1/4
1220/2430
10/30/2018 Print
7. If equipped.
8. Use the General Equipments: Hose Clamp(s), Hose Clamp Remover/Installer
9. Torque: 90 Nm
2/4
1221/2430
10/30/2018 Print
10. Torque: 6 Nm
3/4
1222/2430
10/30/2018 Print
Installation
2. Check the coolant level.
4/4
1223/2430
10/30/2018 Print
Auxiliary Climate Control - Fuel Fired Booster Heater—Gasoline

Print
General Equipment
Hose Clamp(s)
Removal
Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions (100-00
3.
4.
6.
1/3
1224/2430
10/30/2018 Print
7. If equipped.
8. Torque: 6 Nm
2/3
1225/2430
10/30/2018 Print
Installation
3/3
1226/2430
10/30/2018 Print
Auxiliary Climate Control - Electric Booster Heater—LHD FWD

Print
Removal
1.
2.
3.
1/3
1227/2430
10/30/2018 Print

4.
All vehicles
5.
2/3
1228/2430
10/30/2018 Print
Installation
3/3
1229/2430
10/30/2018 Print
Auxiliary Climate Control - Fuel Fired Booster Heater Fuel Pump

Print
Removal
1. Refer to: Fuel Tank (310-01A, Removal and Installation).

Refer to: Fuel Tank (310-01D Fuel Tank and Lines, Removal and Installation).
2. WARNING: Be prepared to collect escaping fluids.
NOTICE: Use suitable paper to absorb any escaping fluid.

Procedures).
Installation
1/1
1230/2430
10/30/2018 Print
Auxiliary Climate Control - Auxiliary Coolant Flow Pump

Print
General Equipment
Hose Clamp(s)
Removal
Installation
1/1
1231/2430
10/30/2018 Print
Auxiliary Climate Control - Fuel Fired Booster

Heater
Print
General Equipment
Flat-Bladed Screwdriver
Disassembly
2.
3.
4.
5.
1/4
1232/2430
10/30/2018 Print
6.
7.
8.
9.
2/4
1233/2430
10/30/2018 Print
Torque: 6 Nm
11.
12.
13.
14.
3/4
1234/2430
10/30/2018 Print
15. Use the General Equipment: Flat-Bladed Screwdriver
Assembly
4/4
1235/2430
10/30/2018 Print
Instrument Panel and Interior Switches

Illumination - Instrument Panel and Interior
Switches Illumination
Print

General Equipment
Instrument Cluster and Dimmable Backlighting

The dimmable illumination utilizes light emitting diodes (LEDs) and bulb(s).
The following dimmable components are backlit using LEDs only:
control panel
audio unit
instrument cluster
heater control panel
transmission control lever
hazard switch
traction control system disable switch
right-hand and left-hand heated front seat switch(es)
Engine/engine compartment or underbody Fuse(s)
components Loose or corroded connector(s)
Fluid levels Instrument cluster
Accessory installation Switch(es)
Wiring Harness
Circuit(s)
LED(s)
Symptom Chart
The table provides all possible symptoms related to the Suspension System. For a detailed diagnosis,
proceed to the Ford diagnostic equipment.

The control illumination is inoperative Fuse
Headlamp switch
Circuit
The instrument panel illumination does not dim Dimmer switch
The Instrument cluster illumination is inoperative Circuit(s)
Instrument cluster
The climate control illumination is inoperative Circuit(s)
Climate control assembly
The audio system control panel illumination is inoperative Circuit(s)
Control panel
1/1
1236/2430
10/30/2018 Print
Instrument Panel Cluster (IPC) - Instrument Panel Cluster (IPC) -

Overview
Print
Instrument cluster level 1-/1 and 3
Item Description
A Instrument cluster level 1-
B Instrument cluster level 1
C Instrument cluster level 3
1 Auto start/stop
2 Hill descent assist
3 Trip recorder reset button
4 Instrument cluster multifunction display, 1.8", monochrome display
5 Instrument cluster multifunction display, 4.2", TFT display
6 Blind spot monitoring
7 Display for information messages
1/5
1237/2430
10/30/2018 Print
The instrument cluster is available in three different versions. The basic version has a reset button in
the center for the trip recorder. The only other difference between Levels 1-/1 and Level 3 is the size
of the multifunction display.
The multifunction display on Levels 1- and 1 is a monochrome display. By contrast, Level 3 has a TFT
display.
All LED (light emitting diode)s are installed in both versions and are activated/deactivated via the
module configuration in accordance with the vehicle's equipment.
The data of the central vehicle configuration is stored in the instrument cluster as data backup.
It forms the gateway between the multimedia HS-CAN (controller area network) and the MS-CAN.
After replacing the instrument cluster, the module must be programmed, the odometer reading must
be written and the backup data of the central module configuration must be added.
Resetting mileage on new vehicles
Is it possible to reset the odometer reading to zero on new vehicles.
The following conditions apply:

The limit of 20 kilometers must not be exceeded.
Under 20 kilometers the odometer can be reset to zero a maximum of three times.
The reset is however only possible up to 50 kilometers in total.
The reset is carried out by pressing the OK button in the steering wheel for 10 seconds.
Entering the mileage in a new instrument cluster
The odometer reading of the old instrument cluster can be entered into the new instrument cluster
via the IDS (Integrated Diagnostic System).
NOTE: Once the odometer reading has been entered in the new instrument cluster, only upward
correction is possible.
Instrument cluster flow diagram
Item Description
1 Input signal, selector lever park position (vehicles with automatic transmission)
2 Operating buttons for instrument cluster menu (LHD (left-hand drive))
3 Operating buttons for instrument cluster menu (RHD (right-hand drive))
2/5
1238/2430
10/30/2018 Print
Instrument cluster self-test

To enter the self-test mode, simultaneously press and hold the trip recorder reset button (Level 1-) or
the center confirmation button (OK button, Levels 1 and 3) for longer than 5 seconds and turn the
ignition switch from position "0" to position "II".
The start of self-test mode is indicated by 'Test' being shown in the display. The trip recorder reset
button or the confirmation button must then be released within 3 seconds. Otherwise the system
exits self-test mode.
Self-test mode is deactivated when the ignition switch is turned to 0, low battery voltage is detected
or the trip recorder reset button/confirmation button is pressed for more than 3 seconds between
tests.
Ford Eco Mode
The Focus has a further integrated function for reducing harmful emissions. This is known as Ford
Eco Mode. Ford Eco Mode analyses the driver's driving style and helps to achieve fuel savings.
This function monitors and evaluates the relevant driver's driving style in terms of three
aspects:
Whether the driver changes up a gear at the right time.
Whether the driver has a smooth, anticipatory driving style so that heavy braking and accelerating
can be avoided.
Whether the driver is driving at fuel-efficient speeds.
The system also looks at engine temperature data to check the proportion of short trips that the
vehicle makes.
The driver is rated using 5 levels depending on the economy of his or her driving. This rating is
represented by a flower in the instrument cluster. The more of the flower's petals that are shaded,
the more economical the driving.
Item Description
1 Trip computer
2 Distance to next refuel
3 Average fuel consumption - Ford Eco Mode
4 Average speed
Ford Eco Mode can be called up from the instrument cluster menu.
This is done by pressing the operating button for the instrument cluster menu on the left-hand side of
the steering wheel (LHD).
General overview display
3/5
1239/2430
10/30/2018 Print
Item Description
1 Overview for manual transmissions - gearshifting, anticipation, speed
2 Overview for automatic transmissions - anticipation, speed
Item Description
1 Early shifting saves fuel
2 Smooth driving saves fuel
3 Lower speed saves fuel
4 60 percent of trips are short trips with cold engine
5 Eco information - see handbook for more tips
The driver also has the option of obtaining a separate rating for each aspect (shifting, anticipation,
speed) in the instrument cluster.
The first driving style recommendations are displayed after 10-20 km.
The analysis is done in all gears, up to a speed of 115 km/h.
If the highest gear is selected and speed drops below 70 km/h, no evaluation is carried out.
4/5
1240/2430
10/30/2018 Print
Driving style can be assigned both positive and negative ratings. If the rating is negative, a
recommendation will be displayed.
This will disappear once most of the flower petals are shaded in.
If more than 50 percent of all journeys are made with a cold engine, the "short trips" display will
appear. The information is expressed as a percentage and influences the overall rating.
Item Description
1 Current shift score
2 Current anticipation score
3 Current speed score
4 Very good - ECO champion
5 Advanced ECO driver
If driving style is adjusted, the flower's individual petals are shaded in green.
Frequent stop & go driving makes it difficult to achieve a positive rating. Quick success can be
achieved when driving on country roads and motorways.
The driver can be awarded two different levels of commendation if he improves his driving style.
5/5
1241/2430
10/30/2018 Print
Instrument Panel Cluster (IPC) - Instrument

Panel Cluster (IPC)
Print
General Equipment
Engine oil filter Fuse(s)
Engine oil level Wiring harness
Engine coolant level Electrical connector(s)
Oil pressure switch Light emitting diode(s) (LED)
Engine coolant level Instrument cluster
Coolant thermostat Selector lever module (if equipped)
Engine coolant temperature (ECT) sensor Generic electronic module (GEM)
Fuel gauge
Collapsed or damaged fuel tank
Recirculation hose
Fuel tank filler pipe/hose
Indicated fuel level
Fuel lines
Fuel tank filler cap
Fuel filter (external to the fuel tank)
Fuel tank
Door adjustment
4. Verify the following warning indicators are working correctly:
Charging.
Turn signals.
Headlamps.
Configuration of the Instrument Cluster

The instrument cluster is a programmable module, which must be configured by selecting the
Programmable Module Installation Routine on the Ford diagnostic equipment.
NOTE: When the new instrument cluster has been configured with the odometer value, its
configuration cannot be decreased or matched. A new configuration will result in an increase in the
displayed odometer value by a minimum of two units.
NOTE: The odometer value must be recorded from the original instrument cluster before removal.
If the odometer value cannot be obtained from the original instrument cluster (display failure) the
customer should supply the approximate value.
In addition, the new instrument cluster will require the original odometer value to be entered.
After the installation and configuration of a new instrument cluster. The passive anti-theft system
(PATS) will require programming by selecting the Security Access routine on the Ford diagnostic
equipment.
1/1
1242/2430
10/30/2018 Print
Instrument Panel Cluster (IPC) - Instrument Panel Cluster (IPC)

Print

501-009
Remover, Head Restraint
Removal
Upload the instrument cluster configuration information using the Programmable Modules
Installation Routine.

Record the odometer value from the original instrument cluster. If the odometer value cannot be
obtained from the instrument cluster (display failure), perform the diagnostic routine. If the value
cannot be obtained after the diagnostic routine, the customer should supply the approximate
odometer value.
3.
4.
1/3
1243/2430
10/30/2018 Print
5.
2/3
1244/2430
10/30/2018 Print
Installation

Download the instrument cluster configuration information to the newly installed instrument cluster
using the programmable modules installation routine.
3/3
1245/2430
10/30/2018 Print
Horn - Horn - Component Location

Print
Item Description
1 Horn
Comments:
Located behind lower engine cover
1/1
1246/2430
10/30/2018 Print
Horn - Horn
Print
General Equipment
The horn system consists of a relay, a steering wheel switch and either one or two horns. The horn(s)
receives voltage from the switched side of the relay, and the relay switch is controlled on its ground
side by the steering wheel switch.
The horn relay, is located in the engine junction box (EJB) and is supplied with a permanent voltage
from the battery.
Electrical
Fuse(s)
Wiring harness
Horn(s)
Steering wheel module
Horn switch
Horn relay
Generic electronic module(GEM)
EJB
4. If the cause is not visually evident, verify the symptom and refer to the symptom based
diagnostic tab within the Ford diagnostic equipment.
1/1
1247/2430
10/30/2018 Print
Horn - Horn
Print
Removal
NOTE: The removal steps in this procedure may include installation details.
1. If equipped.
2. If equipped.
3.
1/2
1248/2430
10/30/2018 Print
4. Torque: 23 Nm
Installation
2/2
1249/2430
10/30/2018 Print
Warning Chimes - Blind Spot Information

System - Overview
Print
General information
Avoidance of a blind spot is an important element in vehicle construction. However, because of the
structural requirements at the B, C and D pillars, blind spots cannot be fully eliminated.
Statistics show that some accidents are directly attributable to drivers moving across into the path of
overtaking vehicles that have not been seen in conventional mirrors. This potential danger has been
reduced by the development of new mirror designs.
However, complete monitoring of a blind spot can only be ensured by a radar-based monitoring
system.
The blind spot monitoring function consists of:
One blind spot monitoring module on each side of the vehicle

An LED (light emitting diode) on each side of the vehicle in the exterior mirror
The system operates with two radar modules and a frequency of 24 GHz. On both modules, the radar
transmit and receive unit and module are combined in one unit. The modules are located behind the
rear bumper surface, symmetrically, one on each side of the vehicle behind the rear wheels. They are
side facing and inclined rearwards at an angle of 17 degrees, which is dictated by the shape at the
rear of the vehicle. Each module is calibrated so that it can detect a vehicle in the driver’s blind spot.
If a vehicle is detected in the blind spot, a yellow LED lights up in the corresponding exterior mirror.
The LED is located immediately beside the corresponding blind spot monitoring system symbols. If
the blind spot monitoring system malfunctions, a yellow warning lamp illuminates in the instrument
cluster. The LED remains switched off and the message 'Blind spot monitoring not available' is shown
in the driver information system display.
The system performs a self-test when initializing, during which the LEDs in the exterior mirrors briefly
illuminate at the same time. Each module does a left/right determination check when the ignition is
switched on. Each module has a different circuit configuration.
The modules receive vehicle speed data on the MS-CAN (controller area network) databus and are
deactivated at speeds below 10 kph. Each module emits radar beams which cover an area greater
than the blind spot.
The area of the blind spot is calibrated into the module during manufacturing.
NOTICE: The blind spot monitoring system acts as a driver aid and is not a safety device. The
driver must always exercise due care and attention whilst driving.
1/1
1250/2430
10/30/2018 Print
Warning Chimes - Blind Spot Information System - System Operation

and Component Description
Print
System Diagram
Item Description
1 Exterior mirror with LED (light emitting diode) and system symbols
4 Blind spot monitoring module
5 DDM (driver door module) or PDM (passenger door module)
A private MS-CAN (controller area network)
B MS CAN
C hard wired
System Operation
The blind spot monitoring modules communicate via a private MS-CAN (known as the X-CAN) with
the GEM. This is done for security reasons, because the modules are easily accessible at the rear
bumper. Otherwise the door modules of the vehicle could be controlled via the MS-CAN and the doors
could be opened.
The GEM is the gateway between the blind spot monitoring modules and the door modules.
The exterior mirrors with the LEDs are hard-wired to the respective door modules.
1/4
1251/2430
10/30/2018 Print
The system can be switched on and off via the instrument cluster. If a fault occurs in the blind spot
monitoring system, a yellow warning lamp comes on in the instrument cluster and a message appears
in the driver information system.
Blind spot monitoring
The blind spot monitoring system recognizes other moving vehicles on both the left-hand side and the
right-hand side of the vehicle and warns of them as soon as they are located in the detection area of
the system. The detection area is larger than the actual blind spot. The detection range of the system
starts at half a meter distance from the side of the vehicle at the height of the exterior mirror, is 3
meters wide and extends 3 meters behind the rear bumper. The system does not warn of
infrastructure, stationary vehicles, vehicles approaching from the other direction or vehicles which are
being overtaken with a difference in speed (relative speed) of more than 10 kph. "Vehicles" in terms
of this system comprises commercial vehicles, passenger vehicles and motorcycles.
By emitting radar beams and analyzing the reflections, the system identifies vehicles that arrive in
the blind spot detection area. The driver is made aware of the danger by the illumination of a yellow
LED in the particular exterior mirror.
NOTE: If imminent overtaking maneuvers are detected on both sides of the vehicle at the same
time, the LEDs in both mirrors will illuminate.
Blind spot monitoring
Item Description
1 Vehicle in process of overtaking
2 Vehicle changing lane
3 Own vehicle in process of overtaking
4 Surroundings
Vehicle in process of overtaking
The system recognizes a vehicle in the process of overtaking, located on the left-hand side in the
blind spot. The driver is warned until the overtaking object has left the area.
Vehicle changing lane
The driver is warned as soon as a vehicle enters the blind spot during a lane change. The warning
disappears when the area is cleared again.
Own vehicle in process of overtaking
The driver is in the process of overtaking another vehicle. The driver is warned if the vehicle being
overtaken remains longer than 2 seconds in the blind spot.
Surroundings
2/4
1252/2430
10/30/2018 Print
There is no warning given for parked vehicles, infrastructure and vegetation.

The warning display only operates while the overtaking vehicle is a maximum of 20 to 30 km/h faster.
At a speed of more than 40 km/h, the system does not detect it any longer.
LED
The lens on the LED is shaped in such a way that the warning symbol is hardly visible to other
drivers. The LED and the system symbols are arranged at the outer edge of the exterior mirror. The
warning symbol does not cover any important objects thereby and the driver is not distracted by the
warning symbol.
The LED outputs the following signals:
Yellow LED permanently lit - system is active, vehicle detected in blind spot
No LEDs lit – system is active, no vehicle detected in blind spot
The system is subject to certain limitations in its operation and under certain conditions will
automatically be shut down. Under these conditions the yellow warning lamp in the instrument cluster
is continuously lit.
The following operating limitations may exist:
The operation of the radar modules may be limited by the presence of magnetic objects in the
detection area
The system only becomes active at driving speeds above 10 km/h.
If the vehicle is operated with a trailer which meets defined criteria, the system will be switched off
(yellow warning lamp in the instrument cluster continuously lit)
The system will be deactivated if reverse gear or park is selected.
If a radar sensor is obstructed or impaired (e.g. by water), if the surface of the module is covered by
mud, slush or snow, the system may switch off in rare cases. The yellow warning lamp in the
instrument cluster will be lit and the warning message 'Blind spot monitoring blocked’ will be
displayed in the driver information system. The system remains deactivated until the
contamination/damage has been corrected, and subsequently a time of about 10 minutes has elapsed
and 2 to 3 vehicles have overtaken or have been overtaken. The restriction can also occur through
heavy rain. When the rain eases, 10 minutes must pass and 2-3 vehicles must have overtaken or
have been overtaken. Alternatively, the blockage message clears with one ignition cycle.
System error
If there is a fault in the system, the yellow warning lamp in the instrument cluster is permanently lit
and a ‘Blind spot monitoring not available’ message is displayed in the driver information system. The
system remains deactivated until the fault is rectified.
Warnings will be output for the following system faults/obstructions:
The system will be deactivated if the radar module signal is obstructed (yellow warning lamp in the
instrument cluster permanently lit and message appears in the driver information system)
The system will be deactivated by a fault (yellow warning lamp in the instrument cluster
permanently lit and message appears in the driver information system)
3/4
1253/2430
10/30/2018 Print
If faults occur in the system, DTC (diagnostic trouble code)s are stored in the particular blind spot
monitoring module. All modules are delivered as a left-hand side module. The modules recognize
where they are installed and the right-hand module configures itself accordingly. However, if new
software needs to be installed, first that for the left-hand module is loaded, then that for the right-
hand module. The modules can be swapped for troubleshooting.
Calibration of the modules using the IDS (Integrated Diagnostic System) enables updates to be
downloaded once new functions become available or any faults require software updates.
4/4
1254/2430
10/30/2018 Print
Warning Chimes - Proximity Warning System -

Overview
Print
General overview
The distance warning system is part of the dynamic speed control system.
Refer to: Geschwindigkeitsregelung - Fahrzeuge ausgestattet mit Dynamischer
Geschwindigkeitsregelung (310-03B, Description and Operation).
Refer to: Geschwindigkeitsregelung - Fahrzeuge ausgestattet mit Dynamischer

Geschwindigkeitsregelung (310-03B, Description and Operation).
1/1
1255/2430
10/30/2018 Print
Warning Chimes - Lane Departure Warning - Component Location

Print
Item Description
1 Bracket with front camera, access flap for cleaning, laser sensor and rain sensor
3 Multifunction switch
4 Steering gear
1/1
1256/2430
10/30/2018 Print
Warning Chimes - Lane Departure Warning -

Overview
Print
Overview of the Lane Departure Warning System

There are many situations in which lack of attention can result in the risk of a vehicle departing
inadvertently from its lane.
In order to determine the position of the vehicle in the lane, a front camera module is positioned in
the center at the top of the windshield.
The front camera module detects the road markings on the left and right in front of the vehicle.
If the vehicle accidentally strays from its lane, the Lane Departure Warning System alerts the driver
by sending vibrations to the steering wheel, and a visual alert is also displayed on the driver
information cluster.
When the driver intentionally changes lane, the indicator signal acts an input signal and deactivates
the vibration alarm.
Provided the system is able to detect the road markings, it becomes active and is ready to warn the
driver at speeds above approx. 65 km/h.
1/1
1257/2430
10/30/2018 Print
Warning Chimes - Lane Departure Warning - System Operation and

Print
System Operation
Bracket with front camera and laser sensor
Item Description
1 Laser sensor
2 Front camera
3 Bracket
4 Rain sensor
5 Cleaning flap
The bracket can be loaded with the following components:

Laser sensor
Laser sensor and rain/light sensor
Laser sensor, rain/light sensor and front camera
Operation
Above a speed of approx. 65 km/h, the front camera detects the lane markings to the left and right in
front of the vehicle.
The lane marking lines can be white, yellow or blue. They are detected from a lane width of approx.
2.5 m.
The maximum lane width is 4 - 4.5 m.
1/5
1258/2430
10/30/2018 Print
The {Acronym.EPS} ({Acronym.EPS}) sends vibrations to the steering wheel as soon as the driver
strays from the lane. In addition, the driver also receives a message in the instrument cluster.
The timing of the warning depends on

the lateral speed
the lateral acceleration
the lane width
the lane behavior of the driver (if the driver tends to drive close to the right-hand lane marking
anyway then any warning about departing the lane to the right will be delayed)
The vibrations are generated by the {Acronym.EPS} motor and transmitted via the linkage.
The vibrations last for approx. 4 seconds.
The driver then needs to react quickly to straighten the vehicle and correct the drifting out of lane.
If the driver operates the indicator when changing lanes then no vibrations will be sent to the steering
wheel.
It is possible to adjust the strength of the vibrations in the steering wheel to three different levels.
The Lane Departure Warning System is only available in conjunction with the level 3 instrument
cluster.
The operating states of the system are displayed with a colored display on the instrument cluster for
the driver.
Operating states:
No lines
- System deactivated or system error present.
Grey lines
- Warning/active steering intervention not available.
- The following reasons for this may be present: Driver has operated the indicator, the vehicle speed
is below 65 km/h, the acceleration is too high, the steering angle is too high, there are no lane
markings present, the ABS (anti-lock brake system) is active or the lane is too narrow.
Green lines
- System status "ready to issue warning", or active steering intervention in progress.
Yellow lines
- Active steering intervention
Red lines
- Warning/vibration active
If the visibility conditions are poor and the front camera is unable to obtain enough information then
the system will not be ready to issue a warning during this period.
Illustration in the instrument cluster
2/5
1259/2430
10/30/2018 Print
Item Description
A Lane departure warning system
B Lane Keeping Aid
1 Lane Departure Warning System and Lane Keeping Aid deactivated
2 Warning/vibration not available
3 Readiness to issue warnings guaranteed on both sides
4 Warning – vibration on the left
5 Active steering intervention unavailable
6 Active steering intervention in progress on both sides
7 Active steering intervention on the left-hand side
Front camera module
3/5
1260/2430
10/30/2018 Print
The front camera module is attached to a dedicated bracket in the center at the top of the
windshield..
The lane change warning signals are forwarded to the CAN (controller area network) via the HS-BCM
(body control module) databus.
Thanks to the cleaning flap on the bracket, it is possible to clean the inner part of the windshield.
The camera-assisted systems operate up to a temperature of 85°C. If the system switches itself off
then the driver receives a delayed warning message in the instrument cluster.
On the Auto High Beam system the temperature threshold is 60 °C. The system switches from high
beam to dipped beam.
Calibration with IDS (Integrated Diagnostic System)
In order to recalibrate the front camera, it is necessary to measure the height of the outer edge of the
wheel housing. The corresponding heights are entered in the relevant menu in the IDS.
The more accurately this measurement is performed, the more accurately the system can perform.
However, there is a tolerance of ± 10 mm.
After the values have been entered, the vehicle must be driven for a distance of 1-10 km.
Calibration requirements:
Straight road with clearly visible, preferably broken lines
Speed above 65 km/h, preferably between 80-120 km/h
While this is being done, a bar chart will appear on the IDS which fills up in steps of 20%.
Multifunction switch
4/5
1261/2430
10/30/2018 Print
Item Description
1 Switch for activating/deactivating the system
2 Lane Departure Warning System symbol
Activation and deactivation of the system are performed via a switch which is positioned on the left-
hand multifunction switch.
The following menu items are available:

OFF
LDW (Lane Departure Warning)
LKA (Lane Keeping Aid)
The sensitivity of the system can be adjusted in two stages in the instrument cluster.
Operating conditions of the system
View of the camera

The area around the front camera must be clean and free of ice. If a line-of-sight obstruction is
determined, the front windshield heating is activated without the driver being notified.
If this does not improve visibility, a message is displayed for the driver in the instrument cluster.
Only genuine windshield wipers and wiper blades must be used. Otherwise it is possible that the
field of vision of the camera might not be cleaned.
Replacement of the windshield

Only genuine Ford windshields with an adhesively bonded bracket for the front camera must be
used.
The bracket is not available as a separate component in service. It is glued in by the company
Securit, as otherwise the tolerances might be exceeded.
It is not permitted to repair any glass damage in the area of the front camera.
Calibration
The camera needs to be recalibrated if the windshield or the front camera module are replaced or if
work is performed on the chassis (wedge suspension).
If the recalibration is not performed then the system will not be able to detect the lane markings to
the best of its ability, and this could result in a malfunction.
Changes in the vehicle load are automatically compensated for.
5/5
1262/2430
10/30/2018 Print
Warning Chimes - Lane Keeping Aid - Overview

Print
Overview of lane keeping assist system

The lane keeping assist system detects the lane in which the vehicle is currently located and helps the
driver to keep the vehicle in that lane.
It performs automatic steering actions to help the driver keep the vehicle in the lane.
This is made possible by the use of a front camera which records lane data and the electric steering
system which can apply a corrective steering torque.
The steering torque is immediately removed if the driver performs a sudden steering maneuver.
1/1
1263/2430
10/30/2018 Print
Warning Chimes - Lane Keeping Aid - System Operation and Component

Description
Print
System Diagram
Item Description
A No intervention of lane keeping assist system
B Intervention of lane keeping assist system
1 Vehicle leaves the lane
2 Vehicle is steered back into the lane
System Operation
Operation
The lane assist system contains two versions:

The lane departure warning system which emits a warning if the vehicle leaves the lane
The lane keeping assist system which helps to keep the vehicle in the lane
The warning zone extends further beyond the lane than the intervention zone.
The driver can select in the instrument cluster which of these functions he wishes to be active. The
respective status is shown in the instrument cluster's TFT display.
If the lane keeping assist system is selected, an image of a vehicle in a lane is displayed on the top
left-hand side in addition to the dotted lines.
The lane keeping assist system intervenes before the driver leaves the lane.
This intervention takes the form of a superimposed steering torque.
The vehicle's steering response at this point is similar to that experienced when the vehicle is being
driven out of a rut.
The vehicle is steered back into the lane.
The steering torque and steering angle are calculated based on the lateral speed at which the vehicle
is drifting out of the lane and the distance from the lane marking.
If required, the driver can deactivate the lane keeping assist system by countersteering slightly. If the
driver does not override this torque, the vehicle will be kept in its lane and guided along.
1/2
1264/2430
10/30/2018 Print
However, when the vehicle is cornering, there may not be enough torque and the steering action may
not be sufficient to prevent the vehicle from leaving the lane. In such cases, a warning is given in the
form of steering wheel vibrations.
Whilst the lane departure warning system is an "open-loop control function", the lane keeping assist
system is a "closed-loop control function".
If the driver takes his hands off the steering wheel completely, the system prompts the driver to take
over by emitting an audible warning and displaying a text message in the instrument cluster.
If the driver does not take hold of the steering wheel within a few seconds, the function switches itself
off automatically.
Deactivating the system prevents the driver from driving without holding the steering wheel and
consequently relying blindly on the system.
The lane keeping assist system is only active if the following conditions are met:
lane markings are detected
vehicle speed over 65 km/h
driver is holding the steering wheel
turn indicators are not active
the driver is not intentionally changing lanes
Steering angle control

Calculating the reference steering angle ensures that the vehicle is kept under control.
The following angles are required for the calculation:

Angle for correcting lateral deviation with respect to the center of the lane
Angle to compensate for the relative yaw angle with respect to the lane
Steering angle required to follow the curvature of the bend
2/2
1265/2430
10/30/2018 Print
Warning Chimes - Driver Alert - Overview

Print
Overview - Driver Alert

The warning system focuses on the movement pattern of the vehicle and evaluates whether it is
proceeding in a controlled manner or not. The lane departure warning system is used to do this.
The system switches on automatically when the vehicle speed exceeds about 65 km/h.
The driver is warned of fatigue and decreasing concentration.
It is not after a potential hazard is detected that the system gives a warning, instead it continuously
gives the driver information about how high his or her current level of concentration is.
This information is represented in the instrument cluster using a green, yellow or red bar and a coffee
cup.
In the end it is every driver's responsibility to recognize whether a break is advisable for reasons of
safety.
1/1
1266/2430
10/30/2018 Print
Warning Chimes - Driver Alert - System Operation and Component

Description
Print
System Operation
Driver Alert display in the instrument cluster
Item Description
1 Driver Alert deactivated
2 Driver Alert green bar
3 Driver Alert yellow bar
4 Driver Alert red bar
The lane departure warning system is used to automatically monitor the driver's level of concentration
at speeds above about 65 km/h.
The level of concentration is assessed by an evaluation of the behavior in the lane. In the process, the
yaw rate sensor plays an important role because a more alert driver causes fewer jumps in the yaw
rate than a tired driver.
The level of concentration can be queried in the instrument cluster menu.
A steering wheel and coffee cup connected by six dashes are shown in the TFT display.
A bar moves from left to right on this dashed line.
The more that the concentration decreases, the further this bar is located to the right.
The Driver Alert system is divided into three stages. If the driver sees a green bar after sending a
request via the instrument cluster menu, the level of concentration is very good. A yellow bar signals
that a rest is recommended and a red bar calls for the driver to rest soon.
The Driver Alert system can be deactivated in the instrument cluster.
Warning messages from the system
1/3
1267/2430
10/30/2018 Print
Item Description
1 Settings menu in the instrument cluster
2 Warning - rest recommended
3 Warning - a rest should be taken soon
As soon as a yellow bar is displayed, an additional window opens in the instrument cluster. This
additional window shows a coffee cup on the left with a yellow dot underneath. A warning message
appears next to the graphic display. This message recommends that the driver should rest.
This message disappears after 10 seconds without any action from the driver.
If the driver's concentration has greatly reduced and the red bar is displayed, an additional window
also appears. The dot under the coffee cup is now red. This additional window requests the driver to
take a rest soon. The message can only be acknowledged via the OK button on the steering wheel.
Switching the ignition off and on also resets the message. The warning message is backed up by an
acoustic tone.
The acoustic warning tone of the Driver Alert can be deactivated separately.
The system is based on the actual driving style of the driver.
If the driver has not taken a rest, then, where applicable, the bar will be set to red faster in the next
driving cycle.
Driver Alert not available
2/3
1268/2430
10/30/2018 Print
Item Description
1 Driver Alert not available
2 Driver Alert - malfunction
3 Driver Alert not available with grey bar
4 Driver Alert - speed too low
If there are faults in the system, the TFT display shows an error message.
In addition, the driver receives an indication if the speed is too low or the system is not available.
A gray bar is shown for a maximum of 30 seconds if the camera does not receive any information
which can be evaluated. An example of this would be an unrecognized lane marking. The driver
receives information as to how high his or her level of concentration was at that time.
3/3
1269/2430
10/30/2018 Print
Warning Chimes - Traffic Sign Recognition -

Overview
Print
Overview of the Traffic Sign Recognition function

The Traffic Sign Recognition function is an optical system for reading speed limits and overtaking
bans.
The system does not offer warnings about roads with speed limits on the basis of data from the
navigation database; instead, it does this purely optically with the aid of a camera and image
recognition software.
While the vehicle is driving the front camera reads the signs to the left and right of the road. In the
process, it recognizes the signs for speed limits and overtaking bans signs which are standardized in
over 80 countries, and these are then displayed in the instrument cluster.
The system informs the driver as soon as the relevant restrictions are canceled again.
1/1
1270/2430
10/30/2018 Print
Warning Chimes - Traffic Sign Recognition - System Operation and

Print
System Operation
Traffic signs
When driving, you often pass so many signs that the important information like speed limits and
overtaking bans can sometimes get lost in the large number of other signs.
The Traffic Sign Recognition system helps here by displaying important information on the instrument
cluster.
At speeds above 0 km/h, the front camera continuously films the roadside and forwards the images to
a computer.
This analyzes the images and looks for familiar patterns like red edges which indicate speed limits.
Image processing software then compares the number in the middle of the sign with stored numbers.
The system detects speed limits in all countries which have signed up to the Vienna Convention on
Road Signs and Signals.
The participating countries have agreed that speed limits should be displayed by means of a round
sign with a red outer border and a number which indicates the maximum speed.
Depending on the lighting situation, the camera detects signs from a distance of around 100 m.
In contrast to the saved static warnings in navigation systems, which only cover around 65 percent of
all speed limits, the Traffic Sign Recognition system reports all current speed limits.
As the system works on the basis of real-time video processing, it is possible for signs to be
incorrectly detected or for them not to be detected at all.
Illustration in the instrument cluster
1/3
1271/2430
10/30/2018 Print
Item Description
1 Adjustment, information, traffic sign display
2 Speed limit of 100 km/h and overtaking ban
3 Speed limit of 100 km/h and speed limit of 120 km/h with additional information (e.g. on weekdays
between 8.30 a.m. - 11.30 a.m.)
The system is only available in conjunction with the level 3 instrument cluster.
The function can be activated and deactivated in the instrument cluster.
As soon as a traffic sign has been detected, the current status is displayed in the header of the TFT
display.
There are always two circles. Sometimes only one of the circles is filled with a traffic sign.
The Traffic Sign Recognition function uses an aging logarithm. The signs which are currently being
detected by the front camera appear bright red. The color then gradually darkens until the signs are
completely grayed out.
The traffic signs are also displayed in gray if the validity is not certain.
If additional information appears, this is only displayed by means of a bar underneath the traffic sign.
The content cannot be read.
The traffic signal is discarded if the driver operates the turn signal indicator or if the vehicle turns off.
The system does not display area information, road types or traffic lane information (i.e. directions).
2/3
1272/2430
10/30/2018 Print
Item Description
1 Speed limit of 120 km/h with additional information and overtaking ban with additional information
(e.g. when wet)
2 Overtaking ban canceled
3 Speed limit canceled
3/3
1273/2430
10/30/2018 Print
Warning Chimes - Warning Chimes

Print

General Equipment

NOTE: The safety belt minder can be accidentally activated if items are placed on the passenger
seat.
2. Check the system to make sure that the safety belt minder has not been deactivated.
REFER to: Seatbelt Minder Deactivating/Activating (413-09 Warning Chimes, General
Procedures).
Safety belt buckle Wiring harness
Safety belt buckle switch
Passenger seat mat minder
Restraints control module (RCM)
1/1
1274/2430
10/30/2018 Print
Warning Chimes - Proximity Warning Radar

Unit Adjustment
Print
General Procedures
1. This procedure is required if a new proximity warning radar unit and, or proximity warning module
are installed or if the proximity warning radar unit needed to be removed or is misaligned in its
position due to another repair operation.
2. Make sure that the vehicle is on level ground.
3. Activate the adaptive speed control system and the system will automatically enter service
alignment mode.
4. The FOLLOW indicator on the information and message center will now be flashing, this indicates
that the vehicle is in service alignment mode and requires driving.
5. Carry out a road test to set the alignment of the adaptive speed control system. The following
recommendations will assist in completion of the alignment process.
6. The vehicle speed must be above 30 mph (48 kph).

Choose a road with plenty of road furniture and use an inside or outside line.
Following vehicles too closely will obscure the stationary targets from the radar, a time gap
of 2 seconds is recommended.
A straight road will produce a quicker and better result, although the process will still
operate on a curved road.
The time the adaptive speed control module takes to align will vary depending on the route,
speed, number of targets and individual module.
When the flashing FOLLOW indicator light extinguishes the adaptive speed control system is
now functional and a required vehicle speed can now be set by the driver. The speed control
system will operate as normal.
7. In general the procedure can be manually triggered by the WDS tester systems. If the WDS is
connected and the procedure is selected in the WDS the procedure will be started and the telltale
will start flashing like described above. An advantage of this manually triggered procedure is the
presence of a bar on the WDS screen that is indicating the progress of the adjustment procedure
while driving.
1/1
1275/2430
10/30/2018 Print
Warning Chimes - Seatbelt Minder

Deactivating/Activating
Print
General Procedures
Preparation
1. Apply the parking brake.
2. Place the transmission selector lever to P (Park) for vehicles with automatic transmission or to
the neutral position for vehicles with manual transmission.
3. Turn the ignition switch to the 0 position.
4. Close all the vehicle doors from the inside of the vehicle.
Deactivating/Activating - Driver and passenger seat

NOTE: Deactivation of the belt minder may also be carried out using IDS. Follow the instructions on
the screen.
1. The deactivation has be done separately for each seat.
2. Unbuckle the safety belt.
3. Turn the ignition switch to position II. (Do not start the engine).
4. Wait at least 15 seconds.
5. NOTE: This step must be completed within 60 seconds or the procedure must be repeated.
Buckle then unbuckle the safety belt four times, ending with the safety belt unbuckled.
Release the red unbuckle switch completely every cycle.
6. The safety belt warning indicator flashes three times to confirm the belt minder status change.
7. Turn the ignition switch to position 0. The deactivation/activation procedure is now complete.
Deactivating/Activating - Rear seats

NOTE: Deactivation of the belt minder may also be carried out using IDS. Follow the instructions on
the screen.
1. Deactivation of one rear seat causes all the belt warnings for the rear seats to be switched off.
2. Unbuckle all safety belts.
3. Turn the ignition switch to position II. (Do not start the engine).
4. Wait at least 15 seconds.
5. NOTE: This step must be completed within 60 seconds or the procedure must be repeated.
Buckle then unbuckle one safety belt four times, ending with the safety belt unbuckled.
Release the red unbuckle switch completely every cycle.
6. The safety belt warning indicator flashes three times to confirm the belt minder status change.
7. Turn the ignition switch to position 0. The deactivation/activation procedure is now complete.
1/1
1276/2430
10/30/2018 Print
Warning Chimes - Proximity Warning Radar

Unit
Print
Removal
1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2.
3. NOTICE:
The component must not be disassembled.
If accidentally dropped install a new sensor.

Torque: 5 Nm
Installation
Refer to: Proximity Warning Radar Unit Adjustment (413-09 Warning Chimes, General Procedures).
1/1
1277/2430
10/30/2018 Print
Warning Chimes - Blind Spot Monitoring

Sensor
Print
Removal
2.
3.
Wagon
4. Refer to: Rear Bumper Cover - Wagon (501-19 Bumpers, Removal and Installation).
5.
1/2
1278/2430
10/30/2018 Print
6.
Installation
2/2
1279/2430
10/30/2018 Print
Warning Chimes - Front Distance Sensing Module (FDSM)

Print
Removal
1.
2.
3.
1/2
1280/2430
10/30/2018 Print
4.
Installation
2/2
1281/2430
10/30/2018 Print
Warning Chimes - Image Processing Module A (IPMA)

Print
General Equipment
Interior Trim Remover
Removal
1. NOTICE: Take extra care not to damage the clips.
2. NOTICE: Make sure that the cable cannot be damaged or cause a noise, vibration or
harshness (NVH) concern.
Use the General Equipment: Interior Trim Remover
1/2
1282/2430
10/30/2018 Print
Installation
1. NOTICE: Make sure that the surface is clean and free of foreign material.
2. Calibrate the Image Processing Module A (IPMA) using the diagnostic tool.
2/2
1283/2430
10/30/2018 Print
Warning Chimes - Active City Stop Module

Print
Removal
1.
2.
WARNING: Invisible laser radiation.

Do not view directly with optical instruments (magnifiers).
Class 1M laser product.
Installation
1/2
1284/2430
10/30/2018 Print
2/2
1285/2430
10/30/2018 Print
Parking Aid - Parking Aid - Component Location

Print
Reversing camera
Item Description
1 SYNC 8" multifunction display with touchscreen
2 Parking aid camera module
3 Parking aid camera
1/1
1286/2430
10/30/2018 Print
Parking Aid - Parking Aid - Overview

Print
Reversing camera
The reversing camera is offered as an option in combination with the SYNC 8" multifunction display
with touchscreen.
The guidelines shown on the SYNC 8" multifunction display with touchscreen help inform the driver of
the steering angle, vehicle width, when to drive in a straight line, and when to corner.
When reverse gear is engaged, the reversing camera shows the area behind the vehicle.
The guidelines are deactivated as soon as a trailer is hitched. The camera remains active.
The camera is deactivated after reverse gear is disengaged.
Guidelines and trailer hitch line displayed by the reversing camera
The guidelines are divided into four zones. The zones extend from 0-0.30 m, 0.30-0.60 m, 0.60-0.90
m and 0.90-3.20 m.
In combination with a parking aid, colored fields assist the driver within the zones.
As soon as the vehicle approaches an object, the field color changes from white to green to yellow
and finally to red.
The fields remain white between an object shown on the display (e.g. green) and the vehicle.
The virtual trailer hitch line is activated by default in the system. It can be deactivated via the menu.
A manual zoom with three levels can be activated if there is a trailer hitch installed. The zoom levels
are 60%, 70% and 90%. This makes trailer operations much easier.
Parking aid module and camera
1/2
1287/2430
10/30/2018 Print
Item Description
A Parking aid camera module
B Parking aid camera
The reversing camera, which is supplied by the company "Magna", is mounted beside the license plate
light.
The parking aid camera module is installed on the right-hand side in the luggage compartment. The
module is configured using the inhale/exhale method.
If the data can still be read out from the faulty parking aid camera module, the configuration can be
loaded using IDS (Integrated Diagnostic System) and transferred to the new module.
Otherwise the as-built data must be used.
The reversing camera cannot be retrofitted.
The camera is exclusively supplied with a configuration for the 5-door Focus. If it is installed in the 4-
door Focus or wagon, the ignition must remain switched on for at least 3 minutes. The camera is
automatically configured during this time. If the ignition is switched off during this configuration
process, the process is interrupted and started again the next time the ignition is switched on.
If the system shows a fault, an error message appears on the SYNC 8" multifunction display with
touchscreen.
2/2
1288/2430
10/30/2018 Print
Parking Aid - Parking Aid - System Operation and Component

Description
Print
System Operation
Parking process of the Active Park Assist
Item Description
1 Activate the Active Park Assist
2 Scanning process
3 Detect parking space
Activate the Active Park Assist
The driver activates Active Park Assist using the switch. If the vehicle is traveling faster than the
maximum speed for scanning (this is at 30 km/h), no parking spaces will be detected.
The driver receives a message via the multi-function display, that the speed needs to be reduced.
Scanning process
The driver is driving at less than the maximum scanning speed and Active Park Assist system scans
on both sides of the vehicle for parking spaces.
Detect parking space
As soon as a parking space is located, it is displayed to the driver in the multi-function display.
The passenger side is established as the active side of the parking. If the driver wishes to change the
parking side, this is identified by operating the turn signal switch.
1/6
1289/2430
10/30/2018 Print
Item Description
4 Parking process starting position
5 Steering angle control mode active
6 Parking process
7 Parking process finished
Parking process starting position
After an adequate sized parking space has been found on the active side of the vehicle, the driver is
informed via the multi-function display that he can stop his vehicle.
As soon as the speed is less than 3 km/h and the vehicle is not in the correct starting position for the
parking process, the driver is requested to move the vehicle further forwards. This message appears
until a Stop message is signaled in the multi-function display.
Steering angle control mode active
The steering angle control mode is activated as soon as the driver has engaged reverse gear. In
addition, the vehicle must be stationary in the correct starting position and the driver must have
removed the hands from the steering wheel.
The system steers the vehicle into the parking space. The driver retains full control as he accelerates
and brakes the vehicle himself. In addition, the driver is supported by the parking system. All ten
sensors now operate as conventional clearance sensors.
Parking process
The driver is supported by the messages in the multi-function display and the parking system. The
driver decides to stop the vehicle.
To change direction, he engages forwards gear. The Active Park Assist continues, the steering system
is still controlled and the parking process proceeds.
Parking process finished
When the vehicle is in the correct position (angle, distance at the side to the curbstone or the
maximum number of backwards and forwards movements has been exceeded), this is indicated to
the driver in the multi-function display.
Active Park Assist is subdivided into two modes:
2/6
1290/2430
10/30/2018 Print
Measurement of parking spaces

Steering angle control
During measurement of parking spaces, the system scans both sides of the vehicle for parking
spaces. Two ultrasonic sensors are used for this, which are secured to the front bumper. The
ultrasonic sensors measure the lateral distance to objects as the vehicle drives past them. The vehicle
can be driven past the objects at a distance of 40-150 cm from them.
The side ultrasonic sensors have a measuring range of about 4 meters.
Using the measured distance, the parking aid module uses a simple geometrical equation to
determine whether the vehicle will fit in the parking space. Suitable spaces are indicated to the driver
with a corresponding message and the audio device outputs a tone. This tone can be switched off
using the menu of the instrument cluster.
After driving past, the parking space will be offered within 1.5 to 3.5 meters. It will be rejected at the
latest after 12 meters. If several spaces occur in succession, the last space is always shown.
Even if the system is not activated by the driver, at speeds below 30 km/h spaces on both sides of the
vehicle are measured. On activation, these are then offered (if appropriate).
When measuring parking spaces, it is basically enough when the system detects an object in front as
the limit of a space. One single vehicle at the side of the road is thus interpreted as a space, so that it
can then be parked behind.
Requirements for parking space measurement:
Engine running.
all CAN (controller area network) signals received
electronic stability program - traction control active
no trailer connected
vehicle speed below 30 km/h
in forward gear or neutral
The steering angle control mode assists the system during parking by taking over the control of
the steering wheel.
The parking aid module calculates a movement path which makes parking possible. As soon as
reverse gear is engaged by the driver, the parking aid module sends a request to the {Acronym.EPS}
({Acronym.EPS}) module. The driver is informed via the multi-function display that he should remove
his hands from the steering wheel. The smaller design of the multi-function display shows a text, all
others show a diagram.
If the driver moves the steering wheel during the automatic parking, the process is discontinued. The
system can however be activated again using the Active Park Assist switch, when this is indicated via
the multi-function display.
Requirement for steering angle control mode:
Checked by the parking aid module

- same requirements as for parking space measurement
- system was activated by the driver
- a suitable parking space was found
- the vehicle has the correct starting position for beginning the parking maneuver and is stationary.
- reverse gear engaged
Checked by the parking aid module and the {Acronym.EPS} module
- vehicle speed is between 0 km/h and 10 km/h
- external torque of the steering wheel is below 2 Nm
- turning speed of the steering wheel is less than 6 °/sec
Checked by the {Acronym.EPS} module:
- {Acronym.EPS} is working normally
- CAN signals of the steering angle request and the vehicle speed are correctly transmitted.
The final alignment of the vehicle in the parking space can be improved by the driver. It
depends on:
the direction of driving by (straight as possible)
the speed of driving by (if possible below 10 km/h)
how far the driver drives backwards and forwards in the space (ideally until the constant tone)
3/6
1291/2430
10/30/2018 Print
Layout of components
Item Description
1 Ultrasonic sensors and sensor mounting, front parking aid
2 Ultrasonic sensors and sensor mounting, Active Park Assist and front parking aid
4 Ultrasonic sensors and sensor mounting, rear parking aid
5 Active Park Assist switch unit
Parking module input signals:
ABS (anti-lock brake system), bidirectional wheel speed sensors, {Acronym.EPS} module, steering
angle sensor, instrument cluster, parking sensors, ultrasonic sensors, parking aid activation switch,
Active Park Assist activation switch, PCM (powertrain control module), ambient air temperature
sensor, GEM (generic electronic module), trailer module, TCM (transmission control module).
Parking module output signals:
{Acronym.EPS} module, instrument cluster, radio, multi-function display, parking sensors,

ultrasonic sensors, parking aid activation switch with LED (light emitting diode), Active Park Assist
activation switch with LED, GEM, reversing camera module.
Difference in the ultrasonic sensors:
conventional ultrasonic sensors - wide beam characteristics - measurement up to 2 meters distance

Ultrasonic sensors - Active Park Assist - narrow, long beam characteristics - measurement up to 4
meters distance
Active Park Assist activation switch
4/6
1292/2430
10/30/2018 Print
Item Description
A Low equipment level
B High equipment level
1 Active Park Assist switch
2 Parking system switch
3 Liftgate release switch
4 Auto start/stop*
* System will be introduced at a later date.
The LED of the switch for the Active Park Assist is on as soon as the system is activated. The LED
goes out when the parking maneuver is completed successfully and the message in the multi-function
display disappears.
If there are faults in the system or the steering angle control mode is canceled, a warning tone
sounds and the LED flashes for several seconds.
Multi-function display
Multi-function display messages
The level 2 multi-function display only shows text messages (see table in attachment). All other
multi-function displays show diagrams as well.
Limitations of the system
The Active Park Assist relies upon a number of sensors to recognize parking spaces, to calculate
movement paths and to move the steering wheel accordingly. The measurement is limited by physical
5/6
1293/2430
10/30/2018 Print
constraints and the accuracy of the individual sensors.

Ultrasonic sensors:
Only objects which reflect enough sound waves will be detected by the sensors. This occurs through
the shape, surface properties and size of the objects. Dirt-covered sensors, heavy rain and snow
can cause spaces not to be recognized. Incorrect sensor positions also lead to a faulty
measurement.
Wheel speed sensor:
The same limitations apply as for standard ABS. Incorrect wheel impulses or alignment of the
sensors cause reduced parking accuracy or abandonment of the maneuver. If a spare wheel or
wheels with a size not specified for the vehicle are fitted, the system will not park correctly.
Extremely worn tires or the incorrect tire pressure cause the same effect.
Steering angle sensor:
Manufacturing tolerances or dismounting the sensor have effects on the measured steering angle,
which leads to a reduction in the parking accuracy.
ABS sensors:
The ABS sensors are designed as bidirectional sensors. They recognize whether the vehicle is
moving forwards or backwards. The speed threshold which causes the steering control mode to stop
is limited to the accuracy of the speed information. This information is based on the front wheels.
Ambient temperature sensor:
The parking aid module calculates the speed of sound based on the ambient air temperature. For
this reason, the ultrasonic sensors of the Active Park Assist can calculate the width of the space with
enough accuracy.
Technical limitations of the system:
Active Park Assist only operates correctly with the original Ford Audio System. If the audio system
is removed or another is installed, the acoustic warning tones will no longer sound. The Active Park
Assist system must be removed or deactivated.
The temperature range of the components of the Active Park Assist is between -40°C and 85°C.
The system defines the passenger side as the standard parking side. If the driver wishes to change
the side, he must operate the turn signal switch.
If the engine stops during the maneuver, the system switches off and the parking space is rejected.
Objects which appear after the measurement of the parking space while driving by are not
considered in the movement path during parking. A warning sounds via the conventional parking
system however.
If the vehicle has been equipped with various enhancements (cycle rack, trailer) which do not have
electrical connections, the Active Park Assist system does not recognize this. The additional
dimensions will not be considered in the calculation of the path.
If an aftermarket trailer hitch is fitted, this must be registered via the central module configuration.
15 cm will be added to the required parking length.
6/6
1294/2430
10/30/2018 Print
Parking Aid - Parking Aid

Print

General Equipment
Principle of Operation
For a detailed description of the parking aid and active park assist system(s), REFER to: (413-13
Parking Aid)
Parking Aid (Description and Operation),
Parking Aid (Description and Operation).
NOTICE: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of

control modules does not guarantee confirmation of a fault, and may also cause additional faults in
the vehicle being tested and/or the donor vehicle.
NOTE: Particular attention should be paid to the following items where Diagnostic Trouble Codes
(DTCs) may not be logged:
Check for contamination (e.g. foreign matter, grime, frosting, ice) around the parking aid sensors, if
so clean as necessary.
Check for the correct installation and alignment of the sensors to the bumper cover.
Spurious detection of the ground may occur during front system operation on an up-slope.
VISUAL INSPECTION
Electrical
Fuse(s)
Relay(s)
Wiring Harness
Front parking aid sensor(s) and retainers
Rear parking aid sensor(s) and retainers
Side parking aid sensor(s) and retainers
Front parking aid speaker (audio system speaker)
Rear parking aid speaker (audio system speaker)
Parking aid switch and LED
Reversing lamp switch
Multifunction display
Parking aid module
Parking aid camera
Parking aid camera module
1/1
1295/2430
10/30/2018 Print
Parking Aid - Parking Assist Control Module (PAM)—5-Door

Print
Removal
1. NOTE: If the eleventh VIN character (assembly plant code) is L, (Michigan Assembly –
Wayne, Michigan), module configuration (PMI) is required when new module is installed.
Other vehicles do not require PMI.1. If a new module will be installed and the eleventh VIN
character is L, upload the module configuration to the scan tool by following the instructions
on the scan tool.
Refer to: Loadspace Trim Panel RH - 5-Door (501-05 Interior Trim and Ornamentation, Removal
and Installation).
2.
Installation
1. NOTE: If the eleventh VIN character (assembly plant code) is L, (Michigan Assembly –
Wayne, Michigan), module configuration (PMI) is required when new module is installed.
Other vehicles do not require PMI.1. If a new module is be installed and the eleventh VIN
character is L, upload the module configuration to the parking aid module (PAM) by following
the instructions on the scan tool.
1/1
1296/2430
10/30/2018 Print
Parking Aid - Front Parking Aid Sensor

Print
Removal
2. 1.
2. If equipped.
3.
4. NOTICE: Pressure must not be applied to the outer face of the parking aid sensor.
1/2
1297/2430
10/30/2018 Print
Installation
2/2
1298/2430
10/30/2018 Print
Parking Aid - Rear Parking Aid Sensor

Print
Removal
4-door
5-door
1/3
1299/2430
10/30/2018 Print
Wagon
Vehicles with ST engine
Wagon
2/3
1300/2430
10/30/2018 Print
Installation
3/3
1301/2430
10/30/2018 Print
Parking Aid - Parking Aid Camera—5-Door

Print
Removal
1. Refer to: Liftgate Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2.
3.
4.
1/2
1302/2430
10/30/2018 Print
5.
Installation
2/2
1303/2430
10/30/2018 Print
Charging System - General Information -

Charging System - Overview
Print
Smart Regenerative Charging

Smart Regenerative Charging is an intelligent charge control system that calculates and regulates the
set generator voltage.
The basic idea of the system is to increase the generator charge voltage when the vehicle is
decelerating and reduce it when it is accelerating.
This means that during the acceleration phase, there is no additional energy demand as a result of
having a high generator load; however generator load is increased when the vehicle is decelerating.
This strategy enables further fuel savings to be achieved.
Battery Monitoring Sensor
The Battery Monitoring Sensor continuously monitors the condition of the battery.
The sensor is equipped to vehicles which have Smart Regenerative Charging or Start-Stop. These
systems require knowledge of the battery state of charge. The Battery Monitoring Sensor is the
sensor used to provide this information.
Battery Monitoring Sensor connection
The Battery Monitoring Sensor is clamped directly to the negative terminal of the battery and grounds
to the vehicle at the chassis ground connection point by means of a thick (25 to 35mm²) cable and
eyelet. External customer loads must only be connected to the vehicle at the customer battery
connection point. If the external customer load is connected at the negative battery post, the Battery
Monitoring Sensor accuracy cannot be guaranteed.
It is recommended that the Battery Monitoring Sensor pole clamp is not removed unless a battery
replacement is required. Should the battery need to be isolated, this should be done by disconnecting
the ground eyelet at the chassis ground.
Battery Monitoring Sensor reset
The Battery Monitoring Sensor also estimates losses in the battery capacity over time. The Battery
Monitoring Sensor should be reset to factory default settings, when the battery is replaced.
It is urgently recommended that the replacement battery has the exact same specification as the
original battery. If it does not, the accuracy of the Battery Monitoring Sensor outputs will be
compromised.
The Battery Monitoring Sensor reset is part of the battery replacement procedure in IDS (Integrated
Diagnostic System).
1/1
1304/2430
10/30/2018 Print
Charging System - General Information - Charging System - System

Operation and Component Description
Print
System Diagram
Item Description
4 Enhanced Flooded Battery
5 Electrical consumers - (vehicle electrical loads)
6 Generator
System Operation
The largest element of the Smart Regenerative Charging Strategy is stored in the BCM module. It
receives all of the important information relating to the battery condition sent by the battery
monitoring sensor via the LIN (local interconnect network) data bus.
The information obtained is used to calculate the required set value for generator charge voltage. This
is sent by the BCM to the PCM via the HS-CAN (controller area network) data bus. This then adjusts
the value received if necessary and passes it on the generator via the LIN data bus. The charging
voltage is adjusted depending on various parameters, such as the current level of engine efficiency.
The smallest possible set value for the generator voltage is 12.2 V, while the maximum charging
voltage may be anywhere between 14.5 and 14.9 V.
1/2
1305/2430
10/30/2018 Print
However, when the battery is in a refresh phase, the voltage may occasionally reach up to 15.2 V.
These refresh phases are required as the battery charge status is 80% over long periods of time,
which increases the risk of sulfation in the cells.
Comparison of Smart Regenerative Charging and Conventional Charging
The diagram below demonstrates the difference between Smart Regenerative Charging and
Conventional Battery Charging.
Conventional charging aims to charge the battery to the highest possible levels. During this process
the battery temperature is monitored and the battery must not be overcharged.
By comparison, Smart Regenerative Charging uses the information from the battery monitoring
sensor to maintain the battery at a calibrated state of charge (approx. 80%) at all times. This means
that the battery has a certain amount of extra charging capacity at all times.
If the battery monitoring sensor detects that the charge status is above the calibrated value (approx.
80%), then the generator charging voltage is reduced in order to discharge the battery. If the
opposite occurs and too low a value is detected, the charging value is increased in order to return the
battery to the calibrated value.
Battery Monitor Sensor

The Battery Monitor Sensor measures temperature, voltage and current throughput of the battery. It
uses this information to calculate the battery SOC (State of Charge).
To function with high accuracy, the Battery Monitor Sensor must be recalibrated at regular intervals.
A recalibration occurs during a rest period when the battery quiescent current is less than 100mA.
This rest period must last for at least 3 hours.
The longer the rest period, the greater the accuracy.
The timeframe in which a recalibration must take place is seven days.
If the system has been unable to carry out a recalibration within 7 days, the SOC accuracy cannot be
guaranteed.
This will result in the Start – Stop and SRC systems being deactivated.
2/2
1306/2430
10/30/2018 Print
Charging System - General Information - Charging System

Print

General Equipment
Midtronics EXP-1050 battery tester
Midtronics GR590-2

WARNINGS:
Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also, shield your
eyes when working near batteries to protect against possible splashing of the acid solution. In case
of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and
get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow
these instructions may result in personal injury.
Batteries normally produce explosive gases which can cause personal injury. Therefore, do not
allow flames, sparks or lighted substances to come near the battery. When charging or working
near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to
follow these instructions may result in personal injury.
Accessory drive belt Fuse(s)
Generator Wiring harness(es)
Generator
Battery junction box (BJB)
Battery
Battery cables
Battery monitoring sensor (BMS)
Charging system warning indicator
4. Check the operation of the charging system warning indicator lamp, located in the instrument
cluster. Normal operation is as follows:
NORMAL CHARGING SYSTEM VOLTAGES
Ignition Switch I Circuit Generator Battery Engine to Charging System

Position B+ Circuit battery ground Warning Indicator
Operation
Position 0 0V 10-12V 10-12V 0V OFF
Position II 0V 10-12V 10-12V 0V Illuminated
Position II with 13-15V 13-15V 13-15V 0V OFF
the engine
running
5. If the cause is not visually evident, verify the symptom and refer to the Component Tests.
Component Tests
Generator On-Vehicle Tests - No-Load Test
1/6
1307/2430
10/30/2018 Print
1. Turn off all electrical loads and the ignition switch.
2. Switch the multimeter to the voltage function.
3. Connect the leads of the multimeter across the battery terminals.
4. Read the voltage (base voltage).
6. Run the engine at 1500 rpm with no electrical load.
7. Read the voltage. The voltage should be in the range of 14.1 volts to 15.1 volts. If the voltage
increase is less than 2.5 volts above the base voltage, carry out the Load Test. If the voltage
increase is greater than 2.5 volts, REFER to the Ford diagnostic equipment.
Generator On-Vehicle Tests - Load Test
1. With the engine running, turn on the air conditioning (if equipped), turn the blower motor to
high speed and the headlamps to high beam.
2. Increase the engine speed to 2000 rpm. The voltage should increase a minimum of 0.5 volts
above the base voltage. If the voltage does not increase as specified, REFER to the Ford
approved diagnostic tool. If the voltage increases as specified, the charging system is
charging correctly.
Battery Identification

1 - Cold crank amp (CCA) rating
2 - Reserve capacity (RC) rating (minutes)
3 - Battery voltage
4 - Ford Part number
5 - FINIS code
6 - EN number (European Norm)
7 - Battery type: Ca = Silver/Calcium; Sb = Lead/Antimony
8 - Amp hour rating
2/6
1308/2430
10/30/2018 Print

1 - Battery performance data
2 - Motorcraft internal labelling
3 - DIN labelling
Battery performance data
NOTE: The data only applies to a new fully-charged battery.
The first group of digits (12V) indicates the battery voltage (12 volts).
The second group of digits (590A) indicates that the battery delivers a current of 590 amps at
-18°C without the terminal voltage falling below 7.2 volts.
The third group of digits (90RC) indicates the time in minutes in which the battery voltage falls to
10.5 volts in the case of a 25 amp load and an ambient temperature of 22°C.
DIN Labelling
The first group of letters (WF) indicates that the battery is maintenance-free.
The first digit (5) indicates that the battery is 12 volts.
The second and third digits (58) indicates the battery capacity is 58 Ah, which means it could power
a 58 amp load for 1 hour.
The last two digits (11) is a sequential serial number.
For general information regarding smart regenerative charging, refer to: REFER to: (414-00 Charging
System - General Information)
Charging System (Description and Operation),
Charging System (Description and Operation).
Midtronics EXP-1050 battery tester
The Midtronics EXP-1050 battery tester is the only battery tester recommended by Ford to test latest
technology batteries including AGM (Absorbent Glass Mat) and EFB (Enhanced Flooded Battery),
previously known as IFB (Improved Flooded Battery) used on Ford Start-Stop vehicles.
3/6
1309/2430
10/30/2018 Print
Main specifications of the Midtronics EXP-1050 battery tester

Tests 6/12V batteries
Tests discharged batteries down to 1V both in and out of the vehicle
Ratings in battery tester: CCA, JIS, EN, DIN, IEC, SAE
CCA range: By Ford battery type 100-1700 A SAE / EN / CCA 100-1000 A DIN / IEC All current JIS
codes
Large LCD display with adjustable backlight
Detects short-circuited cells
Surface charge removal procedure
Dynamic Response procedure for refined decisiveness on battery diagnostics
Upgradeable by SD card
Export data feature to send data to infra red printer
Voltmeter function
Date and time indication with every test
23 languages included within the battery tester
Using the Midtronics EXP-1050 battery tester
Disconnect the battery ground cable at the battery negative (-) post. Note: if using this battery
tester on models where the ground cable is not accessible, the battery does not have to be removed
from the vehicle and may be tested using the vehicle's 'jump start post' if the battery tester is set
to the correct mode. In this case, the battery must be disconnected at the positive (+) post before
testing.
Connect the positive red clamp of the Midtronics EXP-1050 battery tester to the battery positive (+)
post.
Connect the negative black clamp of the Midtronics EXP-1050 battery tester to the battery negative
(-) post or jump start post as appropriate.
A poor connection will prevent testing and the battery tester will display the message CHECK
CONNECTION. If this message appears after you have correctly reconnected the clamps, clean the
terminals and reconnect.
It is recommended that batteries are always tested using both battery posts. However, if used in
'jump start post' mode, the Midtronics EXP-1050 battery tester will compensate for the extra
resistance of the additional cable.
Select BATTERY TEST or START-STOP BATTERY TEST.

- Press the NEXT key to continue.
Select the BATTERY LOCATION
- UNDER HOOD
- UNDER SEAT
- OUT OF VEHICLE
4/6
1310/2430
10/30/2018 Print
Select the negative POST TYPE (IN-VEHICLE ONLY)

- BATTERY POST
- JUMP START POST
- JUMP START POST (Battery Monitoring Sensor)
Select the BATTERY RATING from the drop down list.
- Press the NEXT key to test the battery.
If the battery under test is not listed in the drop down list, it can still be selected with the MANUAL
ENTRY mode. This is item 11 of 11 in the list.
The Midtronics EXP-1050 battery tester will display the word TESTING while it evaluates the battery.
BATTERY TESTER RESULTS AND REQUIRED ACTIONS
Battery Action
Tester
Reading
GOOD Return the battery to service
BATTERY
GOOD - Fully recharge the battery and return it to service
RECHARGE
CHARGE & Fully charge the battery and retest (failure to fully charge the battery before retesting may
RETEST cause false readings)
REPLACE
BATTERY or WARNING: Do not recharge the battery.
BAD CELL Make sure that the surface charge was removed. A "REPLACE BATTERY" result could also
BATTERY mean a poor connection between the battery cables and the battery. Check the
connections are OK and retest. If the result remains the same, INSTALL a NEW battery
REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
In addition it is advisable to check the vehicle electrical system. Check that the generator is functioning
correctly and the vehicle does not have an excessive key-off load (in general this should be under 20mA
after 40 minutes of key off).
Midtronics EXP-1050 Battery Tester Test Code
At the end of the test, use the arrow keys to scroll down the screens to see additional information.
One of these is the TEST CODE.
The TEST CODE has 11 digits, for example: 0021U-B88WKX.
Using the Midtronics GR-590-2
The Midtronics GR-590-2 is both a battery charger and battery tester and automatically removes the
surface charge as part of the normal operating procedure.
5/6
1311/2430
10/30/2018 Print
The Midtronics GR-590-2 can be used on a battery in-vehicle or out-of-vehicle.
Disconnect the battery ground cable.

Connect the positive red clamp from the Midtronics GR-590-2 to the battery positive terminal.
Connect the negative black clamp from the Midtronics GR-590-2 to the battery negative terminal.
Connect the AC power cable to the mains outlet and switch ON.
Follow the instructions supplied with the Midtronics GR-590-2 to charge the battery.
To disconnect the Midtronics GR-590-2, reverse the connection procedure.
The Midtronics GR-590-2 will automatically carry out a charge cycle before giving the resulting test
code. It will bring the battery into a serviceable condition and if required can proceed to fully charge
the battery.
Functions on the front panel of the Midtronics GR-590-2
UP and DOWN button: The UP and DOWN buttons allow the operator to scroll through selections on
the display and increase or decrease values.
ENTER button: The ENTER button allows the operator to accept a selection and continue to the next
step.
INFO button: The INFO button allows the operator to enter the Options menu to access feature such
as Languages, BMC Code, Last Test Data and Print.
STOP button: The STOP button allows the operator to abort a charging cycle or go back to previous
steps in the menus.
Midtronics GR-590-2 Test Code
At the end of the test, use the arrow keys to scroll down the screens to see additional information.
One of these is the TEST CODE.
The TEST CODE has 13 digits, for example: Y74NH-58R36-ESV.
6/6
1312/2430
10/30/2018 Print
Battery, Mounting and Cables - Battery Disconnect and Connect

Print
General Procedures
Disconnect
1. Refer to: Battery and Battery Charging Health and Safety Precautions (100-00 General
Information, Description and Operation).
2. Torque: 22 Nm
3.
Connect
1/2
1313/2430
10/30/2018 Print
1. To install, reverse the removal procedure
2/2
1314/2430
10/30/2018 Print
Battery, Mounting and Cables - Battery

Print
Removal
Procedures).
2. Refer to: Air Cleaner (303-12 Intake Air Distribution and Filtering)
3. Torque: 12 Nm
4. Torque: 12 Nm
5.
6.
1/2
1315/2430
10/30/2018 Print
7. Torque: 8 Nm
Installation
1. NOTICE: If installing a new battery, only install the specified battery type.
NOTE: If installing a new battery, use the scan tool to carry out the Battery Monitoring
System (BMS) reset after the battery is connected.
2/2
1316/2430
10/30/2018 Print
Battery, Mounting and Cables - Battery Tray

Print
Removal
Gasoline
2. If equipped.
3. If equipped.
4. If equipped.
1/3
1317/2430
10/30/2018 Print
Diesel
5. If equipped.
6. If equipped.
7. If equipped.
All vehicles
2/3
1318/2430
10/30/2018 Print
8. Torque: 10 Nm
Installation
3/3
1319/2430
10/30/2018 Print
Generator and Regulator - Generator—1.6L

(70kW/95PS) (T3)
Print
Special Tool(s)
303-1557
Wrench, Generator
Removal

Torque:
1: 45 Nm
2: 39 Nm
Installation
1/1
1320/2430
10/30/2018 Print
Voltage Converter/Inverter - Low Voltage Direct Current/Direct Current

(DC/DC) Converter
Print
Removal
1.
2.
3. Torque: 7 Nm
1/2
1321/2430
10/30/2018 Print
Installation
2/2
1322/2430
10/30/2018 Print
Information and Entertainment System - General Information -

Information and Entertainment System—Vehicles With: SYNC -
Component Location
Print
Item Description
1 Speakers
2 Multi-function display
3 USB/AUX port
4 Microphone
5 Front speakers
6 Rear tweeter
7 Antenna
8 Rear speaker
9 Audio system control unit
10 SYNC module
1/1
1323/2430
10/30/2018 Print
Information and Entertainment System - General Information -

Information and Entertainment System—Vehicles With: SYNC - System
Print
System Diagram
Item Description
2 GPS (global positioning system) module
3 DLC (data link connector) module
6 The ABS sensor
8 Sony control panel with phone equipment
9 audio unit
1/7
1324/2430
10/30/2018 Print
10 Speakers
11 Tweeters
12 SYNC module
13 USB (universal serial bus) port
14 Microphone
15 AUX jack
16 Antenna
17 Operating buttons for the speed control system
18 Audio and telephone operating buttons
System Operation
Overview of multifunction display and operating controls - audio unit
Item Description
1 Level 2 multi-function display
2 Control panel without phone equipment
4 Control panel with phone equipment
6 Sony control panel with phone equipment
The level 2 multifunction display is available with AUX and DAB or AUX and USB.
The level 3 and level 4 multifunction displays are available with SYNC, USB, AUX and GPS module.
Both variants are available with or without DAB.
The reversing camera is available as an option with the level 4 multifunction display.
Overview of audio units
2/7
1325/2430
10/30/2018 Print
Item Description
1 Audio unit with two antenna connections
2 Audio unit with antenna connection
3 Audio unit with antenna connection and USB port
6 different audio units are used in total.
Audio units:
Low equipment level:
- Audio unit with antenna connection and USB port.
- Audio unit with antenna connection and DAB. The AUX port is located in the floor console.
Middle equipment level:
- Audio unit with antenna connection. The USB and AUX port is located in the floor console and is
linked with SYNC.
- Audio unit with antenna connection and DAB. The USB and AUX port is located in the floor console
and is linked with SYNC.
High equipment level (optional):
- Audio unit with two antenna connections. The USB and AUX port is located in the floor console and
is linked with SYNC.
- Audio unit with two antenna connections and DAB. The USB and AUX port is located in the floor
console and is linked with SYNC.
Speakers
The following speakers are available:

6 speakers (low equipment level)
- 2 front speakers
- 2 rear speakers
- 2 front tweeters
8 speakers (high equipment level)
- 2 front speakers
- 2 rear speakers
- 2 front tweeters
- 2 rear tweeters
SYNC module
3/7
1326/2430
10/30/2018 Print
Item Description
2 audio unit
3 Sony audio unit controls
4 SYNC module
The SYNC – module from Microsoft® is installed instead of the communications module.
The SYNC module is located under the glove compartment.
SYNC is available with:

the level 3 multifunction display,
the level 4 multifunction display.
Comparison of the SYNC module and the communication module:
MEDIA PLAYER
SYNC Communication module

iPod streaming with USB iPod control
Bluetooth audio streaming Bluetooth audio streaming
USB USB
USB: Browse folder structure and database structure USB: Browse folder structure
Skip Skip
Seek (without radio) Seek (with radio)
Start of first track Start of current track
Lists displayed in letter groups (ABC, DEF, etc.)
BLUETOOTH CONNECTION

Connection with 12 phones possible Connection with 6 phones possible
Connection with current phone Connection with last registered phone
Manual logout Automatic logout
TELEPHONE.

Phonebook is downloaded Phonebook is downloaded
Phonebook is saved and updated if required Phonebook is downloaded again every
time
4/7
1327/2430
10/30/2018 Print

Phonebook browsing by list (A-C, D-F, etc.) Phonebook browsing by initial letters
Internal call history
Signal strength, provider name, battery status and contact Signal strength and provider name
status
Conference calls
Microphone mute Microphone mute
Read out SMS messages and send standard text
BLUETOOTH AUDIO STREAMING

Play/Pause Play/Pause
Skip Skip
Seek Seek
Additional MP3 information
Repeat
VOICE CONTROL

Phone control Phone control
Music control Music control
Music search
Direct music and phonebook selection
4 languages per module 1 language per module
Supports 9 languages Supports 7 languages
11 languages in text display 11 languages in text display
CD control
A/C control
Radio control
The following languages are supported by the SYNC module voice control feature:
English
French
Spanish
Portuguese
German
Italian
Turkish
Dutch
Russian
Polish and Swedish can only be read in the text display.

The SYNC module is delivered with 4 languages depending on the market. The language packages
cannot be changed.
In addition, the SYNC module is equipped with an emergency call function.
Der Notrufassistent steht in 30 Ländern, außer den Niederlanden, zur Verfügung.
SYNC module calling emergency services
5/7
1328/2430
10/30/2018 Print
Item Description
1 Accident
2 GPS information
3 Emergency call trigger
4 Emergency control center
5 Emergency service
On very quiet roads, accidents may be discovered a long time after they occur. For seriously injured
or unconscious accident victims who cannot make an emergency call, assistance sometimes arrives
too late because of this.
But even if there are witnesses or the occupants of the vehicle are able to call the emergency services
themselves from a cellular phone, they are often unable to state their exact position. The rescue can
also be delayed through this.
An emergency call is triggered after an accident when the airbags are released or the fuel supply is
interrupted.
The function has been developed in conjunction with SYNC to ensure rapid assistance after road
traffic accidents.
To do this, a cellular phone connected via Bluetooth must be in the vehicle.
The system is based on satellites and sends important information to the emergency control center in
case of an accident.
The emergency call is triggered by the RCM (restraints control module). The data is transmitted via
the HS-CAN (controller area network) to the SYNC module.
Vehicle occupants are able to cancel the emergency call by pressing the telephone button on the
audio system control panel or on the steering wheel within 10 seconds.
SYNC uses the emergency number '112' - which works across Europe - to establish a voice connection
to the responsible emergency control center.
As soon as the connection is established, a voice message is played, providing information about the
accident and the current position. The voice message is played in the language of the relevant
country or region, according to the vehicle location. This is independent of the languages supported in
the module.
The connection is then opened up for normal voice communication between the occupants and the
control center.
Even if the vehicle occupants are unconscious or cannot provide specific details for other reasons, the
emergency services can be deployed to the scene of the accident.
6/7
1329/2430
10/30/2018 Print
This function depends on the vehicle electrical system. If the battery voltage fails, no emergency call
is made.
A manual emergency call can be made as normal by speech input or pressing '112' on the keypad.
7/7
1330/2430
10/30/2018 Print
Information and Entertainment System - Audio System - Component

Location
Print
Instrument panel antenna cable
Item Description
1 Antenna cable integrated in instrument panel wiring harness
2 Multifunction display antenna plug
3 Audio unit antenna plug
4 Antenna plug for passenger compartment wiring harness
Instrument panel USB (universal serial bus) cable
1/10
1331/2430
10/30/2018 Print
Item Description
1 USB cable integrated in instrument panel wiring harness
2 Glove compartment USB connection
3 Communication module USB plug
4 USB plug for floor console wiring harness
Floor console USB cable
2/10
1332/2430
10/30/2018 Print
Item Description
1 USB cable integrated in floor console wiring harness
2 USB plug for instrument panel wiring harness
3 Media connection USB plug
4-door model antenna cable
Item Description
1 Antenna cable integrated in passenger compartment wiring harness
2 Antenna plug for instrument panel wiring harness
3/10
1333/2430
10/30/2018 Print
Item Description
1 FM1/AM antenna
2 GPS antenna
4/10
1334/2430
10/30/2018 Print
Item Description
1 FM2 antenna
2 Antenna amplifier
3 Frequency block
5-door model antenna cable
5/10
1335/2430
10/30/2018 Print
Item Description
6/10
1336/2430
10/30/2018 Print
Item Description
1 FM1/AM antenna
2 GPS antenna
3 FM2 antenna
4 Antenna amplifier
5 Frequency block
Wagon antenna cable
7/10
1337/2430
10/30/2018 Print
Item Description
8/10
1338/2430
10/30/2018 Print
Item Description
1 FM1/AM antenna
2 GPS antenna
9/10
1339/2430
10/30/2018 Print
Item Description
1 Antenna amplifier
2 FM2 antenna
10/10
1340/2430
10/30/2018 Print
Information and Entertainment System - Audio

System - Overview
Print
Passenger compartment antenna cable

The antenna cable between the antenna and the plugs for the instrument panel wiring harness (below
the climate control housing) are integrated in the passenger compartment wiring harness for the first
time. If an antenna cable fails, the plugs for the cable to be renewed must be cut off and the new
cable attached to the passenger compartment wiring harness with cable ties. To do this, the
passenger compartment wiring harness must be exposed in the corresponding areas.
Instrument panel antenna cable
The same applies to the antenna cables integrated into the instrument panel wiring hardness. Here
too, if an antenna cable fails, the plugs for the cable to be renewed must be cut off and the new cable
attached to the instrument panel wiring harness with cable ties. To do this, the instrument panel must
be removed to gain access to the instrument panel wiring harness.
USB (universal serial bus) cable
The same repair method is used for the USB cables integrated in the instrument panel wiring harness.
Here, if a USB cable fails, the plugs for the cable to be renewed must be cut off and the new cable
attached to the instrument panel wiring harness with cable ties. To do this, the instrument panel must
be removed to gain access to the instrument panel wiring harness.
If a USB cable integrated into the floor console wiring harness fails, the plugs for the cable to be
renewed must also be cut off and the new cable attached to the floor console wiring harness with
cable ties. To do this, the floor console must be removed to access the floor console wiring harness.
1/1
1341/2430
10/30/2018 Print
Information and Entertainment System - Audio

Unit
Print
Removal
1.
2.
3.
1/2
1342/2430
10/30/2018 Print
Installation
2/2
1343/2430
10/30/2018 Print
Information and Entertainment System - Front

Controls Interface Module (FCIM)—Vehicles
Without: Sony Audio System
Print
Removal
1.
2.
Installation
1/1
1344/2430
10/30/2018 Print

Controls Interface Module (FCIM)—Vehicles
With: Sony Audio System
Print
Removal
1.
2.
Installation
1/1
1345/2430
10/30/2018 Print

Control/Display Interface Module (FCDIM)—
Vehicles Without: Sony Audio System
Print
Removal
2.
Installation

Remove the display protection film.
1/1
1346/2430
10/30/2018 Print

Control/Display Interface Module (FCDIM)—
Vehicles With: Sony Audio System
Print
Removal
2.
Installation
1/1
1347/2430
10/30/2018 Print
Information and Entertainment System - Audio Unit Antenna—5-Door

Print
Removal
1. On both sides.
Refer to: D-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2.
3.
Installation

1/2
1348/2430
10/30/2018 Print
2/2
1349/2430
10/30/2018 Print
Information and Entertainment System - Audio Unit Antenna Amplifier—

5-Door
Print
Removal
1.
2.
Installation
1/1
1350/2430
10/30/2018 Print
Information and Entertainment System - Noise Suppression Filter—5-

Door
Print
Removal
1.
2.
3.
1/3
1351/2430
10/30/2018 Print
4.
5.
2/3
1352/2430
10/30/2018 Print
Installation
3/3
1353/2430
10/30/2018 Print
Information and Entertainment System -

Navigation System Module—Vehicles Without:
Active City Stop
Print
Removal
1.
2.
Installation
1/1
1354/2430
10/30/2018 Print
Information and Entertainment System - Navigation System Module—

Vehicles With: Active City Stop
Print
Removal
2.
Installation
1/1
1355/2430
10/30/2018 Print
Information and Entertainment System - Speech Recognition Module

(SPRM)
Print
Removal
1. Refer to: Climate Control Assembly - Vehicles Without: Center Armrest (412-01 Climate Control,
Refer to: Climate Control Assembly - Vehicles With: Center Armrest (412-01 Climate Control,
2.
Installation
1/1
1356/2430
10/30/2018 Print

Cellular Phone Microphone—Vehicles Without:
Overhead Console
Print
Special Tool(s)
501-125
Removal
2.
Installation
1/1
1357/2430
10/30/2018 Print
Information and Entertainment System - Cellular Phone Microphone—

Vehicles With: Overhead Console
Print
Special Tool(s)
501-125
Removal
2.
Installation
1/1
1358/2430
10/30/2018 Print
Information and Entertainment System - Auxiliary (AUX) Audio Input

Socket
Print
Removal
1.
2.
Installation
1/1
1359/2430
10/30/2018 Print
Information and Entertainment System - Media Hub

Print
Removal
1.
2.
Installation
1/1
1360/2430
10/30/2018 Print

Subwoofer Speaker
Print
Removal
1.
2.
Installation
1/1
1361/2430
10/30/2018 Print
Information and Entertainment System - Instrument Panel Center

Speaker
Print
Removal
1. NOTICE: Take extra care not to damage the edges of the component.
2.
Installation
1/1
1362/2430
10/30/2018 Print
Exterior Lighting - Specifications

Print
HEADLAMP ADJUSTMENT SETTING
TYPE ADJUSTMENT UNLADEN ADJUSTMENT LADEN
Halogen Headlamp X = 120 mm/10 m = X = 100 mm/10 m = 1%

1.20%
HID Headlamp X = 120 mm/10 m = X = 100 mm/10 m = 1%

1.20%
FRONT FOG LAMP ADJUSTMENT SETTING
TYPE ADJUSTMENT UNLADEN ADJUSTMENT LADEN
Front fog lamp N/A X = 150 mm/10 m = 1.5%
Unladen conditions: Maximum amount of petrol is 5 litre.

Laden conditions: At least 90% filled fuel tank and one person or 75KG on the drivers seat.
1/1
1363/2430
10/30/2018 Print
Exterior Lighting - Exterior Lighting - Overview

Print
Automatic main beam

The automatic main beam system uses a camera located at the windshield to detect light sources in
the vicinity and, depending on the traffic conditions, switches the main beam on and off.
On country roads and in wooded areas in particular, every extra meter of additional visual range
increases the chance of recognizing pedestrians, animals or obstructions in good time.
The main beam is switched off again when there are vehicles driving in front or coming in the
opposite direction, as well as when the light conditions are sufficient.
General
Two different types of headlamp are available:

Gas discharge headlamps with LED (light emitting diode)-DRL (daytime running lamps) and
adaptive front light
Conventional headlamps with free-form reflectors
The automatic headlamp and switch-off delay functions are available for all versions.
The light switch design has changed, but it is still actuated in the same way.
The rear lamps are available in two different versions:

Rear lamps without LED
Rear lamps with LED (optional)
The rear lamps of the Wagon are a two-part design.

As on the C-MAX, the coming home/leaving home lighting function can be activated in the
instrument cluster. You can select times of 20, 40 or 60 seconds.
The position lights are switched on when the vehicle is unlocked and when the driver's door is
opened at the end of a journey.
1/1
1364/2430
10/30/2018 Print
Exterior Lighting - Exterior Lighting - System Operation and Component

Description
Print
System Operation
Automatic main beam
Automatic main beam is active at speeds of about 40 km/h and more.

The main beam can be activated automatically inside and outside towns.
This depends on the individual light sources.
It is dipped as soon as the front camera recognizes oncoming traffic, other vehicles driving in front or
sufficient street lighting.
To do this, the system analyses the brightness and color temperature of the light source so as to
emulate an approximately human main beam switching behavior. It is designed so that road users in
a range up to about 800 meters will be recognized.
The main beam will be dipped in the following situations:

When vehicles (including motorcycles) approach from the opposite direction, the system recognizes
the dipped or main beam of the oncoming vehicle.
For vehicles driving in front in the same direction, the automatic main beam system recognizes the
red tail lamp.
In built-up areas, where the sources of light are sufficient.
At low speeds, when driving with main beam does not bring a safety advantage.
Automatic main beam does not require any additional switches or controls. It is activated through the
light control unit when the rotary switch is set to automatic lights.
Automatic headlamps are therefore required for the system.
Automatic main beam can be manually overridden at any time with the usual 'dipped beam function'.
The headlamp flasher can also be used as usual.
This may then be necessary if the driver sees another vehicle approaching from the side before the
front camera detects it.
The system is only intended as an aid for the driver.
Certain weather conditions may cause a reduced performance of the system.
The automatic main beam can be enabled or disabled in the instrument cluster.
The component overview is given in Section 413-09 – Warning Devices.
Lighting switch
1/4
1365/2430
10/30/2018 Print
Item Description
1 Front fog lamps
2 Side lamps, low beams, autolamps
3 Instrument lighting dimmer
4 Headlamp levelling control
5 Rear fog lamp
The light switch is equipped with electronic control and is connected to the BCM (body control
module) via LIN (local interconnect network).
Headlamp
Item Description
1 Side light/ LED (light emitting diode)-DRL (daytime running lamps)
2 main beam
3 Adaptive front light
4 Turn signal lamp
5 dipped beam
A Gas discharge headlamps with LED-DRL
B Conventional headlamps with free-form reflectors
The LED strip consists of 2 x 3 LEDs. The electronics are incorporated into the strip.
The brightness of the side light and the DRL is controlled exclusively by means of PWM (pulse width
modulation).
The DRL has its own cable.
The headlamps can only be replaced as a complete unit. Individual components are not available.
2/4
1366/2430
10/30/2018 Print
The reflectors of the gas discharge headlamps are designed so that the headlamps do not need to be
adapted to the various national traffic conditions (driving on the left/right) when touring.
Rear lamps without LED
Item Description
1 Stoplamp
2 Turn signal lamp
3 Side lamp/rear fog lamp
4 Backup Lamp
A Rear lamp, 5-door model
B Rear lamp, Wagon
Rear lamps with LED (optional)
Item Description
1 Stoplamp
2 Turn signal lamp
3/4
1367/2430
10/30/2018 Print
3 LED side light

4 Rear fog lamp
5 Backup Lamp
A Rear lamp, 5-door model
B Rear lamp, Wagon
The rear lamps with LED are available for the 5-door model and the Wagon.
Bulb monitoring
The current flow of the bulbs is measured by the BCM for this. If a bulb is defective, no current flows.
This is detected by the BCM and then transmitted to the instrument cluster as a CAN (controller area
network) message.
The following bulbs are monitored:

Stoplamp
Low beam
Rear fog lamp
PWM control
At a voltage of over 13.0 V, certain bulbs are actuated with the aid of PWM signals. This limits the
effective bulb voltage and reduces bulb wear.
When the voltage drops below 13.0 V, the bulbs are operated with the normal voltage once more.
The following bulbs are actuated with the aid of PWM signals:
dipped beam
Side lamps
Stoplamp
Rear fog lamp
Daytime running lights
If the customer wishes to have the daytime running lights on a vehicle with conventional headlamps
with free-form reflectors activated in the aftermarket, the menu item in the central vehicle
configuration needs to be changed.
Autolamps
The automatic headlamps have been enhanced.
Once the rain sensor has activated the wipers, the dipped beams will be switched on after 10 seconds
if the light switch is in the Automatic position.
This function is controlled via the rain sensor module.
If the driver switches the wipers to level 1 or 2 manually, the wipers are switched on after 10
seconds.
In this case, the BCM is responsible for actuation.
This function makes the vehicle more readily visible. It can be activated and deactivated in the
instrument cluster.
4/4
1368/2430
10/30/2018 Print
Exterior Lighting - Autolamps

Print

General Equipment

NOTE: Before retrieving the vehicle-specific data make sure that all electrical connections in the
vehicle are reconnected so that the module and the Ford diagnostic equipment can communicate
correctly.
NOTE: If a new generic electronic module (GEM) is being installed, the new module must be
configured following installation. For this purpose, the vehicle-specific data is retrieved from the
module to be changed using the Ford diagnostic equipment and is transferred to the new module.
2. Visually check for any obvious mechanical or electrical damage.
VISUAL INSPECTION
CHECK the windshield for damage/cracks in Fuse(s)
the vicinity of the rain sensor. Lamp(s)
CHECK that the rain sensor retaining frame is Connector(s)
correctly attached to the windshield. Switches
Wiring harness
1/1
1369/2430
10/30/2018 Print
Exterior Lighting - Fog Lamps

Print

General Equipment

correctly.
VISUAL INSPECTION
Electrical
Fuse(s)
Relay(s)
Wiring harness
Bulb(s)
Switch
Lamp(s)
1/1
1370/2430
10/30/2018 Print
Exterior Lighting - Headlamp Leveling

Print

General Equipment
VISUAL INSPECTION
Electrical
Fuse(s)
Relay(s)
Wiring harness
Switch
1/1
1371/2430
10/30/2018 Print
Exterior Lighting - Headlamps

Print

General Equipment

correctly.
NOTE: If a new body control module (BCM) is being installed, the new module must be configured
following installation. For this purpose, the vehicle-specific data is retrieved from the module to be
changed using the Ford diagnostic equipment and is transferred to the new module.
VISUAL INSPECTION
Damage/cracks in the vicinity of the rain Fuse(s)
sensor Relay(s)
Rain sensor retaining frame Wiring harness
Bulb(s)
Switch(es)
Lamp(s)
Rain sensor
Body control module (BCM)
1/1
1372/2430
10/30/2018 Print
Exterior Lighting - Parking, Rear and License

Plate Lamps
Print

General Equipment

correctly.
Electrical
Fuse(s)
Relay(s)
Wiring harness
Bulb(s)
Switch(es)
Lamp(s)
1/1
1373/2430
10/30/2018 Print
Exterior Lighting - Reversing Lamps

Print

Inspection and Varification
correctly.
VISUAL INSPECTION
Electrical
Fuse(s)
Relay(s)
Wiring harness
Bulb(s)
Switch
Lamp(s)
1/1
1374/2430
10/30/2018 Print
Exterior Lighting - Stoplamps

Print

General Equipment

correctly.
2. Visually inspect for obvious signs of electrical or mechanical damage.
VISUAL INSPECTION
Stop lamp switch adjustment Fuse(s)
Relay(s)
Wiring harness
Bulb(s)
Switch(es)
Lamp(s)
1/1
1375/2430
10/30/2018 Print
Exterior Lighting - Trailer Lamps

Print

General Equipment

correctly.
Electrical
Fuse(s)
Lamp(s)
Switch(es)
Wiring harness
1/1
1376/2430
10/30/2018 Print
Exterior Lighting - Turn Signal and Hazard

Lamps
Print

General Equipment

correctly.
VISUAL INSPECTION
Electrical
Fuse(s)
Relay(s)
Wiring harness
Bulb(s)
Switch(es)
Lamp(s)
1/1
1377/2430
10/30/2018 Print
Exterior Lighting - Front Fog Lamp Adjustment

Print
General Procedures
General Equipment
Headlamp Beam Setter
Adjustment
2.
3. NOTE: Make sure that the tire pressures are to specification and that the vehicle is
unladen, maximum amount of petrol is 5 litre.
Alternative the adjustment can be carried out at prescribed tire pressure, a completely filled
fuel tank and one person or 75kg on the driver seat.
4. Place the vehicle on a level surface.

Ensure that the adjustment is made with the suspension set up.
5. NOTE: Always follow the manufacturer's instructions when handling the equipment.
Switch on the front fog lamps.
6. Set the measuring screen of the beam setting equipment to the correct front fog lamp adjustment
setting.
Refer to: Specifications (417-01 Exterior Lighting, Specifications).

Use the General Equipment: Headlamp Beam Setter
7. Adjust the front fog lamps so that the cut-off line touches the horizontal line.
1/2
1378/2430
10/30/2018 Print
2/2
1379/2430
10/30/2018 Print
Exterior Lighting - Headlamp Adjustment

Print
General Procedures
General Equipment
Headlamp Beam Setter
All Vehicles
1. NOTE: Make sure that the tire pressures are to specification and that the vehicle is unladen.
NOTE: Only use a damp cloth to clean the headlamp lens to avoid any electrostatic charging.
Ensure that the adjustment is made with the suspension set up.
2. Place the vehicle on a level surface.
Vehicles with conventional headlamps

3. Repeatedly operate the headlamp leveling switch and then set it to "0".
Vehicles with adaptive front lighting

4. Use the diagnostic tool to make certain that the front wheels are in the straight ahead position.
Vehicles with gas discharge headlamps

5. Calibrate the headlamp leveling system using the diagnostic tool.
All Vehicles
6. NOTE: Always follow the manufacturer's instructions when handling the equipment.
Set the measuring screen of the beam setting equipment to the correct headlamp adjustment
setting.
Refer to: Specifications (417-01 Exterior Lighting, Specifications).

Use the General Equipment: Headlamp Beam Setter
7. Switch on dipped beam.
8. Adjust the dipped beams so that the light/dark boundary touches the horizontal line.
9. NOTE: It is acceptable for a stray portion of the low beam to cross the 15° line.
1/2
1380/2430
10/30/2018 Print
Adjust the headlamps so that the rising line of the boundary line lies at the intersection of
horizontal line and the 15 degree line (left-hand drive vehicle shown).
2/2
1381/2430
10/30/2018 Print
Exterior Lighting - Headlamp Masking

Print
General Procedures
Adjustment
Vehicles with conventional headlamps
1.
Vehicles with high intensity discharge headlamps
2. Refer to: Exterior Lighting (417-01 Exterior Lighting, Description and Operation).
1/1
1382/2430
10/30/2018 Print
Exterior Lighting - Trailer Module (TRM)—5-Door

Print
Removal
1. Refer to: Loadspace Trim Panel LH - 5-Door (501-05 Interior Trim and Ornamentation, Removal
and Installation).
2.
Installation
1/1
1383/2430
10/30/2018 Print
Exterior Lighting - Stoplamp Switch

Print
Removal
Installation
1/1
1384/2430
10/30/2018 Print
Exterior Lighting - Headlamp Switch

Print
Removal
1.
2.
3.
Installation
1/1
1385/2430
10/30/2018 Print
Exterior Lighting - Headlamp Assembly

Print
Removal
1. Remove the screws.
Position the headlamp assembly up and disconnect the electrical connector.
Installation
1. NOTICE: Take extra care when installing the headlamp assembly as the fixings are easily
damaged.

Refer to: Headlamp Adjustment (417-01 Exterior Lighting, General Procedures).
1/1
1386/2430
10/30/2018 Print
Exterior Lighting - Headlamp Bulb—Vehicles With: High Intensity

Discharge Headlamps
Print
Removal
2. Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
3.
4.
1/3
1387/2430
10/30/2018 Print
Vehicles Built From: 12-09-2016

5.
All vehicles
6.
2/3
1388/2430
10/30/2018 Print
Installation
3/3
1389/2430
10/30/2018 Print
Exterior Lighting - Rear Lamp Assembly—5-Door

Print
Removal
1. Remove the rear lamp access panel.
2. Remove the plastic nuts.
3. Position the rear lamp assembly, disconnect the electrical connector and remove the rear
lamp assembly.
Installation

1/2
1390/2430
10/30/2018 Print
2/2
1391/2430
10/30/2018 Print
Exterior Lighting - Front Fog Lamp

Print
Special Tool(s)
501-125
Removal
2. If equipped.
3.
4.
1/3
1392/2430
10/30/2018 Print
6.
Installation
2/3
1393/2430
10/30/2018 Print
3/3
1394/2430
10/30/2018 Print
Exterior Lighting - High Mounted Stoplamp—5-Door

Print
Removal
2. Remove the high mounted stoplamp.
Remove the screws.
Torque: 1 Nm
Position the high mounted stoplamp and disconnect the electrical connector.
Installation
1/1
1395/2430
10/30/2018 Print
Exterior Lighting - Ballast

Print
Removal
1. Refer to: Headlamp Assembly (417-01, Removal and Installation).
2.
3.
Installation
1/1
1396/2430
10/30/2018 Print
Interior Lighting - Interior Lighting - System Operation and Component

Description
Print
System Operation
Overview of LED (light emitting diode)s
Item Description
1 LED – overhead console
2 LED – door handle
3 LED – cup holder
4 LED – map compartment
5 LED – footwell lighting
6 Switch unit - ambient lighting
Nine LEDs can change color.
The driver can choose from 7 different colors for the ambient lighting.
The following colors are available:

purple
Green
ice blue
white
true blue
Orange
true red
1/2
1397/2430
10/30/2018 Print
Each LED has its own ID.
Because of the different IDs, it is important to ensure that they are installed in the correct position.
If an LED is installed in the wrong position, it will not work.
Switch unit - ambient lighting
Item Description
1 Window sun shield controls
2 Color change controls
3 Brightness setting, off to maximum
4 White LED – maximum brightness
5 Manually operated sunroof controls
6 PAD (passenger airbag deactivation) telltale
The switch unit is the master for the LEDs and at the same time is the slave for the BCM (body
control module).
It is connected to the BCM via the LIN (local interconnect network) bus.
When the ignition is switched off, the color of the ambient lighting is regulated via the vehicle. Once
the ignition is switched on, the ambient lighting is changed to the color set by the driver.
If the driver opens a door, the color of the door handle's LED changes to red.
2/2
1398/2430
10/30/2018 Print
Interior Lighting - Interior Lighting

Print

General Equipment

VISUAL INSPECTION
Electrical
Fuse(s)
Transportation fuse pack
Wiring harness
Bulb(s)
Switch(es)
Lamp(s)
Door latch(es)
1/1
1399/2430
10/30/2018 Print
Module Communications Network - Communications Network - System

Print
System Diagram
Item Description
A DLC (data link connector)
B MS-CAN (controller area network) bus
C HS-CAN bus
D HS-CAN multimedia bus
E private MS-CAN bus
F private HS-CAN
G private HS-CAN
H LIN (local interconnect network) bus
I Terminating resistors
J ISO bus
1/5
1400/2430
10/30/2018 Print
1 SYNC Generation II module (at later date)

2 Hands-free phone kit/Bluetooth®/voice control module
3 audio unit
4 Mini audio system control unit (at later date)
5 Multi-function display
6 Digital signal processor
7 GPS (global positioning system) module (at later date)
8 Audio system control unit
10 Fuel fired booster heater
11 Trailer Module
12 EATC (electronic automatic temperature control) module
13 Reversing camera module (at later date)
14 front PDM (passenger door module)
15 front DDM (driver door module)
16 keyless vehicle module
17 Reversing camera (at later date)
18 rear PDM
19 rear DDM
20 Front driver's side switch unit
21 radio receiver, keyless vehicle system
23 Light switch unit
24 Steering wheel module
25 Proximity warning radar unit
26 left-hand module, blind spot monitoring
27 right-hand module, blind spot monitoring
28 Intrusion sensors
29 Anti-theft alarm system horn with own battery
30 Ambient lighting switch unit
31 Electronic steering lock unit
32 Front camera module
33 Proximity warning module
34 Laser sensor module
35 RCM (restraints control module)
39 Voltage stabilizer
41 {Acronym.EPS} ({Acronym.EPS}) module
42 TCM (transmission control module)
43 Gas discharge headlamp module
45 Rain sensor
46 Wiper motor module
47 generator
2/5
1401/2430
10/30/2018 Print
48 Active radiator blind module

49 Gas discharge headlamp, left-hand side
50 Gas discharge headlamp, right-hand side
System Operation
Operation
Seven data bus systems are used:

HS-CAN bus
HS-CAN multimedia bus
Private HS-CAN bus
MS-CAN bus
Private MS-CAN bus
LIN bus
ISO bus
Two modules are designed as gateways:

the BCM between HS-CAN and MS-CAN.
the instrument cluster between MS-CAN and multimedia HS-CAN
Terminating resistors
A total of 12 terminating resistors are installed.
The two terminating resistors, 120 ohms each, of the HS-CAN data bus are integrated into the PCM
and the BCM. Since both 120 ohm resistors are connected in parallel, the total resistance is 60 ohms
(measured at the DLC). If a control unit is disconnected from the network, 120 ohms must be present
between pin 6 and 14 on the DLC.
The termination resistors of the HS-CAN multimedia system are in the instrument cluster and in the
audio unit.
The HS-CAN multimedia bus signals can be picked off via pins 1 and 8.
The RCM is connected with the module CAN via a private HS-ABS bus. Two separate termination
resistors are installed here.
Similarly, two resistors of the private HS-CAN bus are installed in the radar unit and in the proximity
warning module.
The MS-CAN terminating resistors are located in the instrument cluster and in the BCM. The total
resistance can be measured at the DLC between pins 3 and 11 and should be 60 ohms.
The resistors of the private MS-CAN are both in the BCM. The total resistance cannot therefore be
measured at the DLC.
HS CAN
The following HS-CAN networks are used:

HS-CAN bus:
- Front camera module
- Proximity warning module
- Laser sensor module
- RCM
- ABS module
- Steering wheel rotation sensor
- Parking Aid Module
- PCM
- {Acronym.EPS} module
- TCM
- Gas discharge headlamp module
- SYNC Generation II module (at later date)
- BCM
HS-CAN multimedia bus:
3/5
1402/2430
10/30/2018 Print

- Hands-free phone kit/Bluetooth®/voice control module
- audio unit
- Mini audio system control unit (at later date)
- Multi-function display
- Digital signal processor
- Instrument Cluster
Private HS-CAN bus:
- RCM
- ABS module
- Proximity warning module
- Proximity warning radar unit
The private HS-CAN is used for fast, interference-free data exchange.

The HS-CAN bus, the HS-CAN multimedia bus and the private HS-CAN bus have a speed of 500
kBit/s.
MS CAN
The following MS-CAN networks are used:

MS-CAN bus:
- BCM
- Instrument Cluster
- Fuel fired booster heater
- Trailer Module
- EATC module
- GPS module (at later date)
- Reversing camera module (at later date)
- front PDM
- front DDM
- keyless vehicle module
Private MS-CAN bus:
- left-hand module, blind spot monitoring
- right-hand module, blind spot monitoring
The MS-CAN bus and the private MS-CAN bus have a speed of 125 kBit/s.
LIN bus
The following systems are connected to the LIN bus:

Audio system control unit
Reversing camera (at later date)
rear PDM
rear DDM
Front driver's side switch unit
Light switch unit
Steering wheel module
Intrusion sensors
Anti-theft alarm system horn with own battery
Ambient lighting switch unit
Electronic steering lock unit
Voltage stabilizer
Battery monitoring sensor
Rain sensor
Wiper motor module
generator
Active radiator blind module
Gas discharge headlamp, left-hand side
Gas discharge headlamp, right-hand side
The transmission speed within the LIN databus system is 9.6 kBit/s. A LIN databus system consists of
a LIN master and one or more LIN slaves. The LIN master knows the time sequence of all data which
are to be transmitted.
4/5
1403/2430
10/30/2018 Print
This data is transferred by the corresponding LIN slaves when they are prompted by the LIN master.
The LIN bus is a single conductor databus system, i.e. the data is transmitted on one cable. No
termination resistors are used in the LIN network.
The keyless vehicle module is connected with the radio frequency receiver over an ISO bus.
5/5
1404/2430
10/30/2018 Print
Module Communications Network -

Communications Network
Print
General Equipment
VISUAL INSPECTION
Electrical
Fuse(s).
Wiring harness.
Electrical connectors.
1/1
1405/2430
10/30/2018 Print
Wiring Harnesses - Wiring Harness Repair

Print
General Procedures
General Equipment
Crimping Tool
Hot Air Gun
Wire Stripper
Wiring Harness Repair Kit
Disconnect
1. NOTE: Only use the Ford approved repair connectors available from the wiring harness repair
kit.
Use the General Equipment: Wiring Harness Repair Kit
2. WARNING: Do not repair or service restraint system component connector terminals. If

restraint system connector terminals or individual components are damaged, the complete
wiring loom must be replaced. Failure to follow this instruction may result in incorrect
operation of the vehicle safety restraint, which increases the risk of serious personal injury or
death in a crash.
NOTE: For twisted wire circuit repair, the twisting must not be disturbed for more than 5 cm.
Twist the repaired wires in the same direction and with the same general twist rate as the
original wiring. Re-apply the shielding on shielded circuits.
As far as necessary lay bare the wiring harness.
3. As far as necessary remove tape and protective sheathing.
4. NOTICE:
Note the position of each cable.
Avoid mix-up of wires: Cut the first wire and crimp the connection. Cut and crimp
additional wires one by one (finish each wire before starting with the next one)!
Staggered connections to 65mm for minimize harness diameter.
1/4
1406/2430
10/30/2018 Print
Connect
1. Remove the insulation at the cable ends of the single wires.
Use the General Equipment: Wire Stripper
2. Insert the stripped end of the wires into the crimp connector.
3. NOTE: When crimping the connector, make sure that the cross-section of the connector
matches that of the cable and the appropriate crimping chamber matching the wire size.
Use the General Equipment: Crimping Tool
2/4
1407/2430
10/30/2018 Print
4. NOTICE: Take extra care not to damage the wiring harnesses.

Heat the shrink sleeving of the crimp connector until the sleeving is tight on the connector and
sealant emerges from each end.
5. Check the function of the affected elektrical components.
6. Re-apply protective sheathing and tape.
3/4
1408/2430
10/30/2018 Print
4/4
1409/2430
10/30/2018 Print
Wiring Harnesses - Instrument Panel Wiring Harness

Print
Special Tool(s)
501-125
Removal
3.
4.
1/8
1410/2430
10/30/2018 Print
5.
6. On both sides.
7.
2/8
1411/2430
10/30/2018 Print
8. Torque: 9 Nm
9. Torque: 9 Nm
10.
3/8
1412/2430
10/30/2018 Print
11. Torque: 9 Nm
12. Torque: 9 Nm
All vehicles
13.
14.
4/8
1413/2430
10/30/2018 Print
15.
16.
5/8
1414/2430
10/30/2018 Print
17.
18.
6/8
1415/2430
10/30/2018 Print
19.
20.
7/8
1416/2430
10/30/2018 Print
Installation
2. Refer to: Selector Lever Cable Adjustment (307-05, General Procedures).
8/8
1417/2430
10/30/2018 Print
Wiring Harnesses - Passenger Compartment Wiring Harness—5-Door

Print
Special Tool(s)
501-125
Removal
1. Refer to: Fuel Tank (310-01 Fuel Tank and Lines - 1.6L Duratec-16V Ti-VCT (77kW/105PS) -
Sigma/1.6L Duratec-16V Ti-VCT (92kW/125PS) - Sigma/1.6L Duratec-16V Ti-VCT Flex Fuel
(88kW/120PS) - Sigma/1.6L EcoBoost (110kW/150PS) - Sigma/1.6L EcoBoost (132kW/180PS) -
Sigma/2.0L Duratec-HE (110kW/150PS) - MI4/2.0L Duratec-HE (125kW/170PS) - MI4/2.0L
EcoBoost (184kW/250PS) - MI4, Removal and Installation).
Refer to: Fuel Tank (310-01D Fuel Tank and Lines, Removal and Installation).
2.
3.
4.
5.
1/22
1418/2430
10/30/2018 Print
6. Refer to: Floor Covering - 5-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
7.
8.
9.
2/22
1419/2430
10/30/2018 Print
10.
11.
3/22
1420/2430
10/30/2018 Print
12.
13. On both sides.
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
14. On both sides.
4/22
1421/2430
10/30/2018 Print
15.
16.
Vehicles without proximity warning camera

17. If equipped.
5/22
1422/2430
10/30/2018 Print
18. If equipped.
Vehicles with proximity warning camera

19.
6/22
1423/2430
10/30/2018 Print
20.
Vehicles without overhead console

21.
7/22
1424/2430
10/30/2018 Print
Vehicles with overhead console
23.
8/22
1425/2430
10/30/2018 Print
24.
25. If equipped.
All vehicles
26.
27. On both sides.

9/22
1426/2430
10/30/2018 Print
28.
29.
10/22
1427/2430
10/30/2018 Print
30. 1. If equipped.
31. On both sides.
11/22
1428/2430
10/30/2018 Print
32. All.
33.
34.
12/22
1429/2430
10/30/2018 Print
35.
36.
13/22
1430/2430
10/30/2018 Print
37. NOTICE: Take extra care not to crease the headliner.
38. On both sides.
Refer to: Rear Lamp Assembly - 5-Door (417-01 Exterior Lighting, Removal and Installation).
39. On both sides.
14/22
1431/2430
10/30/2018 Print
40.
41.
42.
15/22
1432/2430
10/30/2018 Print
43.
44. Torque: 12 Nm
16/22
1433/2430
10/30/2018 Print
45.
1. Torque: 35 Nm
2.
3. Torque: 12 Nm
46.
17/22
1434/2430
10/30/2018 Print
47.
48. Torque: 12 Nm
18/22
1435/2430
10/30/2018 Print
49. Torque: 12 Nm
50.
19/22
1436/2430
10/30/2018 Print
51.
52.
1. Torque: 35 Nm
2.
3. Torque: 12 Nm
20/22
1437/2430
10/30/2018 Print
53. Torque: 12 Nm
54.
21/22
1438/2430
10/30/2018 Print
55.
Installation
22/22
1439/2430
10/30/2018 Print
Wiring Harnesses - Roof Panel Wiring Harness—5-Door, Vehicles With:

Panoramic Roof Panel
Print

501-125
Hot Glue Gun
Removal
1.
2.
3.
1/12
1440/2430
10/30/2018 Print
4.
5. On both sides.
6.
2/12
1441/2430
10/30/2018 Print
7.

8. If equipped.
3/12
1442/2430
10/30/2018 Print
9. If equipped.

10.
4/12
1443/2430
10/30/2018 Print
11.

12.
5/12
1444/2430
10/30/2018 Print
14.
6/12
1445/2430
10/30/2018 Print
15.
All vehicles
16. On both sides.
17. On both sides.
7/12
1446/2430
10/30/2018 Print
Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
18.
19.
1. On both sides.
Torque: 47 Nm
20. On both sides.
8/12
1447/2430
10/30/2018 Print
21. On both sides.
22. All.
23.
9/12
1448/2430
10/30/2018 Print
24.
25.
26.
10/12
1449/2430
10/30/2018 Print
27.

Use the General Equipment: Hot Glue Gun
11/12
1450/2430
10/30/2018 Print

Installation
12/12
1451/2430
10/30/2018 Print
Wiring Harnesses - Roof Panel Wiring Harness—5-Door, Vehicles With:

Metal Roof Panel
Print

501-125
Hot Glue Gun
Removal
1.
2.
3.
1/12
1452/2430
10/30/2018 Print
4.
5. On both sides.
6.
2/12
1453/2430
10/30/2018 Print
7.

8. If equipped.
3/12
1454/2430
10/30/2018 Print
9. If equipped.

10.
4/12
1455/2430
10/30/2018 Print
11.

12.
5/12
1456/2430
10/30/2018 Print
14.
6/12
1457/2430
10/30/2018 Print
15.
All vehicles
16. On both sides.
17. On both sides.
7/12
1458/2430
10/30/2018 Print
Installation).
18.
19.
1. On both sides.
Torque: 47 Nm
20. On both sides.
8/12
1459/2430
10/30/2018 Print
21. On both sides.
22. All.
23.
9/12
1460/2430
10/30/2018 Print
24.
25.
26.
10/12
1461/2430
10/30/2018 Print


11/12
1462/2430
10/30/2018 Print
Installation
12/12
1463/2430
10/30/2018 Print
Perimeter Anti-Theft Alarm - Perimeter Anti-

Theft Alarm - Overview
Print
The function of the anti-theft alarm system components can be checked using the GEM (generic
electronic module)'s service mode.
If an exact diagnosis is not possible using the service mode, a system diagnosis must be carried out
with the Ford diagnostic unit. The last four trigger signals from the anti-theft alarm signal can also be
read out during this process.
Function check - Intrusion sensors
Activate the anti-theft alarm system is check the function of the intrusion sensors. After a waiting
time of approx. 30 seconds, perform movements on both sides of the vehicle interior through the
open side windows. Each movement that is detected is acknowledged through triggering of the anti-
theft alarm system.
1/1
1464/2430
10/30/2018 Print
Perimeter Anti-Theft Alarm - Perimeter Anti-

Theft Alarm
Print

Refer to Wiring Diagrams Section 419-01A, for schematic and connector information.
General Equipment
Misaligned door(s), hood or liftgate Fuse(s)
Latch(es) Wiring harness
Cable(s) Electrical connector(s)
Switch(es) Relay(s)
Lock cylinder(s) Generic electronic module (GEM)
Linkage(s) Anti-theft alarm horn
Anti-theft alarm horn with integral battery (if
equipped)
1/1
1465/2430
10/30/2018 Print
Perimeter Anti-Theft Alarm - Anti-Theft Alarm Horn—5-Door

Print
Removal
1.
2.
3. Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
4.
1/2
1466/2430
10/30/2018 Print
5.
Installation
2/2
1467/2430
10/30/2018 Print
Passive Anti-Theft System (PATS) - Passive

Anti-Theft System (PATS) - Overview
Print
Programming the key

After exchanging the keyless vehicle module (KVM), all available keys must be reprogrammed using
the Ford diagnostic unit. Both the passive key and the emergency key must be reprogrammed.
In addition, the KVM must be initialized with the following modules using the Ford diagnostic unit:
PCM (powertrain control module)

Steering Lock Unit
If a new key has to be added, only this key must be programmed using the Ford diagnostic unit.
If a key is to be deleted, all keys must first be deleted and the remaining keys reprogrammed.
Up to 8 keys can be programmed.
Transceiver of passive anti-theft system (emergency start function)
Between the emergency key holder and the passive anti-theft system transceiver, there is a copper
ring that ensures the resonant frequency of the transceiver. If this copper ring is not in the correct
position, the function of the emergency key cannot be guaranteed.
1/1
1468/2430
10/30/2018 Print
Passive Anti-Theft System (PATS) - Passive

Anti-Theft System (PATS)
Print

General Equipment
Ignition lock cylinder Fuse(s)
Passive anti-theft system (PATS) ignition key Wiring harness(s)
(blue dot) Electrical connector(s)
Non-PATS ignition key Relay(s)
Use of a non-progammed PATS ignition key PATS transceiver
Use of a non-encoded PATS ignition key Ignition switch
More than one PATS key in close proximity of Powertrain control module (PCM)
the PATS transceiver Instrument cluster
4. If the cause is not visually evident, use Ford diagnostic equipment to retrieve any DTCs and
refer to the Diagnostic Trouble Code (DTC) Index.
DIAGNOSTIC TROUBLE CODE (DTC) INDEX
DTC Indicator Description/Condition Possible Source

Flash Code
0000 - No DTCs, vehicle OK -
B1681 11 PATS transceiver signal is not received PATS transceiver wiring,
PATS transceiver
connector, PATS
transceiver, PCM or
instrument cluster
B1232 and B2103 12 PATS transceiver antenna coil fault, vehicle PATS transceiver, PATS
does not start transceiver mounting
B1600 13 Non-PATS key or damaged encoded ignition PATS encoded ignition
key, or no key code received, vehicle does not key
start
B2431 13 PATS transponder programming failed crypto Ignition key
transponder only, vehicle does not start
B1602 14 Partial key read of PATS key, vehicle does not PATS encoded ignition
start key, PATS transceiver
B1601 15 Incorrect key code, Unprogrammed PATS key PATS encoded ignition
(keycode format OK), vehicle does not start key
(20 second anti-scan invoked)
U2510 16 CAN communication link between the PCM Circuit, PCM or
and instrument cluster, vehicle does not start instrument cluster
B1213 21 Number of programmed PATS encoded keys Incorrect number of keys
below minimum, vehicle does not start programmed or PATS
encoded ignition key
B2141 22 NVM Configuration failure. No security ID PCM or instrument
exchange between PCM and instrument cluster
cluster, vehicle does not start
1/2
1469/2430
10/30/2018 Print
DTC Indicator Description/Condition Possible Source

Flash Code
B2139 23 Data mismatch (received data does not match PCM or instrument
what was expected). Security messages do cluster
not match between PCM and instrument
cluster, vehicle does not start
P1260 - PCM disabled PCM or instrument
cluster
2/2
1470/2430
10/30/2018 Print
Multifunction Electronic Modules - Body

Control Module (BCM)
Print
General Equipment

NOTE: Diagnosis of the body control module (BCM) must be carried out using the Ford diagnostic
equipment.
VISUAL INSPECTION
Electrical
Fuse(s)
Electrical connectors
Circuit(s)
Wiring harness
BCM
1/1
1471/2430
10/30/2018 Print
Multifunction Electronic Modules - Body Control Module (BCM)

Print
General Equipment
Removal
1. NOTICE: Modules are not interchangeable between vehicles.

Download the module information to the diagnostic tool using the Programmable Modules
Installation routine.
Procedures).
3.
4.
1/2
1472/2430
10/30/2018 Print
Installation
2. NOTICE: Refer to the Wiring Diagram to ensure that only fuses with the correct ampere
ratings are used.
Compare the previous and the new unit fuses for number, position and ampere ratings.
Transfer missing fuses to the new unit.

Upload the module information from the diagnostic tool to the module using the Programmable
Modules Installation routine.
2/2
1473/2430
10/30/2018 Print
Multifunction Electronic Modules - Lighting Control Module (LCM)

Print
Removal
1.
2.
3.
1/2
1474/2430
10/30/2018 Print
Installation
2. Refer to: Headlamp Adjustment (417-01 Exterior Lighting, General Procedures).
2/2
1475/2430
10/30/2018 Print
Body System - General Information - Body - Overview

Print
General information
Item Description
A Combi
B 4-door version
C 5-door version
Notchback (4-door):
With this version, the line of the rear part of the body has several steps. In other words, a slanted
rear window is followed by a flat luggage compartment.
In contrast to a fastback or wagon, the luggage compartment is separate from the passenger
compartment on a notchback.
Fastback (5-door):
With this version, the rear part of the body is sloping.
1/2
1476/2430
10/30/2018 Print
The luggage compartment lid, including the rear window, can be opened, enabling convenient
access to the vehicle interior.
Combi:
The combi features an elongated roof line and a large tailgate.
Owing to the elongation of the roof line and the steep rear section, the combi has a larger interior
and a wider load floor.
Ultra-high-strength steels
Item Description
1 A-pillar external reinforcement
2 B-Pillar reinforcement
3 Rocker panel reinforcement
4 A-pillar internal reinforcement
The A and B-pillar reinforcements are made of ultra-high-strength manganese boron steel.
In addition, the rocker panel reinforcement is made from ultra-high-strength martensitic steel
(DOCOL 1400M, electrogalvanized).
NOTE: Note that these sheet metal parts can only be replaced as a complete unit during repairs and
that section repairs are not permitted. Special installation and removal requirements must be
observed during repairs. In addition, special tools are required. The instructions in the current
workshop literature must be observed for this !
2/2
1477/2430
10/30/2018 Print
Front End Body Panels - Active Grille Shutter - Component Location

Print
Item Description
1 Upper radiator shutter
2 Lower radiator shutter
3 Adjustment unit
4 Radiator shutter module
1/1
1478/2430
10/30/2018 Print
Front End Body Panels - Active Grille Shutter - Overview

Print
The primary task of this system is to minimize as much as possible the air flow through the
radiator and the engine compartment. This has a positive effect on the air resistance of the vehicle.
The air resistance is a parameter which affects the fuel consumption and with that also the exhaust
emissions of the vehicle, depending on the vehicle speed.
At a vehicle speed of 70 km/h or higher, it is best if the radiator blind is closed as far as possible.
Closed as much as possible means that the position of the slats must be set so that overheating is
prevented and the exhaust emissions are not adversely affected.
A further task of the system is to ensure that the warm-up phase of the engine is shortened.
The opening cross-section for the air flow to the radiator can be set between fully opened and fully
closed in multiple stages.
Components
Item Description
1 Adjustment unit
2 Upper blind (with three slats)
3 Active radiator blind module with integrated servo motor
4 Drive, radiator blind slats
5 Connector for the active radiator blind module
6 Lower blind (with four slats)
Radiator blinds
The system comprises an upper and a lower blind.

The slats of both blinds are connected to an adjusting unit. The slats of both blinds are therefore
opened and closed synchronously.
Module, active radiator blind
The module comprises:

a servo motor for adjusting the slats and
integrated electronics for controlling the servo motor.
The third slat from the bottom on the lower blind is connected via a gear to the servo motor.
1/2
1479/2430
10/30/2018 Print
2/2
1480/2430
10/30/2018 Print
Front End Body Panels - Active Grille Shutter - System Operation and
Print
System Diagram
Item Description
2 Module, active radiator blind
3 Cooling fan module
System Operation
The required position of the radiator blind is calculated by the PCM.
The PCM communicates with the active radiator blind module via the LIN (local interconnect network).
It sends the required position of the radiator blind over it. In addition, the PCM receives a feedback
signal on the position which has been set, as well as information on any malfunction.
Controlling the radiator blind
The target adjustment of the radiator blind is influenced by many parameters. However, the
position of the radiator shutter is adjusted on the basis of the following input variables:
Powertrain Control Module
A/C compressor refrigerant pressure
ambient air temperature
Intake Air Temperature
Vehicle speed
In general, the radiator shutter is fully open at low vehicle speeds.
Influence of the input variables and the conditions for control of the active radiator blind:
A/C compressor refrigerant pressure:
- Above a certain vehicle speed the radiator shutter starts to close continuously. At increased
refrigerant pressure is it opened between most of the way and fully open.
Coolant temperature:
- During normal driving with the engine under partial load, the coolant temperature does not rise so
high that full opening of the radiator blind is necessary. However, the shutter will open if the vehicle
is driven for an extended period of time at a speed which is too low and the engine temperature
starts to rise.
1/3
1481/2430
10/30/2018 Print
High load:
- If the vehicle is driven up a steep hill and the engine temperature rises, the radiator blind opens.
In addition, it opens when the vehicle is rapidly accelerating.
- When driving with a trailer the radiator shutter is always open. Driving with a trailer attached
is signaled via the trailer hitch socket.
Charge air temperature (vehicles with turbocharger and charge air cooler):
- The temperature of the charge air has an effect on the exhaust emissions. The radiator shutter is
opened if the charge air temperature starts to get near to its maximum permitted limit.
When the engine is stopped, the radiator blind is fully opened.

Initialization
After the ignition is switched off the radiator blind module is supplied with voltage by the PCM
through a relay.
Immediately after the engine is started, the radiator blind is fully closed once and then fully
opened again. In doing so, each of the end positions is determined and saved.
After the end positions have been successfully determined, various intermediate positions can now
also be set.
Effects of faults
Malfunctions at the active radiator blind will be recognized by the module during initialization.
Malfunctions may for example be:
The difference between fully open and fully closed is less than 70 degrees. The radiator blind cannot
be fully opened. The cause may for example be an obstructed radiator blind.
The difference between fully open and fully closed is greater than 110 degrees. The servo motor
runs past the end position. The cause may for instance be too much play in the adjustment unit.
If the PCM detects a malfunction while driving then a suspected fault is set initially in the PCM.
Due to the suspected fault, the PCM then performs one (or more depending on the variant)
initialization routine(s). In the process, the PCM attempts to fully open the radiator shutter and to
then close it again.
If the system detects no malfunction after the initialization then the suspected fault is deleted
again. The cause for a temporary fault could for example be a stone which has become lodged
between the slats while driving.
However, if the fault is confirmed after the initialization then the suspected fault is converted into a
confirmed fault. The PCM then sets a corresponding DTC (diagnostic trouble code), which can be
read out with the aid of IDS (Integrated Diagnostic System).
The driver is not given any indication that there is a malfunction of the radiator blind.
Under certain operating conditions however, a jammed radiator blind (radiator blind can no longer be
opened wide enough) may result in the engine temperature increasing excessively. This is recognized
via the ECT (engine coolant temperature) sensor. In response to this the engine output is
continuously reduced via an emergency running program and the radiator fan is switched on.
Module, active radiator blind
2/3
1482/2430
10/30/2018 Print
Item Description
1 Module with integrated servo motor
2 Drive, radiator blind slats
3 Electrical connection
For adjusting the slats, there is a stepper motor integrated into the active radiator blind module.
With every step, the slats of the blind are moved by 6 degrees. With a total opening angle of about
90 degrees, there will therefore be about 15 steps (depending on the component tolerances) from
fully closed to fully open.
NOTE: The module must not be disassembled during servicing. If the module or the stepper motor
develops a fault, the complete unit must be changed in each case.
3/3
1483/2430
10/30/2018 Print
Front End Body Panels - Cowl Panel Grille

Print
Removal
1. Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
2.
3.
Installation
1/1
1484/2430
10/30/2018 Print
Front End Body Panels - Active Grille Shutter

Print
Removal
2. If equipped.
3. If equipped.
4. If equipped.
1/3
1485/2430
10/30/2018 Print
5.
6. Torque: 25 Nm
7.
2/3
1486/2430
10/30/2018 Print
8.
Installation
3/3
1487/2430
10/30/2018 Print
Front End Body Panels - Fender Splash Shield

Print
Removal
2. If equipped.
3.
Installation
1/1
1488/2430
10/30/2018 Print
Front End Body Panels - Fender

Print
Removal
2.
5.
1/5
1489/2430
10/30/2018 Print
6.
7. Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and
Installation).
8.
2/5
1490/2430
10/30/2018 Print
9.
10.
11.
3/5
1491/2430
10/30/2018 Print
12.
13.
Installation
4/5
1492/2430
10/30/2018 Print
5/5
1493/2430
10/30/2018 Print
Front End Body Panels - Active Grille Shutter

Print
General Equipment
Disassembly
1.
2. NOTICE: Make sure to lift simultaneously.
1/3
1494/2430
10/30/2018 Print
4.
2/3
1495/2430
10/30/2018 Print
Assembly
3/3
1496/2430
10/30/2018 Print
Body Closures - Front Door Alignment

Print
General Procedures
Check
1. 1. 4.0 mm ± 1.5 mm
2. 4.5 mm ± 1.5 mm
3. 4.0 mm ± 1.5 mm
4. 5.3 mm ± 1.5 mm
5. 4.0 mm ± 1.5 mm
Adjustment
1.
2.
1/10
1497/2430
10/30/2018 Print
3. 1.
2.
4.
5.
2/10
1498/2430
10/30/2018 Print
6.
7. 1.
2.
3/10
1499/2430
10/30/2018 Print
10.
11.
4/10
1500/2430
10/30/2018 Print
12. Torque: 20 Nm
13. Torque: 35 Nm
14.
1. Torque: 35 Nm
5/10
1501/2430
10/30/2018 Print
15.
16.
1. Torque: 35 Nm
17.
6/10
1502/2430
10/30/2018 Print
18.
19.
Check
1.
1. 1.0 mm + 1.4 mm/– 1.0 mm
7/10
1503/2430
10/30/2018 Print
2. 2.5 mm ± 1.5 mm
3. 0 mm ± 1.5 mm
4. 0 mm + 1.0 mm/– 1.6 mm
5. 6.4 mm ± 1.5 mm
6. 8.2 mm ± 1.5 mm
7. 1 mm + 1.4 mm/– 1.0 mm
Adjustment
8/10
1504/2430
10/30/2018 Print
3.
4.
5. Torque: 20 Nm
9/10
1505/2430
10/30/2018 Print
6. Torque: 48 Nm
10/10
1506/2430
10/30/2018 Print
Body Closures - Front Door Edge Protector Adjustment

Print
General Procedures
Check
1. NOTICE: Make sure that the component moves freely between the end positions.
1/8
1507/2430
10/30/2018 Print
5.
2/8
1508/2430
10/30/2018 Print
6.
3/8
1509/2430
10/30/2018 Print
7.
8. Repeat the following steps until the component moves freely.
Adjustment
1.
4/8
1510/2430
10/30/2018 Print
2.
3.
5/8
1511/2430
10/30/2018 Print
4. Refer to: Front Door Trim Panel (501-05, Removal and Installation).
5.
1. Loosen:
screws 1 turn(s)
2. Adjust
3. Torque: 1.8 Nm
6. After operation check the alignment and correct if necessary.
7.
6/8
1512/2430
10/30/2018 Print
8.
9.
7/8
1513/2430
10/30/2018 Print
10. Refer to: Front Door Trim Panel (501-05, Removal and Installation).
8/8
1514/2430
10/30/2018 Print
Body Closures - Rear Door Alignment

Print
General Procedures
Check
1. 1. 4.5 mm ± 1.5 mm
2. 5.0 mm ± 1.5 mm
3. 3.8 mm ± 1.5 mm
4. 5.3 mm ± 1.5 mm
5. 4.0 mm ± 1.5 mm
Adjustment
1. Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
1/7
1515/2430
10/30/2018 Print
5.
2/7
1516/2430
10/30/2018 Print
6.
7. Torque: 20 Nm
8. Torque: 35 Nm
3/7
1517/2430
10/30/2018 Print
9. Torque: 35 Nm
Check
1. 1. 0.0 mm ± 1.5mm
2. 2.5 mm ± 1.5mm
3. 1.5 mm ± 1.5mm
4. 0.0 mm ± 1.0mm
5. 0.3 mm ± 1.0mm
6. 4.8 mm ± 1.5mm
7. 0.0 mm + 1.0 mm/
– 1.6 mm
4/7
1518/2430
10/30/2018 Print
Adjustment
5/7
1519/2430
10/30/2018 Print
3.
4.
5. Torque: 20 Nm
6. Torque: 48 Nm
6/7
1520/2430
10/30/2018 Print
7/7
1521/2430
10/30/2018 Print
Body Closures - Rear Door Edge Protector Adjustment

Print
General Procedures
Check
1/7
1522/2430
10/30/2018 Print
5.
2/7
1523/2430
10/30/2018 Print
6. Repeat the following steps until the component moves freely.
Adjustment
1.
3/7
1524/2430
10/30/2018 Print
2.
3.
4/7
1525/2430
10/30/2018 Print
4. Refer to: Rear Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
5.
1. Loosen:
screws 1 turn(s)
2. Adjust
3. Torque: 1.8 Nm
6. After operation check the alignment and correct if necessary.
Installation).
8.
5/7
1526/2430
10/30/2018 Print
9.
10.
6/7
1527/2430
10/30/2018 Print
7/7
1528/2430
10/30/2018 Print
Body Closures - Hood Alignment

Print
General Procedures
Check
1. 1. 3.5 mm ± 1.5 mm
2. 0.6 mm + 1.0 mm/
– 2.0 mm
3. 5.0 mm ± 1.5 mm
4. 2.4 mm ± 1.5 mm
5. 3.8 mm ± 1.5 mm
6. 3.5 mm ± 1.5 mm
7. 1.0 mm ± 2.0 mm
Adjustment
1. On both sides.
Loosen: 2 turn(s)
1/5
1529/2430
10/30/2018 Print
2.
3. On both sides.
Torque: 11 Nm
Check
1. + 1.0 mm/
1. 1.0 mm – 2.0 mm
2. 3.2 mm ± 1.5 mm
3. 3.2 mm ± 1.5 mm
4. 1.3 mm ± 1.5 mm
5. 6.0 mm ± 2.2 mm
2/5
1530/2430
10/30/2018 Print
Adjustment
2. On both sides.
Loosen: 2 turn(s)
3/5
1531/2430
10/30/2018 Print
3.
4.
5. On both sides.
Torque: 25 Nm
4/5
1532/2430
10/30/2018 Print
5/5
1533/2430
10/30/2018 Print
Body Closures - Liftgate Alignment

Print
General Procedures
Check
5-door
1. 1. 2.0 mm ± 1.5 mm
2. 0.7 mm ± 1.5 mm
3. 1.5 mm ± 2.0 mm
4. 4.3 mm ± 1.5 mm
5. 4.5 mm ± 1.4 mm
6. 4.0 mm ± 2.0 mm
7. 6.0 mm ± 2.0 mm
Wagon
2. 1. 2.0 mm ± 1.5 mm
2. 0.7 mm ± 1.5 mm
3. 1.5 mm ± 2.0 mm
4. 4.3 mm ± 1.5 mm
5. 4.5 mm ± 1.4 mm
6. 4.0 mm ± 2.0 mm
7. 6.0 mm ± 2.0 mm
1/17
1534/2430
10/30/2018 Print
Adjustment
5-door
2.
2/17
1535/2430
10/30/2018 Print
4.
5.
6. Torque: 11 Nm
3/17
1536/2430
10/30/2018 Print
7. Torque: 25 Nm
8.
Wagon
4/17
1537/2430
10/30/2018 Print
10.
12.
13.
14. Torque: 11 Nm
5/17
1538/2430
10/30/2018 Print
15. Torque: 25 Nm
16.
Check
5-door
1. 1. 6.0 mm ± 1.5 mm
2. 6.5 mm ± 1.5 mm
3. 4.0 mm ± 2.0 mm
4. 1.6 mm ± 1.5 mm
5. 4.0 mm ± 1.7 mm
6. 1.5 mm ± 1.4 mm
6/17
1539/2430
10/30/2018 Print
Wagon
2. 1. 7.1 mm ± 1.5 mm
2. 7.1 mm ± 1.5 mm
3. 4.0 mm ± 1.5 mm
4. 0 mm ± 1.4 mm
5. 0 mm ± 1.4 mm
6. 2.0 mm ± 1.5 mm
7/17
1540/2430
10/30/2018 Print
Adjustment
5-door
1.
8/17
1541/2430
10/30/2018 Print
3.
5. On both sides.
6. On both sides.
Loosen: 3 turn(s)
9/17
1542/2430
10/30/2018 Print
7.
8.
9. Torque: 30 Nm
10.
10/17
1543/2430
10/30/2018 Print
11. Torque: 25 Nm
12.
13. On both sides.
14. On both sides.
11/17
1544/2430
10/30/2018 Print
15. Carefully close the liftgate.
16. Torque: 4 Nm
17.
18.
12/17
1545/2430
10/30/2018 Print
Wagon
19.
21.
13/17
1546/2430
10/30/2018 Print
23. On both sides.
24. On both sides.
Loosen: 3 turn(s)
25.
26.
27. Torque: 30 Nm
14/17
1547/2430
10/30/2018 Print
28.
29. Torque: 25 Nm
30.
31. On both sides.
15/17
1548/2430
10/30/2018 Print
32. On both sides.
33. Carefully close the liftgate.
34. On both sides.
Torque: 4 Nm
35. On both sides.
16/17
1549/2430
10/30/2018 Print
36. On both sides.
17/17
1550/2430
10/30/2018 Print
Body Closures - Luggage Compartment Lid Alignment

Print
General Procedures
Check
1. Check the luggage compartment lid-to-body dimensions.
1. 4.5 mm ± 1.5 mm
2. 6.0 mm ± 1.5 mm
3. 1.3 mm ± 1.4 mm
4. 1.5 mm ± 1.4 mm
5. 1.5 mm ± 1.5 mm
6. 4.0 mm ± 2.1 mm
7. 3.5 mm ± 1.5 mm
8. 1.5 mm ± 1.4 mm
Adjustment
1.
1/7
1551/2430
10/30/2018 Print
3.
5.
2/7
1552/2430
10/30/2018 Print
6.
7. Torque: 30 Nm
8.
9. Torque: 25 Nm
3/7
1553/2430
10/30/2018 Print
10.
Check
1. Check the body-to-luggage compartment lid dimensions.
1. 0.8 mm ± 1.4 mm
2. 1.5 mm ± 1.4 mm
3. 4.0 mm ± 2.0 mm
4. 6.0 mm ± 2.0 mm
4/7
1554/2430
10/30/2018 Print
Adjustment
1. WARNING: Take extra care when handling the compressed spring.

On both sides.
2.
5/7
1555/2430
10/30/2018 Print
3.
4. On both sides.
Loosen: 2 turn(s)

Adjust the luggage compartment lid bracket.
6. On both sides.
Torque: 30 Nm
6/7
1556/2430
10/30/2018 Print
7. WARNING: Take extra care when handling the compressed spring.

On both sides.
8.
9.
7/7
1557/2430
10/30/2018 Print
Body Closures - Front Door

Print
General Equipment
Trolley Jack
Removal
1. Torque: 30 Nm
2.
3. NOTICE: Use suitable packing material to prevent damage to the component.

Torque: 30 Nm
1/2
1558/2430
10/30/2018 Print
Installation
2/2
1559/2430
10/30/2018 Print
Body Closures - Front Door Edge Protector

Print
Removal
1. NOTE: Make sure that the rubber is not damaged.
2. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
3.
4.
1/3
1560/2430
10/30/2018 Print
5.
6.
2/3
1561/2430
10/30/2018 Print
7.
Installation
Refer to: Front Door Edge Protector Adjustment (501-03 Body Closures, General Procedures).
3/3
1562/2430
10/30/2018 Print
Body Closures - Rear Door Edge Protector

Print
Removal
1. NOTE: Make sure that the rubber is not damaged.
Installation).
3.
4.
1/3
1563/2430
10/30/2018 Print
5.
6.
2/3
1564/2430
10/30/2018 Print
Installation
Refer to: Rear Door Edge Protector Adjustment (501-03 Body Closures, General Procedures).
3/3
1565/2430
10/30/2018 Print
Body Closures - Liftgate

Print
Removal
5-door
1. Refer to: Rear Spoiler (501-08, Removal and Installation).

Refer to: Liftgate Moulding - 5-Door (501-08 Exterior Trim and Ornamentation, Removal and
Installation).

On both sides.
Refer to: Liftgate Window Glass (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
Refer to: Liftgate Latch (501-14, Removal and Installation).
4.
1/4
1566/2430
10/30/2018 Print
5. Torque: 11 Nm
Wagon
6. Refer to: High Mounted Stoplamp (417-01, Removal and Installation).

Refer to: Liftgate Moulding - Wagon (501-08 Exterior Trim and Ornamentation, Removal and
Installation).

On both sides.
Refer to: Liftgate Window Glass (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
Refer to: Liftgate Latch (501-14, Removal and Installation).
2/4
1567/2430
10/30/2018 Print
9.
10. Torque: 11 Nm
3/4
1568/2430
10/30/2018 Print
Installation
2. Refer to: Liftgate Alignment (501-03 Body Closures, General Procedures).
4/4
1569/2430
10/30/2018 Print
Body Closures - Luggage Compartment Lid

Print
Removal
Refer to: Liftgate Trim Panel - 4-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Refer to: Luggage Compartment Lid Moulding (501-08 Exterior Trim and Ornamentation, Removal
and Installation).
Refer to: Liftgate Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and
Installation).
Refer to: High Mounted Stoplamp - 4-Door/Wagon (417-01 Exterior Lighting, Removal and
Installation).
3.
4.
1/4
1570/2430
10/30/2018 Print
5. Refer to: D-Pillar Trim Panel - 4-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
6. On both sides.
7. WARNINGS:
This step requires the aid of another technician.
Take extra care when handling the compressed spring.

On both sides.
2/4
1571/2430
10/30/2018 Print

On both sides.
Torque: 30 Nm
Torque: 30 Nm
3/4
1572/2430
10/30/2018 Print
Installation
2. Refer to: Luggage Compartment Lid Alignment (501-03, General Procedures).
4/4
1573/2430
10/30/2018 Print
Body Closures - Fuel Filler Door Assembly—5-Door

Print
General Equipment
Knife
Removal
2.
3.
1/4
1574/2430
10/30/2018 Print
4. Torque: 9 Nm
5.
6.
2/4
1575/2430
10/30/2018 Print
8. Use the General Equipment: Knife
3/4
1576/2430
10/30/2018 Print
Installation
4/4
1577/2430
10/30/2018 Print
Body Closures - Front Door Weatherstrip

Print
General Equipment
Knife
Removal
1.
Installation
1.
2. NOTICE: Make sure that the components are aligned.

Use the General Equipment: Knife
1/3
1578/2430
10/30/2018 Print
3. NOTICE: Make sure that equal pressure is applied to the full length of the component.
2/3
1579/2430
10/30/2018 Print
4.
3/3
1580/2430
10/30/2018 Deliverable browser
Body Closures - Rear Door Weatherstrip

Print
General Equipment
Knife
Removal
1.
Installation
1.
2. NOTE: Make sure that the installation marks are aligned.
https://www.etis.ford.com/workShopManuals.do?filtered=true&openProc=G1055783#Rear%20Door%20Weatherstrip-G1537624 1/4
1581/2430
3. NOTICE: Make sure that the components are aligned.

1582/2430
4. NOTICE: Make sure that equal pressure is applied to the full length of the component.
1583/2430
5.
1584/2430
10/30/2018 Print
Body Closures - Front Door

Print
Disassembly
1. Refer to: Exterior Mirror (501-09, Removal and Installation).

Refer to: Front Door Window Glass (501-11, Removal and Installation).
Refer to: Front Door Window Regulator (501-11, Removal and Installation).
Refer to: Exterior Front Door Handle (501-14, Removal and Installation).
Refer to: Front Door Latch (501-14, Removal and Installation).
2.
3.
4.
1/4
1585/2430
10/30/2018 Print
5.
6.
7.
2/4
1586/2430
10/30/2018 Print
8. Torque: 48 Nm
9. Torque: 11 Nm
10.
3/4
1587/2430
10/30/2018 Print
11.
Assembly
4/4
1588/2430
10/30/2018 Print
Body Closures - Rear Door

Print
Disassembly
1. Refer to: Rear Door Latch (501-14, Removal and Installation).
2.
3.
4.
5.
1/3
1589/2430
10/30/2018 Print
6.
7. Torque: 11 Nm
8. Torque: 48 Nm
2/3
1590/2430
10/30/2018 Print
9.
10.
Assembly
3/3
1591/2430
10/30/2018 Print
Interior Trim and Ornamentation - A-Pillar

Trim Panel
Print
Removal
1. If equipped.
Installation
1/1
1592/2430
10/30/2018 Print
Interior Trim and Ornamentation - B-Pillar Trim Panel

Print
Removal
1.
1. Torque: 35 Nm
2.
3.
4.
1/2
1593/2430
10/30/2018 Print
Installation
2/2
1594/2430
10/30/2018 Print
Interior Trim and Ornamentation - C-Pillar Trim Panel—4-Door

Print
Removal
1.
Installation
1/1
1595/2430
10/30/2018 Print
Interior Trim and Ornamentation - C-Pillar Trim Panel—5-Door

Print
Removal
1.
Installation
1/1
1596/2430
10/30/2018 Print
Interior Trim and Ornamentation - C-Pillar Trim Panel—Wagon

Print
Removal
1.
Installation
1/1
1597/2430
10/30/2018 Print
Interior Trim and Ornamentation - D-Pillar Trim Panel—4-Door

Print
Removal
1.
2.
3.
1/2
1598/2430
10/30/2018 Print
4.
Installation
2/2
1599/2430
10/30/2018 Print
Interior Trim and Ornamentation - D-Pillar Trim Panel—5-Door

Print
Removal
1.
Installation).
3.
4.
1/2
1600/2430
10/30/2018 Print
Installation
2/2
1601/2430
10/30/2018 Print
Interior Trim and Ornamentation - D-Pillar Trim Panel—Wagon

Print
Removal
1.
2. Refer to: C-Pillar Trim Panel - Wagon (501-05 Interior Trim and Ornamentation, Removal and
Installation).
3.
4.
1/2
1602/2430
10/30/2018 Print
Installation
2/2
1603/2430
10/30/2018 Print
Interior Trim and Ornamentation - Loadspace Trim Panel LH—4-Door

Print
Removal
1.
Installation).
Installation).
4. Refer to: Rear Seat Backrest (501-10 Seating, Removal and Installation).
5.
1. Torque: 47 Nm
6.
1/3
1604/2430
10/30/2018 Print
7.
8.
9.
2/3
1605/2430
10/30/2018 Print
10. 1. If equipped.
Installation
3/3
1606/2430
10/30/2018 Print
Interior Trim and Ornamentation - Loadspace Trim Panel LH—5-Door

Print
Removal
1.
2.
Installation).
5.
1. Torque: 47 Nm
1/3
1607/2430
10/30/2018 Print
6.
7.
8.
2/3
1608/2430
10/30/2018 Print
9. 1. If equipped.
Installation
3/3
1609/2430
10/30/2018 Print
Interior Trim and Ornamentation - Loadspace Trim Panel LH—Wagon

Print
Removal
1.
2.
Installation).
5.
1. Torque: 47 Nm
2. If equipped.
1/4
1610/2430
10/30/2018 Print
6.
7.
8.
2/4
1611/2430
10/30/2018 Print
9.
10.
3/4
1612/2430
10/30/2018 Print
Installation
4/4
1613/2430
10/30/2018 Print
Interior Trim and Ornamentation - Loadspace Trim Panel RH—4-Door

Print
Removal
1.
Installation).
Installation).
5.
1. Torque: 47 Nm
6.
1/3
1614/2430
10/30/2018 Print
7.
8.
9.
2/3
1615/2430
10/30/2018 Print
10.
Installation
3/3
1616/2430
10/30/2018 Print
Interior Trim and Ornamentation - Loadspace Trim Panel RH—5-Door

Print
Removal
1.
2.
Installation).
5.
1. Torque: 47 Nm
1/3
1617/2430
10/30/2018 Print
6.
7.
8.
2/3
1618/2430
10/30/2018 Print
9.
Installation
3/3
1619/2430
10/30/2018 Print
Interior Trim and Ornamentation - Loadspace Trim Panel RH—Wagon

Print
Removal
1.
2.
Installation).
5.
1. Torque: 47 Nm
1/4
1620/2430
10/30/2018 Print
6.
7.
8.
2/4
1621/2430
10/30/2018 Print
9.
10.
3/4
1622/2430
10/30/2018 Print
Installation
4/4
1623/2430
10/30/2018 Print
Interior Trim and Ornamentation - Headliner—4-Door, Vehicles With:

Print

501-125
Hot Glue Gun
Removal
1.
2.
3.
1/16
1624/2430
10/30/2018 Print
4.
5. On both sides.
6.
2/16
1625/2430
10/30/2018 Print
7.

8. If equipped.
3/16
1626/2430
10/30/2018 Print
9. If equipped.

10.
4/16
1627/2430
10/30/2018 Print
11.

12.
5/16
1628/2430
10/30/2018 Print
14.
6/16
1629/2430
10/30/2018 Print
15.
All vehicles
16.
17. On both sides.
7/16
1630/2430
10/30/2018 Print
18. On both sides.
Installation).
19.
20.
8/16
1631/2430
10/30/2018 Print
21. On both sides.
22. On both sides.
9/16
1632/2430
10/30/2018 Print
23. All.
24. On both sides.
Refer to: Front Seat (501-10 Seating, Removal and Installation).
25. Refer to: Parking Brake Control (206-05 Parking Brake and Actuation, Removal and Installation).
26. Torque: 9 Nm
10/16
1633/2430
10/30/2018 Print

27.
28.
29. Torque: 9 Nm
11/16
1634/2430
10/30/2018 Print
30. Torque: 9 Nm
All vehicles
31.
32.
12/16
1635/2430
10/30/2018 Print
33. Remove the passenger front door.
13/16
1636/2430
10/30/2018 Print
All.

14/16
1637/2430
10/30/2018 Print

15/16
1638/2430
10/30/2018 Print
Installation
16/16
1639/2430
10/30/2018 Print
Interior Trim and Ornamentation - Headliner—5-Door, Vehicles With:

Print

501-125
Hot Glue Gun
Removal
1.
2.
3.
1/14
1640/2430
10/30/2018 Print
4.
5. On both sides.
6.
2/14
1641/2430
10/30/2018 Print
7.

8. If equipped.
3/14
1642/2430
10/30/2018 Print
9. If equipped.

10.
4/14
1643/2430
10/30/2018 Print
11.

12.
5/14
1644/2430
10/30/2018 Print
14.
6/14
1645/2430
10/30/2018 Print
15.
All vehicles
16. On both sides.
17. On both sides.
7/14
1646/2430
10/30/2018 Print
Installation).
18.
19.
1. On both sides.
Torque: 47 Nm
20. On both sides.
8/14
1647/2430
10/30/2018 Print
21. On both sides.
22. All.
23.
9/14
1648/2430
10/30/2018 Print
24.
25.
26.
10/14
1649/2430
10/30/2018 Print
27.
11/14
1650/2430
10/30/2018 Print
All.

12/14
1651/2430
10/30/2018 Print

13/14
1652/2430
10/30/2018 Print
Installation
14/14
1653/2430
10/30/2018 Print
Interior Trim and Ornamentation - Headliner—4-Door, Vehicles Without:

Print

501-125
Hot Glue Gun
Removal
1.
2.
3.
1/15
1654/2430
10/30/2018 Print
4.
5. On both sides.
6.
2/15
1655/2430
10/30/2018 Print
7.

8. If equipped.
3/15
1656/2430
10/30/2018 Print
9. If equipped.

10.
4/15
1657/2430
10/30/2018 Print
11.

12.
5/15
1658/2430
10/30/2018 Print
14.
6/15
1659/2430
10/30/2018 Print
15.
All vehicles
16. On both sides.
17. On both sides.
7/15
1660/2430
10/30/2018 Print
Installation).
18.
19.
20. On both sides.
8/15
1661/2430
10/30/2018 Print
21. On both sides.
22. All.
23. On both sides.
9/15
1662/2430
10/30/2018 Print
24. Refer to: Parking Brake Control (206-05 Parking Brake and Actuation, Removal and Installation).
25. Torque: 9 Nm

26.
27.
10/15
1663/2430
10/30/2018 Print
28. Torque: 9 Nm
29. Torque: 9 Nm
All vehicles
30.
11/15
1664/2430
10/30/2018 Print
31.
32. Remove the passenger front door.
12/15
1665/2430
10/30/2018 Print
All.
13/15
1666/2430
10/30/2018 Print


14/15
1667/2430
10/30/2018 Print
Installation
15/15
1668/2430
10/30/2018 Print
Interior Trim and Ornamentation - Headliner—5-Door, Vehicles Without:

Print

501-125
Hot Glue Gun
Removal
1.
2.
3.
1/14
1669/2430
10/30/2018 Print
4.
5. On both sides.
6.
2/14
1670/2430
10/30/2018 Print
7.

8. If equipped.
3/14
1671/2430
10/30/2018 Print
9. If equipped.

10.
4/14
1672/2430
10/30/2018 Print
11.

12.
5/14
1673/2430
10/30/2018 Print
14.
6/14
1674/2430
10/30/2018 Print
15.
All vehicles
16. On both sides.
17. On both sides.
7/14
1675/2430
10/30/2018 Print
Installation).
18.
19.
1. On both sides.
Torque: 47 Nm
20. On both sides.
8/14
1676/2430
10/30/2018 Print
21. On both sides.
22. All.
23.
9/14
1677/2430
10/30/2018 Print
24.
25.
26.
10/14
1678/2430
10/30/2018 Print
11/14
1679/2430
10/30/2018 Print
All.

12/14
1680/2430
10/30/2018 Print

13/14
1681/2430
10/30/2018 Print
Installation
14/14
1682/2430
10/30/2018 Print
Interior Trim and Ornamentation - Headliner—Wagon, Vehicles Without:

Print

501-125
Hot Glue Gun
Removal
1.
2.
3.
1/14
1683/2430
10/30/2018 Print
4.
5. On both sides.
6.
2/14
1684/2430
10/30/2018 Print
7.

8. If equipped.
3/14
1685/2430
10/30/2018 Print
9. If equipped.

10.
4/14
1686/2430
10/30/2018 Print
11.

12.
5/14
1687/2430
10/30/2018 Print
14.
6/14
1688/2430
10/30/2018 Print
15.
All vehicles
16. On both sides.
17. On both sides.
7/14
1689/2430
10/30/2018 Print
Refer to: C-Pillar Trim Panel - Wagon (501-05 Interior Trim and Ornamentation, Removal and
Installation).
18.
19.
1. On both sides.
Torque: 47 Nm
20. On both sides.
8/14
1690/2430
10/30/2018 Print
21. On both sides.
22. All.
23.
9/14
1691/2430
10/30/2018 Print
24.
25.
26.
10/14
1692/2430
10/30/2018 Print
11/14
1693/2430
10/30/2018 Print
All.

12/14
1694/2430
10/30/2018 Print

13/14
1695/2430
10/30/2018 Print
Installation
14/14
1696/2430
10/30/2018 Print
Interior Trim and Ornamentation - Floor Covering—5-Door

Print
Special Tool(s)
501-125
Removal
1.
2. Refer to: Floor Console - Vehicles Without: Center Armrest (501-12 Instrument Panel and Console,
Refer to: Floor Console - Vehicles With: Center Armrest (501-12 Instrument Panel and Console,
3. On both sides.
5. Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).
1/7
1697/2430
10/30/2018 Print
7.
8. On both sides.
9.
1. On both sides.
Torque: 35 Nm
2/7
1698/2430
10/30/2018 Print
10. On both sides.
11. On both sides.
3/7
1699/2430
10/30/2018 Print
12.
1. On both sides.
Torque: 47 Nm
13. On both sides.
4/7
1700/2430
10/30/2018 Print
14. Torque: 9 Nm
15. Torque: 9 Nm
5/7
1701/2430
10/30/2018 Print
16.
17. Torque: 9 Nm
18. Torque: 9 Nm
6/7
1702/2430
10/30/2018 Print
All vehicles
19.
Installation
7/7
1703/2430
10/30/2018 Print
Interior Trim and Ornamentation - Front Door Trim Panel

Print

501-125
Removal
1/4
1704/2430
10/30/2018 Print
5.
6.
2/4
1705/2430
10/30/2018 Print
7. Use the General Equipment: Interior Trim Remover
8.
3/4
1706/2430
10/30/2018 Print

If equipped.
Installation
4/4
1707/2430
10/30/2018 Print
Interior Trim and Ornamentation - Liftgate Trim Panel—5-Door

Print
Removal
1.
2.
3.
1/2
1708/2430
10/30/2018 Print
4.
Installation
2/2
1709/2430
10/30/2018 Print
Interior Trim and Ornamentation - Rear Door Trim Panel

Print
General Equipment
Removal
Vehicles with manual windows
1.
2.
Vehicles with power windows

3.
1/3
1710/2430
10/30/2018 Print
All vehicles
4.
5. Use the General Equipment: Interior Trim Remover
6.
2/3
1711/2430
10/30/2018 Print
Installation
3/3
1712/2430
10/30/2018 Print
Exterior Trim and Ornamentation - Exterior Trim - Component Location

Print
Item Description
1 Front emblem
2 Windshield strip
3 Roof trim strip
4 Tailgate / luggage compartment lid variant sign
5 Emblem - tailgate / luggage compartment lid
6 Lettering - tailgate / luggage compartment lid
7 Rear trim strip, rear door window
8 Lower trim strip, rear door window
9 Front trim strip, rear door window
10 Rear trim strip, front door window
11 Rocker panel moulding with air deflector
12 Lower trim strip, front door window
13 Front quarter panel cover
1/1
1713/2430
10/30/2018 Print
Exterior Trim and Ornamentation - Exterior Trim - System Operation and

Print
System Operation
Depending on the type of attachment, the components are to be reused or replaced.
Components which are attached with adhesive take should be detached with a plastic wedge.
Front emblem
The emblem is secured with adhesive tape.

A new one will need to be fitted after the old one has been removed.
Windshield strip
The trim strip comes in two parts. Part 1 is inserted in part 2 and can be pulled out to the top.
Part 2 is glued and only becomes accessible once the windshield has been removed.
Both parts will need to be replaced with new ones after the old ones have been removed.
Front quarter panel cover
1/9
1714/2430
10/30/2018 Print
The front quarter panel cover is attached with clips.

Depending on the equipment, a decorative strip is attached to the cover with clips.
Both parts can be reused after removal.
Lower trim strip, front door window
The trim strip can only be accessed after removal of the exterior mirror.
The trim strip is a push-fit.
For removal, undo the strip from front to back.
The trim strip can be reused after removal.
Rear trim strip, front door window
2/9
1715/2430
10/30/2018 Print
The trim strip is only accessible after removal of the lower trim strip, opening of the door window and
removal of the door window seal.
The trim strip is a screw and push-fit.
Lower trim strip, rear door window
The trim strip is a push-fit.

For removal, undo the strip from back to front.
Front trim strip, rear door window
The trim strip is only accessible after removal of the lower trim strip, removal of the door window and
removal of the door window seal.
Rear trim strip, rear door window
3/9
1716/2430
10/30/2018 Print
The trim strip is only accessible after removal of the lower trim strip, opening of the rear door window
and removal of the door window seal.
Roof trim strip (5-door)
The roof trim strip is attached with clips.

For removal, undo the roof trim strip at each clip position consecutively, in order to avoid bending the
strip.
The roof trim strip can be reused after removal.
Roof trim strip (4-door)
The roof trim strip is attached with clips.

For removal, undo the roof trim strip at each clip position consecutively, in order to avoid bending the
strip.
The roof trim strip can be reused after removal.
Rocker panel moulding
4/9
1717/2430
10/30/2018 Print
Item Description
1 Replace the clips after removing the trim strip.
The rocker panel moulding is attached with clips.
Air deflector
Item Description
1 Rocker panel moulding
2 Air deflector
The air deflector is attached to the rocker panel moulding. It is only accessible after the rocker panel
moulding has been removed.
The air deflector is attached with clips.
It can be reused after removal.
Emblem - tailgate / luggage compartment lid
5/9
1718/2430
10/30/2018 Print
The emblem is secured with adhesive tape.

A new one will need to be fitted after the old one has been removed.
Lettering - tailgate (5-door)
Item Description
1 40 mm
2 60 mm
The lettering is retained with adhesive tape.
The lettering must be replaced with new lettering after removal.
Tailgate lettering (estate)
Item Description
1 63 mm
2 141 mm
Lettering - luggage compartment lid (4-door)
6/9
1719/2430
10/30/2018 Print
Item Description
1 24 mm
2 62 mm
Variant sign - tailgate (5-door)
Item Description
1 80 mm
2 39 mm
The sign is secured with adhesive tape.
The sign must be replaced with a new one after removal.
Tailgate variant sign (estate)
Item Description
1 108 mm
2 92 mm
Variant sign - luggage compartment lid (4-door)
7/9
1720/2430
10/30/2018 Print
Item Description
1 72 mm
2 33 mm
Tailgate lettering (5-door, RHD (right-hand drive) vehicles)
Item Description
1 23 mm
2 61 mm
Depending on the market and the equipment, there is additional lettering.
Tailgate lettering (estate, RHD vehicles)
Item Description
1 60 mm
2 115 mm
Luggage compartment lid lettering (4-door, RHD vehicles)
8/9
1721/2430
10/30/2018 Print
Item Description
1 26 mm
2 57 mm
9/9
1722/2430
10/30/2018 Print
Exterior Trim and Ornamentation - Liftgate Moulding—5-Door

Print
Removal
1.
2.
3.
4. 1. If equipped.
1/2
1723/2430
10/30/2018 Print
Installation
2/2
1724/2430
10/30/2018 Print
Exterior Trim and Ornamentation - Roof Rail—Vehicles Without:

Print
Special Tool(s)
501-125
Removal
1. Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
2.
3.
1/8
1725/2430
10/30/2018 Print
4. If equipped.
5. If equipped.
2/8
1726/2430
10/30/2018 Print

6. If equipped.
7. If equipped.
3/8
1727/2430
10/30/2018 Print
All vehicles
9.
4/8
1728/2430
10/30/2018 Print
10.
11. On both sides.
12. On both sides.
5/8
1729/2430
10/30/2018 Print
13. All.
14.
15.
6/8
1730/2430
10/30/2018 Print
16.
17. Torque: 10 Nm
7/8
1731/2430
10/30/2018 Print
18.
Installation
8/8
1732/2430
10/30/2018 Print
Exterior Trim and Ornamentation - Luggage Compartment Lid Moulding

Print
General Equipment
Removal
1.
2.
3.
1/2
1733/2430
10/30/2018 Print
4. WARNING: Make sure that the component paintwork is not damaged.

1. If equipped.
Installation
2/2
1734/2430
10/30/2018 Print
Exterior Trim and Ornamentation - Rocker Panel Moulding

Print
Removal
1. WARNING: Before beginning any service procedure in this section, REFER to Safety
2. If equipped.
3. If equipped.
4.
1/2
1735/2430
10/30/2018 Print
5.
Installation
2/2
1736/2430
10/30/2018 Print
Exterior Trim and Ornamentation - Rear Spoiler—4-Door

Print
Removal
1.
2. NOTE: LH (left-hand) side shown, RH (right-hand) side similar.

Torque: 5.4 Nm
3. NOTE: The rear spoiler is held on by double-sided tape.

NOTE: LH side shown, RH side similar.
1/3
1737/2430
10/30/2018 Print
4.
Installation
2. NOTE: LH side shown, RH side similar.
2/3
1738/2430
10/30/2018 Print
3/3
1739/2430
10/30/2018 Print
Exterior Trim and Ornamentation - Rear Spoiler—5-Door

Print
Removal
NOTE: Removal steps may include installation details.
1. Refer to: High Mounted Stoplamp - 4-Door/Wagon (417-01 Exterior Lighting, Removal and
Installation).
2.
1. Torque: 1.5 Nm
2. Torque: 5.4 Nm
3.
1/2
1740/2430
10/30/2018 Print
Installation
2/2
1741/2430
10/30/2018 Print
Rear View Mirrors - Rear View Mirrors -

Overview
Print
Ambient air temperature sensor
On this vehicle, the ambient temperature sensor is located in the passenger side exterior mirror.
Reason for the relocation:
The sensor has been relocated because more accurate measurements can be achieved in this
position.
Until now, the sensor was usually installed behind the bumper. However, the heat radiating from the
engine resulted in inaccurate measurements.
Filters have been programmed into the software of the respective module to filter out these
inaccuracies.
However, using the active radiator blind has increased the inaccuracy which has made it even more
difficult to calculate the ambient temperature accurately.
Relocating the sensor avoids inaccurate measurements caused by the heat radiating from the engine.
NOTE: The sensor cannot be renewed separately. In the event of a fault, the complete exterior
mirror must be replaced.
1/1
1742/2430
10/30/2018 Print
Rear View Mirrors - Rear View Mirrors

Print

2. Visually inspect for obvious signs of mechanical and electrical damage.
Exterior mirror(s) Fuse(s)
Loose or corroded connector(s)
Switch

The exterior mirrors are * Exterior mirror * CARRY OUT the Exterior Mirror Control Switch
inoperative control switch Component Test. REFER to the Wiring Diagrams.
* Circuit(s). * REFER to the wiring diagrams.
A single exterior mirror is * Exterior mirror * CARRY OUT the Exterior Mirror Control Switch
inoperative control switch. Component Test. REFER to the Wiring Diagrams.
* Exterior mirror * REFER to the wiring diagrams.
motor(s).
* Circuit(s).
A single exterior mirror does * Exterior mirror * CARRY OUT the Exterior Mirror Control Switch
not function with switch logic control switch. Component Test. REFER to the Wiring Diagrams.
* Exterior mirror * REFER to the wiring diagrams.
motor(s).
* Circuit(s).
The heated exterior mirror is * Heated rear * CARRY OUT the Heated Rear Window Control Switch
inoperative window control Component Test. REFER to the Wiring Diagrams.
switch.
* Heated rear * REFER to the wiring diagrams.
window relay.
* Heated exterior
mirror
element(s).
* Circuit(s).
The power folding mirrors do * Generic * CARRY OUT the GEM Self-Test.
not operate electronic REFER to: Body Control Module (BCM) (419-10
module (GEM). Multifunction Electronic Modules, Diagnosis and
Testing).
* Exterior mirror * CARRY OUT the Exterior Mirror Control Switch
control switch. Component Test. REFER to the Wiring Diagrams.
The power folding mirrors do * Generic * CARRY OUT the GEM Self-Test.
not operate correctly electronic REFER to: Body Control Module (BCM) (419-10
module (GEM). Multifunction Electronic Modules, Diagnosis and
Testing).
* Exterior mirror * CARRY OUT the Exterior Mirror Control Switch
control switch. Component Test. REFER to the Wiring Diagrams.
* Power fold * REFER to the wiring diagrams.
mirror motor(s).
* Circuit(s).
1/2
1743/2430
10/30/2018 Print
5. If the cause is not visually evident, verify the symptom and refer to the Ford approved
diagnostic tool to diagnose the system.
2/2
1744/2430
10/30/2018 Print
Rear View Mirrors - Exterior Mirror

Print
Removal
NOTE: LH (left-hand) side shown, RH (right-hand) side similar.
NOTE: Not all procedure steps are required for some components.
1.
2. Torque: 6 Nm
3. 1. NOTE: Electrical connectors will vary in number and location depending upon mirror
content.
1/3
1745/2430
10/30/2018 Print
4. NOTE: This step is only necessary when installing a new mirror cover.
5. NOTE: This step is only necessary when installing a new turn signal indicator.
6. NOTE: This step is only necessary when installing a new puddle lamp.
If equipped.
2/3
1746/2430
10/30/2018 Print
Installation
3/3
1747/2430
10/30/2018 Print
Seating - Seats
Print
General Equipment
Switch(es) Fuse
Seat tracks Wiring harness
Seat latch Electrical connector(s)
Hinge(s) Switch(es)
Seat motor(s)
Heater mat
1/1
1748/2430
10/30/2018 Print
Seating - Front Head Restraint Guide Sleeve

Print
Removal
1.
2.
Installation
1/1
1749/2430
10/30/2018 Print
Seating - Seat Occupant Sensor

Print
Removal
1. Refer to: Front Seat Cushion (501-10 Seating, Removal and Installation).
Installation
1/1
1750/2430
10/30/2018 Print
Seating - Front Seat Control Switch

Print
Removal
1. Torque: 3 Nm
2.
Installation
1/1
1751/2430
10/30/2018 Print
Seating - Driver Seat Track

Print
General Equipment
Removal
1. Refer to: Front Seat (501-10 Seating, Removal and Installation).
2.
3. Torque: 47 Nm
4.
2.
3. Torque: 3 Nm
4.
1/5
1752/2430
10/30/2018 Print
5. Torque: 3 Nm
Vehicles with power seats
6. Torque: 3 Nm
2/5
1753/2430
10/30/2018 Print
Vehicles with leather seats

7.
All vehicles
8.
9.
10.
3/5
1754/2430
10/30/2018 Print
11.
12. Torque: 35 Nm
13.
4/5
1755/2430
10/30/2018 Print
14.
Installation
2. Torque: 6 Nm
5/5
1756/2430
10/30/2018 Print
Seating - Front Seat

Print
Removal
1.
2.
4.
1/2
1757/2430
10/30/2018 Print
Installation
3. Torque: 40 Nm
2/2
1758/2430
10/30/2018 Print
Seating - Front Seat Backrest Cover

Print
General Equipment
Hog Ring Plier
Removal
2. Refer to: Front Head Restraint Guide Sleeve (501-10 Seating, Removal and Installation).
3. If equipped.
4.

5.
All vehicles
6.
1/3
1759/2430
10/30/2018 Print
7.
8.
9.
2/3
1760/2430
10/30/2018 Print
Installation
2. Use the General Equipment: Hog Ring Plier
3/3
1761/2430
10/30/2018 Print
Seating - Front Seat Backrest Heater Mat

Print
Removal
1. Refer to: Front Seat Backrest Cover (501-10 Seating, Removal and Installation).
3. NOTE: Touching the adhesive surface will impair rebonding.
Installation
1/2
1762/2430
10/30/2018 Print
2/2
1763/2430
10/30/2018 Print
Seating - Lumbar Assembly

Print
Removal
1. Refer to: Front Seat Backrest Cover (501-10 Seating, Removal and Installation).
2. Torque: 1 Nm
Installation
1/1
1764/2430
10/30/2018 Print
Seating - Front Seat Cushion

Print
Removal
1. Refer to: Front Seat Cushion Cover (501-10 Seating, Removal and Installation).
2. If equipped.
3. If equipped.
Installation
1/1
1765/2430
10/30/2018 Print
Seating - Front Seat Cushion Cover

Print
General Equipment
Hog Ring Plier
Removal
Vehicles with power seats
2. Torque: 3 Nm
All vehicles
3.
2. 2. NOTICE: The component must be removed by hand, the use of tools is

prohibited.
3.
4.
1/4
1766/2430
10/30/2018 Print
4. 1.

5.
All vehicles
6.
7.
2/4
1767/2430
10/30/2018 Print
8.
9.
3/4
1768/2430
10/30/2018 Print
Installation
4/4
1769/2430
10/30/2018 Print
Seating - Front Seat Cushion Heater Mat

Print
Removal
1. Refer to: Front Seat Cushion Cover (501-10 Seating, Removal and Installation).
2.
Installation
1/1
1770/2430
10/30/2018 Print
Seating - Heated Seat Switch—Vehicles With:

Center Armrest
Print
Special Tool(s)
501-125
Removal
2.
Installation
1/1
1771/2430
10/30/2018 Print
Seating - Heated Seat Switch—Vehicles Without: Center Armrest

Print
Removal
1. Refer to: Floor Console - Vehicles Without: Center Armrest (501-12, Removal and Installation).
2.
Installation
1/1
1772/2430
10/30/2018 Print
Seating - Rear Seat Armrest

Print
Removal
1.
Installation
1/1
1773/2430
10/30/2018 Print
Seating - Rear Seat Backrest

Print
General Equipment
Removal
1.
2. 1. NOTE: Note the position of the component before removal.

2.
3.
4.
5.
6. NOTE: Install all the bolts finger tight before final tightening.
Torque: 55 Nm
1/2
1774/2430
10/30/2018 Print
Installation
2/2
1775/2430
10/30/2018 Print
Seating - Rear Seat Backrest Latch

Print
Removal
1. 1.
NOTE: Make sure that the components are installed to the position noted before
removal.
NOTE: Install all the bolts finger tight before final tightening.
Torque: 55 Nm
2.
3.
1/2
1776/2430
10/30/2018 Print
4. Torque: 23 Nm
Installation
2/2
1777/2430
10/30/2018 Print
Seating - Rear Seat Cushion

Print
Removal
2. Torque: 24 Nm
Installation
1/1
1778/2430
10/30/2018 Print
Seating - Rear Seat Backrest

Print
General Equipment
Hog Ring Plier
Disassembly

2.
3.
1/6
1779/2430
10/30/2018 Print
All vehicles
4. Torque: 35 Nm
5. Torque: 35 Nm
6. NOTE: If the safety belt webbing retracts further than the safety belt webbing stop, a new
safety belt retractor must be installed.
2/6
1780/2430
10/30/2018 Print
7.
8.
3/6
1781/2430
10/30/2018 Print
9.
10.
12.
4/6
1782/2430
10/30/2018 Print
13.
14.
15.
16.
5/6
1783/2430
10/30/2018 Print
1. Torque: 23 Nm
2. Torque: 23 Nm
3. Torque: 47 Nm
Assembly
6/6
1784/2430
10/30/2018 Print
Seating - Rear Seat Cushion

Print
General Equipment
Hog Ring Plier
Disassembly
1. Refer to: Rear Seat Cushion (501-10, Removal and Installation).
2.
3.
4.
5.
1/2
1785/2430
10/30/2018 Print
Assembly
2/2
1786/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Glass, Frames

and Mechanisms - Overview
Print
Fixed window glass

The rear quarter panel windows are glued directly into the body apertures with PU adhesive. In
addition to fixing the glass to the body aperture, the adhesive bead also forms a water-tight seal
around the inner edge of the glass.
All vehicles have rear window defrost. A heated windshield is available as an option.
The vehicles have green tinted glass as standard. Privacy glass is an option for all variants on all glass
installed rear of the B-pillar.
An infrared-reflecting windshield is available as an option.
Electric window regulators
Front door window
Item Description
1 FDM (front door module)
2 Front window regulator switch
3 Front door window regulator motor
Rear door window
1/3
1787/2430
10/30/2018 Print
Item Description
1 RDM (rear door module)
2 Rear window regulator switch
3 Rear door window regulator motor
Front electric window regulators are standard. Front and rear electric window regulators and the
global closing function of the electric window regulators are optional. Global closing can only be
operated by using the remote control.
Only the front electric window regulators have a one-touch function for opening the window.
The front and rear electric window regulators have a one-touch down and a one-touch up regulator
function, combined with anti-trap protection which is active whenever the window is closing.
After anti-trap protection is initiated two times in quick succession, the anti-trap protection is
automatically deactivated. Press and hold the window switch to close the window completely. Anti-
trap protection is automatically reactivated when the ignition is turned off and on again, after
20 seconds without further actuation, or after the window has been completely closed.
Initialization of each door window regulator motor is necessary. The initialization process is carried
out before the vehicle leaves the production plant. However, the initialization process will need to be
carried out again whenever the power supply has been disconnected.
Item Description
1 Telltales for rear window regulators / childproof safety locking
Depending on the equipment, the lower switch in the driver's door control panel activates and
deactivates the window regulators in the rear doors. Depending on the equipment level, the electric
childproof safety locking is activated/deactivated at the same time.
Refer to: Handles, Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry
Systems, Description and Operation).
Pressing the switch once
2/3
1788/2430
10/30/2018 Print
deactivates the rear window regulator switches.

- The rear door windows can still be opened and shut using the window regulator switches in the
driver's door.
activates the childproof safety locks (vehicles with electric childproof safety locking).
- The rear doors can only be opened from the outside.
the telltale in the switch in the driver's door illuminates.
the rear window regulator switch illumination is switched off.
Pressing the switch again

enables the rear window regulator switches.
deactivates the childproof safety locks (vehicles with electric childproof safety locking).
the telltale in the switch in the driver's door goes out.
the rear window regulator switch illumination is switched on.
3/3
1789/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Glass, Frames

and Mechanisms
Print

Window seal Fuse(s)
Door window frame Electrical connector(s)
Switch(es)
Circuit(s)
SYMPTOM CHART

All power windows * Driver power * CARRY OUT the Driver Power Window Control Switch
are inoperative window control Component Test in this procedure.
switch.
A single power * Driver power * CARRY OUT the Driver Power Window Control Switch
window is inoperative window control Component Test in this procedure.
- driver side switch.
* Power window * REFER to the wiring diagrams.
motor.
* Circuit(s).
A single power * Driver power * CARRY OUT the Driver Power Window Control Switch
- passenger side switch.
* Passenger * CARRY OUT the Passenger Power Window Control Switch
power window Component Test in this procedure.
control switch.
* Power window * REFER to the wiring diagrams.
motor.
* Circuit(s).
The one-touch down * Driver power * CARRY OUT the Driver Power Window Control Switch
switch.
The defrost system is * Heated rear * CARRY OUT the Heated Rear Window Control Switch
inoperative window control Component Test in this procedure.
switch.
* Heated * CARRY OUT the Heated Windshield Control Switch Component
windshield Test in this procedure.
control switch.
* Rear Window * CARRY OUT the Rear Window Heater Relay Component Test in
Heater Relay. this procedure.
* Generic * CARRY OUT the Generic Electronic Module Self-Test. REFER to:
electronic Body Control Module (BCM) (419-10 Multifunction Electronic
module (GEM). Modules, Diagnosis and Testing).
* Heated rear * CARRY OUT the Heated Rear Window Grid Wire Component
window grid Test in this procedure.
1/3
1790/2430
10/30/2018 Print
wire.
* Heated * REFER to the wiring diagrams.
windshield grid
wire.
* Circuit(s).
The defrost system * Heated rear * CARRY OUT the Heated Rear Window Control Switch
will not shut off window control Component Test in this procedure.
automatically switch.
* Heated * CARRY OUT the Heated Windshield Control Switch Component
windshield Test in this procedure.
control switch.
* Rear Window * CARRY OUT the Rear Window Heater Relay Component Test in
Heater Relay. this procedure.
* Generic * CARRY OUT the Generic Electronic Module Self-Test. REFER to:
electronic Body Control Module (BCM) (419-10 Multifunction Electronic
module (GEM). Modules, Diagnosis and Testing).
Component Tests
Heated Rear Window Switch
1. Remove the heated rear window switch.
2. Measure the resistance between pins 1 and 2 of the switch while operating the switch.
3. The resistance should be less than 5 ohms when the switch is in the ON position and greater
than 10,000 ohms when in the OFF position.
4. If the resistances are not as specified, INSTALL a new heated rear window switch.
Rear Window Heater Relay
1. Remove the heated rear window relay.
2. Using a jumper wire, connect one end to terminal 1 of the relay. Connect the other end to
ground.
3. Using a second jumper wire, connect one end to terminal 2 of the relay.
4. Connect one lead of an ohmmeter to terminal 3 of the relay. Connect second lead to terminal 5
of the relay. Observe the resistance.
5. Momentarily tap the unconnected end of the second jumper wire to the battery power. An
audible click should be heard and the resistance on the ohmmeter should drop to zero.
6. If the relay does not click and the resistance does not drop to zero, INSTALL a new relay.
Heated Rear Window Grid Wire Test
1. Using a bright lamp inside the vehicle, visually inspect the wire grid from the outside. A broken
grid conductor will appear as a brown spot.
2. Start the engine and set the heated rear window switch to ON, the indicator light should
illuminate.
3. Work inside the vehicle with a 12 volt DC voltmeter. Contact the broad red-brown strips on the
rear window, positive lead to the battery side and the negative lead to ground side. The meter
reading should be 10-12 volts. A lower voltage reading indicates a loose heated rear window
ground wire connection at the heated rear window ground wire screws.
4. Contact a ground point with the negative lead of the meter. The voltage reading should not
change.
5. With the negative lead of the meter grounded, touch each grid line of the heated rear window at
its midpoint with the positive meter lead. A reading of approximately six volts indicates that
the line is good. A reading of zero volts indicates that the line is broken between the midpoint
and the B+ side of the grid line. A reading of 12 volts indicates that the circuit is broken
between the midpoint of the grid line and ground.
2/3
1791/2430
10/30/2018 Print
6. Install a new heated rear window using the procedures as described under the general
procedures if necessary.
3/3
1792/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Power Door

Window Initialization
Print
General Procedures
Initialization
1. WARNING: The anti-trap function will not operate during the initialization procedure.
NOTE: Make sure that the window runs are correctly installed and free of foreign material.
NOTE: If the power to a window regulator motor has been disconnected, it is necessary to
initialize that window regulator motor.
NOTE: Wait for a minimum of 1 minute before connecting the battery, fuse or electrical
connector.
Start the engine.
2.
3.
1/4
1793/2430
10/30/2018 Print
4.
5.
6.
2/4
1794/2430
10/30/2018 Print
7.
8.
3/4
1795/2430
10/30/2018 Print
4/4
1796/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Windshield Glass

Print
General Equipment
Adhesive Tape
Direct Glazing Removal/Replacement Equipment
Knife
Materials
Name Specification
Adhesive WSK-M11P57-A3
Adhesive WSS-M11P57-A5
Removal
1. NOTICE:
Refer to: Window Glass Health and Safety Precautions (100-00 General Information, Description
and Operation).
2.
1. Material: WSK-M11P57-A3 (Adhesive)
2. Remove the polyurethane (PU) adhesive cap and heat the 2K-PU adhesive for a minimum of
30 minutes.
Use the General Equipment: Direct Glazing Removal/Replacement Equipment

3. Repairs under warranty:
Material: WSS-M11P57-A5 (Adhesive)
1/11
1797/2430
10/30/2018 Print
Vehicles with heated windshield

4.
5.
2/11
1798/2430
10/30/2018 Print
Vehicles with front view camera
6. Refer to: Image Processing Module A (IPMA) (413-09 Warning Chimes, Removal and Installation).
Refer to: Active City Stop Module (413-09 Warning Chimes, Removal and Installation).
Refer to: Rain Sensor - Vehicles With: Active City Stop (501-16 Wipers and Washers, Removal and
Installation).
Refer to: Navigation System Module - Vehicles With: Active City Stop (415-01 Information and
Entertainment System, Removal and Installation).
Vehicles with autolamps and rain sensor
7. Refer to: Rain Sensor - Vehicles Without: Active City Stop (501-16 Wipers and Washers, Removal
and Installation).
Refer to: Navigation System Module - Vehicles Without: Active City Stop (415-01 Information and
Vehicles with auto-dimming interior mirror

8.
3/11
1799/2430
10/30/2018 Print
Vehicles with manual dimming interior mirror

9.

10.
4/11
1800/2430
10/30/2018 Print
All vehicles
11.
Use a suitable awl to thread the cutting wire.
12.
NOTICE: If the original window glass is to be installed, take care not to damage the
electrical connectors and the weatherstrip (if equipped).
Use a suitable brace to prevent trim damages.
5/11
1801/2430
10/30/2018 Print
13.
Installation
1. 1. NOTE: Minimum 1 mm bead thickness.

Prepare the windshield glass, windshield glass flange and trimmed PU adhesive in
accordance with the instructions supplied with the glass adhesive kit.
2. Apply the activator/ primer in accordance with the instructions supplied with the glass adhesive kit.
6/11
1802/2430
10/30/2018 Print

5. NOTE: Discard the first 100 mm of adhesive as this may have a reduced working time.
NOTE: Make sure that any breakage in the continuous bead of adhesive is overlapped by 20
mm.
Material: WSK-M11P57-A3 (Adhesive)
7/11
1803/2430
10/30/2018 Print
6.
Press firmly and evenly into position.
NOTICE: During the curing time of the polyurethane (PU) adhesive, the door
windows must be left open.
Using tape, secure the windshield glass in the correct position until the PU adhesive has
cured.

7.
8/11
1804/2430
10/30/2018 Print
Vehicles with manual dimming interior mirror

8.
Vehicles with auto-dimming interior mirror

9.
9/11
1805/2430
10/30/2018 Print
Vehicles with autolamps and rain sensor
10. Refer to: Rain Sensor - Vehicles Without: Active City Stop (501-16 Wipers and Washers, Removal
and Installation).
Refer to: Navigation System Module - Vehicles Without: Active City Stop (415-01 Information and
Vehicles with front view camera
11. Refer to: Image Processing Module A (IPMA) (413-09 Warning Chimes, Removal and Installation).
Refer to: Active City Stop Module (413-09 Warning Chimes, Removal and Installation).
Refer to: Rain Sensor - Vehicles With: Active City Stop (501-16 Wipers and Washers, Removal and
Installation).
Refer to: Navigation System Module - Vehicles With: Active City Stop (415-01 Information and

12.
13.
10/11
1806/2430
10/30/2018 Print
All vehicles
11/11
1807/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Front Door Window Glass

Print
Removal
Installation).
2.
3.
4.
5.
1/2
1808/2430
10/30/2018 Print
6.
Installation
2. Perform the power door window initialization
Refer to: Power Door Window Initialization (501-11 Glass, Frames and Mechanisms, General
Procedures).
2/2
1809/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Rear Door Window Glass

Print
Removal
Installation).
2.
3.
4.
5.
1/4
1810/2430
10/30/2018 Print
6.
7.
8.
2/4
1811/2430
10/30/2018 Print
9.
10.
11.
3/4
1812/2430
10/30/2018 Print
Installation
Procedures).
4/4
1813/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Rear Quarter Window Glass

Print
General Equipment
Adhesive Tape
Knife
Materials
Name Specification
Removal
1. NOTICE:
and Operation).
2.
30 minutes.

Installation).
Installation).
Refer to: D-Pillar Trim Panel - Wagon (501-05 Interior Trim and Ornamentation, Removal and
Installation).
4. NOTE: Some resistance may be encountered when cutting through the glass locating
spacers.
1/4
1814/2430
10/30/2018 Print

Use the General Equipments: Adhesive Tape, Direct Glazing Removal/Replacement Equipment

NOTE: Some resistance may be encountered when cutting through the glass locating
spacers.
Installation

2/4
1815/2430
10/30/2018 Print
Prepare the rear quarter window glass, rear quarter window glass flange and trimmed PU
adhesive in accordance with the instructions supplied with the glass adhesive kit.
mm.
3/4
1816/2430
10/30/2018 Print
5.
Using tape, secure the rear quarter window glass in the correct position until the PU
adhesive has cured.
4/4
1817/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Liftgate Window Glass

Print
General Equipment
Adhesive Tape
Knife
Laminated Card
Materials
Name Specification
Removal
1. NOTICE:
and Operation).
2.
30 minutes.

3. Refer to: Rear Window Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
Refer to: Rear Spoiler (501-08, Removal and Installation).
4.
1/6
1818/2430
10/30/2018 Print
5.
WARNING: Make sure that the component paintwork is not damaged.

Use a suitable awl to thread the cutting wire.
6.
WARNING: Make sure that the component paintwork is not damaged.

NOTE: Some resistance may be encountered when cutting through the glass locating
spacers.
Use a suitable brace to prevent paintwork damages.
2/6
1819/2430
10/30/2018 Print

Use suitable adhesive tape or a laminated card to prevent paintwork damages.
Use the General Equipments: Direct Glazing Removal/Replacement Equipment, Adhesive Tape,
Laminated Card
Installation

Prepare the liftgate window glass, liftgate window glass flange and trimmed PU adhesive in
accordance with the instructions supplied with the glass adhesive kit.
3/6
1820/2430
10/30/2018 Print
4/6
1821/2430
10/30/2018 Print
mm.
6.
Using tape, secure the liftgate window glass in the correct position until the PU adhesive has
cured.

5/6
1822/2430
10/30/2018 Print
7.
8. Refer to: Rear Window Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
Refer to: Rear Spoiler (501-08, Removal and Installation).
6/6
1823/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Front Door Window Regulator

Print
General Equipment
Adhesive Tape
Removal
Installation).
2.
3.
4.
1/3
1824/2430
10/30/2018 Print
5.
6. Use the General Equipment: Adhesive Tape
7.
2/3
1825/2430
10/30/2018 Print
Installation
Procedures).
3/3
1826/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Front Door Window Regulator Motor

Print
Removal
1. Refer to: Front Door Window Regulator (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
2. 1.
2.
3. NOTE: Locating studs must not be removed.
Installation
Procedures).
1/1
1827/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Rear Door Window Regulator

Print
General Equipment
Adhesive Tape
Removal
Installation).
2.
3.
4.
1/3
1828/2430
10/30/2018 Print
5.
7.
2/3
1829/2430
10/30/2018 Print
Installation
Procedures).
3/3
1830/2430
10/30/2018 Print
Glass, Frames and Mechanisms - Rear Door Window Regulator Motor

Print
Removal
1. Refer to: Rear Door Window Regulator (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
2. 1.
2.
3. NOTE: Locating studs must not be removed.
Installation
Procedures).
1/1
1831/2430
10/30/2018 Print
Instrument Panel and Console - Instrument Panel

Print
General Equipment
Round-Ended Steel Rule
Removal
Procedures).
2. On both sides.
3.
4.
5.
1/9
1832/2430
10/30/2018 Print
6. Torque: 8 Nm
7.
8.
2/9
1833/2430
10/30/2018 Print
10. Refer to: Front Control/Display Interface Module (FCDIM) - Vehicles Without: Sony Audio System
Refer to: Front Control/Display Interface Module (FCDIM) - Vehicles With: Sony Audio System
11.
12.
3/9
1834/2430
10/30/2018 Print
13.
14.
15.
4/9
1835/2430
10/30/2018 Print
16.
17.
18.
5/9
1836/2430
10/30/2018 Print
19.
NOTICE: Make sure that the steering column lock is engaged.

Torque: 28 Nm
6/9
1837/2430
10/30/2018 Print

Torque: 25 Nm
22. Use the General Equipment: Round-Ended Steel Rule
7/9
1838/2430
10/30/2018 Print
23. If equipped.
24.
25.
26.
27.
8/9
1839/2430
10/30/2018 Print
1. On both sides.
Torque: 3 Nm
Installation
9/9
1840/2430
10/30/2018 Print
Instrument Panel and Console - In-Vehicle Crossbeam

Print
Removal
2.
3. Refer to: Instrument Panel Wiring Harness (418-02 Wiring Harnesses, Removal and Installation).
4. On both sides.
5. On both sides.
Torque: 40 Nm
6.
1/5
1841/2430
10/30/2018 Print
7.
1. Torque: 25 Nm
8.
2/5
1842/2430
10/30/2018 Print
9. Torque: 10 Nm
10. Torque: 25 Nm
3/5
1843/2430
10/30/2018 Print
11. Torque: 25 Nm
Installation
2. NOTICE: Make sure that the tolerance absorbers turn without resistance.
Turn on both sides the tolerance absorber to the stop and turn back a half turn.
4/5
1844/2430
10/30/2018 Print
3. Check on both sides that the tolerance absorber contacts the A-pillar.
5/5
1845/2430
10/30/2018 Print
Instrument Panel and Console - Floor Console—Vehicles With: Center

Armrest
Print
Removal
1. Release the retainers and position the selector lever boot aside.
2. Release the retainers and position the shifter boot and bezel aside.
Disconnect the electrical connector.
All vehicles
1/6
1846/2430
10/30/2018 Print
3. Release the retainers and remove the RH (right-hand) floor console side trim panel.
4. Release the retainers and remove the upper floor console trim panel.
5. Remove the screws and remove the floor console upper trim panel.
Torque: 2 Nm
2/6
1847/2430
10/30/2018 Print
6. Postion the weather strip aside, remove the retainers and remove the LH (left-hand) instrument
panel side trim panel.
Vehicles without driver knee airbag.

7.
3/6
1848/2430
10/30/2018 Print
Vehicles with driver knee airbag.
8. Remove the driver knee air bag.
Refer to: Driver Knee Airbag - Vehicles Built From: 11-06-2012 (501-20B, Removal and
Installation).
9. Remove the retainer and the steering column opening trim panel.
Disconnect and position aside the air sensor.
All vehicles
10. Remove the retainers and the LH floor console side trim panel.
4/6
1849/2430
10/30/2018 Print
11. Remove the bolts and the floor console.
Disconnect the electrical connectors.
Torque: 9 Nm
5/6
1850/2430
10/30/2018 Print
Installation
6/6
1851/2430
10/30/2018 Print
Instrument Panel and Console - Floor Console—Vehicles Without: Center

Armrest
Print
Removal
1. Release the retainers and position the selector lever boot aside.
2. Release the retainers and position the shifter boot and bezel aside.
Disconnect the electrical connector
3. Release the retainers and remove the RH (right-hand) floor console side trim panel.
1/6
1852/2430
10/30/2018 Print
All vehicles
4. Release the retainers and remove the upper floor console trim panel.
5. Remove the screws and remove the floor console upper trim panel.
Torque: 2 Nm
2/6
1853/2430
10/30/2018 Print
6. Postion the weather strip aside, remove the retainers and remove the LH (left-hand) instrument
panel side trim panel.
7.
Vehicles without driver knee airbag or Vehicles without driver knee

airbag
8.
3/6
1854/2430
10/30/2018 Print
Vehicles with driver knee airbag
9. Remove the driver knee air bag.
Refer to: Driver Knee Airbag - Vehicles Built From: 11-06-2012 (501-20B, Removal and
Installation).
10. Remove the retainer and the steering column opening trim panel.
Disconnect and position aside the air sensor.
All vehicles
11. Remove the retainers and the LH floor console side trim panel.
4/6
1855/2430
10/30/2018 Print
12. Remove the retainers and the LH upper floor console trim panel.
13. Remove the bolts and the floor console.
Disconnect the electrical connectors.
Torque: 9 Nm
5/6
1856/2430
10/30/2018 Print
Installation
6/6
1857/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Handles, Locks, Latches

and Entry Systems - Component Location
Print
Item Description
2 EJB (engine junction box)
3 Electronic steering lock
Comments:
Position in LHD (left-hand drive) vehicle shown.
4 Holder, passive key with PATS (passive anti-theft system) transceiver
Comments:
Position in LHD vehicle shown.
5 Start/Stop button
Comments:
Comments:
7 radio frequency receiver
Comments:
8 Central door locking switch
9 Middle antenna, keyless vehicle system
10 Door handle with sensors and integrated front door antenna, keyless vehicle system
Comments:
1/2
1858/2430
10/30/2018 Print

11 Front door latch
12 RDM (rear door module)
13 Door handle with unlocking sensor
14 Rear door latch
15 Tank flap
16 Tailgate external lock release switch (5-door version and Combi)
Comments:
(4-door version: luggage compartment lid external lock release switch)
17 Tailgate locking mechanism (5-door version and Combi)
Comments:
(4-door version: luggage compartment lid latch)
18 Rear bumper antenna, keyless vehicle system
19 RJB (rear junction box)
20 Luggage compartment antenna, keyless vehicle system
22 FDM (front door module)
23 Front antenna, keyless vehicle system
24 Door handle with lock cylinder, sensors and integrated front door antenna, keyless vehicle system
Comments:
Position on LHD vehicle shown.
25 Hood release lever
2/2
1859/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems -

Overview
Print
Vehicles with RKE (remote keyless entry)

A RKE is installed as standard. The lock cylinder in the passenger door is discontinued.
The RKE makes it possible to unlock the vehicle from the outside without using a key in the lock
cylinder.
The remote keyless entry (RKE) system includes the following components:
FDM (front door module)s and RDM (rear door module)s.
Radio frequency remote control with integrated key.
Unlocking the vehicle
The vehicle can be unlocked from the outside by operating the unlock button on the radio frequency
remote control or by unlocking the door lock on the driver's side using the key.
The doors are locked and unlocked from inside the vehicle by operating the central door locking
switch on the instrument panel.
The anti-theft alarm system is switched off when the vehicle is unlocked using the radio frequency
remote control. If the vehicle is unlocked using the key, the anti-theft alarm system switches back on
again after 11 seconds if the ignition is not switched on or a button on the radio frequency remote
control is not pressed before this time has expired.
Refer to: Perimeter Anti-Theft Alarm (419-01A Perimeter Anti-Theft Alarm, Description and
Operation).
The radio frequency remote control can be programmed for the following two unlocking
functions:
A single press of the unlocking button only unlocks the driver's door.
- The other doors can either be unlocked by a second press of the unlocking button within three
seconds or they can be unlocked from inside the vehicle.
A single press of the unlocking button unlocks all the doors.
To change the programming of the unlock function, with the ignition switched off, hold both the
locking and unlocking buttons on the radio frequency remote control pressed at the same time for at
least four seconds. The turn indicator lights flash twice to confirm.
Repeating the step reprograms the original unlocking function.
Locking the vehicle
The doors can only be locked if the front doors are closed. During locking the rear doors may be
open. They are then locked automatically when they are closed.
The doors are locked and unlocked from inside the vehicle by operating the central door locking
switch on the instrument panel.
The vehicle can be locked from the outside by pressing the locking button on the radio frequency
remote control or by locking the door lock on the driver's side using the key.
With the ignition switched off, when the vehicle is locked from the outside, the anti-theft alarm
system is armed as soon as all the doors, the hood and the tailgate/luggage compartment lid are
closed.
Operation).
Double locking
Double locking is model variant dependent.

Double locking can only be activated if all the doors, the hood and the tailgate/luggage compartment
lid are closed.
1/7
1860/2430
10/30/2018 Print
If the vehicle is double locked, it can no longer be unlocked from inside.

If the locking button on the radio frequency remote control is pressed twice within 3 seconds, or the
key in the lock cylinder is turned to the locking position twice within 3 seconds, the vehicle will be
double locked.
Provided the ignition is switched off, the anti-theft alarm system is switched on when the vehicle is
locked.
Tailgate/luggage compartment lid
Item Description
1 Luggage compartment lid external lock release switch, 4-door version
2 Tailgate external lock release switch, 5-door version
3 Tailgate external lock release switch, Combi
The tailgate/luggage compartment lid can only be unlocked if the vehicle is stationary or it is moving
at a speed less than 7 km/h.
To unlock the tailgate/luggage compartment lid:

press the luggage compartment unlocking button on the radio frequency remote control twice within
3 seconds
press the luggage compartment unlocking button on the radio frequency remote control once and
operate the tailgate/luggage compartment lid external lock release switch within 45 seconds
if the driver's door is unlocked, operate the tailgate/luggage compartment lid external lock release
switch
After unlocking, the tailgate/luggage compartment lid can be manually opened and it will then be held
in the open position by the tailgate/luggage compartment lid dampers.
The tailgate/luggage compartment lid is locked automatically when it is closed.
The tailgate/luggage compartment lid external lock release switch remains active as long
as the driver's door is unlocked.
Hood
The hood is released by operating the hood release lever in the footwell on the left-hand side.
Tank flap
2/7
1861/2430
10/30/2018 Print
Item Description
1 5-door version
2 4-door version and Combi
5-door version:
The tank flap is unlatched by pressing and then releasing the rear part of the flap, after which it can
be opened manually.
After closing, the tank flap is latched again by light pressure on the rear part of the flap.
4-door version and Combi:

Pull open the tank flap.
Latch the tank flap back in place when closing it.
Vehicles with electric childproof safety locking
Item Description
1 Telltales for window regulators / childproof safety locking
When the vehicle is equipped with electric childproof safety locking, the system can be operated from
the driver's seat. Mechanical activation/deactivation at the rear doors is no longer provided.
Operating the switch for the window regulators/childproof safety locking in the driver's door control
panel not only deactivates the window regulator switches on both rear doors but also activates the
childproof safety locking.
If electric childproof safety locking is activated, the telltale of the switch for the window
regulator/childproof safety locking illuminates while the illumination of the rear window regulator
switches is turned off.
The rear doors can then only be opened from the outside.
3/7
1862/2430
10/30/2018 Print
Pressing the switch again deactivates the childproof safety locking and activates the rear window
regulator switches.
If the electric childproof safety locking develops a fault, the trip computer outputs an appropriate
message via the display in the instrument panel.
Vehicles with keyless start system
The keyless start system depends on the equipment level. With this system, the usual ignition lock is
replaced by a start/stop button.
The system includes the following components:

keyless vehicle module
passive key (radio remote control with integrated emergency key)
radio frequency receiver
three antennas for the keyless vehicle system, in the front and middle of the vehicle interior and in
the luggage compartment.
electronic steering column lock; replaces the mechanical steering column lock
start/stop button for starting/switching off the engine (the conventional ignition lock is dispensed
with)
Unlocking and locking the vehicle
The vehicle can be unlocked and locked as described in the section 'Vehicles with RKE'.
To unlock and lock using a key, use the emergency key which is contained in the passive key.
Starting the engine.
In order for engine starting to be enabled it is necessary for a valid passive key to be
present inside the vehicle.
The passive vehicle key is detected by the interior antennas.
Operating the start/stop button

switches on the ignition
starts the engine with the ignition in the ON position or directly from ignition OFF
- if the clutch pedal (vehicles with manual transmission) or the brake pedal (vehicles with automatic
transmission) is depressed at the same time.
Switching on the ignition will automatically

deactivate the PATS (passive anti-theft system).
-
Refer to: Passive Anti-Theft System (PATS) (419-01B Passive Anti-Theft System (PATS), Description
and Operation).
unlock the electronic steering column lock.
-
Refer to: Steering Column (211-04 Steering Column, Description and Operation).
On vehicles with a manual transmission, there are two switches for the clutch pedal position, one for
approx. 25% of the operating displacement, the other for approx. 75% of the operating displacement.
If the function of one of the switches becomes impaired, the signal from the other switch is used
during the starting process.
Stopping the engine
The engine is stopped by pressing the start/stop button, provided the vehicle is stationary (vehicle
speed = 0 km/h).
In an emergency, the engine can be stopped at any speed as follows:

By pressing the start/stop button twice within three seconds.
- The engine can be started again after two seconds if the start/stop button is pressed while the
clutch pedal is depressed (vehicles with manual transmission) or the shift lever is in the neutral
position (vehicles with automatic transmission).
By keeping the start/stop button pressed for two seconds.
4/7
1863/2430
10/30/2018 Print
- The engine can be started again immediately if the start/stop button is pressed while the clutch
pedal is depressed (vehicles with manual transmission) or the shift lever is in the neutral position
(vehicles with automatic transmission).
Switching off the ignition will automatically

activate the PATS.
-
and Operation).
lock the electronic steering lock after 45 seconds if the vehicle is stationary.
-
Refer to: Steering Column (211-04 Steering Column, Description and Operation).
Emergency starting function
For a situation when the passive key cannot be recognized, in place of the usual steering lock there is
a PATS transceiver module and a holder for the passive key.
To start the engine the passive key must be in the vicinity of the PATS transceiver module when the
start/stop button is pressed. For this purpose, it can be inserted into the holder after the blanking
plug has been removed or the passive key can be held in the hand near the blanking plug. If a valid
PATS transponder is detected, the electronic steering column lock will be unlocked, the ignition
switched on and the immobilizer deactivated.
Refer to the service instructions in the section 'Vehicles with a keyless vehicle system'.
Vehicles with a keyless vehicle system
The keyless vehicle system allows the vehicle to be operated without conventional keys or without
active actuation of the radio remote control. With this system, the user only needs to carry a valid
passive key.
The system includes the following components:

keyless vehicle module
passive key (radio remote control with integrated emergency key)
radio frequency receiver
capacitive sensors on the door handles for locking (outside, front only) and for unlocking (inside,
front and rear). These sensors react to touch and must not be pressed.
Electric door locks with fast reaction motors
External antennas in the front door handles and in the rear bumper
Three interior antennas
Electronic steering column lock unit which replaces the mechanical steering column lock
Start/stop button for starting/stopping the engine. The conventional ignition lock is no longer
installed.
To gain access to the vehicle, a passive key must be within the range of the appropriate
external antenna:
- External antennas in the door handles of the driver's door or the front-passenger door
Unlocking the tailgate/luggage compartment lid
- external antenna in the rear bumper
External antennas: approximate detection ranges
5/7
1864/2430
10/30/2018 Print
If a valid key is identified, the vehicle can be directly unlocked by touching one of the unlocking
sensors on the door handles.
When touching the sensor, make sure that you do not touch the locking sensor and unlocking sensor
simultaneously. This may result in the wrong operation being performed.
The tailgate/luggage compartment lid is unlocked by pressing the tailgate/luggage compartment lid
external unlocking button.
The anti-theft alarm system is switched off when the vehicle is unlocked.
Operation).
In addition, the vehicle can be unlocked as described in the section 'Vehicles with RKE'.
The following unlocking functions are possible, depending on the programming of the radio
frequency remote control:
Touching the unlocking sensor on the driver's door handle only unlocks the driver's door.
- The other doors can then be unlocked from inside.
- If one of the unlocking sensors on another door handle is touched first, all the doors will be
unlocked.
Touching the unlocking sensor on a door handle unlocks all doors.
Unlocking using the radio frequency remote control and the programming process are described in the
section 'Vehicles with RKE'.
Locking the vehicle
There are two options for central locking of the vehicle:

A single touch of the locking sensor on one of the front door handles.
- When touching the sensor, make sure that you do not touch the locking sensor and unlocking
sensor simultaneously. This may result in the wrong operation being performed.
A single press of the corresponding button on the radio frequency remote control of the passive key.
In order to be able to check the vehicle locking status, the system does not react to an unlocking
request from the passive key in the first three seconds after the vehicle has been locked. This delay
time can be changed or switched off via IDS (Integrated Diagnostic System).
The all-round locking function (including window closing function) can be activated via the front door
handles. To do this, touch the locking sensor for at least 2 seconds.
Provided the ignition is switched off, the anti-theft alarm system is switched on when the vehicle is
locked.
and Operation).
Double locking
The double locking system operates as described in the section 'Vehicles with RKE'.
In addition, double locking can be activated by touching the locking sensor on one of the front door
handles twice within three seconds. Between touches the hand must be moved off the sensor so that
the sensor registers the touches individually.
6/7
1865/2430
10/30/2018 Print
When touching the sensor, make sure that you do not touch the locking sensor and unlocking sensor
simultaneously. This may result in the wrong operation being performed.
Emergency unlocking/locking
If the keyless vehicle system does not detect the passive key, the vehicle can be unlocked and locked
as described in the section 'Vehicles with RKE'.
To unlock and lock using a key, use the emergency key integrated in the passive key.
Tailgate/luggage compartment lid
The tailgate/luggage compartment lid can be unlocked as described in the section 'Vehicles with RKE'.
In addition, the tailgate/luggage compartment lid can be unlocked independently of the locking state
of the doors by pressing the tailgate/luggage compartment lid external unlocking button, provided a
valid passive key is within range of the rear bumper antenna.
If while the tailgate/luggage compartment lid is being closed, there is a passive key in the luggage
compartment which is recognized by the luggage compartment antenna and no passive key can be
recognized outside the vehicle by the rear bumper antenna, the tailgate/luggage compartment lid is
locked briefly and then immediately unlocked again.
Hood
The hood can be unlocked as described in the section 'Vehicles with RKE'.
Starting/stopping the engine
The procedure for starting and stopping the engine is the same as that described in the section
'Vehicles with keyless start system'.
It is not possible to replace the lock cylinder in the driver's door or to reorder a key/emergency
key without the key number. It is not possible to read off the code from the key itself in service.
If a new passive key has to be added, only this one must be programmed using the IDS.
If a passive key needs to be deleted, then all the keys must first be deleted. The remaining keys
must then be reprogrammed. Up to 8 keys can be programmed.
Between the passive key holder and the PATS transceiver, there is a copper ring that ensures the
resonant frequency of the transceiver. This copper ring must be in its position so that the emergency
start function of the passive key is ensured.
After changing the GEM (generic electronic module), all the available passive vehicle keys must be
reprogrammed using IDS.
After changing the keyless vehicle module, the module must be initialized with the GEM using the
IDS.
7/7
1866/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Handles, Locks, Latches

and Entry Systems - System Operation and Component Description
Print
System Diagram
RKE (remote keyless entry)
Item Description
2 DLC (data link connector)
3 Rear door latch, passenger side
4 Rear door latch, driver side
5 RDM (rear door module), driver side
6 RDM, passenger side
7 Control panel in driver's door
9 FDM (front door module), driver side
10 FDM, passenger side
11 Front door latch, driver side
12 Front door latch, passenger side
13 Tailgate / luggage compartment lid latch
14 Tailgate/luggage compartment lid external lock release switch
15 Ignition key with integrated radio frequency remote control
A Radio frequency signal (from the radio frequency remote control to the radio frequency antenna)
Keyless vehicle system
1/9
1867/2430
10/30/2018 Print
Item Description
2 DLC
8 GEM
16 The CPP (clutch pedal position) sensor
Comments:
Vehicles with manual transaxle.
19 Electronic steering lock
20 Front, middle and luggage compartment antennas, keyless vehicle system
22 Passive Key
24 Start/Stop button
25 Holder, passive key with PATS (passive anti-theft system) transceiver
26 The BPP (brake pedal position) sensor
Comments:
Vehicles with automatic transaxle.
A Radio frequency signal (from the radio frequency remote control to the radio frequency antenna)
B Radio signal with low frequency (from an antenna to the passive key)
Keyless Vehicle System
2/9
1868/2430
10/30/2018 Print
Item Description
2 DLC
3 Rear door latch, passenger side
4 Rear door latch, driver side
5 RDM, driver side
6 RDM, passenger side
7 Control panel on the driver's door
8 GEM
9 FDM, driver side
10 FDM, passenger side
11 Front door latch, driver side
12 Front door latch, passenger side
13 Tailgate / luggage compartment lid latch
14 Tailgate/luggage compartment lid external lock release switch
20 Front, middle and luggage compartment antennas, keyless vehicle system
22 Passive Key
27 Door handles with unlocking sensor
28 Door handles with sensors and integrated front door antenna, keyless vehicle system
29 Rear bumper antenna, keyless vehicle system
3/9
1869/2430
10/30/2018 Print
A Radio frequency signal (from the radio frequency remote control to the radio frequency receiver)
B Radio signal with low frequency (from an antenna to the passive key)
System Operation
RKE
When a button on the radio frequency remote control is pressed, a coded signal is transmitted. This is
received by the radio frequency receiver in the GEM and decoded there. If the signal is valid, the
signal is sent on accordingly by the GEM:
The signal from the unlock button is passed via the medium speed CAN (controller area network)
(MS-CAN) to both FDMs and passed there via the LIN (local interconnect network) to the RDMs. The
modules in the doors then activate the respective door latches.
The signal from the luggage compartment release button is sent directly to the tailgate locking
mechanism/luggage compartment lid latch by the GEM.
The signal from the central door locking switch is directed to the GEM and from there via the MS-CAN
to both FDMs, from which it is routed via the LIN to the RDMs. The modules in the doors then activate
the respective door latches.
If a key is turned in the lock cylinder of the driver's door, the unlock signal is sent to the driver side
FDM. The FDM routes the signal to the GEM. Thereupon the GEM sends a corresponding signal to the
FDMs and from there to the RDMs. The modules in the doors then activate the respective door
latches.
If the tailgate/luggage compartment lid external lock release switch is operated, the signal is routed
to the GEM and verified there. If the vehicle is stationary and unlocked, the signal is forwarded from
there to the tailgate locking mechanism/luggage compartment lid latch.
In addition, the signals coming from the radio frequency remote control, via the FDMs/the RDMs/ or
from the tailgate/luggage compartment external lock release switch are used by the GEMs to activate
and deactivate the anti-theft alarm system and to switch on the interior lighting.
Locking the vehicle
The tailgate/luggage compartment lid is locked automatically when it is closed. The tailgate/luggage
compartment lid external lock release switch remains active until the driver's door is locked.
The doors can only be locked if the front doors are closed.
The signal flow for locking the vehicle is the same as that for unlocking it.
Electric child lock
When the safety switch for the rear windows is operated, a signal is sent via the LIN to the FDM on
the driver's side. From there the signal is sent via the LIN to the RDM on the driver side and via the
MS-CAN to the FDM on the passenger side and then onwards via the LIN to the RDM on the
passenger side. The signal is then sent on by the RDMs to the respective door latches.
Keyless vehicle system
In order for engine starting to be enabled it is necessary for a valid passive key to be present inside
the vehicle.
A total of three internal antennas are installed, for identification of the passive vehicle key:
behind the instrument panel,
below the center console,
behind the second row of seats.
Three states can be switched to via the start/stop button:

Switch on the ignition
directly start the engine,
Switch off the engine.
Starting the engine.
The following options are available:

4/9
1870/2430
10/30/2018 Print
Ignition ON:
- actuate the start/stop button.
Starting the engine from ignition ON or directly from ignition OFF:
- operate the clutch pedal (vehicles with manual transmission) or the brake pedal (vehicles with
automatic transmission) and the start/stop button.
When the start/stop button is pressed, the interior antennas of the keyless vehicle module are
activated. The passive vehicle key is then activated and it transmits a coded radio frequency signal.
This coded radio frequency signal is received by the radio frequency receiver.
The signal is then transferred on by the radio frequency receiver to the keyless vehicle system and
from there onwards via the medium speed CAN (MS-CAN) to the GEM.
For security reasons, a code enquiry is made to the PCM before the vehicle can be started.
The code enquiry occurs via the high-speed CAN (HS-CAN). Starting is only enabled once
confirmation has been received from the module.
Stopping the engine
The engine is stopped by pressing the start/stop button, provided the vehicle is stationary (vehicle
speed = 0 km/h).
In an emergency, the engine can be stopped at any speed as follows:

By pressing the start/stop button twice within three seconds.
By keeping the start/stop button pressed for two seconds.
Keyless Vehicle System

By touching the unlocking sensor on a door handle or the unlocking button on the tailgate or luggage
compartment lid, the corresponding exterior antenna emits a low frequency signal.
Three exterior antennas are installed on the vehicle:

one in each of the front door handles,
one behind the rear bumper.
The passive vehicle key is then activated and it transmits a coded radio frequency signal.
This coded radio signal is received by the radio frequency receiver and is passed on from there to the
keyless vehicle module.
If the module detects a valid key signal, the operated door or tailgate/luggage compartment lid will
be unlocked. Unlocking of this door or tailgate/luggage compartment lid is performed directly by the
keyless vehicle module.
If the unlocking function is programmed so that all the doors will be unlocked, the module sends the
unlock request via the MS-CAN to the GEM. The GEM then activates the individual door modules.
NOTE:
If the vehicle goes over 5 days without being unlocked, the system enters energy saving mode. This
mode prevents excessive load on the vehicle battery
In this mode, the response time of the keyless vehicle system during unlocking is slightly longer.
Energy saving mode is deactivated again when the vehicle is unlocked again once after more than 5
days.
Locking the vehicle
If the locking sensor on one of the front door handles is touched, the corresponding antenna emits a
low frequency signal.
The passive vehicle key is then activated and it transmits a coded radio frequency signal.
This coded radio frequency signal is received by the radio frequency receiver.
The radio frequency receiver transfers the signal to the keyless vehicle module.
If the module recognizes a valid key signal, the module sends the locking request via the MS-CAN to
the GEM. The GEM then activates the individual door modules.
5/9
1871/2430
10/30/2018 Print
Starting/stopping the engine
The procedure for starting and stopping the engine is the same as that described in the section
Keyless vehicle system.
Passive Key
The main function of the passive key is to receive requests from the keyless vehicle module and to
send it coded signals.
The passive key also has standard lock, unlock and tailgate/luggage compartment lid release buttons.
Their function is similar to the normal function of the electronic locking systems in vehicles with RKE.
Passive keys have to be programmed to the particular vehicle. Use IDS (Integrated Diagnostic
System) to do this.
Item Description
1 Cover
2 Emergency key
3 Passive Key
The emergency key is located under the cover in the body of the passive key.
When the emergency key is inserted into the recess in the housing, the passive key can be used as a
grip.
Transceiver - passive anti-theft system (emergency start function)
Item Description
1 Passive Key
2 Blanking plug
3 PATS transceiver
6/9
1872/2430
10/30/2018 Print
4 Passive key holder

If the passive key is not recognized when the start/stop button is pressed, a query is made via the
GEM to the PATS transceiver. If a valid PATS transponder is recognized and an appropriate signal from
the CPP sensor and/or BPP sensor is received by the GEM, the ignition is switched on and the starter
motor relay actuated via the PCM.
Electronic steering lock
The electronic steering column lock is only then supplied with electrical power by GEM (Generic
Electronic Module) when the vehicle is stationary and the engine is not running.
One of the following conditions must apply so that the electronic steering column lock can be
unlocked:
The driver's door was opened with a valid passive key or by remote unlocking.
The brake pedal (vehicle with automatic transmission) or clutch pedal (vehicle with manual
transmission) must be operated, and there must be a valid passive key detected in the vehicle.
The start/stop switch is pressed and a valid passive key is recognized in the vehicle.
All the following conditions must apply so that the electronic steering column lock can be
locked:
The ignition has been in the OFF position for more than 45 seconds.
The engine is stopped.
Vehicle speed and wheel speed are zero.
There is no passive key in the vehicle interior.
The electronic steering column lock must be programmed for the particular vehicle. Use IDS to do
this.
If the steering is to be locked or unlocked, then the following sequence occurs:

The power supply for the electronic steering column lock is switched on.
The GEM checks the status which the steering column lock is currently in.
Afterwards the command to lock or unlock is transmitted.
The GEM checks the new status.
Lastly, the power supply for the steering column lock is switched off.
The GEM continuously monitors the cables to the electronic steering column lock. If a short-circuit is
detected on the supply cables, a new switch-on of the ignition or a new engine start are blocked and
an appropriate warning message is displayed in the instrument cluster. The blocking remains until the
short-circuit is rectified and the DTCs in the keyless vehicle system are erased.
Door handle on vehicles with a keyless vehicle system
Item Description
7/9
1873/2430
10/30/2018 Print
1 Front door antenna, keyless vehicle system

2 Door locking sensor
The front door handles contain the following components:

Front/rear door antenna, keyless vehicle system
Locking sensor
Lock cylinder (driver's door only)
Unlocking sensor on the inside of the door handle
The rear door handles also contain an unlocking sensor on the inside of the door handle.
When the back of the door handle is grasped, the keyless vehicle module is activated by the unlocking
sensor. An identification request is sent to the passive key via the front door antenna on the
corresponding side of the vehicle. The other exterior antennas are not activated.
If the passive key is valid, then a signal is sent via the GEM by the keyless vehicle module to activate
the corresponding FDM or RDM to unlock the particular door.
Touching the door locking sensor on one of the front door handles causes the vehicle to be locked in
the same manner. To do this, both front doors must be closed.
On vehicles with double locking, two separate touches of the door locking sensor within 3 seconds will
activate the double locking function. To do this, all the doors, the hood and the tailgate/luggage
compartment lid must be closed.
Start/stop button
Pressing the start/stop switch activates the keyless vehicle system module and an identification query
is made to the passive key via the keyless vehicle system interior antennas.
If a valid passive key is recognized, the GEM actuates the appropriate terminals for the OFF ('0'),
IGNITION ON ('II') and START ENGINE ('III') states. The conventional position 'I' can no longer be
selected for ordinary operation using a switch.
All the following conditions must be satisfied before the starter motor relay will be actuated by
the GEM:
The engine is not running.
A valid passive key is found in the vehicle interior.
The clutch pedal (vehicles with manual transmission) or the brake pedal (vehicles with automatic
transmission) is fully depressed.
The start/stop switch is pressed.
When the start/stop switch is released or the brake or clutch pedal is released, the starting process is
halted.
In the background of the starting process, the PATS in the GEM and in the PCM is deactivated. The
engine start requires that the starter motor relay is electrically actuated by the GEM and on the
ground side by the PCM simultaneously.
While driving, it is only possible to stop the engine with a single press of the start/stop switch if the
vehicle speed is not exceeding the predefined limit value of approx. 7 km/h.
The engine can also be stopped while driving by pressing and holding for 3 seconds or pressing twice
within 3 seconds.
The electronic steering column lock however only operates once the vehicle is stationary.
8/9
1874/2430
10/30/2018 Print
9/9
1875/2430
10/30/2018 Print

Locks, Latches and Entry Systems
Print
General Equipment
Misaligned door(s), hood, liftgate or hood Fuse(s)
Door latch(es) Relay(s)
Liftgate latch Wiring harness
Hood latch Electrical connector(s)
Actuating Cable(s) Door latch(s)
Exterior door handle(s) Liftgate latch
Door latch remote control(s) Vehicle battery
Door lock cylinder(s) Remote transmitter batteries
Liftgate lock cylinder Remote transmitter
Sliding door track(s) RF receiver
Fuel tank flap interlock Liftgate exterior release switch
Liftgate spindle motor(s) Sliding door lock actuator
Door control module(s)
Generic electronic module (GEM)
Battery Junction Box (BJB)
Central Junction Box (CJB)
Rear Junction Box (RJB)
Liftgate spindle motor(s)
Liftgate module
4. If the cause is not visually evident, refer to the Ford diagnostic equipment to diagnose the
system.
1/1
1876/2430
10/30/2018 Print

Ignition Lock Cylinder
Print
Removal
1.
2.
3.
4.
1/2
1877/2430
10/30/2018 Print
5. 1. Turn the ignition key to position I.

2. Using a suitable punch, release the locking tang.
Installation
1. NOTICE: Make sure that the ignition switch and the ignition lock cylinder are aligned
before installation.
2/2
1878/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Radio Frequency (RF)

Receiver—Vehicles Without: Overhead Console
Print
Special Tool(s)
501-125
Removal
2.
1/2
1879/2430
10/30/2018 Print
Installation
2/2
1880/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Radio Frequency (RF)

Receiver—Vehicles With: Overhead Console
Print
Special Tool(s)
501-125
Removal
2.
1/2
1881/2430
10/30/2018 Print
3.
4.
Installation
2/2
1882/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Keyless Vehicle Module

(KVM)—5-Door
Print
Removal
1. Refer to: Loadspace Trim Panel LH - 5-Door (501-05 Interior Trim and Ornamentation, Removal
and Installation).
2.
Installation
1/1
1883/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Keyless Vehicle Front

Antenna
Print
Removal
1. Refer to: Climate Control Assembly - Vehicles Without: Center Armrest (412-01 Climate Control,
Refer to: Climate Control Assembly - Vehicles With: Center Armrest (412-01 Climate Control,
2.
Installation
1/1
1884/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Keyless Vehicle Center

Antenna—Vehicles With: Center Armrest
Print
Removal
1. Refer to: Media Hub (415-01 Information and Entertainment System, Removal and Installation).
2.
Installation
1/1
1885/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Keyless Vehicle Center

Antenna—Vehicles Without: Center Armrest
Print
Removal
1. Refer to: Floor Console - Vehicles Without: Center Armrest (501-12, Removal and Installation).
2.
Installation
1/1
1886/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Keyless Vehicle Luggage

Compartment Antenna—5-Door
Print
Removal
1.
2.
3. Remove the left-hand C-pillar trim panel.
Installation).
5.
1. Torque: 47 Nm
1/3
1887/2430
10/30/2018 Print
6.
7.
8.
2/3
1888/2430
10/30/2018 Print
9.
Installation
3/3
1889/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Exterior Front Door Handle
Print
Removal
1.
2. 1.
2. If equipped.

3.
1/2
1890/2430
10/30/2018 Print
4.
5.
6.
Installation
2/2
1891/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Exterior Rear Door Handle
Print
Removal
1.
2.

3.

4.
1/2
1892/2430
10/30/2018 Print
5.
6.
Installation
2/2
1893/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Front Door Latch

Print
General Equipment
Adhesive Tape
Removal
Installation).
2.
3.
4.
1/5
1894/2430
10/30/2018 Print
5.
7.
2/5
1895/2430
10/30/2018 Print
8. Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal
and Installation).
9.
10.
1. Torque: 8 Nm
11.
3/5
1896/2430
10/30/2018 Print
4/5
1897/2430
10/30/2018 Print
Installation
5/5
1898/2430
10/30/2018 Print

Front Door Lock Cylinder
Print
Removal
1.
2.
Installation
1/1
1899/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Rear Door Latch

Print
Removal
Installation).
Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal
and Installation).
2.
3.
4.
1. Torque: 8 Nm
1/4
1900/2430
10/30/2018 Print
5.
2/4
1901/2430
10/30/2018 Print
Installation
3.
3/4
1902/2430
10/30/2018 Print
4/4
1903/2430
10/30/2018 Print

Liftgate Latch
Print
Removal
Installation).
Refer to: Liftgate Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Refer to: Liftgate Trim Panel - Wagon (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2. Torque: 20 Nm
Installation
1/1
1904/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Hood Latch Release Cable
Print
Removal
Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
2.
3.
4.
1/4
1905/2430
10/30/2018 Print

5.
6.
7.
2/4
1906/2430
10/30/2018 Print
All vehicles
8.
9.
3/4
1907/2430
10/30/2018 Print
Installation
4/4
1908/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Liftgate Release Switch

Print
Removal
1. Refer to: Liftgate Moulding - 5-Door (501-08 Exterior Trim and Ornamentation, Removal and
Installation).
Refer to: Liftgate Moulding - Wagon (501-08 Exterior Trim and Ornamentation, Removal and
Installation).
2.
Installation
1/1
1909/2430
10/30/2018 Print
Handles, Locks, Latches and Entry Systems - Luggage Compartment Lid

Release Switch
Print
Removal
1. Refer to: Liftgate Moulding - 4-Door (501-08 Exterior Trim and Ornamentation, Removal and
Installation).
2.
Installation
1/1
1910/2430
10/30/2018 Print
Wipers and Washers - Wipers and Washers - Overview

Print
General overview
Illustration shows LHD (left-hand drive)
Item Description
1 Driveshaft, front windshield wiper arm
2 Wiper motor bracket
3 Wiper motor
4 Electrical connection (4-pin)
5 Integral electronics
The drive of the front windshield wiper arms is provided directly (direct drive) via two separate,
counter-rotating wiper motors. This means that no additional wiper linkage is needed.
Electronics are integrated in each wiper motor. The BCM (body control module) controls the driver
side wiper motor via the LIN (local interconnect network) databus.
The driver side wiper motor communicates with the passenger side wiper motor via a separate
data cable. Here,
the wiper motor on the driver side is the master and
the wiper motor on the passenger side is the slave.
Both wiper motors look identical from the outside. The software for both motors is also almost
identical, apart from the difference in design with regards to the direction of rotation. However, the
left and right-hand wiper motors do differ in terms of the shape of the bracket. The bracket and
wiper motor are only available as a single component in service. This eliminates the risk of any mix-
up.
When the wiper motors are first take into operation the master/slave assignment is performed
automatically. This is defined by the pin allocation of the relevant wiring harness connector:
On the master (driver side), all of the pins of the 4-pin connector are assigned. In the process, pin
1 provides the LIN connection to the BCM.
On the slave, pin 1 (LIN) is not assigned.
Both windshield wiper blades have the same length of 725 mm.
1/2
1911/2430
10/30/2018 Print
Service position
In order to replace the windshield wiper blades, both wiper arms need to be moved to the service
position. The wipers are moved to this position by pressing and holding the single wipe function within
3 seconds of switching the ignition off (pull the multifunction lever down to do this).
NOTE: The windshield wiper arms must be removed in the starting position (park position).
Alignment of the windshield wiper arms during assembly
NOTICE: Prior to assembly of the windshield wiper arms the ignition must be switched on for a
few seconds. This ensures that the wiper motors are in the starting position (park position).
During installation of the windshield wiper arms the driver side wiper arm must be mounted
horizontally and above the passenger side arm.
NOTE: There are no markings on the windshield or similar guide marks to help with the alignment
of the windshield wiper arms. The alignment of the windshield wiper arms should be judged by eye
alone. The final alignment is performed after the windshield wiper range has been learned by the
system.
Learning the windshield wiper range
After replacing one or both wiper motors and after disassembly of the windshield wiper arms the
windshield wiper range needs to be re-learned.
The learning function needs to be activated and deactivated via the IDS (Integrated Diagnostic
System). Please refer to the corresponding instructions in the current workshop literature for details
of the exact procedure..
2/2
1912/2430
10/30/2018 Print
Wipers and Washers - Wipers and Washers

Print

General Equipment

correctly.
Wiper blade(s) Fuse(s)
Rotating shaft – wiper arm Connectors
Washer reservoir Wiring harness
Hose(s) Washer pump
Nozzles Front/rear window wiper motor
Check the windshield wiper for residue-free Rain sensor
wiping in the vicinity of the rain sensor.
Check the adhesive pad between the rain
sensor and the windshield for trapped air.
Clean wax residues from the windshield in the
vicinity of the rain sensor.
Check the windshield for damage/cracks in the
vicinity of the rain sensor.
Check that the rain sensor retaining frame is
correctly attached to the windshield.
1/1
1913/2430
10/30/2018 Print
Wipers and Washers - Windshield Wiper Motor Initialization

Print
General Procedures
Initialization
WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
section 100-00 General Information. Failure to follow this instruction may result in serious personal
injury.
NOTICE: Do not set the ignition to OFF during the procedure. Setting the ignition to OFF causes
the wiper motors to accept the current windshield wiper arms position as the initialized position.
NOTE: Low battery voltage may prevent the BCM (body control module) from entering Learn Mode.
NOTE: If the FCDIM (front control/display interface module) displays Low Battery Audio Off or the
FDIM (front display interface module) displays Battery Saver System Off, start the vehicle and set
the ignition to OFF to reset the BCM.
NOTE: Make sure the windshield is clean and dry before carrying out this procedure.
1. Ignition "ON".
2. Cycle the windshield wipers "ON" then "OFF". Make sure the windshield wiper arms park in the
correct position.
3. Using a diagnostic scan tool, place the windshield wiper motors in Learn Mode using the WMM
Calibration.
4. Press the wiper and washer lever arm down 3 times within 5 seconds. The windshield wiper arms
move to a preset or pre-initialization position
5.
NOTICE: If the wiper arms are pulled closer to the A-pillar than the specified
distance during this step, do not attempt to move the wiper arms back toward the pre-
initialization position manually. Damage to the wiper motor can occur.
NOTE: Pre-initialization can be reset by selecting INTERMITTENT on the wiper/washer
switch and then selecting OFF.
Gently pull the windshield wiper blades out toward the A-pillar moulding until the distance
between the wiper arm and the edge of the windshield is 50mm (1.97in).
6. Press the wiper and washer lever arm down 1 time. This sets the current windshield wiper arm
position as the approved position and the wiper arms move back to the PARK position.
1/2
1914/2430
10/30/2018 Print
7. Using the scan tool, finish the WMM Calibration by placing the windshield wiper motors in Normal
Mode.
8. Carry out a low speed windshield wipe and make sure the windshield wiper motors and arms park
in the correct position.
9. Carry out a high speed windshield wipe on a wet windshield and make sure the wiper blades do not
contact the A-pillar.
2/2
1915/2430
10/30/2018 Print
Wipers and Washers - Wiper Blade Angle Adjustment

Print
General Procedures
Special Tool(s)
501-027
Aligner, Wiper Arm
501-027-01
Adapter for 501-027
Adjustment
1. NOTICE: Make sure that the motor is in the park position.
2. NOTE: Make sure that the 3 marked points of the special tool are in contact with the glass.
1. Left-hand side wiper arm.
Use Special Service Tools: 501-027, 501-027-01.

2. Right-hand side wiper arm.
Use Special Service Tools: 501-027, 501-027-01.
3. NOTICE: Make sure that the special tool is lifted off the glass when adjusting the angle.
Adjust the wiper arm to an angle of 5° ± 1°.
1/2
1916/2430
10/30/2018 Print
4.
5.
2/2
1917/2430
10/30/2018 Print
Wipers and Washers - Rain Sensor—Vehicles

Without: Active City Stop
Print
Removal
1.
2.
Installation
1. NOTICE:
Make sure that the surface is clean and free of foreign material.
1/2
1918/2430
10/30/2018 Print
Make sure that the insulator pads are correctly positioned to prevent direct contact with
other components.
2/2
1919/2430
10/30/2018 Print
Wipers and Washers - Rain Sensor—Vehicles With: Active City Stop

Print
General Equipment
Removal
2. NOTICE: Make sure that the cable cannot be damaged or cause a noise, vibration or
harshness (NVH) concern.
If equipped.
1/2
1920/2430
10/30/2018 Print
3.
Installation
1. NOTICE:
Make sure that the surface is clean and free of foreign material.
Make sure that the insulator pads are correctly positioned to prevent direct contact with
other components.
2/2
1921/2430
10/30/2018 Print
Wipers and Washers - Windshield Wiper Motor

Print
Removal
2.
3. If equipped.
4. Torque: 7 Nm
1/4
1922/2430
10/30/2018 Print
5. Torque: 9 Nm
6.
7. If equipped.
2/4
1923/2430
10/30/2018 Print
8.
9. Torque: 7 Nm
10. Torque: 9 Nm
3/4
1924/2430
10/30/2018 Print
Installation
2. Initialize the windshield wiper motor.
Refer to: Windshield Wiper Motor Initialization (501-16 Wipers and Washers, General Procedures).
4/4
1925/2430
10/30/2018 Print
Wipers and Washers - Rear Window Wiper

Motor
Print
General Equipment
Two Leg Puller
Removal
1. NOTICE: Make sure that the motor is in the park position.

Use the General Equipment: Two Leg Puller
Torque: 15 Nm
Installation).
3. Torque: 7 Nm
Installation
1/1
1926/2430
10/30/2018 Print
Wipers and Washers - Windshield Washer Pump

Print
Removal
2. If equipped.
3.
Vehicles with headlamp washers

1. 4-door
2. 5-door or Kombi
1/3
1927/2430
10/30/2018 Print
All vehicles

1. 4-door
2. 5-door or Kombi
2/3
1928/2430
10/30/2018 Print
Installation
3/3
1929/2430
10/30/2018 Print
Wipers and Washers - Windshield Washer Reservoir

Print
Removal
2. If equipped.
3.
4.
1/5
1930/2430
10/30/2018 Print

5. 1. Kombi or 5-door
6.
2/5
1931/2430
10/30/2018 Print
All vehicles

8.
3/5
1932/2430
10/30/2018 Print

NOTE: The following steps are only necessary when installing a new component.
9.
10. Refer to: Headlamp Washer Pump (501-16 Wipers and Washers, Removal and Installation).
11. Refer to: Windshield Washer Fluid Level Sensor (501-16 Wipers and Washers, Removal and
Installation).

2. 4-door
4/5
1933/2430
10/30/2018 Print
13. Refer to: Windshield Washer Pump (501-16 Wipers and Washers, Removal and Installation).
All vehicles
NOTE: The following steps are only necessary when installing a new component.
14. Refer to: Windshield Washer Pump (501-16 Wipers and Washers, Removal and Installation).
15.
Installation
5/5
1934/2430
10/30/2018 Print
Wipers and Washers - Headlamp Washer Pump

Print
Removal
2. If equipped.
3.
1/2
1935/2430
10/30/2018 Print
Installation
2/2
1936/2430
10/30/2018 Print
Wipers and Washers - Windshield Washer Fluid Level Sensor

Print
Removal
2. If equipped.
3.
4.
1/2
1937/2430
10/30/2018 Print
Installation
2/2
1938/2430
10/30/2018 Print
Wipers and Washers - Headlamp Washer Jet

Print
Removal
2.
3.
4.
Installation
1/1
1939/2430
10/30/2018 Print
Wipers and Washers - Windshield Wiper Pivot Arm

Print
General Equipment
Two Leg Puller
Removal
NOTE: LH (left-hand) side shown, RH (right-hand) side similar.
2.
3.
1/5
1940/2430
10/30/2018 Print
4. Use the General Equipment: Two Leg Puller
Installation
1. Set ignition switch to the II position (Ignition on).
2/5
1941/2430
10/30/2018 Print
2. NOTE: Make sure the wiper motors(s) stop in the PARK position.
Cycle the wipers "ON" for one complete cycle and then turn the wipers "OFF".
3. NOTE: The ignition must remain "ON" during installation of the wiper pivot arm(s).
3/5
1942/2430
10/30/2018 Print

NOTE: Make sure the wiper motor is in the PARK position.
Position the wiper pivot arm(s) on the wiper motor shaft(s).
Align the wiper pivot arms per measurements.
Align the LH windshield wiper pivot arm to 90 mm (3.54).
Align the .RH windshield wiper pivot arm to 75 mm (2.95 in)
5. Install the wiper pivot arm washer(s) and nut(s)

Torque to 30 Nm (22 lb-ft).
Install the wiper pivot arm nut cover(s).
4/5
1943/2430
10/30/2018 Print
6. Set ignition to the 0 position (Ignition "OFF").
5/5
1944/2430
10/30/2018 Print
Roof Opening Panel - Roof Opening Panel

Print

General Equipment
Roof opening panel Fuse(s)
Seal(s) Electrical connector(s)
Weatherstrip Switch(es)
Alignment Circuit(s)
Wiring harness
Roof opening panel module
Symptom Chart

SOURCES
THE ROOF OPENING PANEL * DRAIN* CHECK THE DRAIN TUBES FOR BLOCKAGE OR
LEAKS HOSES. OBSTRUCTION. REFER TO: (501-17)
ROOF OPENING PANEL FRONT DRAIN HOSE
ROOF OPENING PANEL REAR DRAIN HOSE - 4-
DOOR (REMOVAL AND INSTALLATION),
ROOF OPENING PANEL REAR DRAIN HOSE - 5-
DOOR (REMOVAL AND INSTALLATION).
THE ROOF OPENING PANEL * HEADLINER. * CHECK THE HEADLINER FOR SECURITY. REFER TO:
RATTLES HEADLINER - 4-DOOR, VEHICLES WITH:
PANORAMIC ROOF PANEL (501-05 INTERIOR TRIM
AND ORNAMENTATION, REMOVAL AND
INSTALLATION),
HEADLINER - 5-DOOR, VEHICLES WITH:
PANORAMIC ROOF PANEL (501-05 INTERIOR TRIM
AND ORNAMENTATION, REMOVAL AND
INSTALLATION),
HEADLINER - WAGON, VEHICLES WITH: GLASS
ROOF PANEL (501-05, REMOVAL AND
INSTALLATION).
* GUIDES AND * CHECK FOR WORN OR DAMAGED COMPONENTS.
TRACK. CARRY OUT THE ROOF OPENING PANEL ALIGNMENT.
REFER TO: ROOF OPENING PANEL ALIGNMENT (501-17
ROOF OPENING PANEL, GENERAL PROCEDURES).
THE ROOF OPENING PANEL IS * GUIDES AND * CHECK FOR WORN OR DAMAGED COMPONENTS.
NOISY DURING OPERATION TRACK. CARRY OUT THE ROOF OPENING PANEL ALIGNMENT.
* ROOF REFER TO: ROOF OPENING PANEL ALIGNMENT (501-17
OPENING ROOF OPENING PANEL, GENERAL PROCEDURES).
PANEL
MOTOR.
1/8
1945/2430
10/30/2018 Print
* ROOF
OPENING
PANEL.
THE ROOF OPENING PANEL * ROOF * CARRY OUT THE ROOF OPENING PANEL CONTROL
DOES NOT OPEN OR CLOSE OPENING SWITCH COMPONENT TEST IN THIS SECTION.
PANEL
CONTROL
SWITCH.
* ROOF * UPDATE THE ROOF OPENING PANEL SETTING.
OPENING REFER TO: POWER ROOF OPENING PANEL SETTING
PANEL UPDATE (501-17 ROOF OPENING PANEL, GENERAL
MOTOR. PROCEDURES).
* CIRCUITS. * GO TO PINPOINT TEST A.
THE ROOF OPENING PANEL * GUIDES AND * CHECK FOR WORN OR DAMAGED COMPONENTS.
DOES NOT STOP FLUSH FROM TRACK. CARRY OUT THE ROOF OPENING PANEL ALIGNMENT.
ANY POSITION REFER TO: ROOF OPENING PANEL ALIGNMENT (501-17
ROOF OPENING PANEL, GENERAL PROCEDURES).
* ROOF * CARRY OUT THE POWER ROOF OPENING PANEL
OPENING INITIALIZATION.
PANEL REFER TO: POWER ROOF OPENING PANEL
MOTOR. INITIALIZATION (501-17 ROOF OPENING PANEL,
GENERAL PROCEDURES).
THE ROOF OPENING PANEL * ROOF * GO TO PINPOINT TEST B.
SHOWS UNEXPECTED OPENING
BOUNCE BACK AT HIGH PANEL
SPEED MOTOR.
* CIRCUIT(S).
NO COMMUNICATION WITH * ROOF * GO TO PINPOINT TEST C.
THE ROOF OPENING PANEL OPENING
MODULE PANEL
MODULE.
* CIRCUIT.
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical measurements.
PINPOINT TEST A : THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE
A1: CHECK FOR VOLTAGE TO THE ROOF OPENING PANEL CONTROL SWITCH
1 Ignition ON.
2 CHECK the operation of the roof opening panel control switch
lamp.
Does the roof opening panel control switch lamp illuminate?
Yes
GO to A2.
No
GO to A9.
A2: CHECK THE SUPPLY VOLTAGE TO THE ROOF OPENING PANEL MODULE, CIRCUIT CBP80C
(OG/BK)
1 Ignition OFF.
2 Disconnect Roof Opening Panel Module C9PR32-B.
3 Measure the voltage between the roof opening panel module
C9PR32-B pin 1, circuit CBP80C (OG/BK), harness side and
ground.
2/8
1946/2430
10/30/2018 Print
Is the voltage greater than 10 volts?

Yes
GO to A5.
No
GO to A4.
A3: CHECK THE SUPPLY VOLTAGE TO THE ROOF OPENING PANEL MODULE, CIRCUIT CBP80C
(OG/BK)
1 Disconnect Body Control Module C2AM02-F.
2 Measure the voltage between the body control module C2AM02-
F pin 9, circuit CBP80A (OG/BK), component side and ground.

Yes
REPAIR circuit CBP80A (OG/BK). TEST the system for normal
operation.
No
CHECK the body control module. REFER to the Ford diagnostc
equipment.
A4: CHECK THE ROOF OPENING PANEL CONTROL SWITCH DOWN/OPEN GROUND CIRCUIT
1 Operate the roof opening panel control switch to the
DOWN/OPEN position and keep it pressed.
2 Measure the resistance between the roof opening panel module
C9PR32-B pin 9, circuit CPR40A (YE/OG), harness side and the
roof opening panel module C9PR32-B pin 10, circuit GD138AJB
(BK/WH), harness side.
Is the resistance less than 5 ohms?

Yes
GO to A7.
No
GO to A5.
A5: CHECK FOR CONTINUITY BETWEEN THE ROOF OPENING PANEL MODULE AND THE ROOF
OPENING PANEL CONTROL SWITCH
1 Disconnect Roof Opening Panel Control Switch C9LN57.
C9PR32-B pin 9, circuit CPR40A (YE/OG), harness side and roof
opening panel control switch C9LN57 pin 12 (YE/OG), harness
side.

Yes
GO to A6.
No
3/8
1947/2430
10/30/2018 Print
REPAIR circuit CPR40A (YE/OG). TEST the system for normal

operation.
A6: CHECK THE ROOF OPENING PANEL MODULE GROUND CIRCUIT GD138AJB (BK/WH)
C9PR32-B pin 10, circuit GD138AJB (BK/WH), harness side and
ground.

Yes
INSTALL a new roof opening panel control switch. TEST the
system for normal operation.
No
REPAIR circuit GD138AJB (BK/WH). TEST the system for normal
operation.
A7: CHECK THE ROOF OPENING PANEL CONTROL SWITCH UP/CLOSE GROUND CIRCUIT
1 Connect Roof Opening Panel Control Switch C9LN57.
2 Operate the roof opening panel control switch to the UP/CLOSE
position and keep it pressed.
C9PR32-B pin 8, circuit CPR31A (VT/BN), harness side and roof
opening panel module C9PR32-B pin 10, circuit GD138AJB
(BK/WH), harness side.

Yes
INSTALL a new roof opening panel motor.
REFER to: Roof Opening Panel Motor (501-17 Roof Opening
Panel, Removal and Installation).
No
GO to A8.
A8: CHECK FOR CONTINUITY BETWEEN THE ROOF OPENING PANEL MODULE AND THE ROOF
OPENING PANEL CONTROL SWITCH
C9PR32-B pin 8, circuit CPR31A (VT/BN), harness side and the
roof opening panel control switch C9LN57 pin 11 (VT/BN),
harness side.

Yes
INSTALL a new roof opening panel control switch. TEST the
No
REPAIR circuit CPR31A (VT/BN). TEST the system for normal
operation.
4/8
1948/2430
10/30/2018 Print
A9: CHECK THE VOLTAGE TO THE ROOF OPENING PANEL CONTROL SWITCH LAMP, CIRCUIT
VLN30A (BN/GN)
1 Ignition OFF.
3 Ignition ON.
4 Measure the voltage between the roof opening panel control
switch C9LN57 pin 8, circuit VLN30A (BN/GN), harness side and
ground.

Yes
GO to A10.
No
REPAIR circuit VLN30A (BN/GN). TEST the system for normal
operation.
A10: CHECK THE ROOF OPENING PANEL CONTROL SWITCH GROUND CIRCUIT
1 Ignition OFF.
2 Measure the resistance between the roof opening panel control
switch C9LN57 pin 5, circuit GD138S (BK), harness side and
ground.

Yes
Install a new roof opening panel control switch. TEST the
No
REPAIR circuit GD138AB (BK/WH). TEST the system for normal
operation.
PINPOINT TEST B : THE ROOF OPENING PANEL SHOWS UNEXPECTED BOUNCE

BACK AT HIGH SPEED
B1: CHECK THE OPERATION OF THE MULTIFUNCTION DISPLAY
1 Drive the vehicle.
2 Observe the multi-function display 'Average speed' function.
Does the display operate correctly?
Yes
GO to B2.
No
REFER to: Instrument Panel Cluster (IPC) (413-01A Instrument

Panel Cluster (IPC), Diagnosis and Testing).
B2: CHECK FOR A SHORT TO GROUND
2 Disconnect Body Control Module C2AM02-H.
C9PR32-B pin 6, circuit VMC05B (VT/OG), harness side and
ground.
5/8
1949/2430
10/30/2018 Print
Is the resistance greater than 10,000 ohms?

Yes
GO to B3.
No
REPAIR circuit VMC05B (VT/OG). TEST the system for normal
operation.
B3: CHECK FOR CONTINUITY BETWEEN THE CENTRAL JUNCTION BOX AND THE ROOF OPENING
PANEL MODULE
1 Ignition OFF.
2 Measure the resistance between the central junction box
C2AM02-H pin 3, circuit VMC05A (VT/OG), harness side and the
roof opening panel module C9PR32-B pin 6, circuit VMC05B
(VT/OG), harness side.

Yes
No
REPAIR circuit VMC05B (VT/OG) or VMC05B (VT/OG). TEST the
PINPOINT TEST C : NO COMMUNICATION WITH THE ROOF OPENING PANEL

MODULE
C1: CHECK OPERATION OF THE GLOBAL CLOSING
1 Operate the global closing function.
Do the door windows close?
Yes
GO to C2.
No
REFER to the Ford diagnostic equipment.
C2: CHECK FOR A SHORT TO GROUND
2 Disconnect Body Control Module C2AM02-H.
C9PR32-B pin 2, circuit CPR39A (BU/OG), harness side and
ground.
6/8
1950/2430
10/30/2018 Print
Is the resistance greater than 10,000 ohms?

Yes
GO to C3.
No
REPAIR circuit CPR39A (BU/OG). TEST the system for normal
operation.
C3: CHECK FOR CONTINUITY BETWEEN THE CENTRAL JUNCTION BOX (CJB) AND THE ROOF
OPENING PANEL MODULE
1 Measure the resistance between the body control unit C2AM02-
H pin 5, circuit CPR90A (BU/OG), harness side and the roof
opening panel module C9PR32-B pin 2, circuit CPR90A (BU/OG),
harness side.

Yes
No
REPAIR circuit CPR90A (BU/OG). TEST the system for normal
operation.
Components Tests
Roof Opening Panel Control Switch
1. Measure the resistance between the following:
Roof Opening Panel Control Switch

Roof Opening Panel Terminals
Measurements
Control Switch Position Multimeter Positive Multimeter Negative
Lead Lead
Neutral 1 2 Greater than 10,000 ohms
Neutral 1 4 Less than 100 ohms
First detente Up/Close 2 4 Less than 5 ohms
Fully Up/Close 2 4 Less than 5 ohms
First detente Down/Open 2 4 Greater than 10,000 ohms
Fully Down/Open 2 4 Less than 5 ohms
First detente Down/Open 3 4 Less than 5 ohms
Fully Down/Open 3 4 Less than 5 ohms
First detente Up/Close 3 4 Greater than 10,000 ohms
Fully Up/Close 3 4 Less than 5 ohms
2. If all measurements of the roof opening panel control switch are as noted, return to the Pinpoint
Test. Otherwise install a new roof opening panel control switch.
7/8
1951/2430
10/30/2018 Print
8/8
1952/2430
10/30/2018 Print
Roof Opening Panel - Power Roof Opening

Panel Initialization
Print
General Procedures
WARNING: The anti-trap function will not operate during the initialization procedure.
1. Check the roof opening panel alignment.
Refer to: Roof Opening Panel Alignment (501-17 Roof Opening Panel, General Procedures).
2. Operate the roof opening panel control switch to the up/close position.
3. Release the roof opening panel control switch.
4. NOTE: In one complete cycle the roof opening panel will close, fully open and return to the
fully closed position.
Operate the roof opening panel control switch to the up/close position again within 3 seconds until
the roof opening panel stops (one complete cycle).
1/1
1953/2430
10/30/2018 Print

Panel Setting Erase
Print
General Procedures
1. Operate the roof opening panel control switch to the up/close position until the roof opening panel
motor stops.
3. Operate the roof opening panel control switch again to the up/close position and hold for 30
seconds. With the roof opening panel control switch held, the roof opening panel motor will rotate
in one direction.
5. Operate the roof opening panel control switch to the down/open position. If the roof opening panel
motor does not rotate, the erasing procedure has been carried out successfully.
6. If the roof opening panel motor rotates (with the roof opening panel control switch in the
down/open position), repeat the procedure.
1/1
1954/2430
10/30/2018 Print

Panel Setting Update
Print
General Procedures
WARNING: The anti-trap function will not operate during the initialization procedure.
1. Check the roof opening panel alignment.
Refer to: Roof Opening Panel Alignment (501-17 Roof Opening Panel, General Procedures).
2. Operate the roof opening panel control switch to the up/close position until the roof opening panel
is in the fully vent position.
4. Operate the roof opening panel control switch to the up/close position and hold for 30 seconds
until there is a small movement (approximately 2 mm) and the roof opening panel motor stops.
6. NOTE: In one complete cycle the roof opening panel will close, fully open and return to the
fully closed position.
Operate the roof opening panel control switch to the up/close position again within 3 seconds until
the roof opening panel stops (one complete cycle).
1/1
1955/2430
10/30/2018 Print
Roof Opening Panel - Roof Opening Panel Alignment

Print
General Procedures
1. Starting at the rear of the roof opening panel, remove the roof opening panel guide arm cover
on both sides.
2. On both sides.
3. Push the roof opening panel glass rear edge up or down to give the correct alignment (flush to
+ 1 mm).
4. Make sure that the roof opening panel glass is located centrally in the roof opening and tighten
the roof opening panel glass rear retaining bolt on both sides.
1/3
1956/2430
10/30/2018 Print
5. Push the roof opening panel glass front edge up or down to give the correct alignment (flush to
-1 mm).
6. On both sides.
7. 1. Starting at the front of the roof opening panel, install the roof opening panel guide arm cover
upper edge.
2. Starting at the front of the roof opening panel, install the roof opening panel guide arm cover
lower edge until an audible click is heard.
On both sides.
2/3
1957/2430
10/30/2018 Print
8. Operate the roof opening panel and check the roof opening panel alignment.
3/3
1958/2430
10/30/2018 Print
Roof Opening Panel - Roof Opening Panel—5-Door

Print
Special Tool(s)
501-125
Removal
1. On both sides.
2.
3.
1/12
1959/2430
10/30/2018 Print

4. If equipped.
5. If equipped.
2/12
1960/2430
10/30/2018 Print

6.
7.
3/12
1961/2430
10/30/2018 Print
All vehicles
9.
4/12
1962/2430
10/30/2018 Print
10.
11. On both sides.
12. On both sides.
5/12
1963/2430
10/30/2018 Print
Installation).
13.
14. 1. On both sides.
15. On both sides.
6/12
1964/2430
10/30/2018 Print
16. On both sides.
17. All.
18.
7/12
1965/2430
10/30/2018 Print
19.
20.
21.
8/12
1966/2430
10/30/2018 Print
22.
23.
9/12
1967/2430
10/30/2018 Print
24.
25.
10/12
1968/2430
10/30/2018 Print
Installation
2. Torque: 6 Nm
11/12
1969/2430
10/30/2018 Print

Refer to: Power Roof Opening Panel Setting Erase (501-17 Roof Opening Panel, General
Procedures).
5. Refer to: Power Roof Opening Panel Initialization (501-17 Roof Opening Panel, General
Procedures).
12/12
1970/2430
10/30/2018 Print
Roof Opening Panel - Roof Opening Panel Motor

Print
Special Tool(s)
501-125
Removal
2.
1/4
1971/2430
10/30/2018 Print
3.
4. Torque: 3 Nm
Installation
1. Starting at the rear of the roof opening panel, remove the roof opening panel guide arm cover on
both sides.
2/4
1972/2430
10/30/2018 Print
2. Move the roof opening panel operating cable to align the roof opening panel left-hand guide pin
centrally in the flat area of the roof opening panel guide arm.
3. Move the roof opening panel operating cable to align the roof opening panel right-hand guide pin
centrally in the flat area of the roof opening panel guide arm.
3/4
1973/2430
10/30/2018 Print
4. 1. Starting at the front of the roof opening panel, install the roof opening panel guide arm
cover upper edge.
2. Starting at the front of the roof opening panel, install the roof opening panel guide arm
cover lower edge until an audible click is heard.
On both sides.

Refer to: Power Roof Opening Panel Setting Erase (501-17 Roof Opening Panel, General
Procedures).
7. Refer to: Power Roof Opening Panel Initialization (501-17 Roof Opening Panel, General
Procedures).
4/4
1974/2430
10/30/2018 Print
Roof Opening Panel - Roof Opening Panel Glass

Print
Removal
1. Starting at the rear of the roof opening panel, remove the roof opening panel guide arm cover on
both sides.
2. On both sides.
3.
Installation
1.
1/3
1975/2430
10/30/2018 Print

On both sides.
3. Push the roof opening panel glass rear edge up or down to give the correct alignment (flush to + 1
mm).
4. Make sure that the roof opening panel glass is located centrally in the roof opening and tighten the
roof opening panel glass rear retaining bolt on both sides.
5. Push the roof opening panel glass front edge up or down to give the correct alignment (flush to -1
mm).
2/3
1976/2430
10/30/2018 Print
6. On both sides.
7. 1. Starting at the front of the roof opening panel, install the roof opening panel guide arm
cover upper edge.
2. Starting at the front of the roof opening panel, install the roof opening panel guide arm
cover lower edge until an audible click is heard.
On both sides.
8. Operate the roof opening panel and check the roof opening panel alignment.
3/3
1977/2430
10/30/2018 Print
Roof Opening Panel - Roof Opening Panel

Shield
Print
Removal
1. Remove the roof opening panel glass.
Refer to: Roof Opening Panel Glass (501-17 Roof Opening Panel, Removal and Installation).
2.
3.
4.
Installation
1/1
1978/2430
10/30/2018 Print
Roof Opening Panel - Roof Opening Panel Front Drain Hose

Print
Special Tool(s)
501-125
Removal
3.
1/5
1979/2430
10/30/2018 Print
4.
5.
6.
2/5
1980/2430
10/30/2018 Print
7.
8.
9.
3/5
1981/2430
10/30/2018 Print
10.
11.
4/5
1982/2430
10/30/2018 Print
Installation
5/5
1983/2430
10/30/2018 Print
Roof Opening Panel - Roof Opening Panel Rear Drain Hose—5-Door

Print
Special Tool(s)
501-125
Removal
1. On both sides.
2.
3.
1/12
1984/2430
10/30/2018 Print

4. If equipped.
5. If equipped.
2/12
1985/2430
10/30/2018 Print

6.
7.
3/12
1986/2430
10/30/2018 Print
All vehicles
9.
4/12
1987/2430
10/30/2018 Print
10.
11. On both sides.
12. On both sides.
5/12
1988/2430
10/30/2018 Print
Installation).
13.
14.
15.
1. On both sides.
Torque: 47 Nm
6/12
1989/2430
10/30/2018 Print
16. On both sides.
17.
7/12
1990/2430
10/30/2018 Print
18.
19. On both sides.
8/12
1991/2430
10/30/2018 Print
20. All.
21.
22.
23.
9/12
1992/2430
10/30/2018 Print
24.
25.
10/12
1993/2430
10/30/2018 Print
26.
27.
28.
11/12
1994/2430
10/30/2018 Print
Installation
12/12
1995/2430
10/30/2018 Print
Bumpers - Front Bumper Cover

Print
Removal
Refer to: Headlamp Assembly (417-01, Removal and Installation).

2. On both sides.
All vehicles
3.
4.
1/4
1996/2430
10/30/2018 Print
5. On both sides.
6. 1.
2. If equipped.
2/4
1997/2430
10/30/2018 Print
7.
8.
9.
3/4
1998/2430
10/30/2018 Print
Installation
4/4
1999/2430
10/30/2018 Print
Bumpers - Rear Bumper Cover—4-Door/5-Door

Print
Removal
2. On both sides.
3. On both sides.
4.
1/3
2000/2430
10/30/2018 Print
5. If equipped.
6.
7.
2/3
2001/2430
10/30/2018 Print
Installation
3/3
2002/2430
10/30/2018 Print
Bumpers - Front Bumper Cover

Print

501-135
Punching Tool, Parking Aid Sensor
501-179
501-180
12 mm Drill Bit
15 mm Drill Bit
Air Body Saw
Electric Drill
Flat File
Disassembly
1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
Vehicles with parking aid

2.
3.
1/8
2003/2430
10/30/2018 Print
Vehicles with front fog lamps

4.
All vehicles
5.
2/8
2004/2430
10/30/2018 Print
6.
7.
3/8
2005/2430
10/30/2018 Print
8.
9.
Assembly
10. Use the General Equipment: Air Body Saw
4/8
2006/2430
10/30/2018 Print
Vehicles with parking aid
11. Use the General Equipments: Electric Drill, 12 mm Drill Bit
5/8
2007/2430
10/30/2018 Print
13. Use the General Equipment: Flat File

Use the General Equipments: Electric Drill, 15 mm Drill Bit
6/8
2008/2430
10/30/2018 Print
7/8
2009/2430
10/30/2018 Print
All vehicles
8/8
2010/2430
10/30/2018 Print
Bumpers - Rear Bumper Cover—4-Door/5-Door

Print

501-130
15 mm Drill Bit
Electric Drill
Flat File
Disassembly
1. Refer to: Rear Bumper Cover - 4-Door/5-Door (501-19 Bumpers, Removal and Installation).
3.
1/11
2011/2430
10/30/2018 Print
4.
5.
2/11
2012/2430
10/30/2018 Print
7.
8.
3/11
2013/2430
10/30/2018 Print
9.
Assembly
10.
11.
4/11
2014/2430
10/30/2018 Print
13.
1. Align the flattened side horizontal upwards, before punching each hole.
5/11
2015/2430
10/30/2018 Print
15.
6/11
2016/2430
10/30/2018 Print

17.
7/11
2017/2430
10/30/2018 Print
18.
8/11
2018/2430
10/30/2018 Print
20.
1. Align the flattened side horizontal upwards, before punching each hole.
9/11
2019/2430
10/30/2018 Print
22.
10/11
2020/2430
10/30/2018 Print
All vehicles
24. Refer to: Rear Bumper Cover - 4-Door/5-Door (501-19 Bumpers, Removal and Installation).
11/11
2021/2430
10/30/2018 Print
Seatbelt Systems - Seatbelt Systems

Print
General Equipment
WARNINGS:
All safety belt components including retractors, buckles, front safety belt buckle support
assemblies (slider bar), child safety seat tether brackets and attaching hardware in use during a
collision must be removed and new components installed. New safety belt components should also
be installed where safety belts not in use during a collision, are inspected and found to be damaged
or operate incorrectly. Failure to follow these instructions may result in personal injury.
All vehicles equipped with a passenger air bag have a WARNING sticker attached to the
instrument panel PROHIBITING the use of rear facing child seats in the front seating positions.
Failure to follow this instruction may result in personal injury.
NOTICE: Do not attempt to repair or lubricate the retractor / buckle mechanisms or modify the
belts.
Vehicles equipped with the supplemental restraint system (SRS) are equipped with a driver and
passenger safety belt retractor(s) and pretensioner. The safety belt pretensioners are controlled as
part of the SRS.
REFER to: Airbag and Seatbelt Pretensioner Supplemental Restraint System (SRS) (501-20B
Supplemental Restraint System, Description and Operation).
The rear seat safety belt buckles are mounted directly to the floor pan underneath the rear seat
cushion. When the ignition is turned on the RUN position the SRS warning indicator will illuminate for
three seconds. If the SRS, including the safety belt electrical system, is operating correctly the SRS
warning indicator will be extinguished. If a fault is detected the SRS warning indicator will generate a
lamp fault code.
REFER to: Airbag and Seatbelt Pretensioner Supplemental Restraint System (SRS) (501-20B
The safety belt retractor, mounted within the base of the B-pillar, incorporates a torsion bar load
limiting device. The device consists of a retractor reel which is mounted onto a spindle (torsion bar)
which, once the sensor has locked the retractor reel and predetermined load is applied, twists and
pays out additional webbing into the system. The deceleration force required to initiate this sequence
is approximately the same as that required to initiate air bag deployment. The torsion bar load
limiting device will only react if the safety belt is in use at the time of impact.
Rear seat safety belt retractors do not use this type of retractor, they are equipped with a
conventional retractor.
Emergency Locking Retractor
The retractors in all seat positions feature emergency locking retractor(s). The emergency locking
retractor is part of the safety belt system that in normal operation allows free movement of the belted
occupant. In an emergency the emergency locking retractor will lock, preventing webbing payout and
hence forward movement of the occupant. Locking may be achieved by one of two mechanisms:
Vehicle Motion Sensor
vehicle motion sensor is operated by sudden deceleration of the vehicle or excessive tilt. Once
operated the vehicle motion sensor causes a locking pawl to be engaged, thus locking the retractor,
preventing webbing payout. When the vehicle is stationary, the vehicle motion sensor stabilizes,
causing the pawl to disengage and unlock the retractor, allowing webbing payout.
Webbing Motion Sensor
The emergency locking retractor webbing motion sensor is operated by rapid acceleration of the
webbing. Once operated, it causes a locking pawl to be engaged thus locking the retractor. Webbing
payout is prevented in the same manner as vehicle motion sensor.
1/3
2022/2430
10/30/2018 Print
Mechanical
Safety belt retractor
Safety belt buckle
Safety belt retractor and pretensioner
before proceeding to the next stop.
SYMPTOM CHART

Normal mode - occupant restraint * Safety belt * CARRY OUT the Safety Belt Component Test
system inoperative. retractor. in this section.
Component Test
Poor Retraction
If a safety belt does not retract correctly, check that the anchor covers and trim bezels are correctly
installed and not rubbing against the safety belt webbing. Where necessary, check that the safety belt
webbing is not rubbing at one end of the retractor cover slot and, if so, correct by loosening the
retaining bolt, aligning the retractor to centralize the safety belt webbing and retighten the bolt.
The safety belts are “dual sensitive” which means that they have:
A vehicle motion sensor, which locks the safety belt webbing under braking, cornering, on steep hills
and in adverse camber conditions.
A webbing motion sensor, which locks when the safety belt webbing is quickly extracted.
Both systems should be fully operational and can be checked by the tests below:
Vehicle Motion Sensor Test
Either of the following two procedures may be used to check correct operation of the vehicle motion
sensor. Both methods require two technicians but note that technicians of larger than normal build
should not be asked to conduct these tests. This is to avoid the possibility of a fully unrolled safety
belt webbing being mistaken for a correctly locked safety belt retractor.
Test Method 1 (braking)
WARNING: It is important that during this test, the driver and passenger allow the safety belts
to provide the restraint and do not attempt to anticipate the sudden deceleration. The steering
wheel should not be used as a brace. However, both driver and passenger should prepare
themselves for the possibility that the safety belt will not lock. The passenger should hold their
hands in front of them, just clear of the instrument panel or front seat backrest, depending on
which safety belt is being tested. Failure to follow these instructions may result in personal injury.
Select for this test a quiet or private stretch of road. Make sure that the road is clear and that full
visibility is maintained at all times.
Both driver and passenger should adopt a normal, comfortable seating position. Both occupants
should wear the safety belts and the safety belt webbing must be correctly adjusted, with no slack.
Proceed at a speed of 10 km/h (6 mph). Do not exceed 10 km/h (6 mph) for this test.
Apply the foot brake sharply to stop the vehicle. If the vehicle motion sensitive lock mechanism is
operating correctly, the safety belt webbing will lock and restrain the wearer.
Conduct the test twice in each front and rear passenger seat position.
Any safety belt retractor which does not restrain the wearer during this test must not be reused. A
new safety belt must be installed.
Test Method 2 (turning circle)
2/3
2023/2430
10/30/2018 Print
This method requires a flat open area of private road, sufficient for the vehicle to be driven in a
continuous circle on full steering lock.
The driver should wear the safety belt provided and the belt webbing must be correctly adjusted,
with no slack.
The passenger should occupy a rear seat with the safety belt correctly adjusted, with no slack.
Start the engine and, with the steering on full right-hand lock, drive the vehicle in a continuous
circle at 16 km/h (10mph). Do not exceed 16 km/h (10 mph) for this test.
When the speed is stable, the passenger should attempt to slowly extract the safety belt webbing
from each safety belt retractor in turn. If the vehicle motion sensitive lock mechanism is operating
correctly, it will not be possible to extract the webbing.
Any safety belt retractor from which it is possible to extract the webbing during this test must not
be used. A new safety belt must be installed.
Static Test
With the vehicle stationary and on level ground take firm hold of the safety belt webbing (on the
tongue side of the upper safety belt anchor) and pull out quickly. The retractor should lock within 0.25
meter (10 inches), preventing further webbing payout. Any safety belt retractor from which it is
possible to extract further webbing must not be used. A new safety belt must be installed.
1. If the cause is not visually evident, verify the symptom and refer to theFord diagnostic
equipmentto diagnose the system.
3/3
2024/2430
10/30/2018 Print
Seatbelt Systems - Front Seatbelt Buckle

Print
Removal
2.
All vehicles
3. Torque: 47 Nm
Installation
1/1
2025/2430
10/30/2018 Print
Seatbelt Systems - Front Seatbelt Retractor

Print
Removal
3. Torque: 35 Nm
Installation

1/1
2026/2430
10/30/2018 Print
Seatbelt Systems - Seatbelt Shoulder Height

Adjuster
Print
Removal
1.

Torque: 35 Nm
Installation
1/2
2027/2430
10/30/2018 Print
2/2
2028/2430
10/30/2018 Print
Seatbelt Systems - Rear Seatbelt Retractor—5-Door

Print
Removal
Installation).
2.
1. Torque: 47 Nm
Torque: 40 Nm
Installation
1/1
2029/2430
10/30/2018 Print
Seatbelt Systems - Rear Seatbelt Buckle LH

Print
Removal
1. Refer to: Rear Center Seatbelt Retractor (501-20A Seatbelt Systems, Removal and Installation).
Installation
1/1
2030/2430
10/30/2018 Print
Seatbelt Systems - Rear Center Seatbelt Buckle

Print
Removal
1.
2. 1.
2.
3.
4.
Torque: 55 Nm
Installation
1/1
2031/2430
10/30/2018 Print
Seatbelt Systems - Rear Center Seatbelt Retractor

Print
General Equipment
Webbing Retainer
Removal
1.
2. 1. NOTE: Note the position of the component before removal.

2.
3.
4.
5.
Torque: 55 Nm
3. NOTE: If the safety belt webbing retracts further than the safety belt webbing stop, a new
safety belt retractor must be installed.
Use the General Equipment: Webbing Retainer
1/4
2032/2430
10/30/2018 Print
4.
5.
2/4
2033/2430
10/30/2018 Print
6.

Torque: 47 Nm
3/4
2034/2430
10/30/2018 Print
Installation
4/4
2035/2430
10/30/2018 Print
Supplemental Restraint System - Airbag and Seatbelt Pretensioner Supplemental

Restraint System (SRS) - Component Location
Print
Item Description
1 Inertia reel retractor mechanism (rear row of seats, center)
2 Head airbag (driver and passenger side)
3 Inertia reel retractor mechanism (driver and passenger sides, rear row of seats left and right)
4 Crash sensor (driver and passenger side)
5 Driver Air bag
6 Instrument cluster with airbag telltale and belt warning display
7 Front impact sensor
8 Front passenger airbag
9 PAD (passenger airbag deactivation) (optional)
11 Seat occupant sensor (passenger side only)
12 Side airbag (driver and passenger side)
13 Safety belt switch
1/1
2036/2430
10/30/2018 Print
Supplemental Restraint System - Airbag and Seatbelt Pretensioner

Supplemental Restraint System (SRS) - Overview
Print
General airbag system

The RCM (restraints control module) conducts a self-diagnosis as soon as the ignition is switched on.
All components of the safety restraint system are checked, except the front safety belt buckle
switches and the seat occupancy sensor on the passenger side. If a fault is present, the airbag telltale
is activated.
Belt warning lamp and belt warning display
Item Description
A Left-hand half of the instrument cluster
1 Safety belt indicator
B Belt warning display
To activate the belt warning lamp and belt warning display, the following signals are evaluated:
Driver-side safety belt buckle switch
Passenger's side safety belt buckle switch
Passenger-side occupancy sensor
Safety belt buckle switches with Hall sensors on the rear row of seats
Vehicle speed signal
Reversing signal
Activation of belt warning lamp and belt warning display

The belt warning function for the rear row of seats is optional. If it is installed, the vehicle has a belt
warning display in the center of the instrument cluster. Otherwise, just a belt warning light for the
front seats is active.
When the ignition is switched on, the RCM checks, by means of the seat belt buckle switches and the
seat occupancy sensor on the passenger side, whether the seat is occupied and whether the front-
seat occupants have fastened their seat belts.
If a road speed of 25 km/h has been reached and the seat belt is not fastened, an audible signal is
sounded and the safety belt warning lamp lights up.
In the same ignition cycle, the follow-up audible signal is sounded from a speed of 10 km/h.
The belt warning function for the rear row of seats is active for a period of 30 seconds after the
engine has been started. For this purpose, Hall sensors are installed in the belt buckles which register
the status. The status is indicated by means of green ticks on the corresponding seats. If anyone in a
rear seat should unfasten their seat belt during the journey, this will be shown in the belt warning
display and an audible signal will be sounded.
The location of unbelted front or rear occupants is indicated in the belt warning display by means of
an exclamation mark on the seat.
1/3
2037/2430
10/30/2018 Print
If the occupant does not fasten their belt within the first 30 seconds after the engine has been
started, the system will not detect any occupants in the rear seats. Because no seat occupancy
sensors are fitted, the exclamation mark symbols will not be displayed.
Deactivation/activation of the audible warning for the belt warning lamp and belt warning
display
Permanent deactivation of the audible warning is carried out using the IDS (Integrated
Diagnostic System) or by performing the following steps:
Driver and passenger seat (deactivation carried out separately)
- Turn the ignition switch to position "II"
- Close the belt buckle and open it again four times
- Confirmation by three flashes
Rear seats
- Turn the ignition switch to position "II"
- Close the belt buckle of one of the rear seats and open it again four times
- Confirmation by three flashes of the display
Deactivation of one of the rear seats causes all the belt warnings for the rear seats to be switched off.
The system can be reactivated by repeating the same process.
PAD (passenger airbag deactivation)
Item Description
1 Lock switch PAD
2 PAD telltale
The passenger airbag deactivation system can be retrofitted.
This device is prepared at the factory but must be completed by the authorised dealer.
The parts required are listed in a corresponding TSB.
The telltale is located in the overhead console.
The lock switch is installed at the side in the glove box.
After the components have been installed, the deactivation switch must be registered with IDS via the
central vehicle configuration. After registration, the RCM must be reset.
The driver can operate the switch with the vehicle key to deactivate the passenger airbag. When the
passenger airbag is deactivated, the telltale lights.
RCM
2/3
2038/2430
10/30/2018 Print
The yaw rate sensor for the Stability Assist is incorporated into the airbag module. It does not play
any part in the triggering decision of the airbag system.
The module can be reused up to five times after a crash.
3/3
2039/2430
10/30/2018 Print
Supplemental Restraint System - Airbag and

Seatbelt Pretensioner Supplemental Restraint
System (SRS)
Print

Test and Deployment Lead, Side Air Bag Module
418-555
Simulator, Driver and Passenger Air Bags, Side Air Curtains, Driver and Passenger and
Rear Center Safety Belt Retractor Pretensioners
501-073A
Simulator, Side Air Bags

501-401

Driver air bag module wiring harness
For SRS Depowering,
REFER to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint
For SRS Repowering,
REFER to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint
Electrical
Fuse(s)
Loose or corroded electrical connector(s)
Circuit(s)
Safety belt buckle switch(es)
Passenger seat occupant sensor
Safety belt retractor pretensioner(s)
Driver frontal air bag
Passenger frontal air bag
Driver and passenger side air bags (if equipped)
Driver and passenger side air curtains (if equipped)
Restraints control moduel (RCM)
Air Bag Warning Indicator
1/3
2040/2430
10/30/2018 Print
The air bag warning indicator is incorporated into the instrument cluster. The air bag warning indicator
illuminates for 3.2 seconds at key ON and goes OFF for 4.8 seconds. If the system self-tests OK the
indicator will stay OFF, but if there is a fault condition, the air bag warning indicator will come ON
again and stay illuminated.
A 5Hz-flashing of the air bag warning indicator shows that the RCM has not been configured or that
configuration is in progress (not attached to the CAN BUS, GEM not programmed or the GEM is
defective).
Diagnostic evaluation of the SRS should be made through the DLC using the Ford diagnostic
equipment to establish the nature of the concern.
Diagnosing Customer Concerns Without Hard DTCs
WARNING: To avoid accidental deployment, the restraints control module (RCM) backup power
supply must be depleted. Wait at least one minute after disconnecting the battery ground cable(s)
before commencing any repair or adjustment to the supplemental restraint system (SRS), or any
component(s) adjacent to the SRS sensors. Failure to follow these instructions may result in
personal injury.
NOTE: Following the pinpoint tests when a diagnostic trouble code (DTC) is not present, or the air
bag warning lamp is not permanently illuminated, will result in needless replacement of air bag
system components and repeat repairs.
Speak with the customer to determine if a particular set of conditions must be met in order for a fault
to occur. If an illuminated air bag warning lamp is reported by the customer but is not present when
the vehicle comes in for repair, pinpoint test diagnostics cannot be used.
The following concerns do not trigger a DTC or illuminate the air bag warning indicator:
Symptom Source
Passenger safety belt minder is inactive even if the seat is Passenger safety belt minder mat open circuit.
occupied.
Passenger safety belt minder is active even if the seat is Passenger safety belt minder mat short circuit
unoccupied. to ground.
Belt minder is active all the time. Safety belt buckle switch short circuit to
ground (driver or passenger).
Belt minder does not work at all. Safety belt buckle switch open circuit (driver or
passenger).
Diagnosing Customer Concerns with Hard DTCs
WARNING: Do not use substitute air bag simulators when working on the SRS. Use only the
appropriate tool. Failure to follow these instructions may result in personal injury.
Most air bag system diagnostic procedures require the use of system deactivation and system
reactivation procedures. These procedures require the air bag module(s) and safety belt retractor
pretensioners to be disconnected from the SRS, thereby removing the risk of air bag deployment
while diagnostics are carried out.
Air bag simulators are required to carry out diagnosis and testing of the air bag system. The simulator
contains a resistor, used to simulate an air bag module connection to the system. It is not acceptable
to short-circuit the air bag module connections with a 0 ohm jumper wire. If a 0 ohm jumper wire is
used to short-circuit the air bag module connections, an illuminated air bag warning lamp will be
displayed and a DTC logged by the RCM.
SRS Operation
The vehicle is equipped with a DC fired sensing system.

In the event of a moderate frontal impact only the safety belt pretensioners will be activated.
In the event of a severe frontal or three-quarter frontal impact, in excess of a predetermined limit,
the driver and passenger front air bags and safety belt retractor pretensioners will deploy.
In the event of a severe full side impact, in excess of a predetermined limit, either the driver or
passenger side air bag, side air curtain (if equipped) will deploy.
2/3
2041/2430
10/30/2018 Print
Air bag deployment will only occur, in the event of a severe collision, when the ignition key is in the
RUN position. The passenger air bag deactivation (PAD) switch (if equipped) will deactivate the
passenger frontal air bag in the event of a severe frontal impact; it will not deactivate any other
deployable device.
RCM
The RCM retains full control of the whole system, providing continual system checks and full
diagnostic capabilities. The non-volatile memory stores the diagnostic trouble codes, which can then
be downloaded through the data link connector (DLC) to the Ford diagnostic equipment.
In the event of a failure in the vehicle supply during an accident, the RCM provides a backup power
supply, sufficient to deploy the air bag(s) for a minimum of 150 ms. The backup power supply is
discharged by the RCM within 60 seconds of the battery ground cable being disconnected.
The RCM contains electronic acceleration sensors which measure the longitudinal acceleration and the
lateral acceleration and provide both signals to the micro-controller proportional to the amount of
acceleration measured. The RCM also contains a safing sensor, which prevents unintentional
deployment of the front air bags and safety belt retractor pretensioners in the event of a fault within
the electronic acceleration sensor(s). The RCM compares the values it receives from the crash sensor,
side impact sensors, safing sensor and the internal electronic sensors. If the deceleration due to a
frontal or side impact exceeds a stored threshold value then the RCM triggers the air bags and safety
belt pretensioners as required.
The RCM also contains vehicle dynamic sensors (yaw rate, longitudinal and lateral acceleration) to
support stability assist function. Signals are transmiited on a sensor CAN BUS to the stabilty assist
system. In the case of a malfunction, the stability assist warning lamp will be illuminated and the
relevant stabilty assist DTC will be logged to assist with diagnosis.
Front Crash Sensor
The front crash sensor contains an acceleration sensor, filter, amplifier and an application specific
integrated circuit for signal transmitting and is mounted on the radiator grille opening panel
reinforcement. The crash sensor sends a signal at a level determined by the crash severity to the
RCM. The RCM will evaluate the signal against stored data and deploy the frontal air bags and safety
belt retractor pretensioners and knee air bag (if equipped) when required. Both the crash sensor and
the internal RCM longitudinal acceleration sensor must exceed a preset limit to initiate the air bag.
Side Impact Sensor
The side impact sensors are mounted at the base of the B-pillar on either side of the vehicle, to
facilitate remote lateral impact sensing. Each side impact sensor contains an acceleration sensor,
filter, amplifier and an application specific integrated circuit for signal transmitting. In the event of an
impact, in excess of a predetermined limit, the side impact sensor sends a signal at a level
determined by the crash severity to the RCM. The RCM will evaluate the signal against stored data
and deploy the side air bag on the side the deployment request was initiated. Both the side impact
sensor and the internal RCM lateral acceleration sensor must exceed a preset limit to initiate the air
bag. The RCM retains control of the side air bags, side air curtains.
3/3
2042/2430
10/30/2018 Print
Supplemental Restraint System - Supplemental

Restraint System (SRS) Depowering
Print
General Procedures
Depower

Restraint System (SRS) deployment. Never compromise or depart from these instructions. Failure to
precisely follow all instructions could result in serious personal injury from an accidental
deployment.
2. Determine if a SRS (supplemental restraint system) fault is present. Turn the ignition OFF and wait
10 seconds, then turn the ignition ON and monitor the airbag warning indicator. The airbag
warning indicator illuminates continuously for approximately 6 seconds and then turns off.
Continue to monitor the airbag warning indicator for approximately 30 seconds as this is the time
required for the RCM (restraints control module) to complete testing of the SRS.
3. If a SRS fault is present the airbag warning indicator either fails to light, remains lit
continuously or flashes. The flashing may not occur until approximately 30 seconds after the
ignition has been turned from OFF to ON. If this occurs, diagnose and repair any SRS faults
before proceeding with other repairs.
If after the ignition has been turned ON for 30 seconds the airbag warning indicator remains
unlit with no chime or SRS message displayed in the message center, no SRS fault is
present.
If the airbag warning indicator is inoperative and a SRS fault exists, a chime sounds in a
pattern of 5 sets of 5 beeps or a message displays in the message center. If this occurs,
diagnose and repair the airbag warning indicator and any SRS faults before proceeding with
other repairs.
No SRS Fault Present (with ignition ON, airbag warning indicator

stays off after prove out)
4. WARNING: Turn the ignition OFF and wait one minute to deplete the backup power
supply. Ignition must remain OFF until repair is complete. Failure to follow this instruction
may result in serious personal injury or death in the event of an accidental deployment.
Turn the ignition OFF and wait one minute before continuing vehicle service.
SRS Fault Present

5. Turn the ignition OFF.
6. Remove the RCM fuse and, if equipped, {Acronym.BECMB} ({Acronym.BECMB}) fuse(s). Refer to
Wiring Diagram Cell 11/Section 700-01 for fuse and relay information.
7. For a vehicle equipped with a 3 blade {Acronym.BECMB}/GWM (gateway module A) fuse, install a
2 blade 10A fuse at the GWM position to allow the scan tool to communicate with the vehicle
network.
8. Turn the ignition ON.
9. Using a diagnostic scan tool, carry out a Network Test. Verify that the RCM and, if equipped,
{Acronym.BECMB} does not respond to the Network Test. If the RCM or {Acronym.BECMB} pass
the Network Test, remove the correct RCM or {Acronym.BECMB} fuse and repeat the Network Test
to verify before proceeding.
1/2
2043/2430
10/30/2018 Print
10. Turn the ignition OFF.
11. Disconnect the battery.
Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General
Procedures).
12. Wait at least one minute before continuing vehicle service.
2/2
2044/2430
10/30/2018 Print
Supplemental Restraint System - Supplemental

Restraint System (SRS) Repowering
Print
General Procedures
Repower

Restraint System (SRS) deployment. Never compromise or depart from these instructions. Failure to
precisely follow all instructions could result in serious personal injury from an accidental
deployment.
NOTE: The SRS (supplemental restraint system) must be fully operational and free of faults before
releasing the vehicle to the customer.
No SRS Fault Present At Beginning of Repair

2. Prove out the SRS. Verify all airbags are installed and connected and the ignition is OFF. Wait 10
seconds then turn the ignition ON and monitor the airbag warning indicator. The airbag warning
indicator illuminates continuously for approximately 6 seconds and turns off. Continue to monitor
the airbag warning indicator for approximately 30 seconds as this is the time required for the RCM
(restraints control module) to complete testing of the SRS.
3. If a SRS fault is present, the airbag warning indicator either fails to light, remains lit
If, after the ignition has been turned on for 30 seconds, the airbag warning indicator remains
present.
other repairs.
SRS Fault Present At Beginning of Repair

4. Verify the ignition is OFF.
5. For a vehicle equipped with a 3 blade {Acronym.BECMB} ({Acronym.BECMB})/GWM (gateway

module A) fuse, remove the 2 blade 10A fuse at the GWM position.
6. Install the RCM and, if equipped, {Acronym.BECMB} fuse(s). Refer to Wiring Diagram Cell
11/Section 700-01 for fuse and relay information.
7. Connect the battery.
Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General
Procedures).
8. Sit in the driver seat in an upright position. Make sure no objects are between you and any
pyrotechnic device. Move the driver seat to the rearmost position to maintain the maximum
possible distance from the driver airbag.
9. Turn the ignition from OFF to ON.
1/2
2045/2430
10/30/2018 Print
10. Prove out the SRS. Verify all airbags are installed and connected and the ignition is OFF. Wait 10
seconds, then turn the ignition ON and monitor the airbag warning indicator. The airbag warning
indicator illuminates continuously for approximately 6 seconds and then turns off. Continue to
monitor the airbag warning indicator for approximately 30 seconds, as this is the time required for
the RCM to complete testing of the SRS.
11. If a SRS fault is present, the airbag warning indicator either fails to light, remains lit
If, after the ignition has been turned on for 30 seconds, the airbag warning indicator remains
present.
other repairs.
12. Using a scan tool, clear all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all
modules.
2/2
2046/2430
10/30/2018 Print
Supplemental Restraint System - Clockspring

Adjustment—Vehicles With: Lane Departure
Warning
Print
General Procedures
General Equipment
Adhesive Tape
Adjustment
WARNINGS:
If there is a break between installing the clockspring and steering wheel rotation sensor
assembly and installing the steering wheel, the centralizing of the clockspring must be repeated.
If the centralization of the clockspring is in doubt, the centralizing of the clockspring must be
repeated.
2.
2. NOTICE: Make sure that the U-shaped part of the flat flexible cable is visible in the
window.
1/2
2047/2430
10/30/2018 Print
2/2
2048/2430
10/30/2018 Print
Supplemental Restraint System - Clockspring

Adjustment—Vehicles Without: Lane Departure
Warning
Print
General Procedures
General Equipment
Adhesive Tape
WARNINGS:
If there is a break between installing the clockspring and steering wheel rotation sensor
assembly and installing the steering wheel, the centralizing of the clockspring must be repeated.
If the centralization of the clockspring is in doubt, the centralizing of the clockspring must be
repeated.
2.
2. NOTICE: Make sure that the color marking is visible in the window.
1/2
2049/2430
10/30/2018 Print
2/2
2050/2430
10/30/2018 Print
Supplemental Restraint System - Deployed

Airbag Disposal
Print
General Procedures
WARNING: After deployment, the air bag module surface may contain deposits of sodium
hydroxide, a product of the gas generate combustion, that is irritating to the skin. Use protective
gloves when handling any deployed air bag module. Failure to follow this instruction may result in
personal injury.
1. Remove the deployed air bag module(s). For additional information, refer to the relevant
procedure in this section.
2. Seal the deployed air bag module(s) in the packaging from the new air bag module(s) or a
suitable polythene bag, and then dispose of in accordance with local contaminated waste
regulations.
1/1
2051/2430
10/30/2018 Print
Supplemental Restraint System - Inspection

and Repair after a Supplemental Restraint
System (SRS) Deployment
Print
General Procedures
Inspection
NOTE: Deployable devices such as airbags, pretensioners and inflatable belt inflators, may deploy
alone or in various combinations depending on the impact event.
NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle
repairs affecting the SRS (supplemental restraint system) and safety belt system.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
1. NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices have deployed the RCM (restraints control
module) can be reused up to five times after a crash. The repair of the vehicle SRS is to include
the removal of all deployed devices, the installation of new deployable devices and the removal
and installation of new impact sensors. Diagnostic Trouble Codes (DTCs) must be cleared from all
required modules after repairs are carried out.
2. When any damage to the impact sensor mounting points or mounting hardware has occurred,
repair or install new mounting points and mounting hardware as needed.
3. When the driver airbag has deployed, install a new clockspring.
4. New driver and/or front passenger safety belt systems (including retractors, buckles and height
adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the
driver and/or front passenger safety belt pretensioners.
5. New second/third row safety belt systems (including retractors, buckles and inflators) must be
installed if the vehicle is involved in a collision that results in deployment of the rear inflatable
safety belt system, if equipped.
6. Inspect the entire vehicle for damage, including the following components:
7. Steering column (deployable column if equipped)

Instrument panel knee bolsters and mounting points
Instrument panel braces and brackets
Instrument panel and mounting points
Seats and seat mounting points
Safety belts, safety belt buckles, safety belt retractors and safety belt anchors
SRS wiring, wiring harnesses and connectors
8. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
9. Inspect the fuel system for damage or leaks. Repair the system and install new components as
necessary.
10. Connect a diagnostic scan tool and view the BCM (body control module) CRASH PID
(parameter identification).
If the BCM CRASH PID is present and reads 'Yes', use the diagnostic scan tool to carry out
the BCM Crash Status Reset under "Electrical - Service Functions".
If the BCM CRASH PID reads 'No' or is not present, complete any necessary repairs before
returning the vehicle to the customer.
1/1
2052/2430
10/30/2018 Print
Supplemental Restraint System - Scrapped Vehicle Airbag and Seatbelt

Pretensioner Disposal - In-Vehicle Disposal
Print
General Procedures
Special Tool(s)
418-143
Adapter Box (AC)
418-S055C
Test and Deployment Lead, Air Bag/Pyrotechnic Safety Belt
Disposal
WARNINGS:
To avoid accidental deployment, the restraints control module (RCM) backup power supply
must be depleted. Wait at least one minute after disconnecting the battery ground cable(s) before
commencing any repair or adjustment to the supplemental restraint system (SRS), or any
component(s) adjacent to the SRS sensors. Failure to follow these instructions may result in
personal injury.
To minimize the possibility of premature deployment, do not use radio key code savers when
working on the SRS. Failure to follow this instruction may result in personal injury.
Before deploying the air bag module or safety belt pretensioner pyrotechnic make sure that all
personnel in the vicinity are aware that a loud noise (bang) is about to occur. Do not let anybody
approach closer than 6 meters. Failure to follow this instruction may result in personal injury.
The air bag module or the safety belt pretensioner should not be handled immediately
following deployment as the air bag module will be very hot. Failure to follow this instruction may
After deployment, the inflator(s) becomes inert, direct contact to the skin or eyes of any free
pyrotechnic residues should be avoided. Failure to follow this instruction may result in personal
injury.
Always wear gloves and safety glasses when handling deployed air bag modules and safety
belt pretensioners, Failure to follow this instruction may result in personal injury.
If the air bag module or safety belt pretensioner pyrotechnic residue should contact the eyes,
wash the eyes with clean water and seek medical assistance. Failure to follow this instruction may
If a large amount of air bag or safety belt pretensioner pyrotechnic residue is inhaled, seek
medical assistance. Failure to follow this instruction may result in personal injury.
Procedures).
1/7
2053/2430
10/30/2018 Print
3.
4.
1. 12 volt battery.
Use Special Service Tools: 418-143, 418-S055C.
5.
2/7
2054/2430
10/30/2018 Print
6. 1.
2. 2. WARNING: Make sure to be a minimum distance of 6 meters from pyrotechnic

components during deployment. If possible stand behind a wall.
7. 1.

8. 1.

3/7
2055/2430
10/30/2018 Print
9. 1.

10. 1.

4/7
2056/2430
10/30/2018 Print
11. 1.

12. 1.

5/7
2057/2430
10/30/2018 Print
13. 1.

14. Deployed air bag module(s) and safety belt pretensioners should be sealed in suitable bags and
then disposed of in accordance with local contaminated waste regulations.
15. NOTE: All unserviceable air bag modules have been placed on the Mandatory Return List. All
discolored or damaged air bag modules should be treated the same as any unserviceable live
air bag module being returned.
Refer to: Driver Airbag (501-20B Supplemental Restraint System, Removal and Installation).
Refer to: Passenger Airbag (501-20B Supplemental Restraint System, Removal and Installation).
Refer to: Side Airbag (501-20B Supplemental Restraint System, Removal and Installation).
Refer to: Side Curtain Airbag - 5-Door (501-20B Supplemental Restraint System, Removal and
Installation).
6/7
2058/2430
10/30/2018 Print
16. WARNING: Under no circumstances is an unserviceable air bag module or safety belt
pretensioner to be returned through the local mailing system. Failure to follow this
If an air bag module or safety belt pretensioner fails to deploy, seal the unserviceable air bag
module or safety belt pretensioner in suitable packaging and return to the Exchange Plan Center,
as appointed through the local National Sales Company
7/7
2059/2430
10/30/2018 Print
Supplemental Restraint System -

Unserviceable Airbag Disposal
Print
General Procedures
NOTE: Unserviceable Airbags cannot be deployed and are inoperative because of internal technical
failure.
1. WARNINGS:
To minimize the possibility of injury in the event of premature deployment, always carry
a live air bag module with the bag and trim cover pointed away from the body. Failure to
To prevent premature deployment, live air bag modules must only be placed on work
benches which have been ground bonded. Failure to follow this instruction may result in
personal injury.
NOTE: All unserviceable air bag modules have been placed on the Mandatory Return List. All
discolored or damaged air bag modules should be treated the same as any unserviceable live
air bag module being returned.
Remove the unserviceable air bag module. For additional information, refer to the relevant
procedure in this section.
2. WARNING: Under no circumstances is an unserviceable air bag module(s) to be returned

through the local mailing system. Failure to follow this instruction may result in personal
injury.
Seal the unserviceable air bag module(s) in the packaging from the new air bag module(s)
and address to the appropriate manufacturer. The package should then be forwarded to the
Exchange Plan Center (as appointed through the national sales company) who will arrange
forwarding to the manufacturer.
3. NOTE: Autoliv air bag modules and seat belt pretensioners.

Autoliv Gmbh, Theodor Heuss Strasse 2, 85221, Dachau, Germany.
4. NOTE: TRW air bag modules.

TRW Occupant Restraint Systems, FAO Rene Getto, Industriestr 20, 73551, Aldorf, Germany.
5. NOTE: TRW seat belt pretensioners.

TRW Occupant Restraint Systems, FAO Helmut Goss, Industriestr 20, 73551, Aldorf,
Germany.
6. NOTE: Takata Petri air bag modules.

Takata Petri AG, Grossostheimer Strasse 223, D-63741 Aschaffenburg, (Supplier Code
P790M) Germany.
1/1
2060/2430
10/30/2018 Print
Supplemental Restraint System - Crash Sensor

Print
Removal
2.
1. Torque: 47 Nm
3. Torque: 10 Nm
Installation

1/2
2061/2430
10/30/2018 Print
2/2
2062/2430
10/30/2018 Print
Supplemental Restraint System - Front Impact

Severity Sensor
Print
Removal
2. Torque: 10 Nm
3. Torque: 10 Nm
Installation

1/2
2063/2430
10/30/2018 Print
2/2
2064/2430
10/30/2018 Print
Supplemental Restraint System - Restraints Control Module (RCM)

Print
General Equipment
Removal
NOTE: After an impact, the RCM can be used again up to 5 times if it is not physically damaged and
if it passes a self-test without any faults.

2.

3.
1/6
2065/2430
10/30/2018 Print

4.

5.
2/6
2066/2430
10/30/2018 Print
All vehicles
6.
7.
3/6
2067/2430
10/30/2018 Print
8.
9.
4/6
2068/2430
10/30/2018 Print
10.
11.
Torque: 10 Nm
5/6
2069/2430
10/30/2018 Print
Installation
1. WARNING: Incorrect repair techniques or actions can cause an accidental Supplemental

Restraint System deployment. Make sure the restraint system is depowered before
reconnecting the component. Refer to the Supplemental Restraint System depowering
General Procedure in section 501-20B. Failure to precisely follow depowering instructions
could result in serious personal injury from an accidental deployment.
2. After an impact, connect the diagnostic scan tool to carry out the BCM Crash Status Reset under
"Electrical - Service Functions", if the BCM CRASH PID is present and reads 'Yes'.
Refer to: Inspection and Repair after a Supplemental Restraint System (SRS) Deployment (501-
20B Supplemental Restraint System, General Procedures).
3. NOTE: New units must be configured using the Programmable Module Installation Routine in
the diagnostic tool.
6/6
2070/2430
10/30/2018 Print
Supplemental Restraint System - Driver Airbag

Print
Removal
NOTE: Make sure that the steering column lock is not engaged.
2.
3.
1/4
2071/2430
10/30/2018 Print
4.
5.
2/4
2072/2430
10/30/2018 Print
6.
7.
3/4
2073/2430
10/30/2018 Print
Installation

4/4
2074/2430
10/30/2018 Print
Supplemental Restraint System - Passenger Airbag

Print
Removal
1. Refer to: Supplemental Restraint System (SRS) Depowering (501-20B, General Procedures).
2.
3.
4.
1/3
2075/2430
10/30/2018 Print
5.
1. Torque: 8 Nm
2. Torque: 6 Nm
Installation

2/3
2076/2430
10/30/2018 Print
2. Refer to: Supplemental Restraint System (SRS) Repowering (501-20B, General Procedures).
3/3
2077/2430
10/30/2018 Print
Supplemental Restraint System - Side Airbag

Print
Removal
2.
3.

4.
All vehicles
5.
1/3
2078/2430
10/30/2018 Print
6.
7.

NOTE: Make sure that new nuts are installed.
Torque: 7 Nm
2/3
2079/2430
10/30/2018 Print
Installation

Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint
3/3
2080/2430
10/30/2018 Print
Supplemental Restraint System - Side Curtain Airbag—5-Door

Print
Special Tool(s)
501-125
Removal
2.
3.
4.
1/13
2081/2430
10/30/2018 Print
5.
6. On both sides.
7.
2/13
2082/2430
10/30/2018 Print
8.

9. If equipped.
3/13
2083/2430
10/30/2018 Print
10. If equipped.

11.
4/13
2084/2430
10/30/2018 Print
12.

13.
5/13
2085/2430
10/30/2018 Print
15.
6/13
2086/2430
10/30/2018 Print
16.
All vehicles
17. On both sides.
18. On both sides.
7/13
2087/2430
10/30/2018 Print
Installation).
19.
20.
1. On both sides.
Torque: 47 Nm
21. On both sides.
8/13
2088/2430
10/30/2018 Print
22. On both sides.
23. All.
24.
9/13
2089/2430
10/30/2018 Print
25.
26.
27.
10/13
2090/2430
10/30/2018 Print
28.
All vehicles
29.
Torque: 11 Nm
11/13
2091/2430
10/30/2018 Print
30.
31.
Installation
2.
1.
12/13
2092/2430
10/30/2018 Print
2. NOTE: Only tighten the nuts finger tight at this stage.

4. Torque: 11 Nm
13/13
2093/2430
10/30/2018 Print
Supplemental Restraint System - Clockspring—Vehicles With: Lane

Departure Warning
Print
Removal
1.
2.
3.
1/3
2094/2430
10/30/2018 Print
4. Refer to: Steering Wheel (211-04 Steering Column, Removal and Installation).
5.
6.
2/3
2095/2430
10/30/2018 Print
Installation
2. NOTICE: Make sure that the U-shaped part of the flat flexible cable is visible in the
window.
3. NOTE: This step is only necessary if adjustment is required.

Refer to: Clockspring Adjustment - Vehicles With: Lane Departure Warning (501-20B Supplemental
Restraint System, General Procedures).
3/3
2096/2430
10/30/2018 Print
Supplemental Restraint System - Clockspring—Vehicles Without: Lane

Departure Warning
Print
Removal
1.
2.
3.
1/3
2097/2430
10/30/2018 Print
5.
Installation
2. NOTICE: Make sure that the color marking is visible in the window.
3. NOTE: This step is only necessary if adjustment is required.
2/3
2098/2430
10/30/2018 Print
Refer to: Clockspring Adjustment - Vehicles Without: Lane Departure Warning (501-20
Supplemental Restraint System, General Procedures).
4. Torque: 48 Nm
3/3
2099/2430
Body Repairs - General Information -

Specifications
Print
DESCRIPTION ITEM NUMBER FINIS SPECIFICATION
Stone chip AU7J-M5G39-AA 1720930 WSK-M5G39-B

underbody
protection
Corrosion protection 2U7J-M7C89-AA 1219834 WSK-M7C89-A

wax HP
Cavity wax T-HV4 BU7J-M7C80-AA 1742584 N/A
Profiled butyl seal YS5J-M3G4620-AA 1128983 S-M3G4620-A
Clinched flange 1S5J-M4G245-AB 1790195 WSK-M4G245-B

protection
Metal adhesive kit, 2U7J-M2G400-AA 1203241 Set

2-component
Sealant DH-BR 3U7J-M4G4631-AA 1233502 S-M4G4631-A
Spoiler adhesive kit 2U7J-M2G376-AA 1219837 Set

- 2-component
Body sealant T-SMP AU7J-M4G245-AA 1726412 N/A
Glass adhesive H-PU 9U7J-M2G322-DA 1726389 WSK-M2G322-B1

(2K) (WSK-M11P57-A3)
Glass adhesive set - 9U7J-T03863-AA 1633780 WSK-M11P57-A3

2K
Glass adhesive D2 BU7J-M2G316-AA 1749325 WSS-M2G316-B5

(1K) (WSS-M11P57-A5)
Glass adhesive set - BU7J-T03863-AA 1749324 WSS-M11P57-A5

1K IM
Multi-purpose 1S5J-M4G329-AA 1140216 WSK-M4G329-A

sealing compound
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Specifications-G1538242 1/1
2100/2430

Description and Usage of Body Repair
Literature
Print
The purpose of this document is to give the vehicle body specialist a general overview of possible
repair techniques for body repair on Ford vehicles. Likewise, information about materials and tools to
be used is given.
No model-specific information is given. Such information is saved in the respective Ford Etis workshop
manual. Supplementary or updated information can be found in the Technical Service Information.
Information on repair techniques, materials or tools, which are not necessary for body repair on Ford
vehicles or which are not considered as conventionally in use, are not listed in this document.
Layout:
The general section is divided into the following subject areas:
How to use the document, with information on the symbols used

Health and safety information on using materials and tools
Information on bodywork construction and materials used
Workshop equipment and use of tools
Damage Assessment and determining the extent of the repair area
Explanation of possible repair techniques for body repair
Possibilities of the repair or remedying leaks, noises
Training:
The Ford Service Organization offers basic and more in-depth training on much of the content of this
document. You can obtain an overview of the entire training offering from the Ford Service
Organisation or on the Internet at www.ford-training.de.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Description%20and%20Usage%20of%20Body… 1/1
2101/2430
Body Repairs - General Information - Symbols

Print
Warnings and hazard notices

Warnings and hazard notices are shown in this literature by WARNING, CAUTION and NOTE
indicators. These notices are always shown before a job step which can be associated with an
immediate personal or material danger.
WARNING: This notice is used when failure to exactly follow the instructions given in this
literature or failure to follow them at all may result in a hazard to persons and/or in persons being
injured.
NOTICE: This notice is used when failure to exactly follow the instructions or test procedures
given in this literature or failure to follow them at all may result in damage to the vehicle or to
components.
NOTE: This notice is used when the operator should be made aware of special or extra information.
Symbols used
Symbols are used to graphically represent additional information about the operation, tool or
materials. This information will not be shown separately again as text.
The symbols used in this and other body repair manuals may be used alone as well as in combination
in a diagram.
All the symbols used in these documents can be found in the General Information section.
For additional information, refer to: Symbols Glossary (100-00 General Information, Description and
Operation).
Color coding
Different colors or shading can be used to depict special areas and components.
Blue: Main component which will be removed or installed. Only actual movements will be shown in
blue in the diagram.
Magenta: Materials or fixings, e.g. bolts, clips, spot welds or adhesives.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Symbols-G1538245 1/3
2102/2430
Yellow: Component which is being cleaned or loosened, moved or fastened, but remains in the
vehicle.
Light blue: Color for special tools and color for equipment.
In an assembly operation, the colors show the sequence of removal steps.
Blue: Main component which is being installed, removed, taken away or added.
Green: Component which, in addition to the main component (blue) is being installed, removed,
taken away or added.
Brown: Component which, in addition to the main component (blue) and the additional component
(green) is being installed, removed, taken away or added.
Movement arrows
Necessary work such as clinching flanges or moving lugs etc. will be represented by broken arrows.
Magnified and detailed views

If a detail cannot be clearly seen in the illustration because of its size or location, it is shown enlarged
in a separate window.
Position lines within a diagram

A position line is used to indicate a special position or a component. A spot weld which must be drilled
out through two panel thicknesses is indicated here, different to all the others.
2103/2430
2104/2430
Body Repairs - General Information - Health

Print
General
Appropriate repair methods and their correct implementation are very important for both vehicle
operating safety and personal safety.
WARNING: There is danger of injury through:
High voltage when electrical welding.

- Do not perform welding work in a damp environment or on a wet substrate. Use suitable
insulation underneath.
Flammable substances in the welding area.
- Remove flammable substances from the danger area. Remove the fuel tank and, where required,
those components which supply fuel.
- Completely remove the battery before carrying out any welding in that area.
Welding fumes, which are harmful to health.
Welding spatter and UV radiation.
- Wear protective clothing, gloves and welding mask or welding goggles.
Pyrotechnic components.
- Disconnect the battery negative clamp and cover the battery terminal. Remove any airbag
components.
All the regulations governing Health and Safety at Work must be complied with during body repairs.
Personal protection
Welding gases and grinding dusts can be harmful to the health. For this reason, make sure that rooms
are well ventilated and work using the welding fumes extraction system. Sealants, underbody
protection and paint residues must not be burnt down with an unshielded flame, as this will produce
gases which are damaging to health. A dedicated extraction system must always be used when
welding or brazing.
When working with substances containing solvents, good ventilation must be provided, respiratory
protection must be worn and an extraction system must be used.
Do not weld in damp areas, if necessary use an insulation mat. Welding and grinding work near the
battery presents the danger of explosion. For this reason, it must be removed before the work is
started.
Cutting, grinding and alignment work on metal panels can cause a noise level of 85 to 90 dB (A) or
even more. For this reason, you must always wear ear defenders.
The various body areas are subject to very high forces during realignment work. Should any
component suddenly become detached during this process, there is a very great danger of injury. For
this reason, pulling chains and pulling shackles must be secured with arrester cables.
NOTE: Work on airbag systems may only be performed by persons who have a relevant certificate
of competence.
Some special instructions must be followed when working on airbag systems:
Always stand to the side of it when removing or installing an airbag.

Always store an airbag or an airbag/steering wheel with the airbag side pointing upwards and in a
safe place.
Only install the airbag again when the vehicle is fully repaired and the complete electrical systems
has been tested.
Take into account the location of air curtains and shoulder airbags.
Protection of the vehicle

Protect affected areas from weld spatter and dust during all welding and grinding work on the vehicle.
If metallic dust stays on the vehicle for some time, there is the likelihood of film rust formation.
Grinding or sanding work produce tiny spots of damage to the paint surface, which may cause
corrosion.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Health%20and%20Safety%20Precautions-G153… 1/4
2105/2430
For this reason, make sure to:
Use carbon fibre blankets to protect the vehicle body.

Use covering film to protect the vehicle body from sanding dust and metal dust.
Take appropriate measures to protect the interior equipment of the vehicle during any repair work.
In addition, take into account:
Remove fuel supply components as necessary.

Protect working areas which are in danger of catching fire with a fireproof blanket.
The welding must not cause components of the air conditioning system to become heated.
Removal of any attached components in the space adjoining the repair area.
Use covering paper to protect the interior from grinding dust.
Create a definite barrier between the work area and the interior by using a carbon fibre blanket.
Protective equipment
The following protective equipment must always be used:
Protective helmet or welding mask.

Ear defenders and breathing protection.
Protective gloves and safety boots.
Welding fume extraction.
Electronic components
Increased use of comfort and safety electronics in modern motor vehicles also requires the greatest
attention to be paid during body work. Overvoltages produced during welding and in alignment work
during bodyshell rectification may cause electronic systems to be damaged. In particular, the safety
instructions for performing welding work on vehicles with airbag systems must be adhered to.
NOTE: After disconnecting the power supply and before performing further work, a wait time of up
to 15 minutes must be maintained, depending on the vehicle. Work on airbag systems may only be
performed by persons who have a relevant certificate of competence.
Disconnect the battery negative clamp and cover the battery terminal.
Disconnect the electrical connector at the airbag control module.
If welding is to be performed directly near a control module, it must be removed beforehand.
Never connect the negative cable of the welder near an airbag or a control module.
Connect the negative cable of the welder close to the location of the weld.
For additional information, see: 501-20B Supplemental Restraint System

Liquefied gas vehicles
Alternative fuel vehicles often require special handling in the workshop area. Above all, assembly
operations to some extent require particular knowledge when dealing with the special technology and
the safety regulations.
NOTE: Only fully trained personnel are permitted to work on alternative fuel vehicles.
These special requirements must be understood and taken into account in the body shop as well.
NOTICE: Danger of fire and explosion. The safety instructions must always be followed when
performing service work on fuel/gas systems. Failure to observe this instruction can lead to injury.
If the smell of liquefied petroleum gas (LPG) or compressed natural gas (CNG) is noticed in the
workshop, instruct everyone present as follows:
No smoking and extinguish all naked flames.

Shut off all electrical and air powered equipment.
Evacuate the area.
Ventilate the area.
Contact the fire control authorities.
Move the vehicle to a dedicated, well ventilated area.
Alternative fuels require special handling:
Handle them in a specially dedicated, well ventilated area, which is only accessible to authorized
persons.
2106/2430
Identify the designated area with new warning notices.

If possible close the main shut-off valve and run the vehicle on alternative fuel until it switches
automatically to petrol operation. Only then is it allowed to drive the vehicle into the workshop or
service area.
If possible do not allow any liquefied gas (LPG) to escape.
The ambient temperatures must not exceed 40°C. For this reason the LPG and CNG fuel tanks must
be removed on vehicles with LPG or CNG operation before using a drying oven to dry the paint
where the temperature exceeds 40°C.
Avoid situations in which fuel from an LPG or CNG fuel tank can escape. These situations include:
Extremely hot ambient temperatures.

Parking near a heating device.
Raising the vehicle near a ceiling heater.
Refrigerated conversion vehicles

Apart from the special materials used in building the structure of the refrigerated compartment, such
vehicles have special energy and refrigeration systems which require special handling during repair.
NOTICE:
Danger of injury. Work on the 230 volt system of the refrigeration equipment must only be
carried out by trained specialist personnel.
The refrigeration system is filled with refrigerant R134a. This can cause frostbite if it contacts
the skin. Pay attention to the corresponding warning notices and instructions in the chapter Air
Conditioning Systems.
NOTE: Work on the refrigerant circuit may only be performed by persons who have a relevant
certificate of competence.
Vehicles with a refrigerated compartment are often used to transport foodstuffs. For this reason,
additional hygiene regulations must be complied with during repair work.
Aluminum and plastic are used to construct the two different types of compartment found on
refrigerated vehicles.
The aluminum conversion is a very stable and technically perfect variant. However, against this the
relatively high production costs and a lower payload must be taken into account, because of the
weight of the aluminum conversion itself.
NOTE: Basic and in-depth training is offered on the following topics. You will find an overview of the
complete range listed in the Training brochure published by the Ford Service Organization.
The plastic conversion has developed into a light, clean and economical alternative because of
constant further development of materials and working techniques.
NOTE: The material combinations, the workmanship and the working methods must comply with
the current food hygiene regulations. For this reason, service and repair work on the refrigerated
conversion may only be performed by authorized and specially trained technicians.
Refrigerated compartment constructions are often made using both materials. The floor pan is made
of structured, slip-proof aluminum panels and the wall and ceiling cladding is made of smooth
surfaced plastic elements.
NOTICE: PUR hard foam is flammable. If PUR hard foam is overheated, it will burn on its own
with a brilliant yellowish flame. It produces unpleasant choking and toxic fumes. Special measures
must be taken when welding the vehicle body.
Polyurethane wall and ceiling elements are manufactured using a sandwich principle. An insulating
polyurethane core is coated with food grade ABS plastic on one side.
PUR hard foam does not decompose, is rot resistant and is odorless. These properties make it suitable
for use as insulation.
Because of its closed cell structure, water uptake by PUR hard foam is for the most part only a
problem at edges. Cut edges or other mechanically worked surfaces must however be sealed with the
greatest care.
The conversion to a refrigerated vehicle is performed as made-to-order production. The large surfaces
of the wall and ceiling cladding can be changed and are particularly easy to repair.
2107/2430
If access to the back of a body panel section is needed because of body straightening work, in some
circumstances it is cheaper to perform a cut-out repair instead of removing an element.
The repair process is fully described in the Student Information booklet Refrigeration System
Technology, Transit 2000.5 Freshline.
2108/2430

Environmental Regulations
Print
Orderly and responsible waste management is not only very important for the protection of health
and the environment, but it also has great importance where saving natural resources is concerned.
In body repair shops, since the introduction of the EU directives on the avoidance of vehicle waste
and the promotion of return, re-use and recycling of vehicles and their components (2000/53/EU),
more rigorous attention than before is also paid to avoidance and recycling of waste materials.
NOTE: The organization of disposal in the operation must comply with the country specific waste
regulations:
In this respect, body repair shops must take into account and comply with the following
requirements:
Separate waste according to its recycling and disposal methods.

Produce evidence for the correct transport and disposal of waste.
NOTE: The organization of disposal in the plant must comply with the requirements of the Waste
Avoidance and Management Act.
The avoidance and recycling of waste must always take priority. However, despite all measures which
may be taken, waste cannot be completely avoided.
NOTE: Useable waste which is not allowed in household rubbish, must be disposed of as special
waste
All remaining waste must be treated as commercial waste and disposed of according to the local
requirements.
Only applies to the EU:
The vehicle manufacturer is also under a legal obligation since the older vehicle legislation came into
force throughout Europe in 2002.
This law covers the surrender, withdrawal and environmentally friendly disposal of older vehicles
through the manufacturer.
The older vehicle legislation contains all the necessary information for the environmentally compatible
disposal of older vehicles, starting with preliminary handling involving the removal of all operating
fluids, deactivation of pyrotechnic components, elimination of pollutants and then further handling by
dismantling components for re-use and recycling.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Environmental%20Regulations-G1538247 1/1
2109/2430
Body Repairs - General Information - Body Construction

Print
General
Under bodywork construction, a general distinction is made between monocoque and non-monocoque
bodywork. The safety of the occupants is the main consideration for all types of bodywork
construction. The front and rear sections are designed so that they absorb the energy of the impact
via crumple zones. The use of modern design and manufacturing methods and the use of newly
developed body panels (relating to their deformation and strength properties) mean that, despite the
continuous weight-savings, all safety-related requirements made of the construction can be met.
Integral body-frame
In this method of construction, coverings, reinforcements, retaining panels and profiles are
permanently joined together using a variety of joining techniques (gluing, spot welding, laser welding,
soft soldering or brazing). The load-bearing function of the structure must always be achieved in each
case.
There is no distinction made between components which are purely subject to bending/torsion or
thrust loads and parts which perform sealing/covering functions (as in non-monocoque bodywork for
example). In modern passenger vehicles, monocoque bodywork is very widespread and offers the
advantages of a lightweight and low-cost construction.
The rigidity of the bodywork is achieved by a panel skin and panel cross-section with the largest
possible profile and therefore the largest resisting torque (such as for instance the rocker panel).
Swage lines in the outer area of the bodywork increase the stiffness and the natural vibration
frequency, to prevent possible drumming noises. The mounting points for ancillary components such
as doors and wings are permanently built into the monocoque bodywork.
High rigidity of the bodywork is vitally important to keep the elastic deformations low at the joins to
the ancillary components and to prevent noise when driving. Small gap dimensions are therefore only
possible on vehicles with very stiff bodywork. With high bodywork stiffness, the construction can exert
an influence on the handling of the vehicle (e.g. on poor road surfaces).
Advantages of monocoque bodywork:
Weight reduction.
Economical manufacturing technology.
High torsional rigidity and high flexural strength.
Defined deformation behavior at the front and rear.
Maximum passive safety due to the strong passenger compartment
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Body%20Construction-G1538248 1/5
2110/2430
The protected passenger compartment with strong pillars, rocker panels and doors with integral side
impact protection increase occupant protection. Opening of the doors is ensured, even if there is
extreme deformation.
NOTE: Repair work must always be performed according to the established workshop literature. All
the safety requirements must be guaranteed after any repair work has been performed !
Convertible
Description Description
1 Body components adopted from the Focus 2004.75 (07/2004-)
2 Conventional bodywork construction steel
3 High-strength sheet steel
4 Super-high strength sheet steel
5 Maximum-strength sheet steel
6 Aluminium, can be subjected to high stresses
The body of a convertible differs from the principle of the integral body-frame of a saloon due to the
lack of a roof construction. The body has a high degree of torsional stiffness. This is achieved by using
high, super-high and maximum-strength sheet steel and body reinforcements in specifically-targeted
areas.
These reinforcements can be installed in the area of the doors (diagonal braces etc.) or on the
underfloor. In contrast to the saloon (or other non-convertibles) with square-section side members
(closed profile), these reinforcements have a profile which is open on the underside (U-section).
Special constructional changes within the bodywork structure:
Reinforcing or increase in the thickness of the sheet steel in the pillar area.
Reinforcing or increase in the thickness of the sheet steel in the floor pan structure (rocker panel
area).
Use of heavily structured reinforcing panels in the rocker panel and pillar area.
In the area of the windshield frame and A-pillars, thick-walled reinforcing tubes are used (roll-over
protection).
Because there is no roof, the bridge construction principle cannot be used as it is on the saloon for
example. Flexural and torsional rigidity must be ensured by other components.
Non-monocoque bodywork
Non-monocoque bodywork is built onto a frame or a chassis. Frames used for this have various
construction forms, e.g. the ladder frame or tube frame. Non-monocoque bodywork is the original
way of constructing vehicles.
2111/2430
1 Vehicle body.
2 Frame Assembly
3 Bolted connection
The ladder frame is still commonly used today for truck and off-road vehicles. The bodywork is placed
on the frame or chassis. The total load which occurs while driving is transferred to the chassis.
More sporting vehicles can be built with non-monocoque bodywork, mostly using a lattice tube frame.
Limitations in the design are accepted for the benefit of low weight. The outer skin here is usually
made of plastic or alloy. This type of construction is also common in touring car racing for instance.
Special features of non-monocoque bodywork construction:
Partly large surface panels and high volume shaped parts.

Thicker materials and greater reinforcements in the frame area.
Floor pan as frame structure with high torsional rigidity and flexural strength.
Side panels only make a small contribution to the overall stability of the body.
Instructions for repair:

A different repair technique is necessary during repairs. A deformed frame structure requires high
suction power during straightening repairs. Frequently, the body also has to be detached from the
frame structure in order to carry out separate repair.
Due to the very stable frame structure, please note that the straightening behavior is completely
different to that of a passenger vehicle. The frame and the attached body must be repaired
independently of each other.
Further information can be found in the respective body repair manual.
Special points:
Tailored blanks
2112/2430
Blue: Tailored blank

Arrows: Laser weld seam
The term "tailored blanks" describes the connection of two different panel thicknesses and/or
strengths in the bodywork carcass. This connection is done using laser weld seams. Cut locations
exactly on the laser weld seams are not permitted, as at present no joining techniques are approved
for use in repair procedures that would re-create joins of the same quality.
NOTE: No cutting, no welding and therefore no sectional repairs are permitted in the immediate
area of the laser weld seams. The model specific requirements are documented in the respective
Body Repair Manuals.
Typical application areas are:
Side member
Door inner reinforcement/door frames
Wheelhouses
Rocker panel inner reinforcement
Roof rail inner reinforcement
Deformation behavior
1 Bolted crash element
2 Front side member
3 Rear side member
2113/2430
Different materials and design features lead to staged deformation of the front and rear of the vehicle
in an accident.
Crash element:
At the front of the vehicle there is a crash element which is connected to the side member by
threaded connections. This crash element can absorb light impacts of up to about 15 km/hr. Because
of the threaded connections, the crash element can be changed very quickly.
NOTE: Deformed crash elements must not be straightened or repaired.
Heavier impacts which can no longer be absorbed by the crash element must be absorbed by the side
members or the floor pan structure. Depending on the extent of the damage, a part or complete
replacement can be performed on the side member.
The rear of the vehicle, like the front of the vehicle, has structures which protect the passenger cell
through staged deformation in the event of an accident. The design layouts, however, are adapted to
the requirements of the rear area.
2114/2430

Diagnosis and Damage Evaluation
Print
Assessment of the extent of the damage includes visual inspection and dimensional inspection of the
vehicle. In order to correctly determine the extent of the damage caused by an accident, in-depth
technical knowledge, practical experience with the technical equipment and the testing and measuring
devices is required.
Noticeable damage to the bodywork structure
Positive accidental damage assessment can only be achieved if the service technician is able to
reconstruct the effect of an impact on the body structure.
For example:
If the impact occurs on the front left-hand side member, the right-hand side member will usually also
have been damaged. Often the length of this side member will not have changed, but because of the
rigid body design, it may have become deformed. This damage can be detected through the size of
the gap between the door and fender or by measuring the vehicle.
In the case of more severe impacts, in which the front part of the vehicle cannot absorb all of the
impact energy, the passenger cell is also used to absorb the energy. Here, the energy is transferred
via the A pillar and distributed there. This results in deformations in the roof and the door sill.
NOTE: Because of existing damage to the bodywork structure, damage diagnosis on a vehicle lift
may give extra incorrect diagnosis results.
NOTE: Training courses are offered on this subject. For an overview, please refer to the Ford Service
Organisation's training course brochure.
If for instance the Ford Focus Coupé/Cabriolet is raised on a vehicle lift, the dead weight of the vehicle
will cause the front end to drop by approx. 2 to 3 mm.
The altered door position is clearly recognizable by stiffness of the lock; the door moves upwards.
This causes the lock pin to contact the guide element of the door lock.
It is possible to draw conclusions about the extent of the damage through a visual inspection of the
external damage. In general, the following areas are to be checked during the visual inspection:
Outer panel including seam seals for cracks or flakes in the paint caused by the accident.
Size of the gap on doors and hoods for evenness.
Freedom of movement of door and hood/tailgate locks.
The vehicle roof for folds (gap measurement on vehicles with sunroof)
Dotted flange in door section for deformation and cracked weld spots.
The side members and crash components for crumpling and folding.
Trunk floor and floor pan from above and below for crumpling.
No noticeable damage to the bodywork structure

In addition to external indicators such as flaking paintwork or cracks in the underbody protection, it is
vital to check for damage to the body structure that is not visible from the outside (hidden body
damage) during a damage assessment. Unless ancillary components are removed, it is often
impossible to achieve accurate diagnosis of the underlying body parts.
NOTE: In order to determine the damage as accurately as possible, it may be necessary to remove
ancillary components in the area of the damage.
Particular attention must be paid to the following components:
The A, B and C pillars in the roof area.

Floor pan.
Rear ancillary components, such as bumper, lights, etc.
Trunk floor, spare wheel cavity.
Rear coverings, such as interior trim, carpet, etc.
Lower rubber seals, e.g. in door area (welded flange).
Area under the rear seat.
Attachment points of transmission system, steering, engine, drive shafts, front and rear axles.
Electrical components, e.g. the radio (damage through shaking or through voltage peaks).
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Diagnosis%20and%20Damage%20Evaluation-… 1/2
2115/2430
Non-monocoque bodywork
The chassis and bodywork must always be checked during damage diagnosis on vehicles with non-
monocoque bodywork.
It is also important here to inspect closely for damage the impact area and the areas absorbing
forces.
With these vehicles, simple inspections can already give an indication of possible deformations.
In addition, you must check for the following for vehicles with frame structures:
Cracks in the paint on the frame welds.

Traces of deformation on frame components.
Check attachment points (silent blocks) for position changes and damage.
Changed position of rubber seals.
Fit and function of the ancillary components.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Diagnosis%20and%20Damage%20Evaluation-… 2/2
2116/2430
Body Repairs - General Information - Body Sheet Metal

Print
Types of steel
Steel body panels are still the most important materials used in the fabrication of stressed skin
vehicle bodies. In addition to the familiar types of steel, reinforced high-strength and also ultra-high-
strength special steels are used in vehicle body construction.
Types of steels are classified by their properties of strength and elasticity.
Normal-Strength-Steel has a minimum yield strength of up to about 210 N/mm².

High-Strength-Steels have a minimum yield strength of about 150 to 600 N/mm².
Ultra-High-Strength-Steels have a minimum yield strength of about 400 to 1200 N/mm².
High-Strength- and Ultra-High-Strength-Steels are mostly installed in safety relevant locations

(structural components). Among others, these are side members, pillars, roof frames (Shown on
B299 - Fiesta).
Pos. Used type of steel Application range (Examples)

1 Ultra High Strengh Steel (UHSS) Impact Carriers, Bumper Carriers, A-B-Pillar
Reinforcements
2 Extra High Strengh Steel (EHSS) Frame Side Member; Rocker Reinforcements
3 Very High Strengh Steel (VHSS) Wheel House; Structural Members
4 High Strengh Steel (HSS) Roof Sticks, Fenders
5 Normal Strength Steels (MS) Outer Panel
Normal-Strength-Steels (MS)
Normal strength steels are most often used in body construction. They are relatively soft and are
therefore particularly suitable for the deep drawing processes used in body manufacturing. As well as
very good reshaping properties, the panels also have a relatively high rigidity.
High-Strength-Steels (HSS)
The strength of the material and the nature of the surface can be changed as required by different
engineering processes. In order to achieve suitable configuration and a good match between
construction specifications and what is possible in production, a large range of high strength panels is
available.
The range of the minimum yield strength is from 180 N/mm² to 460 N/mm². High strength thin steel
panels usually have a surface finish. Electrolytic surface sealing is preferred. Within the group of high
strength steels, various types of steel are used in body construction:
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Body%20Sheet%20Metal-G1538250 1/2
2117/2430
Micro-alloyed high strength steels for very difficult drawn components such as fenders, the
internal components of doors, hoods and luggage compartment lids or load bearing components
such as sidemembers, crossmembers etc.
Bake-hardening steels and phosphorus alloyed steels for external panel components with
higher draw depth and subject to higher operational demands.
Isotropic materials for flat shaped outer steel panels on doors, hoods, luggage compartment lids,
roofs.
Extra- and Ultra-High-Strength-Steels (EHSS; UHSS)
These steels are predominately used for body structural components which are relevant to safety.
Despite the reduced thicknesses of the panels used, weight reduction is often achieved together with
greater strength. As with high-strength steels, special types of steel are used in the ultra-high-
strength steels group:
Complex phase steels are used for door side impact carriers, bumper carriers and body
components relevant to crashes. Besides high strength, they have good cold reshaping properties
and are easily welded.
Dual phase steels have the same properties as complex phase steels. Because of their high
strengthening properties they are suitable for body reinforcements.
Residual austenite steels and martensite phase steels have very high strength levels of up to
1200 N/mm² and are mostly used in body structures relevant to crashes.
Manganese-boron steels have ultra high strength levels of up to 1600 N/mm² and are mostly
used in body structures relevant to crashes.
Due to the use of High-Strength-Steels, some special points must be taken into account during body
repair:
EHSS and UHSS must not be straightend!

Increased force required during HSS straightening.
Strong springback tendency during alignment work.
Cutting tools have a shorter useful life.
NOTICE: High-Strength- and Ultra-High-Strength-Steel panels must not be heated!

Work without applying heat! Losses of strength will occur at temperatures as low as 250 °C! The basic
working methods and the tools to be used are the same however.
Coated steel panels
In a similar way to high-strength-steel panels, coated steel panels are finding more applications
because of the better corrosion protection which they offer. There are basically two different process
which are used to apply a zinc layer:
Hot dip zinc coating.

Electrolytic zinc plating.
The following points must be noted when welding:

NOTE: Welding fumes are harmful to health. Make certain that the workspace is well ventilated and
use welding fume extraction.
Zinc starts to melt at about 420 °C.

The zinc vaporizes at a temperature of about 900 °C.
The amount of heating determines the damage to the zinc coating, and therefore to the corrosion
protection.
NOTE: Coated panels have a higher electrical resistance, but this can be compensated for by
increasing the welding current by 10 - 20% .
Resistance spot welding is particularly suitable for welding zinc-coated panels, because no
widespread warming occurs.
With electrolytically zinc-plated panels there is no need for any special preparation because the zinc
coating does not need to be removed.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Body%20Sheet%20Metal-G1538250 2/2
2118/2430
Body Repairs - General Information - Tools and Equipment for Body

Repairs
Print
Alignment systems
NOTE: All the equipment for body work and painting work can be ordered online via the Wielander
& Schill service portal http://fo.oem.wielanderschill.com.
Straightening and alignment repairs are often required to restore a vehicle body to its original shape
after accident damage.
Universal aligning and measuring systems and universal alignment angle systems are suitable for this
work.
1 Universal aligning and measuring system
2 Universal alignment angle system
Basically, the aligning and measuring system must satisfy the following requirements:
Universally applicable to all types of passenger car. Can also be used on light commercial and off-
road vehicles.
Accepts the forces involved during straightening.
High stability and mobility.
Can accept all or part of the weight of the vehicle.
Quick to set up.
Simple to use.
- Stationary design with drive-on ramp.
- Height-adjustable aligning platform.
- Universal gauge extensions with fast anchoring ability around the whole circumference of the
aligning platform.
Facility to test individual body measurement points, with or without aggregates being removed.
Alignment angle devices survey the vehicle at several points on the body. These are usually points
which are also used in production. In addition, a recording over the rocker panels is possible. A
measuring system is not needed, because the necessary body points are specified with gauges. For
this purpose, vehicle specific or universal gauges are available.
Universal alignment systems consist of a vehicle mounting (universal clamps at the rocker panels)
and a pulling device. In addition, a measuring system is required.
NOTE: Because universal clamps are used, the rocker panel area must be reworked for optical and
corrosion protection reasons after the repair is completed.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Tools%20and%20Equipment%20for%20Body%… 1/5
2119/2430
Clean the attachment areas.

Anchor the vehicle free of stress on the relevant system.
Support the aggregates to take strain off the body.
Measuring systems
In order to exactly diagnose a damaged vehicle body, measuring systems are required. Depending on
the measuring method, the systems vary in having mechanical, optical, acoustic and electronic
measuring devices. In some cases, hybrid versions of particular systems are found.
NOTE: When working with each measuring system, the manufacturer's instructions provided in the
description of the measuring equipment must be followed.
Basically, the measuring systems must meet the following requirements:
Universally applicable to all types of passenger car. Also can be used on light commercial and off-
road vehicles.
Suitable for all accident damage.
Fast capture of body measurement points in the underfloor and external areas.
Data catalog to record all measurement points (length, width and height) both with and without the
aggregates being installed.
complete range of training offered in the Ford Service Organization training brochure.
Beam compass
The beam compass is a very practical and straightforward aid for measuring bodywork and especially
floor assemblies. The beam compass can be used to detect dimensional variations across the length
and the width by means of comparison measurements and diagonal measurements.
As a basic principal, body reference points should be chosen which are shown in the body frame
measurement data sheet.
NOTE: To be able to determine difference in measurements, the same reference points must always
be chosen on both sides. For this purpose the beam compass must be positioned symmetrically.
Comparison measurements can also be made on the outside of the body. Depending on the damage,
left/right measurements (symmetry measurements) and diagonal measurements can be made using
the beam compass, telescopic rod or a measuring tape.
Laser measuring systems
These systems use laser beams which are projected in one or more planes.
By the use of two parallel laser heads which can be turned, symmetrical points of a vehicle body can
be tested and compared. Using the linear scales which are attached to the measuring points, the
measurement data is read off with the aid of the projected laser beams.
The integral inclination gauge also allows differences in height to be quickly checked.
Mechanical measuring system
The use of mechanical measuring equipment is an easy and effective way to check a vehicle frame
and chassis assembly quickly, exactly and reliably.
In many cases an assessment of the damage can be made with the help of this system, without the
need for elaborate setting up.
2120/2430
Because of its self-centering mount, measurement can be carried out by one person.
Further advantages:
Fast deployment.
Simple to use.
Can be extended using adapters, measuring probes and measuring tubes.
Measuring systems which are firmly mounted on an aligning platform require more work in setting
them up. They are used to constantly check measurements during alignment work.
This type of mechanical measuring system has measuring scales and measuring slides in three
measuring axes. So that the body can be measured, the vehicle is secured on the aligning platform
base frame using four universal chassis clamps. The exact fixing points are given in each respective
data sheet.
Ultrasonic and mechanical-electronic measuring systems
These measuring systems can be combined with all current aligning platforms. In addition these
measuring systems can be used independently of an aligning platform by using a vehicle lift or
suitable support stands.
1 Ultrasound measuring instrument
2 Mechanical-electronic measuring system
Acoustic or ultrasonic measuring systems use ultrasonic emitters and sensors to survey a body.
To do this, ultrasonic emitters are mounted on the vehicle using special attachments. During the
measuring process the ultrasonic emitters constantly send out signals which are received by sensors
(microphones) and then passed to a computer. The measurements are displayed on the computer
screen and are compared with the required values supplied by the vehicle manufacturer.
The ways in which mechanical-electronic measuring systems can be used are similar to those of the
acoustic measuring systems. They can also be set up on a suitable understructure, without an
2121/2430
alignment jig. After this system has been arranged under the vehicle floor and adjusted to three
undamaged vehicle measuring points, the measuring arm is brought up to the required measuring
points and the readings compared with the reference values. The data is transmitted to a computer
where it is evaluated and the results displayed on a screen.
Welding gear
As in the past, the dominant process in body construction is resistance welding, in particular spot
welding. Depending on body type, up to 5000 spot welds are applied, either by welding robots or in
the multi-point welding machine.
Resistance spot welding permits very high energy to be concentrated on a relatively small area of the
workpiece in the shortest possible time and when high pressure is applied, a permanent joint is
formed. During repairs the resistance spot welds used in production must be re-created accordingly.
1 MIG welding machine
2 Resistance spot welding machine
NOTE: If a suitably powerful welding machine is not available and multi-layer panel joints with a
total thickness of over 3 mm need to be made, puddle welding must be used.
Although in principle, high and ultra-high-strength panels are adequately or well suited to resistance
spot welding, considerable problems may arise because of low welding power, especially where thicker
panels or triple or multi-layer panels have to be welded together in the workshop. In particular, older
welding equipment does not have the latest welding technology nor welding power and therefore
cannot reliably join panel thicknesses greater than 3 mm.
NOTE: When installing body components made of ultra-high strength steel (e.g. boron), only
inverter welding equipment certified by Ford may be used.
CERTIFIED RESISTANCE SPOT WELDING MACHINES (FORD OF EUROPE)
Manufacturer Device (designation)

Pro Spot Europe i5
ARO WELDING TECHNOLOGIES SAS ERGOWELD IT Automatic- R
MV Marketing und Vertriebs GmbH & Co. KG InvertaSpot GT Automatic
Elma-Tech GmbH PREMIUMspot
Elma-Tech GmbH ELMAspot
TECNA S.p.A. 3664 P7
Telwin Spa INVERSPOTTER 14000 SMART AQUA
Alignment Systems AB CTR 12000
GYS GmbH GYSOPT Evolution PTI-s7
IMS SPOT 14500 Trafo
Equipment with inverter technology allows better spot weld quality because of a constant high
welding current. In addition the high welding current makes shorter welding times possible and the
electrodes therefore have a longer working life. Inverter welding is a further development of electrode
welding. In addition, a much higher electrode force (contact pressure of welding tongs) can be
achieved with modern equipment.
Further advantages of the new inverter welding equipment are:
2122/2430
good welding performance with constant quality, even with high switch-on times
recognition of and compensation for disruptive factors: e.g. primer, adhesive, rust-prevention paint
own and pre-set welding programs which can be saved and called up
quality confirmation through logging of all important welding data
fast changing of spot welding clamps or spot welding guns as required
The following functions can be controlled and monitored by programming the welding equipment:
Control of the start conditions by resistance measurement (dirt, paint, bodywork adhesive, shunt
circuit through the next spot weld).
Ensuring the optimum welded connection.
Checking the energy balance, resistance and quality.
In the case of resistance spot welded connections, faults in the weld are difficult to see from the
outside. It is therefore absolutely vital to know the particular properties of the welding machine being
used. A test weld with subsequent peeling test will provide information on the quality of the weld. The
spot weld itself must not separate, it must tear away leaving a hole.
In the production of vehicle bodies, MIG welding plays a minor role as a joining technique. It is used
for components subject to high demands, such as threaded plates for axle mountings, or at locations
which cannot be spot welded for access reasons.
2123/2430
Body Repairs - General Information - Establish

Repair Method
Print
General
Before starting accident repair work, make sure that the necessary spare parts and repair material
are available.
Planning
NOTE: The body interconnection is to be maintained if possible. Repair is preferred to renewal of
body components. Furthermore, check if it is possible to perform a partial repair.
During planning the following job steps must be observed and adhered to:
Determine the repair method taking into account the information made available in ETIS.
Work out which repair components will be needed and obtain them.
Establish what disassembly work is needed.
Separating points at non-load-bearing parts (e.g. outer panels of vehicle body) can be freely chosen
as appropriate to the damage symptom/service part.
Check for specific features such as airbags, route of water drain hoses, electric cables and the
location of NVH elements.
Cut out the old parts (only when the new parts are waiting ready).
Prepare the joint locations.
Attach the new parts.
Prepare the area of the repair for painting (grinding welded beads).
Perform any solder work which is required at the repair location.
Chronological sequence of repair

NOTE: Refer to each vehicle specific chapter in the workshop literature for details on the individual
points.
The actual sequence of repair can be divided into the following steps:
Job steps for the coachbuilder:

Straightening
Establish separating cuts and mark them.
- Take into account the requirements given in the repair instructions.
- Place the new part ready for use and include it in the repair plan.
Separate and remove the old part.
- Take into account the special features particular to the vehicle.
Prepare the joint locations.
- - Sand and align the weld flanges.
- Apply corrosion protection measures.
- Offer up the new part.
Attach the new component.
Rework the welded joints (grind welded seams).
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Establish%20Repair%20Method-G1538252 1/1
2124/2430
Body Repairs - General Information - Alignment Check

Print
General
If there is concern that the body has been deformed, the body must be measured. Several measuring
procedures and tools can be used for this purpose.
With simple measuring systems, it is possible in most cases to draw a conclusion about the extent of
the damage through a quick measurement without time-consuming assembly work (straightening
jig).
NOTE: For the floor pan and the exterior of the vehicle, measuring data is contained in the vehicle-
specific repair instructions for each vehicle. Manufacturers of measuring and straightening jigs
create data sheets for this purpose for each vehicle.
Data sheets with the body frame dimensions for body measurement are specified in the model-
specific repair instructions in each case. Pay attention to the position of the measuring probes for
each of the measurements given. A tolerance of ± 3 mm applies to all specified dimensions.
Measuring points that are specified in a curve are to be measured so that the greatest distance from
the opposite measuring point is reflected. For exact determination of the measuring points, enlarged
sections are shown.
Example of measuring the vehicle superstructure
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Alignment%20Check-G1538253 1/3
2125/2430
Example of measuring the floor pan
2126/2430
2127/2430

Straightening
Print
General
Straightening repairs are often required to restore the original body shape. To do this, the vehicle
must be placed on a straightening jig so that a pulling device can be used.
NOTE: Basic and advanced training courses are offered for the following contents. For an overview
of all training courses offered, please refer to the Ford Service Organisation training course
brochure.
Straightening is considered as the process of pulling out the deformed body parts, up to cutting out
the parts that need replacing. If distorted components remain on the vehicle, then the term alignment
work is used.
Body straightening requires practice and experience. Before starting body straightening, the exact
direction of impact must be determined. The straightening force must be applied in the opposite
direction to that of the impact. Only in this way can it be guaranteed that the original shape will be
achieved again.
Note the following points during the process of body straightening:
Secure the pulling unit with a safety cable.

Do not remove bonded glass prior to straightening.
Never apply heat during straightening.
If necessary, open doors or hoods/lids/liftgates during straightening.
Check dimensions and gaps continuously during straightening.
High-strength steel panels have a stronger tendency to retain their deformed shape.
During the straightening repairs, monitor the attachment of the pulling unit to the vehicle.
Carry out the straightening work in several stages, never in one pulling process. This prevents the
risk of overstretching and of joints tearing out.
During individual straightening steps (under a pulling load), relieve tension by striking the deformed
areas with an aluminum hammer while they are still under tension.
Special features of non-monocoque bodywork

Straightening is different to monocoque body construction because of separate straightening for
bodywork and chassis.
If only the body is damaged in an accident, light straightening repairs can be carried out while still
mounted on the chassis.
NOTE: With strong straightening forces, these bolted connections may be damaged (bodywork to
chassis frame). Monitor the bolted connections continuously during the straightening work. Holding
clamps or alignment angles must be attached directly to the chassis frame.
Straightening of chassis frames
NOTE: High-strength steels must not be heated.
If the body and chassis frame have to be straightened, they must first be separated from each other.
The following conditions must be met:
The repair must be economically justified.

The production quality and stability of a frame must be achieved again after carrying out the repair.
In principle, the driving and operating safety of the vehicle is paramount.
Cold straightening of deformed areas with sharp edged folds cannot be carried out.
Straightening with the application of heat (welding torch) requires much experience and accurate
knowledge of the behavior of steel panels when heated.
The temperature and duration of application of the heat are to be considered in particular.
Individual components of the frame, such as cross members, brackets, etc. can be replaced.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Straightening-G1538254 1/1
2128/2430
Body Repairs - General Information - Complete

Panel Replacement/Partial Replacement
Print
NOTE: Basic and advanced training is offered for the following contents. For an overview of all
training courses offered, please refer to the Ford Service Organisation's training course brochure.
Repairs always mean intervention in the body shell structure and thus also intervention in the
vehicle's passive security system.
NOTE: From an economic perspective, the possibility of a partial replacement (sectional repair)
must be considered when assessing an accident-damaged vehicle.
Partial Replacement
Item Description
1 Join area
2 Original welding
Decision criteria
The following are always crucial for the decision:
How economical the repair is.

Retention of the original join.
In addition, Ford must have given its approval for a sectional replacement solution in the damaged
area. For those partial replacements approved by the factory and described in the model-specific body
workshop literature/technician's information, some spare parts (service parts) specially prepared for
partial replacements are offered through the spare parts sales department.
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.
as appropriate to the damage symptom/service part. Pay attention to any restraint systems, cables,
hoses, etc. beneath the panels. Separating points should not be placed near NVH elements (must be
at least 40 mm away). Exceptions as outlined in the vehicle-specific workshop literature.
Depending on the damaged areas, further facts are to be taken into account when deciding for or
against partial replacement:
Severance cuts should be as short as possible.

The effort for follow-on work on the connections must not be too great.
It must be possible to reproduce the optical path of visible edges on door openings.
Inner reinforcement panels must not limit the straightening work.
Inner reinforcement profiles in the pillar areas must allow for separation.
The Ford regulations for partial replacements on structural frame sections must be taken into
account.
The large surface welding seams at the connections must be restored.
Advantages of a partial replacement

A partial replacement repair offers many advantages for a professional repair of accident damage:
Repairs can be made both in the outer panel area (e.g. side frame) and in the inner areas (e.g.
structural member, trunk floor).
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Complete%20Panel%20Replacement/Partial%2… 1/2
2129/2430
The repair can be limited to the actual damaged area.

Reduction of repair costs, as aggregates and other components can usually remain in the vehicle.
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.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Complete%20Panel%20Replacement/Partial%2… 2/2
2130/2430
Body Repairs - General Information - Corrosion Prevention

Print
The corrosion protection provided in production must be carefully maintained and reproduced during
body repair work, in order to ensure the long-term warranty for Ford vehicles.
NOTE: Please take the notes in the model-specific repair descriptions into account. Please also note
the manufacturer's instructions when handling the different anti-corrosion agents.
Only Ford original bodywork components and Ford approved repair materials are to be used for body
repairs. The Ford logo is stamped onto every Ford original spare part.
Panel coatings and corrosion protection
Body steel panels are provided with a coating for corrosion protection purposes. The coating material
is predominantly zinc in a variety of composition forms. Aluminum is also used to some extent.
Basically, all types of steel sheet can be coated.
A variety of coating processes are used:
Hot dip zinc coating.

Electrolytic zinc plating.
Organic coating.
Hot dip aluminum coating.
NOTE: Welding fumes are harmful to health. Make certain that the workspace is well ventilated and
use welding fume extraction.
The following points must be noted when welding:
Zinc starts to melt at about 420°C.

The zinc vaporizes at a temperature of about 900°C.
The amount of heating determines the damage to the zinc coating, and therefore to the corrosion
protection.
Resistance spot welding is particularly suitable for welding zinc-coated panels, because no
widespread warming occurs.
With electrolytically zinc-plated panels there is no need for any special preparation because the zinc
coating does not need to be removed.
NOTE: Coated panels have a higher electrical resistance, but this can be compensated for by
increasing the welding current by 10 - 20% .
Corrosion protection measures during repair work
NOTICE: Always be extremely careful when handling solvents, sealants and adhesives. Some
products contain substances harmful to health or give off harmful or poisonous vapors. Always
follow the manufacturer's instructions. If there is any doubt as to whether a particular solvent is
suitable, it must NOT be used.
All Ford bodywork components have a cathodic primer. Moreover, most parts are zinc-plated on one or
both sides. If possible, these protective layers must not be damaged.
Before welding
Interior surfaces of new bodywork components which will no longer be accessible after installation
must be painted beforehand. The welding flanges are treated with a special welding primer. The joint
areas are not always accessible from inside later. Therefore, prepare these areas so that no soot is
produced by burning paint during welding.
NOTE: In order to ensure that the corrosion protection produced in production is not destroyed, the
working area must be kept as small as possible.
NOTE: Do not touch cleaned bare metal any more with the bare hands. The dampness of your
hands will corrode the metal.
Procedure:
Remove the primer or paint/zinc layer in the welding area using a tress wire brush to prevent the
formation of soot from the paint.
Thoroughly clean the welding area with a metal cleaning agent and rub dry.
Coat the welding flange with welding primer on all sides and allow to dry.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Corrosion%20Prevention-G1538256 1/5
2131/2430
NOTE: The welding primer must only be applied thinly to the spot welding area, to minimize
spattering when welding.
After welding
During repair work, body panels are often heated at very high temperatures, which results in the
destruction of the corrosion protection.
Reworking of the affected areas is therefore vital:
Grind the welded seams flat and clean thoroughly with silicone remover. Dry with a lint-free cloth.
If the join area is accessible from the inside, the transition area to the paint must be abraded for all
types of join so that good adhesion of the primer is achieved later.
If the join area is not accessible from the inside, the cleaning and sanding work is not done. For this
reason, ensure that there is as little contamination as possible in the area of the repair. This allows
the cavity wax applied later to penetrate the join area without hindrance.
NOTE: Only apply a small amount of panel cleaner to the cleaning cloth when cleaning the repair
area. Make sure that no cleaner reaches the connecting flange, so that the welding primer is not
washed away again.
Priming after welding
Primer is applied to the welded flanges after cleaning. A check must also be made that the production
corrosion protection is present in the area of the flanges. Any damage must also be re-primed.
Sealing work
If MIG welding is carried out during a sectional repair on a connecting flange with sealant or
adhesive material, the material must be applied at a distance of approx. 10 mm from the weld spot.
These areas must be sealed very carefully after the work has been completed.
Depending on the type of repair, the clinched flanges on the hood, doors, tailgate and trunk lid must
be sealed with clinched flange sealer.
Clinched flange protection with flat nozzle
Clean the clinched flange area of the new component with silicone remover and dry with a lint-free
cloth.
The sealant must be applied to the dry primed surface (i.e. dip priming as for delivery).
Apply clinched flange protection to the clinched flange using one of the flat nozzles supplied. The
nozzle must be cut to the necessary width beforehand and the guide stop cut as required.
During application the clinched edge must be covered with an overlap of at least 3 mm. The
beginnings, ends and edges or interruptions in the sealer bead need to be reworked by forming with a
brush or a spatula, to ensure a 100% tight sealing of the flange.
The speed and angle of application are decisive for a good appearance and a bubble-free bead.
Always apply the sealer with as few as possible interruptions to avoid sealer rework. Never use
solvents or thinners as this will considerably slow down the hardening process of the sealer.
For an application thickness of 3 mm of the clinched flange sealer it is recommended to allow to dry
over night at room temperature. A minimum hardening time of 5 hours is required anyhow before a
2-component primer can be applied.
Clinched flange protection applied to the correct width and thickness.
2132/2430
Underbody protection/stone chip protection
The underbody protection is used as corrosion protection and must also be applied such that it
matches the original condition, from a visual perspective.
Two main application methods are used in production:
The underbody protection is applied as a sprayable sealing compound.

In the area around the structural members, the underbody protection is sprayed on and spread
across a wide area.
Because of the coarse surface structure of the stone chip protection material, it is recommended to
only perform a repair over the whole surface, if there is damage over visible areas. Otherwise there is
the danger of serious irregularities on the surface.
The thickness and appearance of the underbody protection and stone chip protection must be
matched to the original. Special spray guns are used to work the materials for this reason. A test
spray must always be performed beforehand however, to determine the correct appearance and layer
thickness.
Cavity protection
After painting work has been completed, a general check is made of the work that has been done.
Before final reassembly of the vehicle, the cavity wax protection in the area of the repair must be
renewed. Cavity wax protection must be performed carefully so that the quality of the repair
conforms with Ford standards:
Guide the cavity wax probe carefully in the area of the repair so that targeted corrosion protection
is achieved.
Pay special attention to edges and swage line on stepped joints, the wax must cover the inner edge
areas.
The cavity wax must flow along the stepped sheets so that the wax is drawn between them by
capillary action.
A hole may be drilled in a suitable place for areas which are not accessible for the application of cavity
wax. The diameter depends on the size of plugs available. When this is done it is vital to make sure
that no drilling swarf remains in the cavity (rust will form if any remains). The edge of the hole must
be treated with cavity wax. Finally close with a plug and seal with underseal.
Only on components with clinched flange edges:
After painting, the inner clinched flange edge must be sealed as far as is possible with cavity wax. For
this, the repaired component should be positioned upright and corrosion protection wax sprayed into
the water drainage holes and/or the thread holes for the hinges in both directions (50 ml corresponds
to about 20 seconds spraying time).
For doors, tilt and turn the component to spread the corrosion protection wax over the whole edge of
the flange.
Wax application
2133/2430
Corrosion protection for the floor pan (example)
Item Description
1 Injection points for cavity wax protection
2 PVC stone chip protection at the wheel arches
3 PVC underbody protection
4 PVC stone chip protection
5 PU primer
2134/2430
2135/2430
Body Repairs - General Information - Corrosion

Damage/Corrosion Repair
Print
Modern vehicle bodies are protected from corrosion by elaborate measures. Multilayer coatings on the
panel surface prevent direct contact between the metal and oxygen, and so protect it from corrosion.
In the long-term however, corrosion on a vehicle cannot be completely prevented.
complete range of training in the Training Brochure issued by the Ford Service Organization.
What is corrosion?
Corrosion is destruction of a subsurface caused by chemical or electrochemical effects which operate
from the outer surface.
If the protective layers become damaged, electrochemical conversion processes are initiated, which
allow the metal to oxidize. This leads to the formation of corrosion.
The following factors lead to corrosion:
Mechanical damage such as stone chips and scratches which penetrate through to the steel panel.
Damp interiors.
Unfavorable weather or environmental conditions, as may occur in areas with high humidity, high
salt content in the air or serious air pollution due to aggressive gases and dusts.
Insufficient corrosion protection after repairs.
Lack of care by the vehicle owner of the painted and corrosion proofed surfaces or areas on the
vehicle.
In order to maintain long-term corrosion protection, the vehicle must be checked at regular intervals.
In doing so, the follow areas must be inspected and any damage rectified:
Damage to the paint surface cause by scratches or stone impact must be suitably rectified
according to the specifications.
Damage to the PVC underbody protection or the PU stone chip protection must be refinished.
Damage to the PVC underbody protection or the PU stone chip protection must be refinished.
Incomplete or damaged sealing at clinched flanges must be renewed.
Check the cavity protection and renew it if incomplete.
Poorly installed or damaged covers and stone chip protection fixtures must always be renewed.
Check seals and seal carriers for wear and correct mounting. Any damaged seals must be renewed.
All rubber grommets and blanking plugs must be present and correctly installed.
A damp or wet floor inside the vehicle indicates that there are leaks in the bodywork. The interior
must be dried out and the leaks must be completely rectified.
The corrosion formation can vary in extent.

With rust film or edge rust formation, the surface of the paint has small traces of corrosion present.
The traces of corrosion can possibly be removed in such cases by polishing the paint surfaces. If this
is not possible however, the traces of corrosion must be rectified by using a touch-up technique.
If the corrosion is just starting, with up to 1 mm rusting below (in the form of a dot or a line) the
damage is rectified as follows:
Clean the defective location.

Mechanically remove the rusting which is starting below the surface.
If the area is small, apply primer and allow it to dry, then use the paint pencil to touch up the area -
if not, respray the damaged area.
If rust is already under the paint finish to the steel panel, then the whole paint finish in the affected
area must be sanded away.
Furthermore, the existing traces of corrosion in the body panel must be carefully and completely
removed.
Finally a new paint finish must be applied in this area. In the case of rusting through, the affected
body panel is already completely destroyed. Such damage requires complete or at least partial
replacement.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Corrosion%20Damage/Corrosion%20Repair-G1… 1/2
2136/2430
NOTE: : In the general section there are several chapters which present the techniques necessary
for a professional corrosion repair.
The outcome of this is the following repair sequence:
Remove the rusted-through part.

Remove the remaining traces of corrosion.
Offer up the new part.
Prepare the joint areas.
Weld the new part into place.
Produce the corrosion protection.
For a professional repair it is essential to reproduce the corrosion protection during and after the
repair.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Corrosion%20Damage/Corrosion%20Repair-G1… 2/2
2137/2430
Body Repairs - General Information - Sealer,

Underbody Protection Material and Adhesives
Print
Sealants, adhesives, cavity wax and underbody protection materials are used during the various body
repairs. In this area Ford offers a range of products which have been tested and matched to each
other.
NOTICE: Always be extremely careful when handling solvents, sealants and adhesives. Some
products contain substances harmful to health or give off harmful or poisonous vapors. Always
follow the manufacturer's instructions. If there is any doubt as to whether a particular solvent is
suitable, it must NOT be used.
Clinched flange protection
One-component adhesive/sealer which can be applied by brush or spraying, based on MS polymer,
with a flat nozzle for application and with the following properties:
Can be sanded
Permanently elastic
Non-corrosive
Very good adhesion
Rapid hardening and resistant to ageing
Can be over-painted with almost all proprietary paints
Seam sealant T Anthracite

One-component sealer based on MS polymer, for sealing joints and seams, with the following
properties:
Silicon-free
Solvent-free and low-odor
suitable for gluing HVH elements into position in their respective body areas
Body sealant T beige

Sealer with the following properties:
Stable
Contains solvent
Especially suitable for visible seams
After hardening can be overpainted with two-pack paint
Underbody Coating
Underbody protection is necessary for permanently elastic corrosion protection of vehicle
underbodies. It is very durable and has good resistance to abrasion,
Cavity wax
This touch-proof, transparent corrosion protection wax is used for the preservation of cavities and
flange joints.
Anti-corrosion wax
Anti-corrosion wax is a coating material which can be applied in fine spray, forming a very thin and
grease-like protective film, therefore offering very good corrosion protection.
2-component metal adhesive
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Sealer,%20Underbody%20Protection%20Materi… 1/2
2138/2430
For joining metal to metal and plastic to metal. The adhesive reduces droning noises and improves
corrosion protection.
Windshield sealant
Solvent-containing, stable sealing material. The sealer is permanently elastic and does not form a
skin on the surface.
1-component window glass adhesive kit
For direct glazing. The vehicle is ready to drive after 6 hours (passenger airbag). Prevents contact
corrosion.
2-component window glass adhesive kit
For direct glazing. The vehicle is ready to drive after 1 hour (passenger airbag). The adhesive is not
an electrical conductor and permits interference-free radio reception. Prevents contact corrosion.
Using a 150ml additional cartridge, the adhesive can also be used for large windows or to produce a
double seam of adhesive.
PU glass adhesive
150ml additional/replacement cartridge for direct glazing using 2-component window adhesive kit.
Suitable for double beads or larger windows. Also suitable for sealing NVH elements.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Sealer,%20Underbody%20Protection%20Materi… 2/2
2139/2430
Body Repairs - General Information - Cutting Technique

Print
NOTE: Without exception, before starting work you must read the safety and warning instructions in
the chapter "Safety Instructions". In addition, pay attention to the warning instructions of the
particular equipment manufacturer.
NOTE: After all separation work, make certain that the metal swarf is completely removed from the
vehicle body.
Possible cut lines (example)
Depending on the separating tools used, there are some fundamental points to bear in mind:
Only start the cutting work once the new part is to hand.
Compare the new part with the old part for shape and size.
The straightening work must be completed before any body components to be replaced are cut out.
Before separation work is started, all welded connections which cannot be seen must be freed of
underbody protection, sealant etc.
as appropriate to the damage symptom/service part. Pay attention to any restraint systems, cables,
hoses, etc. beneath the panels. Separating points should not be placed near NVH elements (must
be at least 40 mm away). Exceptions as outlined in the vehicle-specific workshop literature.
Spot weld milling tool

Resistance spot welds are separated using a spot weld drilling machine or a spot weld milling tool.
NOTE: Steplessly variable machines increase the working life of the cutting tool. Use of a suitable
lubricant can increase this even further.
A spot weld milling tool usually has an adjustable depth stop and a safety fixing system. These
prevent the machine from drilling too deep and the cutter from slipping while working.
Rod sander
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Cutting%20Technique-G1538259 1/2
2140/2430
Another option for separating resistance spot welds is to use the rod sander.
If spot welds and MIG welds are difficult to reach, a rod sander may offer an alternative.
Short stroke saw
The short stroke saw is suitable for separating vehicle body components and for making a separating
cut for partial repairs.
NOTE: In order not to damage panels, wiring harnesses, hoses or similar components which lie
behind, remove them beforehand as necessary.
The narrow design of the saw blade permits cutting in tight curves. Straight cuts require a relatively
great deal of practice.
Orbital saw
Where use of the short stroke saw is difficult because of the body construction, the orbital saw can be
used.
The cutting depth of the orbital saw can be set. This allows separating cuts to be made, despite
panels or other components lying in danger behind. Straight cut lines can be more easily made using
the orbital saw.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Cutting%20Technique-G1538259 2/2
2141/2430
Body Repairs - General Information - Panel Beating Technique and

Smart Repairs
Print
General
Smaller scale body repairs, where damaged panels do not need to be replaced, can often be carried
out by realignment work. Whether the repair is economical however, often depends on the
accessibility of the affected body area.
NOTE: Basic and in-depth training courses are offered on the topics which follow. An overview of
the complete range of training offered is provided by the Ford Service Organization Training
brochure.
During damage assessment, the following technical points must be taken into account:
Small mild dents (without damage to the paint), which are in areas that make access from the
inside possible, can be rectified using undamaged paint panel beating.
If the inner side of the damaged area (with paint damage) can be accessed, then conventional
panel beating techniques can be used.
If the damaged area has no access from inside, then it can only be rectified using outside panel
beating techniques.
If the component in the area of damage is bonded to other components, it is important to make
sure the bonded connection is not damaged during repair work.
Dent removal using special panel beating levers

NOTE: In the Undamaged Paint Dent Removal section, you will find more information on pressure
techniques.
1 Deflection by a hook arrangement
2 Pressure tool
This panel beating technique with pressure is mainly used to rectify smaller dents as a result of hail
impact, transportation or parking, without the paint being damaged.
Small dents are removed from the inside of the body panel by pushing them outwards in a
mechanical process using panel beating levers.
Because of the great variety of shapes of these levers, it is possible to use this panel beating
technique on almost all areas of the vehicle body.
Dynamic puller with counter bearing
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Panel%20Beating%20Technique%20and%20S… 1/5
2142/2430
1 Puller device for minor damage, with integral copper electrode
2 Puller device for more extensive damage
3 U-washers spot-welded in place
4 Puller bits spot-welded in place
5 Attachment for U-washers or puller bits
This method can be used to reshape dents or more extensive damage from the outside.
For minor damage, the copper electrode in the tool is secured onto the panel surface by spot-welding
and the puller device is used to pull out the damage without jolting.
For more extensive damage, puller bits or U-washers (depending on the application area) are spot-
welded to the panel surface and the area pulled out using the puller device.
Because of the versatile puller and the variable counter bearing, a wide variety of damage can be
worked and rectified using this repair method.
Because of the mechanical lever operation, the variable counter bearing and the optimum controlled
application of power, this external dent removal system allows dents in almost all vehicle body areas
to be pulled out.
Hollow leveling (removing dent without a dolly)
Hollow leveling can only be used on areas which are accessible from the rear.
1 Center of dent
2 Spoon
2143/2430
During hollow leveling, the dent is removed from the inside a using suitable panel beating tool and
applying knocking or pressing movements. High spots around the edge of the dent area are flattened
with blows from the aluminum or wooden headed hammer.
The usual tools are for instance hammers of various designs, dollies, levering irons and various spoon
irons. The correct choice of tool is made depending on the shape of the dent and the access which is
possible.
Dent removal using hammer and dolly
Panel beating can only be performed using a hammer and dolly if access can be gained from the rear
side.
1 Aluminum hammer
2 Box file
The purpose of the dolly in this case is to transfer the force of the impacts from the hammer to the
steel panel which is in between. As this is done, the deformed body panel is smoothed (dressed) and
the tension fields in the body panel are removed.
The favored tool for this repair process is the aluminum hammer and as opposite support the
universal hand dolly. To rectify minor panel damage, the box file should be used as opposite support.
Because of its serrated surface, the box file prevents normal stretching of the body panel which would
otherwise occur.
Heat-induced material shrinking
Material shrinking, also called settling in, can be performed in a variety of ways depending on the
extent of the damage and the access to the repair area.
These repair processes differ depending on the type of heating and subsequent working of the heated
surface. They sub-divide into two basic processes:
Heating using a carbon electrode.

Heating using the oxy-acetylene torch.
In the carbon electrode process the working is done exclusively by warming. In this case the access
to the repair position is only from the outside.
2144/2430
1 Carbon electrode
2 Spiral shaped heating pattern
If the damage is concentrated in a spot and is in the form of a more rigid raised area, then the carbon
electrode must be replaced by a copper electrode. As heat is applied, slightly more pressure is applied
to the raised area.
In the method using heating by the oxy-acetylene torch, material shrinking is achieved by a
combination of heat and mechanical working of the damaged area.
1 Overstretched area
2 Point heating using the oxy-acetylene torch
3 Spiral shaped knocking back with dolly
The repair area must always be accessible from both sides, so that the heated area can be properly
worked mechanically.
If the component in the repair area is bonded to other components, the area must not be heated.
Otherwise, this would damage the bonded connection and may also adversely affect the function of
safety-relevant components.
2145/2430
The combination of heating and mechanical working is very effective.

As soon as the warm point is established, hammering is immediately started using the aluminum
hammer together with a suitable dolly on the inside of the repair surface, working in spiral
movements towards the warm point. This causes material to build up in the center of the warmed
area.
Lead loading
Despite good external panel beating techniques, it is not always possible to rectify every surface
unevenness. For this reason, application of lead loading is an important part of panel beating.
NOTICE: Poisonous gases and dust can be produced when working solder. Use an extraction
unit and, if required, a protective mask.
NOTE: Since 07/2003, lead compounds have been ruled out for production. Appropriate lead-free
tin solders and pastes must also be used in the workshop.
Typical application areas:
Body components with limited or no access from the rear.

Body components with very narrow cross-section.
Body components which are particularly exposed or which can move.
Weld seams of partial repairs.
Rocker panel areas, wheel arch edges, side panel areas.
Doors, hood, luggage compartment lid.
Swage lines and joint areas.
Tin has the following advantages:
Excellent bonding on bare metal surfaces.

Good moulding properties.
Good properties for the production of shapes and contours.
Permanent shape.
Heat expansion is the same as steel.
To create a basis for the actual lead loading process, a lead loading paste is first applied to the panel.
The paste is then heated and wiped away with a cloth. Now the tin can be applied and moulded with a
brazing block.
After the repair site has cooled down, it is worked using for example the body plane until the surface
is smooth and has no transitions.
2146/2430
Body Repairs - General Information - Paintless

Dent Removal
Print
General
Application is restricted to body surfaces which are accessible from both sides. This repair technique
is seldom feasible on double-skinned body components or closed body profiles. The same applies to
edge areas, swage lines and seams on body components, which are very dimensionally stable.
The following characteristics must be present for a dent to be removed:
The diameter must be no more than 50 mm.

No material stretching in the centre of the dent.
Repair area must be accessible
Furthermore, sufficient experience in the use of special tools and knowledge of materials are also
requirements for a successful repair.
Item Description
1 Deflection by a hook arrangement
2 Pressure tool
Mild dent
Satisfactory repair results are only possible on mild dents with little depth and small deformation
radii. Therefore this repair method is particularly suitable for hail, parking and transportation damage.
Dent with material stretching
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Paintless%20Dent%20Removal-G1538261 1/2
2147/2430
If strong and direct force during the damage process causes the material to stretch in the middle of a
dent, then the result is a small and sharp edged dent. Such damage cannot be rectified without
visible deformation.
Advantages of a planishing technique:
Economical in time and materials

The original paint is retained
Environmentally friendly (no sanding or painting work)
While carrying out the repair, the following itemized repair route and process flow must be complied
with:
1. Damage diagnosis
2. Repair preparations
3. Perform repair
4. Paint finishing, corrosion protection and quality control
In order to ensure corrosion protection, all inner areas of the repair must be treated afterwards.
Where it is possible, the paint is repaired. In every case the inner area of the repair must be treated
with cavity wax.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Paintless%20Dent%20Removal-G1538261 2/2
2148/2430
Body Repairs - General Information - Plastic

Repairs
Print
General
The proportion of plastics used in vehicle construction continues to rise. Up to now damaged plastic
components often had to be replaced. These days, plastic repairs are becoming more and more
widely accepted because of the increasing cost of spare parts.
NOTE: Plastic adhesives are chemical products and are subject to the safety instructions of the
manufacturer.
In repair work, the material properties of plastics are highly significant. There are two main groups:
Thermoplastics.
Thermosets.
NOTE: Elastomers make up a third group of plastics. These are not mentioned below because they
have no plastics repair applications.
Thermoplastics
Heat causes thermoplastics (also called TP polymers) to transform from the solid state into the
thermoelastic state and then into the thermoplastic state. When thermoplastics are cooled, they
return to solid state.
Brief description Plastic

ABS Acrylonitrile butadiene styrene copolymer
PA Polyamide
PC Polycarbonate
PP Polypropylene
PP/EPDM Polypropylene/ethylene propylene diene copolymer
PC/PBT Polycarbonate/polybutylene terephthalate
Hard PVC / soft PVC Polyvinylchloride
Thermosets
Thermosets (also called TS polymers) are much harder and more brittle than thermoplastics. Their
strength remains largely unchanged when they are heated. Thermosets are destroyed when heated
above the critical temperature. Also, the original state will no longer be restored on cooling.
Brief description Plastic

GRP Glass reinforced plastic
PUR Close-meshed cross-linked polyurethane
PUR Wide-meshed cross-linked polyurethane
Plastic identification
Normally the appropriate identifier is marked on the plastic components used in vehicle construction.
The capital letter sequences used for this are standardized in DIN EN ISO 1043-1 and DIN ISO 1629
(for rubber) and can be looked up in the tables which they contain. In addition the string of
characters provides information about the exact mixture ratio and the proportion of certain fillers.
Examples of the identification of plastics
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Plastic%20Repairs-G1538262 1/6
2149/2430
NOTE: The identification of the type of plastic is necessary for the plastic welding process in order
to determine the correct welding rod (welding material) to use.
If an identifier is missing or cannot be made out, the following easy to perform tests will help:
Visual Inspection
Visual inspections mainly serve to identify PUR and GRP materials. Thermoplastic components are
often painted and are therefore difficult to identify.
Identification characteristics:
When PUR cracks or similar damage occurs, pores of foam can be seen.
GRP can be recognized by the glass fiber structure on the inside.
Mechanical test:
The plastic group can be determined by a sound test:
Degree of hardness - the higher-pitched the sound, the harder the plastic.
Elasticity - the more muffled the sound, the higher the elasticity of the plastic.
Sanding test
In this a place is chosen which will not be visible later, and the finger belt sander is used to sand the
plastic.
The plastic group can be determined using the pattern of the dust:
Thermosets produce a white dust.

Thermoplastics smear and do not produce dust.
Float test in water:

Take a small piece of plastic from the component to be repaired and test whether it floats on water
(PP-EPDM, HD-PE, PP) or sinks (PVC/U, PVC/P, ABC, PC).
Nature of the surface
The surface of plastics can be categorized as rigid (PVC-U, PVC-P) and waxy (PP/EPDM, HD/PE, PP).
Adherence test using welding rod
Heat a welding rod that is identified with the type of material and the plastic component using the hot
air gun. Press the welding rod onto the plastic component to be welded. When the welding rod cools
down, if it remains stuck to the component or can only be removed with great difficulty, then it can be
assumed that the two are made of the same plastic. When pulling away from PP/EPDM, HD/PE and PP,
this can lead to strings.
2150/2430
NOTICE: Danger of poisoning! When burned, most plastics release vapors harmful to health.
Ventilate the room well and use respiratory protection. Where possible work using an extraction
system.
Burning test
Every plastic has a characteristic behavior and smell when burned. Using a knife, cut off a small piece
from the component to be repaired, remove any dirt and paint residues and set light to the small
chip. Now observe the burning behavior. Compare the color, type and smell of the smoke with the
results from the following table.
Short description Plastic recognition using a burning test

ABS Blackish smoke, the material drips like a candle when burning and smells like
wax.
PA No smoke, draws filaments, smells like burnt horn.
PC Yellowish, sooty smoke. Smells sweetish.
PP No smoke, the material drips like a candle when burning and smells like burnt
oil.
PP/EDM No smoke, the material drips like a candle when burning and smells like burnt
oil.
PC/PBT Hard and shiny, burns yellow, fluffy soot.
Hard PVC / soft PVC Blackish smoke and acrid smell.
Safety instructions
In addition to the general safety instructions, the relevant regulations and accident prevention
legislation must be observed.
NOTE: Without exception, before starting work you must read the safety and warning instructions in
the chapter "Safety Instructions". In addition, pay attention to the warning instructions of the
particular equipment manufacturer.
Information sheets, safety notices and guidelines for the processing of adhesives containing
isocyanate, polyester resin, adhesives, solvent and thinners provide more details on their use.
The following instructions must always be followed:
Polyester resin, adhesive, solvents and thinners are inflammable and must not be used near naked
fire or flames.
Sawing and grinding operations must only be carried out in rooms equipped with extraction
systems.
If no rooms with extraction systems are available, only use tools with extraction equipment.
Protective equipment such as gloves, protective goggles, aprons and breathing masks are essential.
Because of the various compositions of plastics, repair work to plastic parts involves a variety of
repair methods.
The following methods are used:
Thermoplastic straightening.
Plastic welding.
Plastic adhesive bonding.
Plastic lamination techniques.
Thermoplastic straightening
Damage to thermoplastics can be rectified by heating using the hot air gun (temperature about
100°C) while the deformation is pressed out until the shape is regained.
Plastic welding
Splits formed in plastic bumpers are typical possible plastic repairs.
NOTE: Do not carry out plastic welding in the area of fixed foam backing. The foam backing will
usually be destroyed and the function of the component is then no longer guaranteed.
If repair using adhesive methods is not possible because of unfavorable conditions at the rear of the
repair location, plastic welding is a possible repair process.
There are two methods of welding: hot air draw welding and hot air fanning welding.
2151/2430
Plastic welding set
Item Description
1 Various welding rods
2 Scraper (heart-shaped)
3 Hot air blower (approx. 1500 W)
4 Clamps
5 Welding nozzles
In addition to the components listed, plastic welding requires tools already found in the workshop
such as scrapers, sanders, face cutters etc.
As with all other welding processes, only certain material combinations can be joined together using
plastic welding.
NOTE: The manufacturer's data must be taken into account when choosing welding materials and
the correct temperature setting of the hot air gun.
Repair sequence during plastic welding:
To prepare the location for welding, remove paint residues and sand the weld area.
If parts of the material have been pushed in by an impact, the damaged area can be brought back
to shape by heating.
Drill out the ends of the split to stop it spreading further. Machine the location of the weld into a 90°
V-shaped groove, to accept the welding rod.
Lay the welding rod in the groove.
Perform the welding. Hot air draw welding or hot air fanning welding.
Rework the weld seam. After cooling, sand the raised weld seam.
Clean the sanded repair surface using plastic cleaner. Apply plastic primer thinly to the repair
surface and paint it.
Despite good preparation and the correct choice of welding materials, weld faults may occur.
The following points must be noted when welding plastic:
Weld together like with like:

- With very few exceptions, only the same materials can be welded together, e.g. PP with PP.
Correct temperature:
- The correct choice of temperature is important for the success of the repair. The plastic must be
warmed until it plasticizes (dough-like, soft).
Guideline values for welding temperature:
Brief description Plastic Temperature

ABS Acrylonitrile butadiene styrene copolymer 360°
PA Polyamide 400°
PC Polycarbonate 370°
PP Polypropylene 280°
PP/EPDM Polypropylene/ethylene propylene diene copolymer 280°
PUR Polyurethane 300°
Hard PVC Polyvinylchloride 340°
Soft PVC Polyvinylchloride 370°
Even pressure:
- When rod welding, the pressure is applied by pressing on the welding rod.
2152/2430
Steady speed:
- To achieve a good weld, care must be taken that the working speed is steady.
Possible causes of weld faults:
Deformation caused by overheating of the repair area or tensions in the material while welding the
component.
Plastic material too thin.
Poor weld joint because the weld temperature was too low or the welding speed was too fast.
Welding different materials together.
Weld seam dropped because the split gap was too wide or the welding temperature was too high.
A good weld is recognized by a slightly raised, smooth and even weld bead on the surface of the
component.
The weld bead must only be worked once it has fully cooled down.
Plastic adhesive bonding
Adhesive bonding of plastics has some advantages over welding methods:
Within the group of thermoelastic plastics, all semi-rigid ancillary components (such as bumpers,
front grilles, etc.) can be repaired without identification.
A two-component polyurethane based adhesive is used for all thermoplastic parts.
Reinforcement strips can be attached behind splits (split length up to max. 100mm) and openings
to ensure the original strength properties.
Tools and equipment also familiar from paint repairs can be used in making adhesive repairs to
thermoplastic components.
Angle grinders and belt sanders can be used to grind out scratches and splits. Orbital sanders with
extractors are used for fine sanding.
The infrared heater is used to provide fast and certain drying throughout.
Plastic adhesive set
Item Description
1 2-component adhesive
2 Cartridge gun
3 Mixing tube
Apart from the components shown, other materials may be needed to bond plastics, depending on the
repair position.
For large scale repairs, it may be necessary to insert reinforcement panel strips and reinforcement
matting as fixing aids.
Repair sequence during plastic adhesive bonding:
NOTE: Follow the manufacturer's guidelines when using adhesives.
Prepare the location of the bond. Remove paint residues and sand the area to be bonded. Drill out
the ends of the split to stop it spreading further. Prepare the bond location into a V-shape and clean
it with plastic cleaner.
Apply the adhesive. The two-component adhesive is applied to the cleaned and primed repair
location using a hand gun. Spread and smooth the adhesive using a flexible plastic spatula.
Rework the bond location. After cooling, sand the raised adhesive. Clean the sanded repair surface
using plastic cleaner. Apply plastic primer thinly to the repair surface. Apply paint.
2153/2430
GRP repairs
GRP material is hard and brittle in its strength properties. Because of these material properties, splits
and openings often result in cases of serious damage.
The stability of GRP parts is impaired if the glass fiber reinforcement is cracked. The component must
be replaced in cases of serious damage that affect the structure.
Minor damage (such as abrasion, splits up to 80mm, holes up to approx. 60mm diameter, etc.) can be
repaired to a technically and visually perfect standard, provided that the damage does not occur in
heavily used or hard-to-reach areas.
To ensure perfect repair results, observe the following points:
The room temperature should be at least 15°C and the air should be as dry as possible.
The repair location must be thoroughly dry and clean.
Before the repair, the GRP part being repaired must be dried using an infrared heater or in a drying
oven.
In cases of large splits and fractures, the strength of the outer skin can be re-established by
backing with a reinforcement material.
Tools and equipment from the paint shop can be used to carry out repairs to GRP parts. Angle
grinders and belt sanders can be used to grind out scratches and splits. Orbital sanders with
extractors are used for fine sanding.
GRP repair set
Item Description
1 Polyester resin
2 Glass fiber mats
3 Hardener
Scissors, paintbrush and cleaning materials are other materials which will be needed to perform a
GRP repair.
NOTE: Follow the manufacturer's instructions when using the repair materials.
The repair process for a GRP repair is as follows:
Prepare the repair location. Remove paint residues and sand the repair area.
Drill out the ends of the split to stop it spreading further.
The repair location must be sanded by hand. If machine working is attempted, the resin will be
heated so much that the surface structure will be changed. The result is inadequate adhesion.
Perform the GRP repair. Apply polyester resin thinly to the repair location. Lay the glass fiber mat in
place and apply polyester resin over it again.
Rework the location of the repair. Sand away any polyester resin which stands proud after it has
hardened.
Clean the sanded repair surface using plastic cleaner. Apply plastic primer thinly to the repair
surface and after it has dried apply the paint finish.
2154/2430
Body Repairs - General Information - Special Repair Techniques

Print
Cabriolet vehicles
The body of a cabriolet vehicle is different to the self-supporting body of a saloon car because of the
special roof construction (folding top). The stability requirements must therefore be ensured by
construction changes within the body structure.
These are for instance:
Longitudinal and torsional reinforcing components which compensate for the lack of the roof.
Reinforcements to the floor assembly, particularly in the rocker panel area.
Reinforcements in the pillar areas.
High-strength and ultra-high-strength steel panels with single panel thicknesses of up to 2.5 mm,
which in combination can become up to 6mm thick (e.g. reinforcements in the floor area, rocker
panels).
If deformation to load carrying components occurs, the stability of the whole body shell can be
adversely affected.
On a cabriolet, accident damage repair to the components mentioned above is considerably different
in certain aspects compared with the usual repairs (closed body construction):
A model specific alignment angle system must always be used during straightening and repair work,
securing using clamps at the rocker panel area is not always adequate for the cabriolet.
To avoid damage to the doors, they must always be open during straightening work. In the case of
more severe damage, additional tension and compression spindles must be used to stabilize the
door cut-outs (between the A- and B-pillars).
In load bearing areas such as the rocker panels, side members and floor pan, increased
straightening forces are necessary due to the additional reinforcements.
NOTE: Additional information on welding can be found in the section Welding Equipment and
Joining Techniques.
High-power welding equipment for panel thicknesses in overall combination of up to 6 mm total
material thickness.
The fitting accuracy and longitudinal rigidity of the affected component is especially important to
ensure that the doors, door windows and the roof fit and close correctly.
Liquefied gas vehicles

Alternative fuel vehicles often require special handling in the workshop area. Above all, assembly
operations to some extent require particular knowledge when dealing with the special technology and
the safety regulations.
NOTE: Only fully trained personnel are permitted to work on alternative fuel vehicles.
These special requirements must be understood and taken into account in the body shop as well.
NOTICE: Danger of fire and explosion. The safety instructions must always be followed when
performing service work on fuel/gas systems. Failure to follow these instructions may result in
personal injury.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Special%20Repair%20Techniques-G1538263 1/2
2155/2430
NOTE: You will find further information about working on liquefied gas vehicles in the section Health
and Safety Information.
Refrigerated conversion vehicles
Apart from the special materials used in building the structure of the refrigerated compartment, such
vehicles have special energy and refrigeration systems which require special handling during repair.
NOTICE: Danger of injury. Work on the 230<SP>volt system of the refrigeration equipment
must only be carried out by trained specialist personnel.
NOTE: Work on the refrigerant circuit may only be performed by persons who have a relevant
certificate of competence.
Vehicles with a refrigerated compartment are often used to transport foodstuffs. For this reason,
additional hygiene regulations must be complied with during repair work.
Aluminum and plastic are used to construct the two different types of compartment found on
refrigerated vehicles.
The aluminum conversion is a very stable and technically perfect variant. However, against this the
relatively high production costs and a lower payload must be taken into account, because of the
weight of the aluminum conversion itself.
The plastic conversion has developed into a light, clean and economical alternative because of
constant further development of materials and working techniques.
NOTE: The material combinations, the workmanship and the working methods must comply with
the current food hygiene regulations. For this reason, service and repair work on the refrigerated
conversion may only be performed by authorized and specially trained technicians.
Refrigerated compartment constructions are often made using both materials. The floor pan is made
of structured, slip-proof aluminum panels and the wall and ceiling cladding is made of smooth
surfaced plastic elements.
NOTICE: PUR hard foam is flammable. If PUR hard foam is overheated, it will burn on its own
with a brilliant yellowish flame. It produces unpleasant choking and toxic fumes. Special measures
must be taken when welding the vehicle body.
Polyurethane wall and ceiling elements are manufactured using a sandwich principle. An insulating
polyurethane core is coated with food grade ABS plastic on one side.
PUR hard foam does not decompose, is rot resistant and is odorless. These properties make it suitable
for use as insulation.
Because of its closed cell structure, water uptake by PUR hard foam is for the most part only a
problem at edges. Cut edges or other mechanically worked surfaces must however be sealed with the
greatest care.
The conversion to a refrigerated vehicle is performed as made-to-order production. The large surfaces
of the wall and ceiling cladding can be changed and are particularly easy to repair.
If access to the back of a body panel section is needed because of body straightening work, in some
circumstances it is cheaper to perform a cut-out repair instead of removing an element.
The repair process is fully described in the Student Information booklet Refrigeration System
Technology, Transit 2000.5 Freshline.
NOTE: You will find further information about working on vehicles with a refrigerated compartment
in the section Health and Safety Information.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Special%20Repair%20Techniques-G1538263 2/2
2156/2430
Body Repairs - General Information - Joining Techniques

Print
Welding
Before welding work is performed on a vehicle body, all safety measures for the protection of people,
modules and electrical components must be observed.
NOTE: Before beginning the work, please refer to the safety instructions and warnings in the
chapter Safety Instructions. Please also note the warnings of the respective equipment
manufacturer.
Resistance spot welding and MIG welding are the most common techniques used in body
construction. During repair work, the welded connection must be restored to be equivalent to the
original.
Resistance spot welding.
NOTE: Before starting the work, please refer to the chapter on safety instructions.
In doing so, the repair welds must match the standard of those produced in production in number and
diameter.
Preconditions for resistance spot welding:
The panels to be welded overlap.

The weld spot is accessible on both sides for the electrodes.
The shape and alignment of the weld electrodes is correct.
The resistance welding equipment is powerful enough to be able to reproduce the production spot
weld diameter.
NOTE: The welding equipment settings and the adjustment of the individual parameters are to be
made in accordance with the device manufacturer's specifications.
Well-prepared welding flanges are a prerequisite for a problem-free welded joint. This means:
The welding flanges must lie perfectly flat to one another.

The welding flanges must be clean and free of oil or grease on both sides.
Welding primer (zinc-coated and conductive) must be applied as corrosion prevention.
Only in limited cases can welding errors in resistance spot weld joints be detected from the outside .
Therefore, a test weld should be carried out before each repair weld. The peel test carried out after
the welding gives information on the quality of the welding. The spot weld itself must never separate,
it must tear away leaving a hole.
MIG welding
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Joining%20Techniques-G1538265 1/10
2157/2430
Basically, three methods of MIG welding are used:
Puddle weld.
Continuous bead welding
Intermittent bead welding
Fields of application
Any joins that are MIG welded in production must also be replaced by MIG welds.
Puddle welding may be used in certain cases, if there is insufficient access.
If the overall panel thickness is greater than 3 mm, without correspondingly powerful spot welding
equipment, puddle welding should be used.
When dealing with any MIG brazed joints which are present, follow the vehicle-specific repair
instructions.
NOTE: The increased application of heat during MIG welding destroys the corrosion protection
layers over a much larger area than during resistance spot welding. For this reason, greater care
must be taken when applying the corrosion protection afterwards.
Welding repairs can only be carried out properly if the equipment is set up correctly and all welding-
related preparations are complied with accurately.
Please note the instructions of the respective welding equipment manufacturer.

The hose assembly must be untwisted.
The core must be free from particles of wire debris.
The gas and current nozzles must be free of slag and scale residue.
Pay attention to the quality of the welding wire and the gas flow rate.
Ensure that the joint surface is perfect.
Prepare a bare metal joint surface.
Maintain the correct gaps (root formation).
Produce a test weld.
Plug Weld
Special features to note when puddle welding:
The panels to be joined must lie perfectly flat to one another.

The panel flanges must be treated with corrosion protection. The position of the weld must be bare.
Prepare the holes depending on the thickness and number of the panels. The hole size should be 6-
10 mm, or match the original weld spot.
Start the welding procedure on the panel at the bottom so that the hole is filled completely.
Continuous bead welding

A welded joint with a full seam is suitable for joining highly profiled body parts. Pillar and sill areas
are typical application areas.
2158/2430
Special features to note during bead welding:
Both parts of the panel must be bare on both sides over a width of 5 mm.
Align the parts precisely with clamps.
To prevent the panel from warping, tack longer joints before welding them.
Intermittent bead welding

Intermittent bead welding is used when the connecting flanges are stepped. This form of seam is
mainly used on the external panel area for sectional repairs.
Special features to note when intermittent bead welding:
Weld gap.
Spot weld interval.
Apply alternate tack welding across the entire length of the seam. This keeps warping to a
minimum.
Joining techniques
Butt joints
2159/2430
1 Join areas
2 Profile
3 Full seam
The butt joint is a joining technique frequently used in body repairs. The butt joint is typically used for
repairs in the pillar and rocker panel area.
Areas that are suitable for the use of the butt joint:
short seam lengths.

highly profiled structures.
The edges of the panels to be joined are placed against each other and are joined with a full seam in
whilst maintaining a required welding gap (welding gap same as panel thickness).
NOTE: The butt joint requires a high degree of accuracy and care when trimming and cutting. For
correct execution of the welding, an exact, even welding gap must be maintained.
Preparation of the joint areas includes:
Sanding the connection areas bare on both sides.

Removal of the zinc layer in the welding area.
Carrying out welding tests on an equivalent sample panel before the actual welding, if necessary.
Tack welding in the join area: From the edges to the centre, then check the shape.
Joining new and old parts with a full seam weld.
Joggled joint
1 Body part
2 Joggled area
3 New panel
The joggled joint variant is restricted to body areas with a good surface condition without
beads/swage lines or profiles. A sectional replacement with a joggled joint is welded using a
continuous seam. This procedure is used, for example, at the transition from the side panel to the
rocker panel (3-door vehicles).
When cutting the new part, slight measuring tolerances are permitted, as these are covered by the
joggled area.
2160/2430
Preparation of the joint areas includes:
Sanding the connection areas bare on both sides.

Removal of the zinc layer in the welding area.
Preparation of a joggled strip.
Carrying out welding tests on an equivalent sample panel before the actual welding, if necessary.
Joining the new and old panel with continuous seam welding.
Lead loading the weld seam.
MIG brazes
1 Rear side member / wheelhouse reinforcement
2 Apron panel reinforcement / A-pillar
Metal Inert Gas (MIG) brazing is increasingly used in production for certain body areas.
In areas where resistance spot welding is not possible due to limited space or higher strength
requirements, MIG welding was previously used.
Increasingly, these MIG welded seams are being replaced by MIG brazes. The temperature range used
during MIG brazing is significantly lower. This keeps the damage to the anti-corrosion zinc layer on
zinc-coated panels to a minimum.
This results in the following advantages of the MIG brazed seam:
No corrosion of the brazed seam.

Low erosion of the zinc coating in the joining area.
Low level of heating and thus little warping.
Easy finishing of the brazed seam.
Good for bridging gaps.
Technicians performing MIG brazing must use a Ford-certified MIG brazing device and must have
been given appropriatetraining on the brazing techniques which are used.
2161/2430
Only use the Ford-approved brazing solder SG-CuSi3 (SG-CuSi3Mn1).

Unless specified otherwise, a minimum gap of 30 mm must be maintained between the MIG brazed
seam and any adhesive bonds.
NOTICE: MIG welds must not be carried out on or near existing MIG brazed seams as even the
smallest amount of brazing solder can result in a reduction in the strength of the weld seam.
If MIG brazing cannot be used then the factory-installed MIG brazed joints should be replaced with
MIG welds in a different place during service repairs. These MIG welds must not be carried out on or
in the immediate vicinity of existing MIG brazed seams as even the smallest amount of brazing solder
can result in a reduction in the strength of the weld seam. Consequently, the corresponding graphics
offer two alternative repair techniques (1: MIG brazing; 2: MIG welding).
1 Preparation of the MIG brazing: Flatten the old brazed seam with a grinder.
2 Preparation of the MIG welding: Grind the old brazed sean and the surrounding area until
they are clean, and remove any residue of the brazed seam.
2162/2430
1 MIG brazing: Braze a new seam in the same place as the factory location for the seam.
2 MIG welding: Weld the seam away from the location of the factory-installed MIG brazed
seam.
Apart from in the locations used in production, MIG brazing can also be performed on non load-
bearing outer body skin panels and floor panels.
NOTICE: Without prior approval from Ford, MIG brazing must not be performed on structural
parts of the chassis or body.
Soft soldering
WARNING: The roof repair may only be carried out in Ford-approved special workshops and
only by specially trained personnel.
NOTE: The roof is secured to the side walls with laser soldered seams in production. When repairs
are carried out, these laser-soldered seams must be replaced by soft-soldered seams.
2163/2430
WARNING: Poisonous gases and dust can be produced when working solder. Use an extraction
unit and, if required, a protective mask.
NOTE: Ford offers basic and in-depth training on the following topics.
NOTE: Areas for soft soldered joints require careful preparation. It is extremely important that the
joint surfaces are exactly aligned and that a bare metal joint surface is prepared.
This means:
Thorough cleaning of the surfaces to be brazed.

Close contact of the panels at the brazing position.
Use the soldering iron to warm the location of the seam to be joined.
The liquid brazing material is drawn between the panels through capillary action.
Rivets
With riveting, two or more panels are joined together using a joining element (rivet). In body
construction, pop rivets and punched rivets are used.
Advantages of riveted connections:
Metallic and non-metallic materials can be joined together.

Different thicknesses of materials can be used.
The material does not have to be heated, and therefore does not warp.
Low level of preparation required.
NOTE: For detailed instructions on the procedure, please refer to the equipment manufacturer's
operating manual.
Disadvantage:
During dismantling procedures, swarf/rivet remains can fall into inaccessible cavities, which can
lead to rattling and rusting.
2164/2430
1 Panels
2 Pop rivet
Pop rivets are used if only one side of the panel is accessible. In this process, overlapping panels are
drilled and connected with a pop rivet.
Pop rivets can be inserted pneumatically, hydraulically or manually with rivet guns.
Bonding
1 Butt joints
2 Bonded connection
Bonded connections are used more and more in modern body designs. Here, a distinction is made
between bonds for stabilization purposes and bonds for adhesive strength. Bonds for stabilization
purposes are found on clinched flanges and on cross beams in doors or on the roof.
WARNING: Risk of poisoning! Adhesive can be harmful to health. Ventilate rooms well and use
breathing protection. Where possible, work with an extraction unit.
NOTE: Adhesives are chemical products and are subject to the safety regulations of the
manufacturer.
Please refer to the specifications in the general part of the particular manual for information on the
repair adhesive which is to be used.
Advantages of glued joints:
They are air and watertight.

High corrosion protection
Different materials can be connected.
Bonding can be combined with resistance spot welding.
NOTE: The quality of the bonded connection is largely dependent on the care taken during
preparatory work. When gluing bodywork parts, follow the work instructions from the adhesive
manufacturer.
Bonding and welding
On some vehicle models, (such as the Ford Ka), bonding is combined with resistance spot welding.
This connection technique has the following advantages:
Tight, anti-corrosion connection seam.

High strength due to additional resistance weld spots.
Please note the following points during the repair work:

2165/2430
Only use adhesive suitable for welding (conductive).

Carry out resistance spot welding on the connection flanges before the adhesive hardening process.
Carry out test welding with the adhesive applied.
If MIG welding is carried out during a sectional repair on a connecting flange with sealant or
adhesive material, the material must be applied at a distance of approx. 10 mm from the weld spot.
These areas must be sealed very carefully after the work has been completed.
Bonding and riveting

As with welding, bonding can also be combined with riveting. This connection technique has additional
advantages. These are:
Metallic and non-metallic materials can be joined together.

Different thicknesses of materials can be used.
The material does not have to be heated, and therefore does not warp.
The rivet connection stabilizes the connected components during the adhesive hardening phase.
2166/2430
Body Repairs - General Information - Impact

of Insufficient Repair Quality
Print
Body repairs usually require a significant level of intervention in the existing body shell structure. The
corrosion protection, seals and NVH components are destroyed and must be replaced.
To prevent the vehicle quality from being reduced due to a poor quality repair, all repairs carried out
in all repair sections must be inspected during and after the accident repair.
Simply checking the vehicle at the time of delivery is not sufficient to guarantee the repair quality.
Rather, continuous checking of the work carried out is recommended.
NOTE: Logs of the acceptance of individual operations are a useful tool for quality assurance. A
comprehensive final inspection can be carried out based on a final acceptance log.
In the process, the entire repair sequence must be split into meaningful sections, with the creation of
check points to which particular attention must be paid.
The following are some possible sections:
During and after body work.

Final assembly, ancillary components, functional tests.
Vehicle delivery.
NOTE: The following points offer an indication of possible test logs. They can be combined and
supplemented differently, depending on the individual operating procedures.
During and after body work the following areas should be checked:
After completion of the body repairs, the following areas should be checked:
Manufacturing inspection for functionality and originality in the accident area.

Check snug fitting of metal panel parts (welding and screw connections).
Check snug fitting of ancillary components (doors, hoods, glazing).
Check surface condition of the welded seams.
Check seals, blanking plugs, NVH components.
Check corrosion prevention measures
Check that the repair work is in the correct condition for painting.
Final assembly, ancillary components, functional tests

After final assembly, not only a visual inspection is required, but also the functionality of many
components must be checked:
Check repair area for originality.

Check ancillary components for correct installation.
Check precision fitting of all parts.
Check that the doors and flaps are working correctly.
Check that all mechanical parts, such as the window winder are working correctly.
Check for leaks in the repair area.
Vehicle delivery
Vehicle delivery again offers the opportunity of checking the repair quality. In the process, the
following points are to be checked again:
Corrosion protection, sound damping matting and rubber seals.

Check for traces of leftover paint.
Check the cleanliness of the vehicle.
Functional check of the mechanical and electrical components.
Road test the vehicle.
Check for noise, vibration and harshness (NVH).
Check for wind noises.
After repair work on the body and vehicle, not only the visual restoration of the damaged vehicle, but
also the functional restoration must be guaranteed.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Impact%20of%20Insufficient%20Repair%20Qua… 1/2
2167/2430
Customers are making increasingly high demands of vehicles, particularly in terms of driving comfort.
Customers find noise, vibrations and harshness (NVH) as well as squeaking and rattling annoying,
particularly after repair work. It is therefore important that the condition of the vehicle at the time of
production be restored after an accident repair.
After body repairs, the entire repair area must be checked for any water leaks. It is crucial that a leak
test be carried out as part of the final inspection so that water leaks can be detected and eliminated
even before delivery of the vehicle to the customer.
The requirements of the vehicle manufacturer are to be taken into consideration during all
inspections. Only in this way can it be guaranteed that the vehicle quality is not reduced through
insufficient repair quality.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Impact%20of%20Insufficient%20Repair%20Qua… 2/2
2168/2430
Body Repairs - General Information - Water Leaks

Print
Water leaks can occur after body repair work, but can also occur on new vehicles. The test methods
described below allow the various causes to be identified. In all cases, a systematic and logical
procedure is required to locate water leaks.
General
When searching for faults, it must be taken into account that water can enter the vehicle passenger
compartment in various ways and circumstances. Therefore, it is sometimes not sufficient to perform
a water test on a stationary vehicle.
Before beginning extensive checks, a thorough visual inspection must be carried out. The following
points are to be taken into account in the process:
Check the clearance and accurate fit of ancillary components such as the trunk lid and doors.
Check for correct installation and possible damage to sealing elements such as blanking plugs, seals
and rubber door seals.
Check that the water runoff openings and pipes are free of obstructions
Test method
Water test
NOTE: Do not use a power washer. Use a normal garden hose with a spray nozzle or sprinkler head.
Make certain that all windows and doors are completely closed.
Water leaks into the vehicle passenger compartment cannot usually be located immediately, as the
water often spreads across a large area. For this reason, the passenger compartment must be dried
before the leak tests. Any ancillary components that block the view must be removed. During the
water test, the vehicle is sprayed or sprinkled with water at the suspected location of the leak. At the
same time, a second person checks the passenger compartment for places where water enters the
vehicle. Depending on the test and the vehicle, it may take some time before there is any sign of
water entering the vehicle. We recommend laying blotting paper under the location being tested so
that the water entry can be localized.
Example: Water test with sprinkler head (rain test)
Car wash test

Certain leak problems only appear in a car wash or can only be simulated there. The concerned area
of the passenger compartment should be inspected with a torch during the wash procedure.
Road Test
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Water%20Leaks-G1538267 1/8
2169/2430
Some leaks only appear when the vehicle is moving. If no leaks are detected during the above-
mentioned tests, road tests should be carried out on wet roads:
At various speeds.
On various road surfaces (asphalt to cobbles).
With loaded or unloaded vehicle.
Driving through puddles (splash water).
Test with UV lamp

A leak test can also be performed using a UV lamp and a special contrasting agent. The advantages of
using contrast agent are:
No need to dry out wet areas beforehand.

The water entry and its subsequent path can be seen more clearly.
No need to remove most ancillary components from the vehicle.
NOTE: The equipment manufacturer's instructions must be followed when using a UV lamp and
contrast agent.
Procedure for using a UV lamp.
Wet the test area with clear water from the outside.
Prepare test liquid and apply it from the outside using a suitable water sprayer.
Illuminate the relevant area from the inside using the UV lamp. The test liquid which enters will
make the leak visible.
Chalk/powder test
This test checks the contact surfaces of seals on doors, hatches and lids.
Process using a door seal as an example:
To do this, the door seal is coated with powder or brushed with chalk. A thin layer of grease is applied
to the contact area of the seal. The door must then be slowly closed and reopened. The width and
continuity of the imprint can now be checked on the seal.
Smoke test
Flow checking device
1 Test pipe
2 Test pipe opener
3 Puffer ball
Operating principle
The flow checking device is a set made up of a flow-testing pipe, a test pipe opener, puffer ball and
closing-off caps for the pipe.
The test pipe contains a filling layer which is impregnated with fuming sulfuric acid. When air is blown
through the pipe by the puffer ball, sulfuric acid is emitted as an aerosol in the form of a white
smoke.
2170/2430
NOTE: Pay attention to the instructions for use and the safety directions issued by the
manufacturer. The smoke test can only be performed in a draft-free environment.
This test can be used to detect leaks visually. Procedure:
Break off both tips of the pipe in the pipe opener, in exceptional cases in the top of the packaging.
Insert the pipe into the puffer ball so there are no leaks.
Close the hole in the puffer ball with your thumb and press the air contained in the ball through the
pipe.
Set the ventilation blower in the passenger compartment to the highest setting.
Close all doors so that a slight overpressure can build up in the passenger compartment.
Move the smoke pipe along the outside of the body to the areas to be checked.
Leaks can be detected through the irregular movement of the smoke.
Stethoscope test
This procedure is very similar to the smoke test. Instead of the smoke pipe, move a stethoscope past
the areas of the body that are at risk. Leaks can now be detected acoustically.
Stethoscope
Ultrasonic detection
This test uses ultrasonic waves to locate the positions of leaks. When an ultrasonic transmitter is
placed inside the vehicle, it sends out ultrasonic waves. A leak is located by running a detector along
the suspected area. The position with the loudest reception of the escaping ultrasonic waves is the
location of the leak.
Procedure:
Place the ultrasonic transmitter in the vehicle.

Completely close the vehicle.
Search the exterior of the vehicle using the detector.
The detector provides a simple indication of a leak.
Ultrasonic test device
Workflow for tracing water entry

2171/2430
Stage Testing Result Action

1st Ask customer for a detailed list of Yes Dry out the vehicle and repair the
possible reasons for the water entry. damage. Perform a water test as a
Does this information allow the cause of check (see test method).
the leak to be identified?
No Step 2.
2nd Perform an initial visual inspection on Yes Dry out vehicle. Repair damage.
the vehicle. Look for signs of water Perform a water test as a check (see
entry. Can the cause of the leak be test method).
identified immediately?
No Step 3.
3rd Is it possible that water is getting into Check the seal for damage. Check the
the vehicle through a seal (door seal, creation of the seal using the chalk
trunk lid seal)? test (see test methods). Step 4.
No Step 5.
4th Is the contact area for the seal Yes Step 5.
adequate?
No Perform work as described under
Areas with possible water leaks -
Door seals. Dry out vehicle. Repair
damage. Perform a water test as a
check (see test method).
5th Before starting any further work, use Yes Dry out vehicle. Repair the damage
the VIN to look for model-specific using the information found. Perform
information in eTIS. Perform Oasis a water test as a check (see test
query and check TSIs. Does this method).
information allow the cause of the leak
to be identified?
No Step 6.
6th Establish the extent of the damage. To Yes Dry out vehicle. Repair leak. Perform
do this, expose wet areas. Remove a water test as a check (see test
parts. Investigate the suspected area method).
for signs of water. Does an investigation
of the suspected area allow the cause
of the leak to be identified?
No Step 7.
7th Check exterior areas (seals, seal Yes Dry out vehicle. Repair leak. Perform
welds). Check interior areas: Signs of a water test as a check (see test
water, plugs, seal welds. Can the cause method).
of the leak be identified?
No Step 8.
8th Perform water test or ultrasound test. Yes Dry out vehicle. Repair leak. Perform
Can the cause of the leak be found? a water test as a check (see test
method).
No The water entry may only occur
under dynamic driving conditions.
This requires intensive tests to be
repeated with the corresponding
climatic influences (rain).
Possible complaints and corrective actions

NOTE: Water leaks and changed vehicle acoustics can have similar causes. For this reason,
information from the Wind noise or Noise, vibrations, roughness chapters may be useful in
identifying the fault.
An outline of the possible complaints due to water leaks is provided below. The causes of water leaks
and the possible remedies are presented using selected examples. They are intended to provide
troubleshooting tips and suggestions for the user but do not represent an exhaustive faults list.
Glued windows
A broken pasted seam can cause water to enter around the window. A broken pasted seam can be
located using a water test or by carefully blowing compressed air onto the inside of the window seal.
2172/2430
Corrective action
Broken adhesive seams -Arrow- can be sealed from inside using PU glass adhesive.
If this seal does not resolve the problem or the broken pasted seam is too extensive, it is necessary
to remove the window and glue it back into place.
Door seals
If water appears at the bottom of the door, it is possible that the door seal behind the door trim is
damaged. If the door is intact, water can enter through the window weatherstrip and flow out through
gaps on the underside of the door. If the door seal adhesion is faulty or the door seal is damaged,
water can get into the interior.
1 Seal/adhesion
2 Clips
3 Door speaker
Fastening bolts could be loose or clips incorrectly positioned on door modules.
Corrective action
Depending on the door seals used, different sealing methods can be used.
NOTE: The drainage holes on the underside of the door may not be blocked - if they are, clean
them. Defective films and foam seals must be replaced.
Once the adhesive surfaces have been cleaned, plastic films must be stuck with double-sided
adhesive tape or replaced.
Leaky foam seals are sealed with Butyl tape or replaced.
Plastic door modules are fitted with a weatherstrip, which cannot be replaced. Seal the leaky point
with Butyl tape or replace the part.
Door weatherstrip
2173/2430
Leaks can be caused by badly fitted seals. In particular, areas with radii -Arrow- must be thoroughly
checked.
Door seals can develop leaks due to:
Damaged or expanded seals.

Ageing.
Insufficient contact pressure.
Inadequate contact area for seal on body part.
Uneven welded flange thickness because of several layers of body panels or production tolerances.
Kinks.
The contact pressure of a seal can be determined using a strip of paper. If a strip of paper trapped in
the closed door can be pulled out easily, the contact pressure is too low.
To resolve
Replace damaged or aged seals. Prevent kinks.

The contact pressure can be changed by adjusting the catch bolt or correcting the panel flange.
Even out the uneven welded flange thicknesses. Properly repair any paint damage that occurs. If
the bodywork flanges are very uneven, appropriate alignment work must be performed. Pay
particular attention here to the new corrosion protection which needs to be applied afterwards.
If water entry is caused by a spot weld (burr on the surface), this must be rectified and appropriate
corrosion protection applied.
Tailgate sealing rubber
Leaks at the tailgate rubber seal have the same causes and remedial measures as for door rubber
seals. Especially vulnerable areas -arrows- must be thoroughly checked.
Rubber grommets / plugs
Rubber grommets or plugs are fitted at numerous points on the body. They are frequently used as
seals for cables, hoses or actuating links. Rubber plugs are frequently used for gaps caused during
production.
Example: Possible problem locations in the tailgate area
2174/2430
1 Hinge seal
2 Cable duct
Leaks can be caused by badly fitted or damaged rubber grommets and plugs.
Damaged cable insulation can also cause leaks.
Where components are bolted on, water can enter if there are inadequate seals at the connection
point.
To resolve
Correctly fit rubber grommets / plugs. During fitting, ensure that the sealing lips are not trapped
and are applied properly.
The contact area of the rubber grommets / plugs can also be sealed with PU sealing compound.
Replace the damaged rubber grommets and repair the damaged cable insulation.
Smooth the panel deformations in the contact area of the plugs.
Heater housing/ventilation
Loose butyl sealing strips, damaged sealing surfaces or a trapped carpet can cause leaks around the
heater housing / ventilation Arrow. Badly positioned or badly fitted hoses can also be responsible for
water entry. Water drains must not be blocked
NOTE: A large quantity of water flows through the water tank. If there are leaks in this area, it is
essential to ensure that the water drainage mechanisms function correctly. Drainage openings may
not be blocked or stuck. Leaves and other dirt must be removed before troubleshooting.
Corrective action
Before the actual repair, make sure that the water drains are not blocked or stuck.
Remove the heater housing / ventilation and fit a new Butyl sealing strip. Damaged sealing surfaces
must first be adjusted. A trapped carpet must be removed.
Seal welds
2175/2430
PU sealing beads are applied to welded or riveted connections Arrows to seal the interior of the
vehicle. Incorrectly applied or damaged seal welds can allow moisture to penetrate into the interior of
the vehicle. It is also possible that sealing beads whose shape and size appear to be intact actually
have poor adhesion.
Corrective action
Incomplete seal welds must be supplemented with PU sealing compound. Damaged seal welds must
be removed and re-applied properly. Make sure that any residual moisture is effectively removed
before a new seal is applied.
Attached parts
The add-on parts include:
Exterior mirros, handles, controls.

Mouldings, roof mouldings, lettering.
Roof aerial, roof rack or connections for roof rack systems.
Bumper mountings.
Injection nozzles, door contact switches, bump stop rubber.
Control unit seals.
Tail lamps.
All kind of screwed connections (pedal block, door and tailgate hinges)
Example: Possible water entry points at the rear lamp
1 Clips
2 Gaskets.
3 Rubber grommet
Add-on body parts must be fitted with seals, grommets or sealing compound to prevent water entry.
However, even when a sealing system is fitted, the screw thread may still cause leaks.
Corrective action
Seals must be tested and, if necessary, replaced. Check contact surface and adjust if necessary.
Points sealed with sealing compound must be thoroughly cleaned and the seal replaced. Check
grommets and replace if necessary. At all screwed connections, seal the thread with an appropriate
sealing material.
2176/2430
Body Repairs - General Information - Wind Noise

Print
Wind noises as well as other general noises are dealt with under Noise, Vibration and Harshness
(NVH).
complete range of courses in the Training Brochure issued by the Ford Service Organization.
Due to the continuous reduction in drivetrain noises, wind noises have come to the fore in the vehicle
and are perceived to a greater extent by the customer.
There are various causes of wind noises. They can be due to the design of the vehicle, or they can
occur after a repair. They are mostly caused by poorly mounted components, which must be located
and installed in the correct position.
General information
In order to carry out targeted diagnosis, it is important to know the basics of noise formation and
sound transmission.
Potential areas of wind noises
Item Description
1 Wiper arms
2 Windscreen seal
3 Antenna/antenna base
4 Sun roof/roof rail
5 Tailgate
6 Door handles
7 Exterior Rear View Mirror
8 Door seals
9 Headlamps
10 Radiator grille.
Noises are categorized according to their type and formation as follows:
"Normal" air flow noises:
Normal air flow noises are caused by air blowing against even, flat vehicle surfaces, such as the roof,
doors and side windows. When the vehicle is moving fast, air layers (turbulence) form, which cause
variations in air pressure. These variations in air pressure spread in the form of sound waves and are
transferred to the vehicle interior via the side windows and seals.
Noises caused by deviations in air flow and circulation around separate components:
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Wind%20Noise-G1538268 1/10
2177/2430
If air flows over an edge on a vehicle, the air flow cannot follow the shape of the surface, but
separates at the edge. Eddies are formed, which collapse again after a certain time or distance. The
associated fluctuations in air pressure create a corresponding sound wave which is noticeable by for
instance a rushing noise at the A-pillar or the outside mirror.
Turbulence and the associated radiation of noise can also occur at the vehicle underbody. Air
circulation around small components and also flow through small gaps (e.g. the radiator grille) cause
the rushing noise to change to a whistling, which rises and becomes louder as the vehicle speed
increases.
Noises caused by vibrating seals:
Seals which do not make firm contact at the door or window area can be made to vibrate by pressure
variations outside the vehicle, which in turn mean noise radiating into the interior of the vehicle.
Noises caused by air flowing out:
Noises caused by air flowing out are created by leaks at the vehicle interior sealing system, when
stationary air mixes with flowing air. As a result, the noise increases as the speed of the air flowing
out increases. Example: Letting air out of a tire.
Cavity noises:
Cavity noises are those created when the air volumes found in bodywork cavities are caused to
vibrate by an opening located in the airflow. The frequency of the tone does not vary with the vehicle
speed but depends on the volume of the cavity and the size of the opening. Example: Blowing across
the top of a bottle.
Wind noises overview:
Workshop diagnosis
Assessment Type of wind noises Place of origin

Normal "Normal" wind noises Roof, side windows
Normal Noises caused partly by changes in the A-pillars, outside mirrors, antennas
direction of air flow and by air flow
around separate components
Serious Noises caused by vibrating seals Door gaps too large, door/window
seals not making firm contact
Serious Air escape and air passage noises Leaks in the bodywork/sealing system
Serious Cavity noises Unsealed bodywork cavities
Those noises listed under "Serious" indicate a possible source of the fault.
Workshop diagnosis
There are two ways that the level of noise in the vehicle interior can be reduced and the character of
the noise can be improved through assessment and diagnosis in the service department:
Reducing the intensity of the noise sources.

Reducing the noise transfer routes.
Before carrying out repair work, a visual inspection of the vehicle must be carried out. The gaps in the
doors, the sunroof and at all other body parts must be checked in particular.
When the doors are adjusted to fit exactly, development of wind noises at high speeds can often be
eliminated (lifting of doors off the seals). Furthermore, the following points should be noted:
The windows and doors must be fully closed.

The air guides and air grilles must be correctly seated.
All of the trim strips and plastic components must be firmly fixed down without gaps.
All blanking plugs present.
Test method
The test procedures given in the chapter Noise, Vibration and Harshness can also be used to diagnose
wind noises.
Road tests
Wind noises can usually only be localized by road tests
2178/2430
NOTE: There should always be two people present during road tests to find noises. A driver who
reconstructs the situation causing the noise, and a person to carry out the checks.
The following points should be taken into account for such road tests:
Check that the tire pressure is correct.

Remove non-standard ancillary components from the vehicle.
Choose a dry, flat road with as little traffic as possible.
Carry out the road test in all speed ranges. Use a high gear so that the engine noise is low.
Do not perform a road test near any sound reflecting objects.
If it is difficult to detect the noise sources, the search can be made easier by masking potential areas.
Chalk/powder test
This test checks the contact surfaces of seals on doors, hatches and lids.
Process using a door seal as an example:
To do this, the door seal is coated with powder or brushed with chalk. A thin layer of grease is applied
to the surface against which the seal makes contact. The door must then be slowly closed and
reopened. The width and continuity of the imprint can now be checked on the seal.
Smoke test
Flow checking device
Item Description
1 Test pipe
2 Test pipe opener
3 Puffer ball
Mode of operation:
The flow checking device is a set made up of a flow-testing pipe, a test pipe opener, puffer ball and
closing-off caps for the pipe.
The test pipe contains a filling layer which is impregnated with fuming sulfuric acid. When air is blown
through the pipe by the puffer ball, sulfuric acid aerosol is emitted in the form of a white smoke.
NOTE: Pay attention to the instructions for use and the safety directions issued by the
manufacturer. The smoke test can only be performed in a draft-free environment.
This test can be used to detect leaks visually.
Procedure:
Break off both tips of the pipe in the pipe opener, in exceptional cases in the top of the packaging.
Insert the pipe into the puffer ball so there are no leaks.
Close the hole in the puffer ball with your thumb and press the air contained in the ball through the
pipe.
Set the ventilation blower in the passenger compartment to the highest setting.
Close all doors so that a slight overpressure can build up in the passenger compartment.
Move the smoke pipe along the outside of the body to the areas to be checked. Leaks can be
detected through the irregular movement of the smoke.
2179/2430
Ultrasonic test
This test searches for leaks in the system of seals or rather acoustic bridges. When an ultrasonic
transmitter is placed inside the vehicle, it sends out ultrasonic waves. A leak is located by running a
detector along the suspected area. The position with the loudest reception of the escaping ultrasonic
waves indicates places where noises occur.
Ultrasonic test device
Procedure:
Place the ultrasonic transmitter in the vehicle.

Completely close the vehicle.
Search the exterior of the vehicle using the detector.
The detector provides a simple indication of a leak.
Stethoscope test
Stethoscope
Diagnosis
Wind noises often have similar causes as the general NVH noises. For instance, a windshield which is
incorrectly bonded in position can cause normal driving noises to become more noticeable.
Asking the customer detailed questions and a road test together with the customer are the
requirements for a targeted diagnosis.
NOTE: Take the customer concern seriously. But do not confirm that a noise is a problem until you
are sure that it is something which is not normal for the vehicle series.
Possible questions:
How long has the noise been there?
Has any work been done on the vehicle?
Where does the noise come from?
In which driving situation does the noise appear?
2180/2430
Is there any special situation in which the noise appears?
Remember that a noise is often more or less noticeable depending on where you are sitting in the
vehicle.
Stage to test Result Reference or Action

1st Road test the vehicle with the Yes Step 2.
customer. First let the customer drive
to demonstrate the noise, before you
drive the vehicle yourself. Check that
the concern is justified. Is this a noise
which gives cause for concern?
No Explain the noise and tell the
customer what is causing it. Possibly
offer a comparable vehicle for a road
test.
2nd Visually inspect the vehicle. Look for Yes Eliminate the noise or carry out a
loose, damaged or missing repair as the case may be. Check
components. Check that the vehicle is whether the measures have been
to standard production series successful.
specification. In particular, check for
any after-market components which
may have been installed. Depending on
the type of noise, check the suspected
area. Could a cause of the noise be
found?
No Step 3.
3rd Before starting any further work, use Yes Take the action specified in the Oasis
the VIN to look for model-specific or TSB information. Check whether
information in eTIS. Perform Oasis the measures have been successful.
query and check TSBs. Can a cause for
the noise be determined based on the
information available?
No Step 4.
4th Localize the noise. In doing so, check Yes Step 5.
whether it is an unusual noise or if it is
a usual driving noise that is more
noticeable because of inadequate
sealing. Is it an unusual noise?
No Step 7.
5th Determine the source of the noise. Can Yes Eliminate the noise or carry out a
the cause be determined? repair as the case may be. Check
whether the measures have been
successful.
No Step 6.
6th Determine the path of the noise using Yes Eliminate the noise or carry out a
the stethoscope. By way of a trial, repair as the case may be. Check
mask the suspected area or whether the measures have been
components or remove them. Can the successful.
cause be determined?
No Step 7.
7th Check the vehicle for inadequate or Yes Renew the seal or perform the
damaged seals. The sealing of a vehicle appropriate repair as necessary.
can be checked using the stethoscope, Check whether the measures have
the powder test, the smoke test and been successful.
the ultrasonic detector. (See under test
method.) Could a leak be detected?
No Step 8.
8th Under certain circumstances there may
be a constructional problem which is
not yet known about. Record the
problem in an Express Service Report
and send it on by the usual method.
2181/2430
Possible concerns with corrective measures

NOTE: Instructions on general noise are summarized separately in the Noise, Vibration and
Harshness section. These can be useful when searching for the causes of wind noises.
There follows an outline of the possible concerns relating to wind noises. Selected examples are given
showing the causes of wind noises and the ways in which they can be eliminated. They are intended
to provide troubleshooting tips and suggestions for the user but do not represent an exhaustive faults
list. The topics are subdivided by the different groups of components.
The test procedures described in the Noise, Vibration and Harshness section can be used when
troubleshooting.
Seals
In general, seals are very important when eliminating wind noises. Special attention should always be
paid here to the possible causes of wind noises.
Take the following points into account:
Seals age, i.e. they become porous and with time they lose their original elasticity. If the vehicle is
relatively old and there are already visible signs of distortion or damage to a seal, then it should be
replaced.
At high speeds the doors or hatches may lift slightly from the seal surfaces because of variations in
air pressure. Wind noises are caused when the preload on the sealing surface is not sufficient. The
preload depends on the installation position of the components, the elasticity of the seal and the
location of the sealing flange.
The contact surface of the seal must be sufficient. This can be checked using the chalk test. If the
specifed width of the contact surface is not known, you must determine it on another component of
identical construction.
A bulging seal carrier indicates that the sheet metal of the retaining flange is uneven.
Seals must be correctly installed. Special attention must be paid at corners -arrow- that the
installation follows the contours.
The seal must not show any kinks or folds or any other damage.
Seals must seal all around their circumference. Gaps in seals result in openings which lead to an
increased incidence of noise. In this respect, it is especially important to pay attention to the seals
in the area of the windows.
Remedial Action
Renew older seals which no longer have adequate preload. Deformed or widened retaining flanges
must be reworked and provided with a new seal.
2182/2430
The corner areas -arrow- of a seal must be properly seated. In some circumstances, a butyl sealing
strip must be affixed to support the sealing at a corner.
Bonded joints
Glass is usually installed today using a bonded joint. Gaps in the bonded joint can lead to noises in
the vehicle interior. If there are noises which are believed to be associated with window glass, the
following points should be checked:
Gap in window bonding
The window must be bonded without any gaps -arrow-. Leaks can be found using the ultrasonic
tester or compressed air carefully blown from inside onto the window glass bonding.
The installed position of the window glass must be correct. It must not have been bonded into a
position which is too low or offset to one side.
The sealing or trim strips must fit tightly and the glass must be mounted so that it is fully enclosed.
If a sealing or trim strip has not been applied with enough pressure, high air speeds can cause it to
lift up. This can lead to wind noises at higher speeds. Apply masking tape to these areas for test
purposes.
Corrective measures
Leaking areas of the window glass bonding material can be sealed using PU sealing compound. Pay
special attention at the front windshield, that any breaks in the bonding are not too large. Otherwise
the glass must be removed and bonded in place again.
The installed location of a window glass cannot be corrected. It must be removed and bonded into
place again.
Replace the trim strips or secure the lip seal using PU adhesive.
Gaps, edges
Door gaps and edges are places where air turbulence can form. This causes noises which can be
perceived as troublesome.
Gaps and edges - problem areas
2183/2430
Doors, hood and tailgate can cause wind noises because of gaps -arrow- which are too large. If the
components are not installed flush to the bodywork or the neighboring component, air break edges
can arise, which in turn can create a wind noise.
The sun roof may be the cause of whistling noises in the roof area. The sun roof may be incorrectly
adjusted or the seal on the sun roof may be damaged.
Noises from the door area could come from a window which does not fully close. Side guides (seals)
can also be the cause of wind noises.
The covers of window frames can be incorrectly mounted or aligned. The quarter-lights in doors must
also be checked for correct installation.
Corrective measures
Check the gaps and adjust them according to the specifications. If there are problems at the sun roof,
correct the adjustment and if necessary replace the seals.
Problem area at side windows
Side windows which do not fully shut -arrows- must be adjusted. If the vehicle is equipped with
electric window regulators, the remedy may be to perform the window regulator learning process
again. In all cases, make certain that the glass enters far enough into the seal.
Ancillary Components
Components installed on the bodywork may cause noises when they are not correctly mounted.
When troubleshooting it may be helpful to remove the suspected component or, when this is not
possible, to mask it off with suitable covering tape.
Roof moldings, roof rail, roof antennas
Moldings and roof moldings must touch the bodywork along their whole length without any gap.
Check the end sections in particular. These must neither have any splits nor stand away from the
bodywork.
Noises may come from the roof rail if the seal between it and the roof is not correctly installed or is
cracked. Gaps at the mounting grooves of the carrier can also create wind noises.
The roof antenna and antenna foot seal must be correctly secured. The seal must lie completely on
the roof and must not be damaged.
Roof moldings mounting
2184/2430
If the original mounting points of the roof moldings are in good condition, the fixing can be improved
using silicone sealant -arrow- if necessary. Align or renew the seals of the roof rail. Reduce the
clearances of the mounting grooves.
Corrective measures
If the original mounting points of the roof moldings are in good condition, the fixing can be improved
if necessary using silicone sealant -arrow-.
Exterior mirrors
Exterior mirrors or covers of exterior mirrors which are not correctly mounted cause noises. The cover
must lie evenly on the component and must not lift during driving. There are ducts present on the
doors for the electrical or mechanical adjusters for the exterior mirrors. If there are leaks, wind noises
will be caused. Holes can also be present at the transition to other components.
Exterior mirror seals
There are ducts present on the doors for the electrical or mechanical adjusters for the exterior
mirrors. If there are leaks, wind noises will be caused. Holes can also be present at the transition to
other components.
Remedial Action
If there is inadequate sealing of the foam seals -2- they must be replaced or supplemented with
suitable material. Transitions to other components can be sealed with butyl sealing compound -1-.
Moldings, covers, door handles, windshield wiper arms
Moldings and covers especially tend to cause wind noises because of their location. These components
interrupt smooth bodywork surfaces and air turbulence therefore arises at the edges. If there are
noise concerns in the area of the doors, check especially for gaps and projections. Moldings must not
stand away from the bodywork or the door. There must not be any gaps or discontinuities at the
location of joints.
Incorrectly adjusted windshield wiper arms can cause wind noises. Especially if they are too far over
the glass surface when in the rest position.
Wind noises in the transition area between the air cowl cover and the wing or the windshield can be
caused by an incorrectly installed air cowl cover. At high air speeds the air cowl cover may lift and
noises will then occur.
Because of their necessary mechanical features, door handles have a range of openings and edges
which allow noise to be generated. The door handle can be masked off for testing purposes. If a
reduction in wind noises is noticed, inadequate sealing may be the reason for the noises.
Remedial Action
2185/2430
Openings which are used to secure trim panels must be checked for leaks. Any leaks found can be
rectified using butyl strips.
Loose or damaged outer trim on the pillars -arrow- must be secured or replaced.
A butyl sealing strip -1- can be laid underneath the cover in the transition area between the air cowl
cover and the wing or windshield.
The sealing of the door handles must be renewed when required. In addition, noise absorbing
material can be applied to the back of the door handles.
2186/2430
Body Repairs - General Information - Noise, Vibration and Harshness

Print
Noise, coming from the vehicle and which can be heard inside and outside the vehicle.
Vibrations, oscillations that are felt and noticeable inside the vehicle.
Harshness, noises which come from the vehicle and which can be heard, felt and noticed inside and
outside the vehicle.
These terms are grouped together under the title Noise, Vibration, Harshness, or NVH for short.
The task of vehicle development and production is to ensure that noises caused by the vehicle do not
disturb the driver and passengers. Moreover, the the external noises emitted by the vehicle must not
exceed the thresholds set by law.
NOTE: Basic and advanced training courses are offered for the following contents. For an overview
of all courses offered, please refer to the Ford Service Organisation's training course brochure.
Noise types and causes
Noises in and around the vehicle are assigned specific descriptions:
Humming and droning are perceived as low tones.

Buzzing and whirring are middle tones.
Howling, whistling, squeaking are assigned to the high tones.
Low to middle tones are considered to be unpleasant. They are palpable and noticeable as oscillations
and vibrations throughout the body. Loud howling and whistling is painful to the ears.
A noise usually consists of a superimposition of different tones which spread as oscillations.
Each of these oscillations has a specific oscillating time and can be measured in frequencies. The
frequency describes the number of oscillations per second. The frequency unit is specified in Hertz
(Hz).
The human ear can perceive frequencies between 20 and 20000 Hz.
Where the different notes come from in a vehicle:
Low notes are mostly produced by the engine.

Low tones can also be produced by the roadbed, particularly on rough surfaces. This is a form of
droning which can be felt by the vehicle occupants as vibration or roughness.
High tones however, which are experienced as howling or whistling noises, are often air currents
(wind noises) or come from ancillary components such as the generator, power steering pump or
drivebelt.
There are also clattering noises which can occur when driving over an uneven road. These jerking
noises are produced by, for example, the shock absorbers, chassis components or loose articles
inside the vehicle.
Noises can already be contained where they occur or, if this is not possible, can be confined with
suitable measures.
The basic procedures here are the damping of oscillating parts, the insulation of components or the
absorption of the noises through appropriate materials.
Damping
If a damper is installed next to an oscillating mass, the characteristic of the damper will reduce the
movement of this mass accordingly (e.g. bumper on chassis).
Damping affects the resonance of an object or system.
Isolation
In oscillation technology, the term isolation means decoupling (separation) of components and
systems. An engine is mounted in sprung elements, so that as little oscillation as possible is passed to
the vehicle.
In automotive technology, the isolation technique used is nearly always rubber mounting. Rubber has
a large internal damping capacity. The elasticity of the rubber acts like a spring.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Noise,%20Vibration%20and%20Harshness-G15… 1/5
2187/2430
Absorption
Sound waves are reflected from hard surfaces Through the use of absorption material, sound waves
hit soft surfaces and are absorbed by them.
The composition and thickness of the material used plays an important role here. A soft surface,
depending on its composition, absorbs the sound waves and reduces their energy.
NVH elements
NVH elements are installed to prevent airborne sound transfers to the passenger compartment in
different body cavities.
Item Description
1 C-pillar area
2 B-pillar area
3 A-pillar area
On the Focus 2004.75 (07/2004-) these elements are located in the cavities of the A, B and C pillars.
On the estate version, they are also located in the D pillars.
The NVH material consists of a carrier plate which has compressed isolation material at the edges. In
the drying system of the painting equipment used in production, the body is heated to approx. 170°
C. At this temperature the isolation material expands to seal the gap between the carrier plate and
the bodywork.
NOTE: NVH elements must not be damaged during work on the vehicle body. NVH elements
deformed through impact must always be replaced. PU adhesive must always be applied to the
edges of new and reused NVH elements during repair work.
2188/2430
Item Description
1 NVH element
2 PU adhesive
For the exact installation position of an NVH element, please refer to the vehicle-specific repair
instructions.
If an NVH element is to be reused, the bonding on the body panel must be detached. To do this, the
body panel must be heated in the area around the NVH element. The bonding can be detached at
approx. 170° C. The damaged panel part can now be carefully dismantled.
Before installing the new panel part, a PU adhesive must be applied to the contact areas between the
panel and the NVH element.
Test techniques, measuring devices
The shortest route to an accurate diagnosis results from:
general information on the problem vehicle and a comparison test with a vehicle of the same
construction, without NVH problems.
vehicle history, including repair history and usage patterns.
condition history, especially any relationship to repairs or sudden change.
knowledge of probable causes.
application of diagnosis procedures in which the vehicle is split into corresponding areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
general information on the problem vehicle and a comparison test with a vehicle of the same
construction, without NVH problems.
vehicle history, including repair history and usage patterns.
condition history, especially any relationship to repairs or sudden change.
knowledge of probable causes.
application of diagnosis procedures in which the vehicle is split into corresponding areas.
NOTE: The diagnosis of droning problems is one of the most difficult tasks in the NVH area. With
the exception of installed components under stress, a certain diagnosis of droning problems (or
boom) on customer vehicles makes great demands on the automotive technician. The performance
of measuring equipment and their practice-orientated application can only be obtained through
suitable instruction (NVH training). The successful use of these devices requires a great deal of
experience on the part of the user.
The diagnosis and correction of noise, vibration and harshness concerns requires:
a road or system test to determine the exact nature of the concern.
Analysis of possible causes:
checking of the cause and elimination of the faults found.

a road test or system test to make sure the concern has been corrected or brought back to within
an acceptable range.
It is often very difficult to locate noises that are audible in the passenger compartment based on
the problem description provided by the customer and the road tests performed. The direction of
the noise can be detected subjectively, but the source of the noise cannot be found.
NOTE: For a selection of simple test tools, see the wind noises section.
Electronic NVH tester
2189/2430
NOTE: Before using the NVH tester in the service, the service technician should take part in an NVH
training course to ensure effective use of this device during the road test. A description of the
function and application of the NVH tester is enclosed with the device.
The measuring device described below is used for diagnosis of the solid-borne sound and solid-borne
sound transmission paths. The device is particularly suitable for medium and high frequency noise
analyses. It principally enables noise diagnosis in the area of solid-borne sound and helps to identify
solid-borne sound transmission routes.
In order to obtain a positive diagnosis of droning problems (low frequency noises) and their sources,
you must have sufficient experience of how to use this measuring device.
The device works according to the following operating principle: Accelerometers (transmitters) are
fitted on various vehicle components or body areas. The signals recorded here can be listened to one
after the other on headphones or speakers via the different channels. Simultaneous illustration of
several or all measuring channels (for comparison) is only possible visually on the display of the
measuring device.
Layout and operation:
The test device has six different channels for noise diagnosis.
Each channel is marked in color on the terminal, cable and test device.
The solid-borne sound recorded is transmitted to the test device or the headphones by the magnetic
accelerometers (transmitters).
There is an amplifier on the test device with which the signal strength and the corresponding
channel can be set.
Only the noises from a transmitter are transferred to the headphones.
All connected cables can be visually illustrated individually or simultaneously on the display.
The test device saves the recorded data.
The recorded data can be imported to a PC and evaluated.
The NVH tester is equipped in addition with mobile magnetic sensors which are particularly suitable
for the following noise tests:
Internal noises at the dashboard

Engine noise
Electrical noises (sparking/voltage transmissions)
Wind noises
Vacuum - leaks
Chassis noise tester (chassis ear)
2190/2430
Used to diagnose solid-borne sound and its transmission routes. The device is particularly suitable for
medium and high frequency noise analysis and principally enables noise diagnosis in the area of solid-
borne sound and helps to identify solid-borne sound transmission routes.
In order to obtain a positive diagnosis of droning problems (low frequency noises) and their sources,
you must have sufficient experience of how to use this measuring device.
Layout and operation:
The test device has six different channels for noise diagnosis. This means that six microphones
equipped with clamps can be attached to different components on the vehicle. The emitted or
transmitted solid-borne sound will be transferred from microphone to the headphones. There is an
amplifier between the microphone and the headphones at which the signal strengths and the
corresponding channel can be set.
Only the noises from one microphone are transferred to the headphones. Each channel is color-coded
on the clamp, cable and amplifier.
NOTE: In order to be able to relate the positions of the different microphones during the test
process, they are entered in a special test sheet according to their colors. Microphones, clamps and
cables must be carefully routed and attached.
Test process (example for transmission noise):
Attach microphones to various positions on the transmission or mountings. This first allows the
source of the noise to be determined, and then the possible transfer routes.
A road test can be performed after all the clamps have been attached to the vehicle and all the
cables connected to the amplifier.
Firstly, all the channels are switched through one after the other in neutral, to check the operation
of the different channels as well as the noise level in neutral.
During the road test, all channels are listened to in the different gears, engine speeds, vehicle
speeds and loads. This procedural method permits unambiguous diagnosis of the cause of the noise
and the route of the noise until it enters the bodywork structure.
The characteristics of the noise which is the cause of the concern should match those of the noise
which is heard. This means compare the sound.
Depending on the input signal level, there may be a great deal of difference in the noise level in the
individual channels.
Always set the amplifier volume to zero before switching to another channel.
In order to be able to make any comparisons, the volume settings of the different channels must be
recorded on the test sheet.
2191/2430
Body Repairs - Vehicle Specific Information and Tolerance Checks - Body and Frame
- Component Location
Print
Body, side view
Item Description
A Estate (wagon)
B 4-door version
C 5-door version
Jacking points
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Body%20and%20Frame%20-%20Component%… 1/4
2192/2430
SRS locations (shown on the 5-door version)
Item Description
1 Inertia reel retractor mechanism (rear row of seats, center)
2 Head airbag (driver and passenger side)
3 Inertia reel retractor mechanism (driver and passenger sides, rear row of seats left and right)
4 Crash sensor (driver and passenger side)
5 Driver Air bag
6 Instrument cluster with airbag telltale and belt warning display
2193/2430
7 Front impact sensor

8 Front passenger airbag
9 PAD (passenger airbag deactivation) (optional)
11 Seat occupant sensor (passenger side only)
12 Side airbag (driver and passenger side)
13 Safety belt switch
NVH Expandables, 4-door version
NVH Expandables, 5-door version
NVH Expandables, estate (wagon)
2194/2430
2195/2430
Body Repairs - Vehicle Specific Information and Tolerance Checks - Body

and Frame - Overview
Print
Introduction
As of model year 2011.25, the Ford Focus is being replaced with a completely new vehicle. The in-
house model designation is C346. The Focus will be available in 4-door, 5-door and estate (wagon)
body versions. With the new model variants, there is no longer a 3-door version. The new Focus
offers better occupant protection thanks to the use of high-strength steels and an enhanced safety
pack. The high-strength and super-high-strength steels used make extra demands on the tools to be
employed for some body repairs.
Super-high-strength steels
Super-high-strength steels
Item Description
1 A-pillar external reinforcement
2 B-Pillar reinforcement
3 Rocker panel reinforcement
4 A-pillar internal reinforcement
The A and B-pillar reinforcements are made of super-high-strength manganese boron steel. The
rocker panel reinforcement is made from super-high-strength martensitic steel (DOCOL 1400M,
electrogalvanized). These super-high strength steels have a tensile strength in the region of 1500
MPa.
Sectional repairs to components made from manganese-boron steel and Docol are not permitted!
The required continuous MIG weld seam in the cut area would cause structural changes in the steel
and lead to a significant loss in strength.
In the event of damage, the complete component must therefore always be renewed.
Because of the strength of these components, it is not always possible to work them with
conventional body repair tools.
For welding work (resistance spot welding and inert gas puddle welding), additional preparation
work and/or special welding equipment are required.
Refer to: Body Sheet Metal (501-25 Body Repairs - General Information, Description and
Operation).
Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information,
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Body%20and%20Frame%20-%20Overview-G… 1/12
2196/2430
Refer to: Joining Techniques (501-25 Body Repairs - General Information, Description and
Operation).
Refer to: Special Repair Techniques for High-Strength Steel (501-25 Body Repairs - General
Information, Description and Operation).
Radiator support
It is not necessary to paint the radiator support during the service. Paintwork during production is
only process-related (installation before paintwork).
Important features distinguishing Focus and C-Max Grand spare parts
Due to the platform strategy, some body parts of the different C-vehicles (e.g. Focus, C-Max, Kuga)
have a very similar external appearance. Despite their external similarities, however, they are made
of different materials or have different material strengths. These parts must under no
circumstances be interchanged! During repair work, do not use any spare parts if you are uncertain
as to the vehicle they belong to! Below are some parts for which the differences are highlighted by an
additional identification.
Crash elements, front
2197/2430
Shown on front right crash element

Item Description
1 Focus
Comments:
Top and bottom of front crash element with bore
2 C-MAX Grand
Comments:
Top and bottom of front crash element without bore
On each of the side members at the front and rear of the vehicle there is a crash element attached by
threaded connections. These crash elements can absorb light impacts of up to about 15 km/h.
Because of the threaded connections, a crash element can be changed very quickly. The crash
elements are joined together by a transverse impact absorber. This forms a connection between the
ends of the two side members and therefore contributes to an increase in passive safety.
NOTE: Deformed crash elements must not be straightened or repaired.
NOTE: The crash elements are an important part of the vehicle's safety concept.
The materials, design and processing methods used all play an equally important role in ensuring they
perform as intended. The use of non-tested service parts can destroy this safety concept.
Heavier impacts which can no longer be absorbed by the crash element must be absorbed by the side
members or the floor pan structure.
Front side member, inner part
2198/2430
Front side member, interior

Item Description
1 Focus
Comments:
Side member inner part without recess
2 C-MAX Grand
Comments:
Side member inner part with recess
Front side member, outer part
Front side member, exterior

Item Description
1 Focus
Comments:
Side member outer part without recess
2 C-MAX Grand
Comments:
2199/2430
Side member outer part with recess

Bulkhead crossmember
Item Description
1 Focus
Comments:
Bulkhead crossmember without cutout
2 C-MAX Grand
Comments:
Bulkhead crossmember with cutout
Bulkhead crossmember gusset
Shown on left-hand gusset

Item Description
1 Focus
2 C-MAX Grand
Sheet metal parts for sectional repair of side panel

2200/2430
Front side panel - all body variants
Rocker panel - all body variants
Side panel sectional repair - 4-door version
2201/2430
Rear side panel - 4-door version
Side panel sectional repair - 5-door version
2202/2430
Rear side panel - 5-door version
Side panel sectional repair - estate
2203/2430
Rear side panel - estate
Corrosion protection
Underbody
2204/2430
Item Description
1 Underbody PVC stone chip protection
2 Injection points for cavity wax protection
NOTE: The original corrosion protection must be re-created after working on the bodywork.
Door cavity wax
NOTE: The original corrosion protection must be re-created after working on the bodywork.
Tailored blanks
Tailored blanks are sheet metal plates, which are normally made from different materials and/or
material strengths. The different parts are usually laminated together by a laser welding procedure.
The prefabricated component is then shaped into the desired component through further processing
(e.g. pressing, deep drawing). Cut locations exactly on the laser weld seams are not permitted, as at
present no joining techniques are approved for use in repair procedures that would re-create joins of
the same quality.
Tailored blanks on the front side members
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Body%20and%20Frame%20-%20Overview-… 10/12
2205/2430
Item Description
1 ZStE 260 P - 1.5 mm
2 DP600 - 1,5 mm
Tailored blanks on the back panel and reinforcement

Estate (wagon)
On the estate, the exterior back panel is a tailored blank comprising items (2) + (3).
Item Position Tailored blank Item Thickness (mm)

1 Interior No ZStE 340 1.2
2 Exterior Yes ZStE 260 1.8
3 Exterior Yes ZStE 340 0.9
5-door version
2206/2430
On the 5-door version, the interior back panel is a tailored blank comprising items (2) + (3).

1 Exterior No MS 0.8
2 Interior Yes ZStE 260 2.0
3 Interior Yes ZStE 260 0.8
4-door version - No tailored blank
On the 4-door version, no tailored blank is used for the back panel! The two exterior retainer plates
(2) are only welded onto the sheet (3) after they have been molded.

1 Exterior No MS 0.7
2 Interior No ZStE 220 P 2.0
3 Interior No MS 0.75
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Body%20and%20Frame%20-%20Overview-… 12/12
2207/2430
Body Repairs - Vehicle Specific Information and Tolerance Checks -

Frame Tolerance Check
Print
General Procedures
1. Body dimensions, vehicle front

All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the
centre of each hole or panel edge using a symmetrically adjusted measuring gauge.
MEASURING POINTS AND DIMENSIONS
1 - 2 = 341 mm 1 - 6 = 1103 mm
1 - 3 = 509 mm 1 - 7 = 1278 mm
1 - 4 = 1176 mm 1 - 8 = 1642 mm
1 - 5 = 1278 mm 1 - 9 = 1189 mm
3- 4 = 1019 mm
2. Body dimensions, side view front

edge of the steel panel using a symmetrically adjusted measuring gauge.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Frame%20Tolerance%20Check-G1538275 1/7
2208/2430
The detailed views of measuring points 9, 10, and 12 are shown looking outwards from inside
the vehicle.
1 - 10 = 948
2 - 11 = 1244 mm
9 - 12 = 864 mm
3.
4. Body dimensions, side view rear

edge of the steel panel using a symmetrically adjusted measuring gauge.
The detailed views of measuring points 3, 7, and 8 are shown looking outwards from inside
the vehicle.
3 - 6 = 952
2209/2430
4 - 7 = 1071 mm (4/5-door)
4 - 7 = 1081 (Wagon)
5 - 8 = 785 mm
5. Body dimensions, rear view 4-door

center of the welded flange using a symmetrically adjusted measuring gauge.
1 - 4 = 1144 mm 2 - 5 = 472 mm
3 - 6 = 1146 mm
2210/2430
6. Body dimensions, rear view 5-door

1 - 6 = 1151 mm 3 - 8= 1149 mm
2 - 7 = 853 mm 4 - 10 = 1305 mm
5 - 9 = 972 mm
2211/2430
7. Body dimensions, rear estate (wagon)

1 - 5 = 1196 mm 3 - 7 = 1192 mm
2 - 6 = 885 mm 4 - 8 = 1110 mm
2212/2430
8. Passenger compartment, body dimensions

The detailed views of the measuring points are shown looking outwards from inside the
vehicle.
1 - 2 = 1442 mm 3 - 4= 1442 mm
5 - 6 = 1432 mm 7 - 8 = 1442
9 - 10 = 1442 11 - 12 = 1440
13 - 14 = 1258
2213/2430
2214/2430
Body Repairs - Vehicle Specific Information and Tolerance Checks -

Underbody Tolerance Check
Print
General Procedures
1. Body dimensions, 4-door and 5-door (quick measurements using the Allvis system)
All dimensions are measured from the middle of the hole or bolt head or from the edge of the
panel, using the Allvis system, with component assemblies installed.
A tolerance of ± 3 mm applies to all measurements given. All detailed illustrations correspond
to the left-hand side of the vehicle.
ALLVIS SPECIFICATIONS
Point of measurement Intermediate part Height setting of the test probes

1 Probe 360 mm
2 17 mm (adapter) 280 mm
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Underbody%20Tolerance%20Check-G1538276 1/2
2215/2430
2. Body dimensions, estate (wagon) (quick measurements using the Allvis system)
All dimensions are measured from the middle of the hole or bolt head or from the edge of the
panel, using the Allvis system, with component assemblies installed.
A tolerance of ± 3 mm applies to all measurements given. All detailed illustrations correspond
to the left-hand side of the vehicle.
ALLVIS SPECIFICATIONS
Point of measurement Intermediate part Height setting of the test probes

1 Probe 360 mm
7 Probe 390 mm
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Underbody%20Tolerance%20Check-G1538276 2/2
2216/2430
Front End Sheet Metal Repairs - Front Side Member Section

Print
General Equipment
10 mm Drill Bit
8 mm Drill Bit
Air Body Saw
Grinder
Locking Pliers
Measurement and Alignment Angle System
MIG/MAG Welding Equipment
Resistance Spotwelding Equipment
Spot Weld Drill Bit
Removal
1.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Front%20Side%20Member%20Section-G1538… 1/12
2217/2430
2.
3. Use the General Equipment: Spot Weld Drill Bit
2218/2430
4. Use the General Equipment: Grinder
2219/2430
2220/2430
2221/2430
Installation
1. Use the General Equipment: 8 mm Drill Bit

2222/2430
4. Use the General Equipments: Locking Pliers, Measurement and Alignment Angle System
5. Panel thickness 3 mm and greater!
Use the General Equipments: Resistance Spotwelding Equipment, MIG/MAG Welding Equipment
2223/2430
Use the General Equipments: Locking Pliers, Resistance Spotwelding Equipment
7. Use the General Equipment: MIG/MAG Welding Equipment
2224/2430
Use the General Equipments: Locking Pliers, Resistance Spotwelding Equipment
Use the General Equipment: Resistance Spotwelding Equipment
10. Use the General Equipment: Resistance Spotwelding Equipment
2225/2430
13. Use the General Equipments: MIG/MAG Welding Equipment, Measurement and Alignment Angle
System
2226/2430
Use the General Equipments: Resistance Spotwelding Equipment, Measurement and Alignment
Angle System
Use the General Equipments: Resistance Spotwelding Equipment, Measurement and Alignment
Angle System
2227/2430
2228/2430
Front End Sheet Metal Repairs - Fender Apron Panel Reinforcement

Print
General Equipment
Air Body Saw
Grinder
MIG Brazing Equipment
Spot Weld Drill Bit
Removal
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Fender%20Apron%20Panel%20Reinforcement-… 1/6
2229/2430
2230/2430
7. Do not cut in panels below!
Use the General Equipment: Air Body Saw
Installation
1. MIG brazes
Operation).
2.
1. Prepare for MIG Brazing
Use the General Equipment: Grinder

2. NOTE: Make sure that the component is clean and free of foreign material.
Prepare for MIG/MAG Welding
2231/2430
2232/2430
6.
MIG Brazing
Use the General Equipment: MIG Brazing Equipment

MIG/MAG Welding
Use the General Equipment: MIG/MAG Welding Equipment
2233/2430
9. Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, Description and
Operation).
2234/2430
Front End Sheet Metal Repairs - Front Side Member and Fender Apron
Panel LH
Print
General Equipment
8 mm Drill Bit
Air Body Saw
Blind Rivet Gun
Grinder
Locking Pliers
Spot Weld Drill Bit
Removal
1.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Front%20Side%20Member%20and%20Fender… 1/14
2235/2430
2.
2236/2430
2237/2430
2238/2430
Use the General Equipments: Spot Weld Drill Bit, Air Body Saw
2239/2430
Installation
Operation).
4. Tack weld
2240/2430
Use the General Equipments: Measurement and Alignment Angle System, Locking Pliers, MIG/MAG
Welding Equipment
5. Use the General Equipments: Measurement and Alignment Angle System, Locking Pliers, MIG/MAG
Welding Equipment
6. Use the General Equipments: Measurement and Alignment Angle System, Resistance Spotwelding
Equipment, Locking Pliers
2241/2430
Equipment, Locking Pliers
8. Tack weld
Use the General Equipments: Measurement and Alignment Angle System, Locking Pliers, MIG/MAG
Welding Equipment
2242/2430
9. Use the General Equipments: Locking Pliers, Resistance Spotwelding Equipment
10. Use the General Equipments: Measurement and Alignment Angle System, Locking Pliers, 8 mm
Drill Bit, MIG/MAG Welding Equipment
Equipment
2243/2430
Equipment
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Front%20Side%20Member%20and%20Fend… 10/14
2244/2430
2245/2430
2246/2430
Equipment
Equipment
23. Use the General Equipment: Blind Rivet Gun
2247/2430
24. Sealing work: All areas must be sealed to production level.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, Description and
Operation).
2248/2430
Roof Sheet Metal Repairs - Roof Panel—5-Door

Print
General Equipment
6 mm Drill Bit
Hot Air Gun
Spherical Cutter
Spot Weld Drill Bit
Materials
Name Specification
Body Sealant -
Adhesive WSK-M2G322-B1
Removal
1. Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Installation).
Installation).
Refer to: Headliner - 5-Door, Vehicles Without: Panoramic Roof Panel (501-05 Interior Trim and
Ornamentation, Removal and Installation).
Refer to: Headliner - 5-Door, Vehicles With: Panoramic Roof Panel (501-05 Interior Trim and
2. On both sides.
Use the General Equipments: Spot Weld Drill Bit, Spherical Cutter
3. On both sides.
Use the General Equipment: Spot Weld Drill Bit
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Roof%20Panel-G1538285 1/5
2249/2430
4. On both sides.
Installation
Operation).
2. On both sides.
2250/2430
On both sides.
4. On both sides.
Material: WSK-M2G322-B1 (Adhesive)
5. On both sides.
Material: - (Body Sealant)
2251/2430
6. On both sides.
7. On both sides.
2252/2430
8. On both sides.
Operation).
Installation).
Installation).
Refer to: Headliner - 5-Door, Vehicles Without: Panoramic Roof Panel (501-05 Interior Trim and
Refer to: Headliner - 5-Door, Vehicles With: Panoramic Roof Panel (501-05 Interior Trim and
2253/2430
Side Panel Sheet Metal Repairs - A-Pillar Outer Panel

Print
General Equipment
6 mm Drill Bit
Air Body Saw
Hot Air Gun
Spot Weld Drill Bit
Materials
Name Specification
Body Sealant -
Removal
1. Refer to: Front Door (501-03 Body Closures, Removal and Installation).
Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
2. Cut Lines depend on damage and Service Part.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#A-Pillar%20Outer%20Panel-G1538289 1/6
2254/2430
2255/2430
Installation
Operation).
3. Bonding and welding
Operation).
2256/2430
4. Material: WSK-M2G322-B1 (Adhesive)
2257/2430
2258/2430
Operation).
Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
2259/2430
Side Panel Sheet Metal Repairs - A-Pillar Outer

Panel Section and Reinforcement
Print
General Equipment
6 mm Drill Bit
8 mm Drill Bit
Air Body Saw
Hot Air Gun
Spot Weld Drill Bit
Materials
Name Specification
Body Sealant -
Removal
1. Refer to: Front Door (501-03 Body Closures, Disassembly and Assembly).
Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
2. Cut Lines depend on damage and Service Part.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#A-Pillar%20Outer%20Panel%20Section%20and… 1/8
2260/2430
2261/2430
Installation
2262/2430
Operation).
2263/2430
Operation).
Operation).
2264/2430
2265/2430
2266/2430
Operation).
Refer to: Front Door (501-03 Body Closures, Disassembly and Assembly).
2267/2430
Side Panel Sheet Metal Repairs - Rocker Panel

Print
General Equipment
6 mm Drill Bit
Air Body Saw
Hot Air Gun
Spot Weld Drill Bit
Materials
Name Specification
Body Sealant -
Removal
1. Refer to: Health and Safety Precautions (501-25 Body Repairs - General Information, Description
and Operation).
Refer to: Airbag and Seatbelt Pretensioner Supplemental Restraint System (SRS) (501-20B
Refer to: Front Seatbelt Retractor (501-20A Seatbelt Systems, Removal and Installation).
Installation).
Installation).
Installation).
Installation).
Installation).
Installation).
Refer to: Floor Covering - 4-Door (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Installation).
Refer to: Floor Covering - Wagon (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2. Available Service Part
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Rocker%20Panel-G1538291 1/7
2268/2430
3. Cut Lines depend on damage and Service Part
2269/2430
2270/2430
Installation
Operation).
Operation).
2271/2430
Operation).
2272/2430
Operation).
and Operation).
2273/2430
Installation).
Installation).
Installation).
Installation).
Installation).
Installation).
Installation).
Installation).
Installation).
Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
2274/2430
Side Panel Sheet Metal Repairs - Rocker Panel Inner Reinforcement

Print
General Equipment
6 mm Drill Bit
8 mm Drill Bit
Hot Air Gun
Spherical Cutter
Spot Weld Drill Bit
Materials
Name Specification
Body Sealant -
Removal
1. Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs,
Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
Use the General Equipment: Measurement and Alignment Angle System
3. Use the General Equipment: Spherical Cutter
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Rocker%20Panel%20Inner%20Reinforcement-… 1/7
2275/2430
2276/2430
7.
Installation
Operation).
Operation).
2277/2430
3. Use the General Equipment: Measurement and Alignment Angle System
Equipment
2278/2430
2279/2430
Operation).
12. Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs,
Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
2280/2430
2281/2430
Side Panel Sheet Metal Repairs - B-Pillar Outer Panel

Print
General Equipment
6 mm Drill Bit
Air Body Saw
Hot Air Gun
Spot Weld Drill Bit
Materials
Name Specification
Removal
and Operation).
Installation).
Installation).
Installation).
2. Cut Lines depend on damage and Service Part
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#B-Pillar%20Outer%20Panel-G1538293 1/6
2282/2430
2283/2430
Installation
Operation).
2284/2430
2285/2430
2286/2430
Operation).
and Operation).
Installation).
Installation).
Installation).
2287/2430
Side Panel Sheet Metal Repairs - B-Pillar and Reinforcement

Print
General Equipment
Grinder
Spherical Cutter
Spindle Milling Cutter
Spot Weld Drill Bit
Removal
1. Refer to: B-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
Use the General Equipment: Measurement and Alignment Angle System
2. Use the General Equipments: Spherical Cutter, Grinder
4. Use the General Equipments: Spherical Cutter, Grinder
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#B-Pillar%20and%20Reinforcement-G1538294 1/5
2288/2430
Installation
Operation).

Service Parts
2289/2430
4. Use the General Equipments: Spherical Cutter, Spindle Milling Cutter
5. Use the General Equipments: Spherical Cutter, Spindle Milling Cutter
Equipment
2290/2430
2291/2430
Operation).
12. Refer to: B-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
2292/2430
Rear End Sheet Metal Repairs - Back Panel and Reinforcement—5-Door

Print
General Equipment
6 mm Drill Bit
Spot Weld Drill Bit
Removal
1. Reposition the carpeting and the wiring harness away from the working area.
2. On both sides.
3. On both sides.
4. On both sides.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Back%20Panel%20and%20Reinforcement-G15… 1/4
2293/2430
5. On both sides.
Installation
1. On both sides.
2. On both sides.
2294/2430
3. On both sides.
4. On both sides.
5. On both sides.
2295/2430
6. On both sides.
Operation).
2296/2430
Rear End Sheet Metal Repairs - Rear Side Member Section—5-Door

Print
General Equipment
6 mm Drill Bit
Air Body Saw
Spot Weld Drill Bit
Removal
1. Refer to: Rear Floor Panel Section - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
Refer to: Rear Floor Panel - 5-Door (501-30, Removal and Installation).
2. Possible Cut Lines
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Rear%20Side%20Member%20Section-G1538301 1/4
2297/2430
Installation
2.
1. Tack Weld

2. Complete Weld with Rear Floor Panel
Refer to: Rear Floor Panel Section - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal
and Installation).
2298/2430
2299/2430
Operation).
Refer to: Rear Floor Panel Section - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
2300/2430
Rear End Sheet Metal Repairs - Rear Floor Panel—5-Door

Print
General Equipment
6 mm Drill Bit
Air Body Saw
Spherical Cutter
Spot Weld Drill Bit
Removal
1. Reposition the carpeting and the wiring harness away from the working area.
Refer to: Back Panel and Reinforcement - 5-Door (501-30, Removal and Installation).
2. Rough Cut - Do not cut in panels below!
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Rear%20Floor%20Panel-G1538304 1/8
2301/2430
5. On both sides.
Use the General Equipment: Spherical Cutter
2302/2430
6. On both sides.
2303/2430
Installation
2304/2430
2305/2430
Operation).
6. On both sides.
2306/2430
7. On both sides.
8. On both sides.
2307/2430
9. Complete weld with:
Operation).
2308/2430
Rear End Sheet Metal Repairs - Rear Floor Panel Section—5-Door

Print
General Equipment
6 mm Drill Bit
Air Body Saw
Spherical Cutter
Spot Weld Drill Bit
Removal
1. Refer to: Back Panel and Reinforcement - 5-Door (501-30, Removal and Installation).
2. Possible Cutting Area
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Rear%20Floor%20Panel%20Section-G1538307 1/8
2309/2430
5. Use the General Equipment: Spherical Cutter
2310/2430
2311/2430
Installation
1. Use the General Equipments: 6 mm Drill Bit, Air Body Saw
2312/2430
2313/2430
2314/2430
2315/2430
9. Complete weld with:
Operation).
2316/2430
Rear End Sheet Metal Repairs - Quarter Panel LH—5-Door

Print
General Equipment
6 mm Drill Bit
Air Body Saw
Grinder
Hot Air Gun
Spot Weld Drill Bit
Materials
Name Specification
Removal
1. Refer to: Rear Quarter Window Glass (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
2. Available Service Part - Partial replacement due to damage and service part is possible and
reasonable.
reasonable.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Quarter%20Panel%20LH-G1538310 1/11
2317/2430
reasonable.
reasonable.
2318/2430
2319/2430
2320/2430
11. Use the General Equipments: Air Body Saw, Hot Air Gun
2321/2430
Installation
Operation).
Operation).
2322/2430
4. Bonding ans Welding
Operation).
Operation).
2323/2430
2324/2430
2325/2430
2326/2430
12.
Operation).
14. Refer to: Rear Quarter Window Glass (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
2327/2430
Rear End Sheet Metal Repairs - Inner Quarter Panel and Wheelhouse—5-
Door
Print
General Equipment
8 mm Drill Bit
Air Body Saw
Spot Weld Drill Bit
Materials
Name Specification
Removal
1. Refer to: Water Drain Panel Reinforcement - 5-Door (501-30 Rear End Sheet Metal Repairs,
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Inner%20Quarter%20Panel%20and%20Wheel… 1/13
2328/2430
2329/2430
2330/2430
Use the General Equipments: Spot Weld Drill Bit, Air Body Saw
2331/2430
Installation
Operation).
2332/2430
2333/2430
8. Complete Weld with:
Refer to: Water Drain Panel Reinforcement - 5-Door (501-30 Rear End Sheet Metal Repairs,
2334/2430
2335/2430
Refer to: Quarter Panel LH - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
2336/2430

https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Inner%20Quarter%20Panel%20and%20Whe… 10/13
2337/2430
Installation).
2338/2430
2339/2430
Operation).
22. Authoring Template
Refer to: Water Drain Panel Reinforcement - 5-Door (501-30 Rear End Sheet Metal Repairs,
2340/2430
Rear End Sheet Metal Repairs - Rear Lamp Mounting Panel—5-Door

Print
General Equipment
6 mm Drill Bit
Spot Weld Drill Bit
Removal
Installation).
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Rear%20Lamp%20Mounting%20Panel-G1538316 1/5
2341/2430
2342/2430
Installation
Operation).
2343/2430
2344/2430
Operation).
Installation).
2345/2430
Rear End Sheet Metal Repairs - Water Drain Panel—5-Door

Print
General Equipment
Air Body Saw
Spot Weld Drill Bit
Materials
Name Specification
Removal
1. Refer to: Rear Lamp Mounting Panel - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Water%20Drain%20Panel-G1538318 1/3
2346/2430
Installation
Operation).
2347/2430
Operation).
6. Refer to: Rear Lamp Mounting Panel - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
2348/2430
Rear End Sheet Metal Repairs - Water Drain Panel Reinforcement—5-Door

Print
General Equipment
6 mm Drill Bit
Spherical Cutter
Spot Weld Drill Bit
Removal
1. Refer to: Water Drain Panel - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Water%20Drain%20Panel%20Reinforcement-G… 1/7
2349/2430
2350/2430
7. Use the General Equipments: Spot Weld Drill Bit, Spherical Cutter
2351/2430
8. Use the General Equipments: Spot Weld Drill Bit, Spherical Cutter
Installation
Operation).
2352/2430
2353/2430
2354/2430
Operation).
9. Refer to: Water Drain Panel - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
2355/2430
Paint - General Information - Description and

Usage of Paint Literature
Print
Vehicle paints are subject to severe demands caused by external influences. Moisture, air-borne
deposits in the form of various chemicals and UV light constantly affect a paint surface. Furthermore,
mechanical damage occurs through grit, stones and sand. Bird droppings, insect residues, pollen and
tree sap also attack the paint surface.
The present literature not only informs the specialist about current repair painting techniques, but
also provides tips and instructions on modern and economical repair processes.
High quality bodywork paints require the use of the most modern technologies and regular updating
of the technician's knowledge of painting techniques, because of the constantly new developments in
paint technology.
Information about different materials is listed under Specification.
Furthermore, information on the fundamental principles of repair painting and paint materials is
provided in several chapters. The safety instructions indicate the possible health hazards and other
sources of danger. There are also notes about tools and materials as well as on basic painting
methods.
In the model specific repair instructions, only the most important repair steps or special features are
referred to. Detailed information on the generally applicable painting procedures is given in this paint
manual.
Direct supply of repair paints by Ford has been discontinued. There is however an agreement with
many paint manufacturers, which ensures fast and problem-free supply to the dealer undertakings.
Paint suppliers:
DuPont
Glasurit
PPG
Sikkens
Spies Hecker
Standox
When using painting materials, it should be taken into account that the manufacturers have exactly
matched their products between each other. In order to avoid quality defects, difficulties in working
and losses in corrosion protection, these may not be substituted with other products.
NOTE: The Ford Service Organization organizes basic and more in-depth training on much of the
content of this paint manual. As well as the practical part of the training, a further component is the
Student Information document, which offers supplementary information in the form of a brochure.
During all work it must always be ensured that personal safety and the operational capability of the
vehicle are not threatened by the choice of methods, tools and components.
The information given in the diagrams in the chapter "Paint Damage" is provided by the repair paint
manufacturer.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Description%20and%20Usage%20of%20Paint… 1/1
2356/2430
Paint - General Information - Symbols

Print
General
Various symbols, signs, instructions and illustrations are used in this literature. Warnings and cautions
have different meanings and require different ways of proceeding. Diagrammatic representations are
provided with instructional signs for improved clarity. These are briefly explained below:
WARNING: This caption is used when failure to follow instructions exactly or failure to follow
them at all may result in a hazard to persons or in persons being injured.
NOTICE: This caption is used when incorrectly following the test procedures or instructions or
failure to follow them at all could lead to damage to the vehicle or components.
NOTE: This caption is used when attention needs to be drawn to special or extra information.
When reading this handbook, you will come across the points WARNING, CAUTION AND NOTE. These
instructions are always given immediately before the corresponding job steps.
Hazardous materials designations
Many accidents occur because of ignorance. In the area of personal health protection, it is particularly
important to clearly emphasize sources of danger and their effects on human organs.
Only with knowledge of hazardous material designations can it be certain that the necessary
precautions are taken when handling substances which are harmful to health.
NOTE: Pay attention to the manufacturer's data on the containers and given in the Safety Data
Sheet.
Hazardous material symbols

2357/2430
1 - Very poisonous, T+ (extremely toxic), small quantities can be fatal.

2 - Poisonous, T (toxic), causes serious damage to health
3 - Corrosive, C (corrosive), destroys living tissue.
4 - Harmful to health, Xn (noxious).
5 - Irritant, Xi (irritant), can cause inflammation.
6 - Explosive
7 - Highly flammable, F+ (extremely flammable), already flammable at temperatures
below 0° C.
8 - Flammable, F (flammable), forms a flammable mixture with air.
9 - Oxidizing, O (oxidizing), reacts with combustible substances.
As well as the danger symbols, there is more comprehensive manufacturer's information to be found
on the containers and in the Safety Data Sheets, and you must pay attention to this information.
Instructions on measures to be taken for personal protection.
As well as the information about sources of danger, there are mandatory instructions which draw your
attention to the personal protection measures to be taken.
Mandatory symbol

1 - Breathing protection must be worn
2 - Eye protection must be worn
3 - Ear protection must be worn
4 - Protective gloves must be worn
5 - Protective footwear must be worn
Icons
So that the necessary information for optimal handling is clear, unambiguous and can be quickly
understood, the leading paint manufacturers have agreed a standard symbolic language. Language
independent representations in the form of icons provide handling instructions which are
supplemented with quantity or time information.
Pretreatment
2358/2430

1 - Clean
2 - Sand
Mix

1 - 2 component mixture
2 - 3 component mixture
3 - Use a measuring rod
4 - Addition of hardener
5 - Addition of additives
Process
2359/2430

1 - Flow-beaker spray gun
2 - Suction-beaker spray gun
3 - Spray passes
4 - Filler
5 - Coat
6 - Underbody protection spray gun
Dry

1 - Ventilate
2 - Drying time
3 - Drying time with infra-red dryer
Further processing
2360/2430

1 - Hand abrade (wet)
2 - Hand abrade (dry)
3 - Eccentric sander (wet)
4 - Eccentric sander (dry)
5 - Oscillating sander (wet)
6 - Oscillating sander (dry)
Store

1 - Protect from moisture
2 - Store in a frost-free environment
3 - Store in a cool place
4 - Close the container
Other
2361/2430

1 - Stir by hand
2 - Stir using a mixing machine
3 - Polish
4 - Roll
2362/2430
Paint - General Information - Health and

Safety Precautions
Print
General instructions for the paint shop and handling paint materials
Hazardous areas in repair paint shops:
Danger from fires, explosions and hot surfaces.

Dangers to health and safety from the effects of harmful substances because of their absorption
through the skin and/or inhalation.
Dangers caused by electricity, compressed air, power tools and noise.
WARNING: During painting work there is an increased danger of fire or explosion. Prevent any
sparks being created. Fire, naked lights and smoking are forbidden.
Measures:
Wear protective footwear made from anti-static material.

Only use tools made of wood, brass or copper to clean stands and extraction ducts. Do not use tools
made of steel.
Only fill or decant paint materials in a specially marked area.

As well as these general instructions on the dangers in repair paint shops, all national and
international regulations must be observed:
Health and Safety at Work Act

Ordinance on Hazardous Substances
Technical Rules for Hazardous Substances
Regulations for the Prevention of Industrial Accidents
EU Directive on Hazardous Substances, 98/24/EU
EU Directive on Noise, 2003/10/EU
EU Directive on Volatile Organic Compounds (VOC), 1999/13/EU, 2001/81/EU, 2004/42/EU
Safety instructions of equipment and tool manufacturers
Personal protection
Besides the body and limbs, several organs vital to life are in very particular danger. Because damage
is mostly irreparable, special attention and comprehensive protection are necessary.
WARNING: Solvents cause damage to the health through inhalation. Splashes in the eyes or on
the skin can cause bodily harm. When working with solvents, always use suitable means of
protection.
2363/2430

1 - Protective hood with fresh air supply
2 - Protective clothing
3 - Protective gloves
4 - Protective footwear
During painting work and in the preparations for painting, gases, vapors, mists or dusts can appear in
dangerous concentrations in the areas where fellow employees breath.
For short periods of work or minimal concentrations of hazardous substances, breathing protection
devices with a combination filter are suitable as breathing protection equipment.

1 - Activated charcoal filter
2 - Coarse filter
For higher concentrations of harmful substances, breathing protection devices which are independent
of the local atmosphere are suitable.
In these types of isolation systems, a compressed air hose carries natural air from the compressor
line into the protective mask. During supply, the air undergoes pressure reduction, water removal,
fine filtration and usually warming to natural breath temperature.
WARNING: Vapor or spray mist containing isocyanate as a paint base or hardener can cause
toxic respiratory disease (conditions similar to asthma) leading to permanent damage, even when
inhaled in the lowest concentrations.
Filter masks with wadding, sponge or colloid filters and also paper masks are all unsuitable for
working with coating materials because they do not stop solvent vapors.
2364/2430
The instructions for use provided by the manufacturer must be observed when working with breathing
protection equipment.
Skin protection
Spray painters who are subject to considerable exposure to coating materials must wear suitable
protective work clothing (flame-proof and anti-static).
NOTE: Also, when working with water based materials, comprehensive skin protection must be
worn, because these materials are very easily absorbed through the skin.
The protective clothing must be changed at the proper intervals. Items of clothing which are
contaminated with coating materials can easily catch fire.
When selecting protective clothing, it must be taken into account that cloth containing a high
proportion of easily melted plastic thread considerably increases the degree of burns injury (melted
plastic on the skin!). This must also be taken into account in the choice of underwear.
For areas of skin which are not covered by protective clothing, suitable skin protection, skin cleaning
and skin care agents must be used.
Eye protection
Working with portable hand sanding machines on which the tools move unguarded, at speed and with
power is fundamentally dangerous.
Goggles must be worn not only when sanding, but also when working with paints and their additives.
These contain substances which are harmful to the eyes. Damage ranging from irritation of the
cornea to incurable illnesses are possible.
The protective goggles must be inert toward splashes of solvent, and fully enclose the areas at the
side of the eyes on both sides. The best protection during spray painting is offered by full mask
respirators or helmet respirators with a built-in visor.
Ear protection
Noise disturbance in repair paint shops caused by various sources is particularly high. Sanding and
compressed air machines, paint cabin extractor fans (compressors) and extractor ducts in the work
rooms are the causes of the high levels of noise.
WARNING: Avoid damage to your hearing! Wear ear protection.

Suitable ear protection is offered by ear plugs or ear defenders.
2365/2430
Paint - General Information - Environmental

Regulations
Print
Waste disposal in the repair paint shop

More than ever before, since the introduction of EU directives, rigorous attention is paid to the
avoidance of waste materials and to recycling in repair paint shops. In this respect, repair paint shops
must take into account and comply with the following requirements:
Separate waste according to its recycling and disposal methods.

Produce evidence for the correct transport and disposal of waste.
NOTE: The organization of disposal in the plant must comply with the requirements of the Waste
Avoidance and Management Act: The avoidance and recycling of waste must always take priority.
However, despite all measures which may be taken, waste cannot be completely avoided.
NOTE: Waste which is not allowed in household rubbish, and which can no longer be utilized, must
be disposed of as special waste.
Paint residues containing solvent, application residues, sanding dust, waste containing peroxides,
solvents, soiled cleaning cloths and paint slurry all count as special waste. Each of these must be
collected in a separate, sealed and suitably labeled metal container and properly disposed of using a
specialist company.
Careful separation allows some waste to be usefully re-used.
Empty metal containers can be sent for scrap instead of being disposed of as waste.
Contaminated cleaning thinners can be separated by distillation.
Packing material and masking paper can be added to the recycled paper collection.
Residues which cannot be used must be correctly disposed of.

All remaining waste must be treated as commercial waste and disposed of according to the local
regulations.
The new VOC (Volatile Organic Compounds) solvent regulation
Keeping the air clean protects the environment and the population from the heath-damaging effects
of air pollutants.
In certain atmospheric conditions, volatile organic compounds contribute to summer smog.
NOTE: For comprehensive information, please refer to the European VOC Directive, 1999/13/EU.
Furthermore, the effective national regulations must be complied with.
The European VOC (Volatile Organic Compounds) Directive has controlled the limits for such
compounds since August 2001. It applies to production coating companies and those which undertake
repair painting of private and commercial vehicles.
Not least because of the VOC legislation, modern, low solvent and solvent-free lacquers and paints
are finding greatly increased distribution across industry and the trade. Up to the year 2007,
emissions from painting work will drop by at least 40%.
At the same time, the paint manufacturers guarantee for example that they will produce a ready-to-
spray product consisting of base paint + hardener + thinners, with a permitted VOC level.
A company in business today can conform with the stipulated requirements by introducing water-
based paints and using the other necessary products from the relevant paint manufacturers.
For more detailed information, please refer to the EU VOC Directive.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Environmental%20Regulations-G1538327 1/1
2366/2430
Paint - General Information - Factory Paint

Application
Print
General fundamentals of paint technology

Paint is a pigment-containing liquid which undergoes chemical and/or physical processes after it has
been applied to a surface, so changing into a solid film covering.
Repair paint consists of binder, pigments, filler and solvent.
NOTE: Organic solvent is being replaced by solvent based on water.
Constituents of paint
Binder
- Mostly semi-fluid resins which bind together the other components of the paint when it dries.
- Makes the paint durable.
- Ensures good surface coverage.
Pigments
- Fine, colored powders, which give color to the paint.
- Cover the components below (covering power).
Additives
- Additives give the paint special properties.
- e.g. flow improver, softener, drying accelerator, thickener.
Solvent
- Thins the paint and allows it to flow more freely.
- Evaporates during drying.
Painting process and corrosion protection.

In production, painting consists of individual steps which are optimally matched to each other.
Bodywork consists almost entirely of steel panels which have been pre-coated with zinc. The zinc
layer is between 5-10 µm thick and acts as the first corrosion protection layer of the steel panel.
Production sequence:
Clean and de-grease

- In the first step, the bare bodywork is initially dipped in a cleaning bath and cleaned with a
degreasing solution.
Phosphatising
- The cleaned bodywork is dipped in a bath containing various phosphate salt solutions. This creates
a crystalline metal-phosphate layer which offers the optimal prepared surface and also corrosion
protection.
CDP base
- The cataphoretic dip paint (CDP) base acts as a further corrosion protection layer.
- In this process the bodywork is completely immersed in a bath consisting of a paint and
electrolyte solution.
- By application of an electric voltage, an electric field is created.
- Positively charged paint particles settle on the negatively charged bodywork and form a protective
layer up to 20 µm thick.
- Next the bodywork is placed in a dryer, where the CDP base is hardened at 180°C.
Sealing, stone-chip protection
- Edges, seams and but joints are sealer with a sealing compound.
- Vulnerable areas are coated with stone-chip protection.
Filler
- Filler protects the body panels from stone impacts. Furthermore, any unevenness of the metal
surface is flattened out, in order to create the most homogenous and fault-free undersurface
possible.
- Once the filler is dry, it serves as the base on which paint is applied.
Top coat
- The top coat is applied as a single layer or two layers of paint.
- When working with two layer paint, in the first job step the initial colored base paint is applied. In
the second job step, a clear lacquer is applied, giving the base paint shine and hardness.
The structure of an original paint finish

https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Factory%20Paint%20Application-G1538328 1/2
2367/2430
During construction of the original paint, a total surface thickness of between 120 and 130 µm is
achieved. The thicknesses of the layers may vary however, because they are greater for horizontal
surfaces than vertical ones.
Paint layers

1 - Steel panel
2 - Phosphate layer 2.9 g/m², corresponding to 2 µm.
3 - Cathodic dip paint 30-35 µm
4 - Filler 30-35 µm
5 - Base paint 15-20 µm
6 - Clear varnish 55 µm
Colored fillers applied in production

Filler which gives color is used in production. Its use makes the base paint and clear varnish
unnecessary on certain vehicle interior surfaces (engine, doors).
Not every exterior paint has its own matching filler. It is more that the tones of the filler are color
compatible, i.e. they have similar intensity to the top coat.
During repair painting the filler color tones must be used according to the manufacturer's instructions.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Factory%20Paint%20Application-G1538328 2/2
2368/2430
Paint - General Information - Paintwork

Defects and Damage
Print
Diagnosis and Damage Assessment

Paint concerns, regardless of their causes, are part of the everyday work in the paint shop. Correct
damage assessment and determination of the cause are preconditions for a professional resolution of
a paint concern.
Paint concerns can still occur through a variety of causes, despite improved paint materials and new
spray methods.
NOTE: A first appraisal of the paint damage should be done before cleaning. External factors such
as rust, droppings, incorrect or insufficient paint care can then be more easily detected.
Diagnosis is best done in daylight but not in direct sunlight. Exact evaluation can also be done under
artificial light from special luminescent lamps.
Paint damage guide
The most important paint damage concerns which make a paint repair necessary are:
Damage from biological paint contamination such as bird or insect droppings, tree resin and aphids.
Chemical paint damage caused by industrial contaminants such as smoke, fuel, acids, oils.
Mechanical damage caused by stone impact during operation, scratches in the car wash and
parking.
Damage caused by faults in treatment. Application defects such as paint runs or orange peel.
Dirt inclusions in the paint layer, e.g. caused by dust in top coat or textile lint.
Damage due to corrosion.
Before repair of such paint concerns, exact diagnosis must be performed to determine the cause
exactly. On the spot diagnoses using simple aids and processes are often enough.
Diagnosis without disturbing the paint is done by:

Optical inspection without visual aids, under suitable light conditions from a suitable angle and
correct distance.
Optical inspection with the help of a magnifying glass.
pH paper.
Measurement of the thickness using FE / NFE coating thickness meters for ferrous (FE) and non-
ferrous metals and non-magnetic steel (NFE) - magnetic process on steel panels, eddy current
process on non-metals.
A test method where the traces of testing can be easily removed again is the finger nail test. With
suitable experience the existing hardness of the paint can be determined.
Test methods where the paint is partially destroyed are:

Pencil hardness test.
Adhesion test using adhesive tape.
Lattice cut test process to check the strength of adhesion.
Under certain circumstances these test methods are not enough for a certain diagnosis. In this case,
paint diagnosis under laboratory conditions must be performed.
Measuring and testing equipment for painted surfaces
Coating thickness measuring devices

Magnifying glass
pH paper (together with water)
Suitable photographic equipment with macro lens
Shine measuring equipment
Paint damage caused by environmental factors
Bee droppings
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Paintwork%20Defects%20and%20Damage-G1… 1/18
2369/2430
Bird droppings
Insects
Tree resin and sap
Aphid secretions
Tar spots
Cement, plaster and slaked lime
Rust film/deposits from industrial fallout
Battery acid
Brake fluid
In all the cases of paint damage described below, if the damage is irreversible a new paint
finish must be applied.
Paint damage cause by bee droppings
Bee droppings can be recognized on a paint surface through its yellow or brown color and sausage or
drop-like shape with a diameter of 3-4 mm.
Cause/damage pattern:
In combination with heat and high air humidity, bee droppings leave discolorations and cause paint
decomposition.
The paint can be destroyed down to the filler.
Repair of damage:
If the damage is light, perform a polishing repair.
Paint damage caused by bird droppings
Bird dropping damage appears most often as matt, etched topcoat areas of various sizes. If left on
the vehicle for a long time, crack formation and etching down to the filler will occur.
Bird droppings are particularly harmful in combination with heat and moisture. The urea (white
part) has a very high salt content and is very aggressive.
The intensity of the damage varies depending on the type, quantity, contact time and extent.
Cracks, etching, marks up to dissolution of the top coat are the results.
Repair of damage:
If the damage is light, perform a polishing repair.
Paint damage caused by insects
2370/2430
At insect impact locations on the hood, roof and bumper, small etched or etched through paint marks
with partially visible spots of filler.
The top coat layer is destroyed in a short time by surface swelling and etching.
Colliding insects stick to the paint surface. In combination with moisture and heat, because of the
resulting acids the insect bodies sink into the paint top coat.
The corrosion is G, C, U or O shaped and is only a few millimeters thick.
Repair of damage:
Wash the vehicle, treat the affected area with insect remover. Clean the paint surface several times.
Protect with hard wax.
Paint damage caused by tree resin or sap
Small yellow-brown marks or drops on the horizontal parts of the vehicle. The drops melt in sunlight.
Resin damage only occurs in the warm summer months.
Because of their chemical composition, tree resins combine with or adhere very well to paint top
coats and cause them to swell. The higher the temperature, the more intensive is the chemical
bonding between the resin and the paint topcoat surface.
Repair of damage:
Soak several times using a cloth saturated with a petrol & paraffin mixture.
NOTE: After successful cleaning the top coat must be preserved.
Swellings can be removed by warming.
Paint damage from aphid secretions
Small, round, matt marks about 1 mm diameter and etching with small islands down to the filler.
Fresh aphid excrement looks like small drops of honey.
Aphids produce a mixture of starch, leaf acid and sugar from sap in leaves. Under the effects of
warming and moisture this can turn into alcohol.
The round shape of the damage and the island of intact paint are typical.
2371/2430
Repair of damage:
Remove the excrement as soon as possible.
Small single matt locations without etching can be repaired using a polishing repair.
Paint damage caused by tar spots
Yellow or dark marks.
Firmly stuck spots of tar which lead to discoloration of the surface. In some cases penetration
through the clear lacquer into the top coat.
Repair of damage:
Clean the paint surface with tar remover and polish.
Paint damage caused by cement, plaster and slaked lime
Damage appears as whitish matt marks on the top coat.
Corrosive alkaline compounds interacting with moisture.
Repair of damage:
Wash immediately if the contamination is fresh.
If the contamination has dried on, dissolve and neutralise it with vinegar, then thoroughly wash off
with water and rinse.
Rectify mild damage using a polishing repair.
Rust film/deposits from industrial fallout
2372/2430
Small round marks, about 1 mm in size, in all shades from black, grey, blue to reddish, on the
horizontal surfaces of the vehicle.
Deposits from oil fired systems and industrial plant, especially at high humidities and inversion
weather conditions, cause damage to the paint top coat.
As the activity time increases so called rust halos form. They spread as long as the deposits
corrode.
Industrial fallout containing iron will no longer be removable after a few days!
Repair of damage:
Remove the dust using an industrial fallout remover and thoroughly wash.
Polish the paint surface.
NOTE: Never try to remove the particles of industrial fallout by polishing or rubbing!
Use cleaning dough.
Damage caused by battery acid.
Splashes of battery acid caused by carelessly topping up the battery.
WARNING: Batteries contain sulphuric acid. When working near the battery, or where there is
battery acid on the vehicle body, protect the skin and eyes from contact with the acid. If battery
acid contacts the skin or enters the eyes, flush the affected area immediately with water (flush for
at least 15 minutes) and call a doctor without delay. If acid is swallowed, call a doctor immediately.
Failure to follow these instructions may result in personal injury.
NOTE: High temperatures accelerate the attack on the top coat. At 50°C the top coat layer breaks
down after about 15 minutes!
Etching of the paint layer to decomposition of the paint finish.
Repair of damage:
Flush the acid splashes with plenty of water and neutralize with car washing liquid.
If the contact time of the acid was short, perform a polishing repair.
Paint damage caused by brake fluid.
Careless handling of brake fluid. The glycols contained in the fluid cause swellings.
2373/2430
The temperature and contact time are critical. Splashes lead to loss of shine and lightening of color.
Repair of damage:
Flush immediately with plenty of water.
The swellings can often be made to recede completely by treatment with the radiant heater or in
the paint drying oven at max. 60°C for about 1 hour.
Mechanical damage
Stone impact damage or mechanical damage
Mechanical damage caused by impact of stones or other hard objects and extending down to the
metal panel lead very quickly to corrosion and rusting under the paint on the adjoining surface.
Paint damage caused from the outside, down to filler, primer or metal panel.
Repair of damage:
Sand or blast out.
Use anti-corrosion primer.
Apply top coat.
Damage due to corrosion

Blistering/rusting below
Air or water filled blister-shaped raised areas in the paint film.
Overpainting corroded steel panel.
Condensation in the spray air.
Sanding water not dried out or salt crystal residues.
Road chippings and road winter grit containing salt.
2374/2430
Repair of damage:
Sand the affected area of damage or the body component and re-create the paint finish.
More severe and larger areas of rusting below must be repaired using the corresponding repair
painting, Repair Level III or IV.
Damage caused by faults in treatment
Craters
Paint boils
Adhesion defects
Adhesion defects - clear lacquer
Sanding scores
Formation of stripes
Peeling/blistering on plastic parts
Blistering on polyester material
Peroxide marks in metallic paints
Crack formation
Shrinking back/zone edge marks
Blistering
Etching
Paint wrinkles/puckering
Cloud formation
Spots/metallics
Metamerism/color deviations
Washing out
Loss of gloss
Covering ability/areas of thin paint
Flow problems/orange peel
Dirt embedded in metallic base paint
Dirt embedded in top coat
Water marks
Paint runs
Swirl marks
Craters
Crater-like single or extensively occurring depressions with raised edges, in top coat or the
intermediate layers.
Substrate not adequately cleaned with silicone remover.
Spray air contaminated by oil residues and water accumulations.
Filter ceiling not adequate for requirements.
Use of polishes, cleaning agents or sprays (e.g. interior sprays) containing silicone.
Oil, wax, grease, silicone containing residues.
Working clothes contaminated by materials containing silicone.
2375/2430
Repair of damage:
Sand paint surface, clean with silicone remover and apply one thin spray pass. Let it begin to dry
well, then apply several thin and dry sprayed passes.
Paint boils
Small, hard, closed or burst blisters in the paint top coat. They appear locally in groups or spread
individually across the whole surface. Sanding opens up a larger cavity, under which the primer can
often be seen.
Paint applied in layers which were too thick.
Specified flash-off and drying times between coats were not adhered to.
Specified working viscosity and spray pressure were not adhered to.
Use of unsuitable hardener and thinner materials. (Solvent combinations in paint system not
optimally matched).
Poor booth conditions.
Repair of damage:
Single boil blisters can be removed using polishing.
After thorough drying, sand the top coat at the affected areas, clean with silicone remover and re-
paint. Fill any fine pores still present with 2-component acrylic filler.
On larger areas of damaged topcoat, sand completely away and apply new paint finish.
Adhesion defects
Whole coating detached from substrate or individual layers one from another. Sometimes adhesion
defects can only be noticed after an external influence such as stone impact.
Substrate not adequately prepared (rust, grease, moisture, sanding, cleaning).
Unsuitable material used.
Drying times, flash-off times too short.
Base paint not sprayed wet-in-wet, instead the intermediate drying times were too long.
Failure to intermediate sand.
Condensation formed because of temperature fluctuations.
Unprofessional preparation (especially on plastics).
Overheated CDP/intermediate filler.
2376/2430
Repair of damage:
Sand out the damage and recreate the paint finish. Create the paint finish strictly in accordance
with the general technical information.
Adhesion defects in clear lacquer.
Clear lacquer detched from base paint.
Base paint layer too thick.
Intermediate and final flash-off times of base paint too long.
Incorrect mixture ratio clear lacquer/hardner.
Repair of damage:
Refinish sanding and recreate the paint finish.
Sanding scores
Single or wide area clusters of scoring or sanding marks, often with raised edges. Noticeable on
metallic paints as light-dark stripes.
Stopper sanded too coarsely.
Filler sanded too coarsely.
Filler not thoroughly dried bfore sanding.
Old paint sanded too coarsely.
Soft elastic substrates, e.g. TPA base, treated with thinners which was too aggressive and therefore
etched.
Top coat applied too thinly.
Repair of damage:
2377/2430
If the damage pattern is minimal, after the top coat has dried fine sand the paint surface and
refurbish by polishing.
If the damage is great or on metallic paints, sand the paint surface or substrates and if necessary
remove them, then cover the bare metal and re-paint.
Formation of stripes
Differing, stripe shaped color/effect formations in dark/light areas of a metallic paint finish.
Spray gun (nozzle) not perfect.
Incorrect spray pressure.
Thinners not suitable.
Incorrect spray viscosity.
Flash-off time too short.
Unsuitable working temperature.
Repair of damage:
Apply base paint evenly.
Repair spray gun.
After clear lacquer has thoroughly dried, sand surface and paint again.
Peeling/blistering on plastic parts
Paint adhesion insufficient between top coat and filler and/or primer layer. It often happens that the
whole of the paint finish detaches from the plastic.
Plastic item not cleaned sufficiently, not or inadequately tempered.
Unsuitable cleaning agent used.
Unsuitable materials used.
Moisture.
Paint finish underbaked or overbaked.
Poor or lack of intermediate sanding.
Repair of damage:
Sand away faulty paint coats and re-apply paint finish.
In extreme cases use a new part.
Blistering on polyester material
Color shade differences or marks in paintwork subsequently applied to previously unpainted plastic
material.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Paintwork%20Defects%20and%20Damage-G… 10/18
2378/2430
Plastic material is not suitable for painting.
Incorrect bonding agent.
Paint used not solvent resistant.
Repair of damage:
Repaint using suitable materials.
Install unpainted new part (after consulting customer).
Peroxide marks in metallic paints
After longer period of drying, abnormal marks where the color shade varies.
Too much hardener added to polyester stopper (over 3% can cause this damage pattern).
Polyester stopper not well enough mixed.
Repair of damage:
Sand, fill with polyester or epoxide filler and re-paint.
Crack formation
Cracks of different lengths and depths running in all directions.
Layers too thick.
Painted several times.
Temperature fluctuations.
Mechanical effects e.g. distortions.
Substrate not thoroughly hardened.
Old paint not completely dried out.
No or insufficient hardener added.
2-component materials used on nitro or TPA.
Repair of damage:
Sand away layers until sound substrate is reached and create new paint finish (prime, fill, apply
topcoat).
Shrinking back/zone edge marks
Lifting or dropping in of edge zones (edges which accentuate themselves in the top coat), flow
problems and loss of shine in top coat.
2379/2430
Old paintwork not rubbed down to a seamless transition.
Stopper and filler on a viscoplastic base primer.
Filler sanded and overpainted when not thoroughly hard.
Previous materials overworked too early, substrate not sufficiently hardened.
Primer applied in layers which were too thick, and not dried for long enough.
Sanding paper too coarse.
Top coat thinned too much.
Repair of damage:
After hardening off the top coat, fine sand the surface and polish up, apply filler if necessary and
paint once more.
Blistering
Small, spot-like, air-filled or water-filled blister shaped high-spots in the paint construction. Their
dimensions can range from pin-head to pin-point size in a closed paint film. Arrangement and
accumulation very variable. In the advanced stages, circular flaking of the paint from the substrate.
These are neither boils nor corrosion.
Moisture absorption by substrate.
Insufficient drying of the substrate after wet sanding (especially on polyester material).
Humidity too high before painting; condensation formation because of temperature fluctuations.
Pores/sink holes in substrate not sanded out.
Polyester material not covered.
Sweat from hands.
Salts and minerals in sanding water.
Spray air contaminated.
Repair of damage:
Sand away damage, matt sand remainder of surface, clean with silicone remover, fill and re-paint.
Etching
The base paint is etched by the clear lacquer. This causes the aluminum pigments to change their
alignments. The color of the etched base paint seems more grey than that of normal base paint.
Result is that the surface structure of the clear lacquer becomes increasingly more matt.
Base painted too wet.
No intermediate flash-off time.
2380/2430
Layers too thick.
Repair of damage:
Sand and re-paint.
Paint wrinkles/puckering
Lifting/puckering of the paint surface.
First paint not hardened through or can be etched.
Areas of clear lacquer which were sanded through to base paint have not been not isolated with
filler, or with unsuitable filler.
Unsuitable substrate (e.g. spray can painting with TPA or nitro).
Use of unsuitable primer, paint and thinner materials.
Paint systems not matched to each other.
In wet-in-wet process, specified flash-off times not adhered to.
Synthetic resin top coat (alkyd resin) worked over too soon.
Repair of damage:
After thorough drying, completely remove the top coat together with the attacked substrate at the
affected areas and re-create a new paint finish.
Before applying top coat, rub down the complete surface.
Cloud formation
Differing, blotchy color/effect formations in dark/light areas of a metallic paint finish.
Spray gun, spray nozzle, spray pressure not perfect.
Varying spray viscosity, spraying method, flash-off times, spray booth temperature.
Thinners not suitable.
2381/2430
Repair of damage:
Droplet method before clear lacquer application.
After clear lacquer has thoroughly dried, sand surface and re-paint.
Spots
Points rising up from the paint film.
Metallic base paint sprayed too dry, so that the metal particles could not incorporate into the paint.
The clear lacquer could not cover these vertical standing particles because the spray air was too hot
or the booth temperature was too high.
Repair of damage:
After the paint surface has dried, lightly sand it with grade P800 sanding paper, clean with silicone
remover and re-apply clear lacquer.
Metamerism/color deviations
Noticeable when identical color shades undergo a change of hue as the light source changes
(daylight/artificial light). Different pigment composition between original and repair paint.
Use of paints with pigmentation which was not compatible with the standard, e.g. a green can be
formulated from yellow and blue, or directly from green.
Use of an unsuitable mixed or ready made paint to re-tone.
Repair of damage:
Repaint using the correct paint.
Washing out
2382/2430
On paint which has been newly applied but not yet dried, the interaction of surface tension and very
different specific gravities of the different pigments can lead to swirl-like turbulence which results in
separation of the pigments.
Layer too thick, paint not stirred enough.
Repair of damage:
Sand and re-paint.
Loss of gloss
Milky, dreary tarnishing of the paint with more or less even loss of gloss.
Cold with low air humidity.
Heat with high air humidity.
Substrate can be etched.
Hardener fault or wrong hardener used.
Paint thinned too much.
Proportion of pigment too high because of poor stirring.
Not optimum drying.
Repair of damage:
After drying, remove the matt effect by polishing. If unsuccessful, rub down complete area and
paint again.
Covering ability/areas of thin paint
Different color shades in the surface. The minimum layer thickness is not achieved here. The effects
range from local minor shade variations through mottled spray zones to completely missing top coat.
No correct, uniform substrate (effect paint).
On three-layer systems, wrong filler.
Insufficient top coat application.
2383/2430
Repair of damage:
Sand surface and recreate the paint finish.
Flow problems/orange peel
Surface structure bumpy, grained. The surface is similar to the peel of an orange.
Paint viscosity too high.
Use of fast evaporating, highly volatile thinners.
Booth temperature too high.
Spray gun distance too great, too little material applied.
Nozzle too large.
Incorrect spray pressure.
Repair of damage:
Small surfaces: fine sand and polish.
Sand out the surface and recreate the paint finish.
Dirt embedded in metallic base paint.
Inclusions of contamination in metallic base paint, of different sizes and shapes (grains or lint).
Dust was not properly removed from the surface to be painted.
Paint material not sieved.
Function of the painting facilities not optimum.
Filter contaminated.
Wearing unsuitable clothing.
Repair of damage:
Sand and repaint.
Dirt embedded in top coat
Inclusions of contamination in top coat or under paint layers, of different sizes and shapes (grains or
lint). Optical adverse effect.
Dust was not properly removed from the surface to be painted.
Paint material not sieved.
Function of the painting facilities not optimum.
2384/2430
Filter contaminated.
Wearing unsuitable clothing.
Repair of damage:
Single inclusions: after thorough hardening, sand out using 1200 - 1500 grade paper and repolish
using a suitable silicone-free sanding or painting paste.
Large area contamination: sand and repaint.
Water marks
Ring shaped marks appearing on the paint surface.
Evaporation of water droplets on freshly painted and not yet fully hardened paint finishes (mostly
only found on horizontal surfaces).
Layer too thick.
Drying time too short.
Hardening faults or hardener no longer useable.
Use of unsuitable thinners.
Repair of damage:
Rub down only slight marks with sanding paper grade P1000 - P1200 and then polish.
For heavy marking, sand the surface matt, clean with silicone remover and repaint.
Paint runs
Wave-like paint run tracks in top coat or in an intermediate layer on vertical surfaces. Mostly in the
area of swage lines, seams or openings (there they are paint runs, otherwise curtains).
Uneven paint application.
The specified viscosity was not complied with.
Use of unsuitable thinner materials.
Air, material or room temperature too low.
Layers too thick.
Spray gun (nozzle) not perfect.
2385/2430
Repair of damage:
After thorough drying, sand unevenness flat, if necessary leave to dry afterwards.
Small areas of damage can be equalised using the paint plane, then sand, polish or repaint.
Swirl marks
Three dimensional appearance in the paint surface in the form of smears or blotches. This effect is
intensified in direct sunlight.
Polishing using polishing machine on paint which has not yet hardened throughout.
Polishing intervals too long or none at all.
Pressure too high while polishing.
Incorrect polishing material or polishing tool.
Repair of damage:
Allow the paint to harden completely and then polish.
If the damage is irreversible, rub down and apply new clear lacquer.
2386/2430
Paint - General Information - Tools and

Equipment for Paint Repairs
Print
General work equipment

In the repair paint shop there is a range of painting tools which make the work of the painter easier
and improve the quality of the repair paintwork.
Among these are small tools which are used for the following work:
Measuring beakers to measure and mix various paint materials.

Measuring rods with which the required combination amounts of paint and primer filler are
gauged and mixed.
Viscosity measuring beaker with a calibrated opening of 4mm, used to set the correct paint
viscosity.
Paint filter/paint sieve for filtering foreign bodies out of mixed paint or primer. Care must be
taken that the correct filter is used for each paint.
Color sample plates onto which the mixed paint is applied, and the shade is then compared to
that of the vehicle. Other aids which should help the painter to find the correct shade are color
sample cards and color panels, which are offered by many paint manufacturers.
Dust bonding cloths which are impregnated with a tacky resin and which pick up dust particles
particularly well. A surface to be painted must be cleaned with a dust binding cloth immediately
before paint is applied.
Compressed air guns are used to remove sanding residues and to dry sanded surfaces.
Filler and spray guns

NOTE: Regular maintenance, cleaning after use and careful handling of all individual parts of the
spray gun are essential for a high-quality paint finish.
The spray gun is the most important implement in the paint shop. Application of paint using the spray
gun can produce a layer with absolutely constant thickness and a smooth paint surface.
Principle of operation

1 - Air supply
2 - Paint supply
3 - Nozzle needle
Because of the construction design and with the aid of compressed air, a spray-ready paint mixture is
dragged out of the container to the nozzle by the venturi effect, and is applied to the surface being
worked.
When the trigger of the spray gun is pressed to the first pressure point, only the compressed air
passage opens. If the trigger is pressed further, the nozzle needle displaces and the air stream drags
paint with it at high speed. This produces a spray mist consisting of micro-droplets of paint.
Types of spray gun
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Tools%20and%20Equipment%20for%20Paint%… 1/8
2387/2430

1 - Suction-beaker spray gun
2 - Flow-beaker spray gun
In the flow-beaker spray gun, the paint container is mounted above the spray gun. On the suction-
beaker spray gun, it is below.
Furthermore, spray guns are categorized by their air pressure requirement into high and low pressure
guns.
High pressure guns have the disadvantage that they exhibit high consumption of energy and
materials. The spray pressure they require is between 1 - 6 bar.
Because of the high air pressure and the large amount of air needed, the result is a powerful paint
mist formation (paint transfer rate approx. 35%).
Current practice is mainly to work with reduced mist spray systems (RP and HVLP systems).
Reduced pressure (RP) guns are optimized high pressure guns which have an input pressure at the
gun of approx. 2.5 bar and an atomization pressure at the air cap of 1 - 2 bar. In practice this spray
technology is preferred for spraying clear lacquer because of the finer atomization.
Low pressure guns have the advantage that they exhibit minimal paint mist formation and because of
this the paint transfer rate rises to approx. 65%. The spray pressure required in this case is between
1 - 5 bar. Nozzle sizes from 1 - 2.2 mm can be used.
HVLP spray guns

1 - Quantity control
2 - Working pressure control
3 - Spray pattern control
2388/2430
The high volume low pressure (HVLP) spray gun is a high performance spray gun which forms a soft,
fine and homogenous spray pattern. The atomization pressure at the air cap is 0.7 bar when the input
pressure at the gun is 2.0 bar.
The low atomization pressure of 0.7 bar together with greatly reduced spray mist provide high
material ejection. The low nozzle internal pressure minimizes rebound of the paint droplets from the
object and thus the proportion of overspray.
This spray technology has a very high application efficiency. By matching the size of the nozzle, the
HVLP spray gun can be used for all repair painting materials.
HVLP spray guns are often used in practice for the application of water based paints.
Mini spray guns are often used for small, localized touching-up work. Use of HVLP spray technology
and nozzle sizes of 0.3 - 1.2 mm permits very fine work, so that the area of the repair can be kept as
small as possible.
In order to ensure that a spray gun operates efficiently for a long time, careful cleaning is absolutely
vital after use.
NOTE: During cleaning you must distinguish between water based and solvent based materials.
Cleaning by hand:
Empty the paint beaker immediately after use.

Flush the gun with cleaner.
Clean it inside and outside with a brush.
Dismantle the gun to clean it thoroughly.
Clean the air cap using a suitable brush.
Use nozzle cleaning needles to clean bores and nozzles.
A spray gun washing machine is recommended if the painting work is highly intensive.
New types of paint processing systems are replacing the conventional mixing beaker, filter and spray
gun flow beaker. This reduces the amount of solvent required for cleaning and the amount of routine
waste which remains.
Paint preparation system (PPS)

1 - Beaker
2 - Color bag
With this system, which is suitable for both suction and flow beaker spray guns, only one beaker is
required for mixing and painting.
2389/2430
A bag is inserted in the beaker, in which paint can be mixed, processed and stored after use or
completely disposed of.
The small quantity of paint remaining in the gun is removed using a minimum quantity of solvent
from the pipette bottle.
The amount of cleaner used is reduced because only the spray gun needs to be cleaned.
Hand and machine sanding tools
Sanding is used to prepare a surface for application of a paint layer, enabling it to adhere well.
Sanding materials have a great influence on the quality of a repair paint finish. The correct sanding
medium must therefore be chosen for every material.
During sanding, material is mechanically removed from a surface.
In the paint shop, carborundum or silicon carbide abrasive on a substrate of paper or cloth are the
most common sanding materials used.
Carborundum is a very hard mineral consisting mostly of aluminum oxide. During use carborundum
becomes blunt and wears away.
Silicon carbide has a very high degree of hardness, but is more brittle than carborundum. When
silicon carbide is used, the mineral grains break. New long and pointed profiles are formed.
Use of the correct sanding paper depends on the application, the substrates and the tools used. The
following table can be used as a guideline, but the recommendations of the supplier of the auxiliary
materials and additive materials must be followed.
Application Working area Grade

Sanding system
Body work, corrosion damage Equalizing paint system transition to P150
Orbital sander, dry
Hand sanding, dry
Stopper Rough sand P80 - P150 Orbital sander, dry
Fine sand P240 - P320 Orbital sander, dry
Hand sanding, dry
Spray stopper Rough sand P120 - P180 Orbital sander, dry
Fine sand P240 - P320 Orbital sander, dry
Hand sanding, dry
Filler sanding work Filler fine sand P400 - P500 Orbital sander, dry
P800 - P1200 Hand sand, wet
Top coat Old paint P400 - P500 Orbital sand, dry
P800 - P1200 Hand sand, wet
Touch-up paint surfaces P1000 - P2000 Hand sand, wet
Paint damage Sanding out faults P2000 - P3000 Hand sand, wet
Soft Pads are recommended for manual refinishing of contours, curves and difficult to reach areas. On
a Soft Pad the abrasive is found on a coarse structured fleece. Because of this, it is very flexible, does
not kink and does not slip in the hand. This enables a fine and even finish to be achieved.

1 - Extraction bores
2 - Connection for extraction equipment
Notes on working with sanding tools:
Tools with a rigid backing pad do not adjust to fit the surface. They are used for flat surfaces.
2390/2430
Tools with a flexible backing pad are used for fine sanding of a surface because they adjust to the
shape of the surface.
Build up an even working pressure over the sanding surface.
Keep the sanding paper tight on the tool (use self-gripping systems).
Align the extraction holes in the sanding paper with the holes in the tool.
Guide the tool flat over the surface to be worked. Do not tilt it.
Hand sanding can be carried out dry but also wet. Wet and dry paper with particle size P 80 to P 1200
is used for this in the paint field.
Ways of sanding
Sanding tools are driven either by electricity or compressed air.

1 - Sanding machine
2 - Polishing machine
3 - Orbital sander
The disadvantage of electrically driven machines is that their own weight is high compared with
pneumatic systems. They also become warm during work. They do not however need any special
operating equipment for their energy supply.
Sanding machines are categorized by their type of sanding movement.
Rotational sanders
On these machines the sanding paper turns.
Advantage:
- Ideal for heavy sanding work.
- Fast and aggressive sanding possible.
Disadvantage:
- Large amount of heat developed.
- Difficulty sanding flat surfaces.
Application:
- Removal of old paint layers.
- Preparation of panel for stopper.
- Removal of rust.
Oscillating sander
On these machines the sanding paper oscillates. The backing pad is rectangular.
Advantage:
- Large sanding surface.
- Ideal for large and flat surfaces.
Disadvantage:
- Hardly useable on rounded surfaces.
- Flexible backing pad not possible.
- Vibrations because of the poor support of the backing pad.
Application:
- Sanding of polyester stopper.
- Sanding processes on flat surfaces.
Orbital sander
On these machines the sanding paper turns and oscillates.

2391/2430
Advantage:
- Easy to handle and good sanding power.
- Minimal heat development.
Disadvantage:
- Not suitable for sanding stopper on flat surfaces.
- Smooth guidance important, otherwise sanding marks will occur.
Application:
- Sanding of paint layers.
- Well suited for final preparation of a primer.
NOTE: Comply with the manufacturer's recommendations when setting the orbital sander.
On the orbital sander, stroke settings of approx. 3 mm for fine sanding work and approx. 5 - 7 mm for
coarse sanding work have been established.
Polishing and finishing tools
The term polishing in the context of paint repairs means the elimination of paint flaws and high shine
polishing of neighboring parts.
During polishing the fine sanded surface is returned to a high shine using a special abrasive polish.
Before the actual polishing, all flaws in the paint surface must be removed and the following working
procedures must be adhered to:
Thoroughly clean the vehicle.

Remove spray mist from all surfaces.
Sand out and polish particle inclusions.
Sand down paint runs and polish them out.
Examine the exactness of the color match in daylight.
Remove masking edges.
Remove sanding water, sanding dust and polish residues.
After the polishing process the results must be tested using a special test spray.
Infrared drying technology
The drying process in a painting/drying cabin occurs through heat conductance (convection). When an
infrared dryer is used, the drying process is through heat radiation.
The infrared rays penetrate the air and the paint layer without warming them. Because the infrared
rays are reflected from the steel panel, the paint coat is warmed from the inside outwards.
Advantages of infrared drying:
The drying process occurs from the inside to the outside.

The drying time is shorter than for warm air systems.
Because the infrared dryer consists of several cassettes which can be switched on independently,
the drying area can be optimally controlled.
Independent of the manufacturer's instructions, pay attention to the following:
Flash-off time of the paint before switching on the infrared dryer.

Distance between the infrared dryer and the surface.
Duration of the irradiation.
The most common use of the infrared dryer is to dry stopper and primers. The wait time between the
job steps is shortened without having to use the painting/drying cabin.
The painting/drying cabin can then be used exclusively for application and drying of topcoat.
2392/2430
There are two types of infrared dryer:
Infrared dryer with short wavelength radiation.

Infrared dryer with medium wavelength radiation.
As an indication, the following drying times are listed for some materials (at 80 cm distance):
NOTE: Observe the material manufacturer's and supplier's specifications.
Polyester stopper 2 minutes.

Spray stopper 2 to 7 minutes.
Water based primer-filler 7 to 9 minutes.
Primer 3 to 8 minutes.
Top coat 7 to 10 minutes.
Air dryers
The air dryer is suitable in places where drying needs to be done, but without great outlay
(painting/drying cabin or infrared dryer).
NOTE: Air from the compressor is often too cold for effective drying.
Air dryers use the venturi effect to blow the warm ambient air over the paint surface in a gentle air
flow.
Paint mixing system
Because of the many different color variants, it is now seldom possible to store all color shades as
ready-made mixtures.
For this reason, vehicle manufacturers make the mixture proportions of their paints available as color
codes. The required color shade can be obtained from the paint mixing system using this color code.
All the color components are combined according to their proportions by weight using a precise
computer scales to produce a finished color shade.
Painting cabin
The air requirement in a painting cabin is large. The outside air which is drawn in must be passed
through filtering and warming equipment. This particularly applies during colder times of the year and
especially for combined types of building where the painting cabin is also used as a drying cabin.
It is primarily used to keep the air free of dust. At the same time, explosive solvent-air mixture
concentrations are prevented
NOTE: Vacuum will lead to contamination of the newly applied paint. The outside air flows through
door gaps, wall joints and other openings and as it does so, brings dust deposits with it.
The air supply quantity depends on the size of the painting space and the quantity of extracted air.
Enough air must be supplied to cause positive pressure in the painting space. An air extraction : air
supply ratio of about 1 : 1.05 is sufficient.
The filters should have a dust-removal grade of not less than 99.8% and must always be kept clean.
It is especially important that the air supply does not cause strong air currents in the painting cabin.
If not, the following problems could occur:
Paint contamination cause by paint mist, which persists in air eddies and gradually falls on the fresh
paintwork.
Flow problems in the paint because of the high speed of the air, causing the paint to thicken very
quickly on the surface.
Loss of gloss and wrinkle formation because the surface dries too fast.
2393/2430
Painter disturbance while working.
In modern paint cabins the air supply is provided from the complete surface of the ceiling. The air
speed should be 0.3 m/sec (measured in the unrestricted cross-section of the spray cabin). At the
same time, the air in the cabin should change about 350 times per hour.
Air extraction is best achieved through extraction channels in the floor of the painting cabin.
NOTE: Refer to the manufacturer's specifications for the operating instructions, safety instructions
and notes on the maintenance of a paint cabin.
Smooth walls in the paint cabin should prevent dust deposits. Regular cleaning is necessary however.
Special easily washed adhesive-bonding paint can be applied to the walls to protect the cabin from
paint mist.
2394/2430
Paint - General Information - Refinishing

Materials
Print
The manufacturer's instructions must always be followed when dealing with all materials!
The information given in the following text is data which is independent of the manufacturer, and it
should only be used as an indication.
Stopper materials
1-component nitro-combination stopper

2-component polyester stopper
2-component plastic stopper
Use suitable primer to protect from corrosion areas which have been sanded bare before applying
stopper.
1-component nitro-combination stopper
Nitro-combination stopper has mostly been superseded by 2-component polyester stopper.

Fast drying fine stopper for the smoothing of irregularities.
The working properties of 1-component nitro-combination stopper can be improved by the addition of
nitro thinners.
Drying time increases with thickness of the layer.
Application 1-component nitro-combination stopper

Layer thickness Max. 80 µm
Drying time up to 2 hours at 20°C
Sand P240 - P400
2-component polyester general stopper
NOTICE:
Do not exceed the quantity of hardener specified by the manufacturer, excess peroxide can
cause staining of the paint top coat.
Mix the stopper base and the hardener well to avoid a marble-like effect.
Check that the manufacturer permits use on the substrate to which it will be applied.
2-component polyester stopper is available in coarse and fine grades. The coarse stopper can be used
for very uneven areas and surfaces and fine stopper or spray stopper should be applied afterwards.
Application 2-component polyester coarse stopper

Use Rough equalization of unevenness
Hardener quantity approx. 3 - 5%
Working time approx. 4 - 6 minutes
Drying 20°C approx. 12 minutes
Short wavelength infrared approx. 4 minutes
Medium wavelength infrared approx. 5 - 10 minutes
Sanding tool Eccentric, sanding disk by hand
Grade P80 - P150
Application 2-component polyester fine stopper
Use Equalization of unevenness
Grade P80 - P240
Application 2-component polyester glass fiber stopper
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Refinishing%20Materials-G1538331 1/4
2395/2430
Application 2-component polyester glass fiber stopper

Use Equalization of unevenness; blending in of vehicle
extensions; repair of GRP components
Grade P80 - P150
2-component polyester fine stopper should always be applied after 2-component polyester glass fiber
stopper.
Application 2-component polyester spray stopper

Use Equalization of unevenness
Layer thickness 200 µm or 4 - 8 spray passes
Drying 20°C approx. 3 hours
Grade P80 - P150; fine sand - P280
Application 2-component plastic stopper for flexible thermoplastic
Use Equalization of scratches or unevenness
Drying 20°C approx. 15 - 30 minutes
60°C approx. 15 min
(Short wavelength infrared approx. 8 minutes)*
(Medium wavelength infrared approx. 8-10 minutes)*
Grade P80 - P150; fine sand - P280
*Infrared drying may adversely affect adhesion, therefore check the manufacturer's
instructions.
Plastic stopper has a very great tendency to shrink back, so that the edge of the stopper repair
becomes visible.
Plastic stoppers are flexible and universally applicable on all types of plastic (except for pure PE and
PP, these are plastics which cannot be painted). The manufacturer's instructions must be very exactly
followed in order that no adhesion problems occur. A special plastic etch primer is specified for some
materials.
Primers
Application 1-component primer

Use Isolation of bare sanded areas.
Spray gun HVLP 1.3 mm
Spray pressure 2.0 bar
Coat application Wet on wet, no intermediate sanding
Application 2-component primer
Use Corrosion protection and bonding agent (steel sheet,
zinc coated steel sheet, aluminum)
Spray gun HVLP 1.3 mm
2396/2430
HS primer filler and HS tinted filler
Note:
Primer filler is available as 1-component and 2-component water based and solvent based forms.
1-component products are only suitable for isolation of sanded through bare areas and new
painting.
Water based products are also used for the skinning of thermoplastics and substrates which are
sensitive to solvents.
Tinted fillers can be individually matched to the top coat color and therefore find uses in effect
paints and paints with poor covering power.
Use dry sand or wet sand filler according to application in order to avoid unnecessary sanding work.
On critical substrates the use of epoxy resin base filler is recommended in order to avoid adhesion
problems.
Application HS primer filler and HS tinted filler

Use Equalization of unevenness, edge zones, sanding scores
Spray gun HVLP 1.6 - 1.9 mm
Layer thickness 50 - 70 µm to 150 µm possible
Drying 20°C approx. 2.5 hours
(60°C approx. 25 min)*
(Short wavelength infrared approx. 8 minutes)*
(Medium wavelength infrared approx. 10-15 minutes)*
*In order to avoid boiling out, drying should be performed slowly.
Paint
The base and the clear lacquer must be matched to one another.
Application Water based paint

Use Two layer metallic effect paint and Uni-paint finishes
Spray viscosity At 20°C 18 - 20 s
Layer thickness 15 - 20 µm
Drying 20°C approx. 2.5 hours
Coat application Wet on wet
Ventilation time approx. 5 minutes
The base paint must be dried matt before the clear lacquer is applied.
Application 2-component HS clear lacquer

Use Gloss providing protective coat for base coat substrate
Application 2K HS Uni top coat
Use Color and gloss providing paint layer
Spray pressure 2.0 bar - 3.0 bar
2397/2430
Application 2K HS Uni top coat

Medium wavelength infrared approx. 10 -15 minutes
2398/2430
Paint - General Information - Additional

Materials
Print
The manufacturer's instructions must always be followed when dealing with any materials!
The information given in the following text is data which is independent of the manufacturer, and it
should only used as an indication.
Adhesive sealants
Adhesive sealants are permanently elastic, long-lived, can be painted and accept filler.
Application: Sealing of visible and normal seams.
Can be over-painted with 2-component paint, primer and fillers after having dried throughout.
Contamination can be removed using cleaner and thinner.
1-component PUR adhesive sealant
Note:
Hardens using oxygen from the air. For that reason, it must only be stripped after it has completely
dried through.
2-component MS polymer adhesive sealant
2-component MS polymer adhesive sealant is free of isocyanate, solvent and silicones and can be
spot-welded.
MS polymer adhesive sealant
Can be over painted with water-based paints.

Suitable for spraying and brushing to obtain a composition true to the original.
MS polymer adhesive sealant is free of isocyanate, solvent and silicones and can be spot-welded.
Underbody protection
Underbody protection products are immune to abrasion, permanently elastic, adhere well and are
suitable for a true to original texture.
Underbody protection based on solvent
Application:
Underbody protection for visible areas.
Properties:
Can be over-painted, also with 2-component paint.
Can be colored with a proportion of up to 40% paint.
Note:
Contamination can be removed using cleaner and thinner.
Water based underbody protection
Can be over-painted with water based paint.

Can be colored with water based paint.
Contamination can be removed using water.
Application Water based underbody protection

Use Underbody protection for visible areas
Spray viscosity ready to use
Spray gun Suction beaker HVLP gun 3 - 4 mm
Spray pressure 4 - 6 bar
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Additional%20Materials-G1538332 1/4
2399/2430

Drying approx. 6 hours at 20°C
approx. 45 - 60 minutes at 60°C
Use Isolation primer for peroxide marks, bloomed old
paintwork and thermoplastics.
Spray viscosity Thin as necessary with distilled water
Spray gun HVLP gun 1.9 mm
Spray pressure 2.0 - 3.0 bar
approx. 30 minutes at 60°C
Paint additives
Application Sanding test color

Use To test sanding results
Layer thickness Spray drifted
Application Fixer additive
Use Converts solid top coat into two layer solid; multicolor
painting
Spray viscosity 18 - 20 secs at 20°C
Layer thickness max. 30 µm
Coat application Wet on wet
Ventilation time approx. 15 - 30 minutes
Maintain maximum layer thickness without fail.
Must always next be overpainted with clear lacquer.
Application Drying accelerator

Use Accelerates drying with only minimal reduction in
working life
Working life approx. 5 hours at 20°C
Cannot be used in all paints, read the manufacturer's instructions.
Particularly suitable for partial painting.
Application Elastifier additive in primer material

Use Elastifies the complete paint structure on plastics.
Addition Up to 25%
Layer thickness 50 µm
2400/2430
Application Elastifier additive in primer material

Application Elastifier additive in top coat
Addition Up to 25%
Application Matting additive in solid paint
Semi-gloss addition Up to 25% in the paint without hardener and thinner
Silk gloss addition Up to 35% in the paint without hardener and thinner
Silk matt addition Up to 45% in the paint without hardener and thinner
NOTICE: Do not dry using infrared.

Application Matting additive in clear lacquer
Semi-gloss addition Up to 25% in the paint without hardener and thinner
Silk gloss addition Up to 35% in the paint without hardener and thinner
Silk matt addition Up to 45% in the paint without hardener and thinner
Note:
When mixing, first put in the matting additive, then the hardener and thinners.
Stir immediately after adding the matting additive.
Do not store after addition of the matting additive, storage will change the degree of gloss.
Also suitable for use on plastics without addition of elastifier additive.
Application Matting paste

Use Matts, elasticizes and gives structure to solid paint and
clear lacquer during painting of bumpers or hard plastic.
Addition 1:1 or 2:1 depending on manufacturer in solid paint
without hardener or thinners.
Drying approx. 6 - 10 hours at 20°C
Note:
The paint must not be filtered.
2401/2430
Application Anti-silicone additive

Use Prevents silicone craters
Addition 2% to maximum 5%
Note:
Only add away from the paint cabin and immediately remove contaminated cloths.
If anti-silicone additive is used in the first coat, then it must be used in the following coats, and in
at least the same proportions.
Additive materials
Variety of adhesive tapes
For profile, fine and large area masking work.
Properties:
Withstands heat.
Withstands water-based paint.
Accepts paint.
Easily removed without leaving adhesive residues.
Masking film.
For masking of large areas on vehicles.
Properties:
Accepts 2-component and water-based paints.
Withstands heat.
Withstands water spray and condensation.
Withstands solvent.
Easily cut.
Environmentally friendly and can be recycled.
Polishing materials.
Polishing means microfine sanding. For this reason, polishes must only contain abrasives, and no
silicones.
During polishing repair, a good shine is achieved through the step-by-step use of polishes, starting
with a highly abrasive polish and ending with a polish having very slight abrasive action.
Polishes are available in graduations from coarse to fine.
Abrasives
Please refer to the "Tools" chapter for information on abrasives.
2402/2430
Paint - General Information - Paint Repairs

Print
General information
There is a great difference between painting in production and repair painting.
In production, only the bodyshell is painted, it has no trim, upholstery or assemblies. Because of this,
other paints, tools and processing techniques can be used.
In contrast to that used in production, paint used in the workshop must dry at low temperatures.
Plastics and the vehicle electronics must not be subjected to temperatures greater than 70°C.
The painting process in the case of repair work consists of two phases:
Pre-treatment of the surface for corrosion protection and the smoothing of irregularities.
Top coat application.
The precondition for a professional paint finish on a vehicle is the permanently maintained cleanliness
of work spaces, tools and equipment,
Original materials must be worked according to the manufacturer's instructions, so that no problems
arise in the processing nor during drying.
The room temperature must be 20 - 25°C and the humidity must be low. Temperatures which are too
low or too high can lead to porosity, poor flow and boiling. High humidity leads to paint damage such
as tarnishing of the paint film (matt film), adhesion problems and craters.
Pre-treatment of the surface
Perfect preparation of the subsurface is the precondition for a brilliant paintwork result. Faults in the
preliminary stages delay completion and cause unnecessary extra work. The working steps described
here demonstrate how important it is to follow these instructions step by step.
NOTE: Thorough cleaning of the vehicle and especially of the area being repaired is particularly
important because of the danger of contamination of the paint.
Clean the area of the damage
Clean the damaged surface thoroughly, to allow the extent of the damage to be seen. Use silicone
remover to produce a grease-free surface.
NOTE: The treated surface must be rubbed with a clean dry cloth before the solvent evaporates,
otherwise there will be no cleaning effect.
Effective de-greasing is important not only before the application of paint, but also before all sanding
stages, for two reasons:
During sanding of grease contaminated surfaces, globules may form with the sanding dust. Sanding
marks will occur and the sanding medium quickly becomes unuseable.
Oil and grease are embedded by the action of the abrasive particles, and are then very difficult to
remove.
Establish the area of damage and the repair stages. In doing so, establish how much disassembly
work must be undertaken. Perform a color test at this stage.
Mask off the area of the repair ready for preparatory work.
Sand out the damage location
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Paint%20Repairs-G1538333 1/7
2403/2430
When sanding, produce smooth transitions from the painted area to the bare metal.
Use an eccentric sander and P80 or P120 abrasive sheets. Finish off sanding with P150 or P180. The
remaining adhering sanding dust must be completely removed.
Cleaning, de-greasing
Use silicone remover to thoroughly clean the surface in order to remove grease residues, sweat from
the hands and other contamination.
NOTE: Use a solvent test to establish whether the old paint can be etched. Apply 2-component
thinners to the damaged area using a clean cloth and rub lightly for about 1 minute. If the
subsurfaces can be etched away, special pre-treatment is necessary. See "Tips and Tricks"
Apply primer filler
Before applying stopper, apply primer to the sanded and bare surface.
Allow the primer to dry and then lightly sand by hand using P220 - P400 dry.
NOTE: Most stopper can be applied directly to bare metal. But application of a primer filler provides
better corrosion protection.
NOTE: Avoid sanding through to the bare metal. Points which are sanded through must be retreated
with primer filler.
Stopper application
2404/2430
Pre-sand the hardened stopper using an eccentric sander and P80 dry, then final-sand using P120 -
P140 dry. Clean the sanded surface using silicone remover.
Apply 2-component stopper to the filled surface. The stopper compound must only be applied thinly.
NOTE: Use of a testing powder is recommended so that the sanding process can be more easily
checked.
Apply filler
Filler can now be applied to the dried repair area. Choose the correctly toned filler according to the
manufacturer's instructions.
NOTE: Alternatively, filler with the correct tone can be mixed with the aid of colour matching cards.
Sand the filler.
The working area is expanded by applying new masking. This makes it possible to even out the
transition from the damage area to the vehicle paintwork.
NOTE: The primer filler must be carefully sanded. Faults in the primer filler layer will be visible in
the top coat.
The sanding process consists of two stages. Coarse sanding levels out the surface of the filler primer.
Fine sanding ensures the necessary surface structure which allows the top coat to adhere well and
cover sanding marks.
Sand the filler using the eccentric sander and P400 - P500 used dry. Clean the sanded filler finished
surface using silicone remover.
The painted area is matted using a fine matting sponge, and then thoroughly cleaned.
Surface ready for paint
The surface which has been repaired and then prepared according to the manufacturer's instructions
is now ready for basic paint application.
Top coat application
2405/2430
It is important for a good paint result that the recommended process data is adhered to, i.e. mixture
proportions, layer thickness, viscosity, drying time etc.
First of all the work area is carefully masked ready for paint application. The correct adhesive
materials and techniques must be used so that no hard transitions and edges are created during
painting.
NOTE: The chapter "Tips and Tricks" gives in-depth information on masking work.
Thoroughly check the surface once more and rub-off with a dust-bonding cloth.
NOTE: Once more check the paint material and that the spray gun is correctly adjusted before
applying the paint.
Paint application
The base paint is applied in two or three steps. First of all only the repair area is painted with the first
paint application.
Flash off
Allow the paint application to flash off until the surface has a matt appearance. So that the transition
to the original paint is optimally created, the next paint application is applied to a wider area.
After the base paint has dried for the specified time, the clear lacquer is applied. Next the transitions
to the original paintwork are treated with fade-out remover. This removes the spray mist and forms
an ideal paint surface.
Repair stages for repair painting
The required time and material data is divided into four painting levels for calculations concerning
repair painting. Proceed according to these divisions for every calculation.
Level 1 - Painting of new components
On new components, all inner surfaces, seams and edges which will no longer be seen after assembly
must be primed and pre-painted.
NOTE: The cathodic dip primer must not be sanded away. Cleaning with silicone remover or light
sanding of the primer is all that is required.
Job steps:
Wash off, prime and pre-paint inner surfaces, seams and edges which cannot be reached at all or
only partly after the component is installed.
Sand new component with P280 - P320 or a fine sanding pad.
Clean subsurface with silicone remover.
Carry out masking work (when painting an installed component).
Apply one spray run of filler, dry.
Sand the filler. P1200 wet or P500 dry.
2406/2430
Clean filler application with silicone remover.
Then the prepared surface can be painted with solid or 2-component paint.
If the new part has mild transport damage, this must be rectified beforehand.
To do so, add the following steps:

Grind out the scratch.
Finely sand the surrounding surfaces.
Use a steel cleaning agent to thoroughly clean and then rub dry.
Apply corrosion protection primer to the bare areas.
Level II - Top surface painting (color tone matching)

Complete bodywork surfaces which are to be painted without the need to apply stopper belong to this
group. In addition, surfaces with faults in the top coat surface which cannot be removed by polishing.
The following faults are included:

Loss of gloss.
Sanding scores.
Heavy paint runs.
Large dust and dirt inclusions.
The scope of the work is as follows:

Sand the surface.
Sand out paint damage and faults.
Treatment of small areas which have been sanded through.
Masking work (when painting an installed component).
Apply top coat according to the painting process (one or several coat process).
Dry the top coat and perform finishing work.
Level III - Repair painting with stopper applied to up to 50% of the surface.
If in addition to painting, work with stopper application must be performed, then the repair levels III
or IV must be used.
In repair level III, apart from painting the complete bodywork surface, partial stopper work is carried
out on up to 50% of the surface to be painted. The necessary primer and filler work are also included.
The following damage must be rectified in this level:

Slight panel unevenness.
Damage due to corrosion.
Dented body surfaces.
Weld locations.
Deep scores or scratches.
The scope of the work is as follows:

Fine sand pre-treated bodywork surfaces (e.g. lead-loaded areas).
Sand out existing damage.
Perform all necessary masking operations on the vehicle.
Apply primer.
Partial stopper application on up to 50% of the surface to be painted (two to a maximum of three
stopper applications).
Fill the repair area.
Apply stone chip protection (when present in production).
Apply top coat according to the painting process (one or several coat process).
Dry the top coat and perform finishing work.
Level IV - Repair painting with stopper applied to more than 50% of the surface.
In repair level IV, apart from painting the complete bodywork surface, partial stopper work is carried
out on more than 50% of the surface to be painted. The necessary primer and filler work are also
included.
The following damage must be rectified in this level:
2407/2430
Damage due to hail.

More extensive stone chip damage.
Extensively dented body panels.
Sectional repairs with large weld seams.
Surfaces with severe corrosion damage.
The scope of the work is different to level III because of the partial application of stopper to more
than 50% of the area to be painted. In addition, more extensive sanding work is usually required.
Polish
In order to achieve faultless quality, it is sometimes necessary afterwards to polish a newly painted
surface.
Even after the most careful painting, it sometimes happens that dirt inclusions and paint runs occur in
work with top coat or clear lacquer. Before polishing, such paint faults must be removed with the
sanding cylinder ("Finiball") and hand sanding or eccentric sander in a wet sanding process.
Sanding cylinder
The special sanding compound -1- (sanding bloom) for the sanding cylinder is self-adhering and
available in grades from P1000 to P2500.
P1000 - P1500 for pre-sanding of runs and large imperfections in the paint.
P1500 - P3000 for subsequent sanding of runs and sanding out of dust inclusions.
A small eccentric sander can be used for more extensive working areas. When doing so, first of all put
the eccentric sander in place and then switch it on, so that the danger of sanding through on edge is
reduced.
Finally polish the sanded area to a high gloss with suitable polish. To this end the various
manufacturers recommend materials and process techniques which are specially suited to their
products.
NOTE: The polishing is to be done in the same way as that used to remove swirl marks.
Polish
NOTE: Before using the nap sponge for the first time and after any long pauses in working, dampen
the nap sponge with polish.
Job steps:
Clean and degrease the area to be polished using silicone remover.
Apply the polish to the polishing disc and spread it.
Place the polishing machine down flat on the area to be polished and before switching it on, gently
distribute the polish over the underlying surface.
Polish out the location for 10 - 15 seconds with the edge, working with a criss-cross motion.
2408/2430
Subsequently polish the location for about 10 seconds with the machine laid down flat.
Wash off and clean the polished location using the professional polishing cloth and then clean the
polished surface.
It is absolutely vital to carry out a visual check after finishing the polishing procedure. If any swirl
marks are not completely removed by the first polishing procedure, then process must be repeated.
Aids
Cleaning putty
Cleaning putty allows deposits on the paint surface to be removed easily and gently. The following
paint faults can be removed using cleaning putty:
Metal deposits and iron dust.
Paint or color mist.

Tree resin and tar.
Insect residues.
The surface to be worked must be thoroughly cleaned before the cleaning putty can be applied. Then
the surface is sprayed with soapy water. Now the cleaning putty can be slid over the surface until all
unevenness is removed.
2409/2430
Paint - General Information - Painting Plastic

Parts
Print
General
Although these days plastics can be produced in all colors and with a matt or gloss surface, painting is
often necessary.
NOTE: Manufacturer's limitations concerning the feasibility of painting certain components must
always be observed.
Reasons in favor of applying paint to plastic are:
Individual coloring, matching the body paint.

More gloss and color brilliance through painting.
Removal of production imperfections.
Protection from atmospheric exposure.
Nowadays painting plastic presents no problems because the materials are known and matched to the
paint. In order that the painter can use the correct painting materials, the type of plastic must first be
correctly determined.
To allow this, plastics are marked on the rear in accordance with the recommendations of the
Association of Vehicle Manufacturers.
Once the type of plastic is determined it is an easy matter to assign special paint recommendations,
matched to that particular plastic. Unmarked plastics require knowledge of materials so that a correct
choice of paint materials can be made and the component can be reliably painted.
Plastic groups
Thermoplastics
When warmed these undergo a reversible transformation into a plastic deformable state and once
cooled they maintain their shape. They consist of string-like (linear) or only slightly branched
molecular chains.
Thermosets
Thermosets are hard and have the form of a close-meshed network in all directions. They do not
undergo plastic deformation, are especially resistant to chemicals, are difficult to swell and are
insoluble. At normal temperatures they are hard to brittle. At first the material does not undergo any
change when heated, but when it reaches a critical point, the thermoset is totally destroyed.
Elastomers
Elastomers are characterized by high elasticity over a wide temperature range. They have properties
like rubber or a sponge and after compression or distension they return to their original state.
Types of plastic
The plastics used in the automotive area:
ABS - Acrylonitrile butadiene styrene (polymer)

PA - Polyamide
PC - Polycarbonate
PE - Polyethylene
PP - Polypropylene
PP/EPDM - Polypropylene/ethylene propylene diene copolymer
PC/PBT - Polycarbonate/Polybutylene terephthalate
PBT/PC - Polybutylene terephthalate/Polycarbonate
PUR - Polyurethane
GRP - Glass reinforced plastic
NOTE: PE and PP are plastics which cannot be painted, or can only be painted using special
techniques.
As well as the pure plastics, so-called 'blends' are also used. This means combinations of different
plastics. If we were dealing with metals they would be called alloys.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Painting%20Plastic%20Parts-G1538334 1/4
2410/2430
Plastic identification
Normally the identifier is marked on the plastic components used in vehicle construction.
One method to determine the plastic group is the sanding test. In this a place is chosen which will not
be visible later, and the finger belt sander is used to sand the plastic.
The plastic group can be determined using the pattern left by the sanding and the dust:
Thermosets produce a white dust.

Thermoplastics smear and do not produce dust.
The plastic group can be determined by a sound test:
Degree of hardness - the higher-pitched the sound, the harder the plastic.
Elasticity - the more muffled the sound, the higher the elasticity of the plastic.
Cleaning plastic
Plastic components are manufactured using complicated moulds and presses or other highly
engineered tools, mostly using an injection moulding process or reactive injection moulding process.
In order to be able to remove the component from a particular tool, a separating agent is used, which
in some cases adheres very strongly to the plastic.
This separating agent on the plastic components must be completely removed before any surface
coating is applied.
Warm storage (tempering) before actual cleaning brings the following advantages:
The separating agent sweats out of the plastic.

Tensions in the plastic are released.
Air inclusions can be recognized and removed.
Intensively clean the item several times using a pad and fresh cleaning agent.
NOTE: A single wipe, even with cleaning agent, is not usually sufficient in most cases. Clean
textured components with the aid of a soft brush.
After cleaning, it is absolutely vital that cleaning agent absorbed by the plastic should be expelled by
tempering again. If the ventilation is good and the room temperature is about 20°C the solvent can
be evaporated away by overnight storage.
Painting new components
It is absolutely vital that the substrate of an unpainted new component is free of separating agent.
Paint can only be applied directly to very few plastics. The plastic must first be identified exactly and
then worked with a repair system which is matched to the type of plastic. In most cases a plastic etch
primer must be applied as adhesion base to all plastics which can be painted.
NOTE: Plastics have a tendency to become electrostatically charged. This can easily cause
contamination during painting. Special antistatic cleaning cloths prevent electrostatic charging.
Work process for thermoplastics:

Thoroughly clean the surface.
Temper the plastic.
Afterwards clean with antistatic cleaner or antistatic cloths.
Apply the bonding agent.
Apply elastic filler. After it has dried, sand and clean.
Apply one coat Uni-paint with elasticizer additive. For two layer painting the elasticizer additive is in
the clear lacquer.
NOTE: Follow the paint manufacturer's guidelines during all work.
Work process for thermosets:

As a rule, thermosets can be handled in the same way as normal body components.
Work process for PUR soft foam:

The work process is the same as for thermoplastic.
Instead of using bonding agent, a filler wash is applied to close the pores of the PUR soft foam.
2411/2430
The primer which has been applied to a primed new component can vary greatly. If no manufacturer's
data is available, the composition and suitability for further working must be tested.
Painted components with an already ascertained and intact paint coat present no problems for
possible repainting. After sanding and careful cleaning with plastic cleaner or thinners, painting can be
done directly.
Unknown primer
When dealing with unknown substrates it is important to carry out an adhesion test on the existing
paint before any repainting is attempted. First of all a mechanical test must be carried out, for
instance using a lattice cut and tear-off band. If the adhesion of the old paint is not acceptable, it
must be mechanically removed and new paint finish applied.
If the adhesion is acceptable, then an etch test is performed using 2-component thinners. If no
etching can be detected in this test, application of the the paint finish can be started directly.
Otherwise the old paint must be removed and a new paint finish created.
With the help of universal or special plastic primers and with only a few materials complementary to
those previously present anyway, the painter can now apply a long-lasting paint finish to all popular
vehicle attachments made of plastic.
Paint faults on plastic substrates
NOTE: Paint faults are fully described in the chapter Paint Defects and Damage.
The most common paint faults which can occur when painting plastic components and the methods of
repair are briefly described.
Discoloration
Plastic material is not suitable for painting.
Incorrect bonding agent.
Paint used not solvent resistant.
Repair of damage:
Repaint using suitable materials.
Install a new unpainted component.
Softening
Substrate not carefully cleaned.
Air humidity too high or working temperature too low.
Drying time incorrect (too short).
Materials for substrate not correctly matched to each other or not mixed correctly.
Repair of damage:
Dry out, sand, re-isolate and paint.
Paint damage caused by detachment, poor adhesion
Insufficient paint adhesion between top coat and filler. The whole of the paint finish detaches from
the plastic.
Plastic not cleaned sufficiently, not or inadequately tempered.
Unsuitable cleaning agent or materials used.
Poor or lack of intermediate sanding.
Paint finish underbaked or overbaked.
Repair of damage:
Paint damage caused by blisters, craters, sink holes
2412/2430
Painting on PUR plastic which was not painted in production.
Surface of the plastic material too porous.
Flash-off time not adhered to.
Drying temperature too high.
Moisture in plastic material.
Layers too thick.
Repair of damage:
Clean the damaged area, sand, re-isolate and paint.
Remove the paint layers and re-paint.
Crack formation
Overexpansion of painted PUR plastic components.
Use of unsuitable paint materials.
Paint materials not suited to each other or incorrect mixture ratio.
Repair of damage:
It is not possible to repair overexpanded PUR plastic components.
On other plastics, sand away damaged layers, isolate and repaint.
2413/2430
Paint - General Information - Spot Repairs

Print
General
In general, partial surface painting at a point is called a spot repair. Using this technique, minor paint
damage can be resolved economically and to time.
Advantage of this method
Because this application remains confined to the area of the damage, it is often unnecessary to
remove components or color match against neighboring components. The material used is very much
reduced because only a part of the repair area is coated.
Practical application areas
Only occasionally can satisfactory results be achieved in the centre of larger surfaces and/or on
difficult colors. In addition, unprofessional application may cause tear-off edges to appear in clear
lacquer. Only certain application areas are recommended.
NOTE: The final decision on whether to spot repair or paint the component must be made by an
expert.
Application areas:
2-layer paint.
Depending on the damage zone, paint damage up to a diameter of 3.5 cm or a length of 10 cm.
Scratches.
Clear lacquer application up to an area of DIN A4 max.
Smaller areas which are optically broken up by other components such as trim strip, tail lights,
swage lines and edges.
Boundary zones and edge areas of larger components.
The best application areas have proven to be optical break lines such as corners, narrow surfaces,
fenders and wheel arches.
Because of their locations, the violet colored areas are the most suitable for spot repair painting. The
turquoise areas are only marginally suitable and the rest of the areas are not suitable for spot repairs.
Repair process
Perfect preparation of the subsurface is the precondition for a brilliant paintwork result. Faults in the
preliminary stages delay completion and cause unnecessary extra work. The working steps described
here demonstrate how important it is to follow these instructions step by step.
Illustration of damage
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Spot%20Repairs-G1538335 1/4
2414/2430
A typical case for spot repair is a small stone chip on the fender.
Cleaning
First of all the component is thoroughly cleaned using silicone remover and refurbished using
abrading and polishing paste. This re-creates the original degree of shine and ensures exact color
matching on the touch-up surface.
Sand out
Sand out the damaged location using P180 - P320. Only small sanding blocks and small sanding
machines must be used, so that the area of the repair remains as small as possible.
Sanding is completed by rubbing down the surrounding surface with a fine sanding pad or P1000
paper. Remove sanding residues and clean the repair area with silicone remover. The peripheral zone
must then be masked for application of the filler.
NOTE: The size of the repair area must be kept as small as possible (maximum size DIN A4).
Filling
The filler layer is applied in stages. First of all, filler is only applied to the location which has been
sanded away. After a wait time for flashing off, the second coat is applied so that it spreads over onto
the existing paintwork.
2415/2430
The filler must be dried according to the instructions of the material supplier.
Rubbing down
The repair location is now rubbed down with P400 - P500 and the bordering surface with P2000 -
P4000. Remove sanding residues and clean the repair area with silicone remover.
Paint
Before painting, clean the area for the final time using a dust-bonding cloth. Then apply the basic
paint in thin layers using a spray gun until enough coverage is achieved.
After drying, apply clear lacquer in 1 or 2 coats (depending on product). In doing so, spray so that
only the newly applied basic paint is completely covered. Finally a touch-up thinners is sprayed over
the edge of the clear lacquer to dissolve the clear lacquer spray mist.
Dry
Now dry the clear lacquer according to the manufacturer's instructions using an infrared gun.
Polish
Polish the component using a polisher and polish and check the polished area for any swirl marks
which may be present. Polish away any swirl marks which are present.
2416/2430
Dirt inclusions
Sand out
Minor damage can be removed with a small sanding machine or preferably with an eccentric sander
with P1500 - P2000. Very fine spray mist can be removed using P2000 - P4000 paper and a larger
eccentric sander.
2417/2430
Paint - General Information - Corrosion

Prevention
Print
General
Although corrosion protection measures and painting processes in production have reached a very
high technical standard and will be continuously developed further, in the long term corrosion on a
vehicle cannot be totally avoided. Further demands are therefore made of the paint specialist besides
his knowledge of normal repainting of vehicles which have been repaired after an accident, in addition
specialist knowledge is required for assessing and rectifying damage due to corrosion.
During repair painting, take care over the maintenance and re-creation of the corrosion protection
applied in production, in view of the long-term warranty on Ford vehicles. Only those repair materials
which are approved by Ford may be used for body repair work and repair painting.
For detailed information on corrosion protection measures during body repairs, please refer to chapter
501-25.
Furthermore, information on corrosion protection measures is repeated in individual chapters of the
paint manual.
In particular, pay attention that the layer thicknesses specified in production are maintained. The
complete system of solid one-layer on galvanized steel panels must equal at least 90 µm and the total
system of two-layer on galvanized steel panels must equal at least 105 µm.
It is important that sealing operations, as far as they are necessary, should be undertaken after the
application of the paint to specification, in order to ensure the best corrosion protection. All
components which form hollow cavities such as pillars, rails, side components etc. must be provided
with a coating of cavity protection wax.
Causes of corrosion
Corrosion of steel is an electrochemical process during which the steel combines with oxygen. The
following factors lead to corrosion:
Acidic compounds contained in the air, such as carbonic acid and sulphur dioxide, combined with
oxygen from the air and/or water. Salts such as sodium chloride used as road salt accelerate the
corrosion process.
Mechanical damage such as stone chips and scratches which penetrate through to the steel panel.
Lack of care by the vehicle owner of the painted and corrosion proofed surfaces or areas on the
vehicle.
Unfavorable weather or environmental conditions, as may occur in areas with high humidity, high
salt content in the air or serious air pollution due to aggressive gases and dusts.
In the case of mechanical damage, formation of rust can often be seen, beginning to spread into the
painted surface from a point (stone chip) or from a line (scratch). If these faults are not professionally
rectified in good time, the result is rusting through from the outside to the inside. Rusting penetration
from the inside to the outside occurs when for instance the cavity protection was inadequate.
Operations after painting
NOTE: The manufacturer's instructions must be followed when working with the various corrosion
protection materials.
After painting, treat all cavities in the repair area with cavity protection wax. In doing so, pay
particular attention to the weld seams. In dead-end applications with a panel insert, the cavity
protection wax must be applied so that it also reaches the area of the panel insert.
Seals which were applied in production and not over painted must be reapplied. Seals protect
vulnerable parts of the bodywork, keep moisture away, reduce wind and road noise and dampen
vibrations.
Apply transparent wax.
Definition of the degree of rust

In workshop practice, in order to be able to carry out a consistent and objective evaluation of the
scope of the damage, a degree of rust on the scale of 1 to 5 is determined by the DIN 53 210
2418/2430
standard. The main criterion here is the extent to which rust exists under the paint structure. It is
determined in millimeters (mm).
Underlying rust grade: R1 < 1 mm
Corrosion starting with up to 1 mm of rust underlying (in the form of a spot or a line).
The damage can be rectified by cleaning the defective location and mechanically removing the
underlying rust. For a small extent, apply a primer using a brush and allow it to dry. Touch-up the
location with a paint pen or provide a new paint coating.
Underlying rust grade R2 < 1 - 2 mm
Advanced corrosion with up to 2 mm underlying rust.
Rectifying the damage:

Clean the defective location.
Remove the underlying rust mechanically down to the paintwork carrier.
Apply 1-component filler and then 2-component "Vario" filler.
Provide the damage location with new paint coat on visible outer surfaces. Only locally touch-up
areas which are not optically conspicuous.

More advanced corrosion with up to 4 mm underlying rust. The damage must be rectified in the same
way as for R2. A permanent cure of this type of damage pattern is still just possible
Notably advanced corrosion with up to 5 mm underlying rust. The damage must be rectified in the
same way as for R2. If it is found that for whole areas this is only possible with a great deal of work,
or is not possible at all, then a new component must be used.
Underlying rust grade R5 > 5 mm
Extreme corrosion, with more than 5mm underlying rust (panels, flanges or load-bearing components
partially rusted or rusted through).
Such damage can no longer be repaired because in many cases the constructional strength of the
component can no longer be produced. The risk in making a repair is too great. Install a new
component and paint it.
2419/2430
Paint - General Information - Color

Identification and Chromatics
Print
Basic color theory

In order to achieve optically perfect painting results it is vital to understand the physical principles of
the origin of color impression.
Color
Color itself is a sensory perception.
This perception arises through the combined effect of the following components:
Light (sunlight or artificial light irradiates the object).
Surface of the object (reflection from the object of certain constituent parts of the light).
Eye (perception of the reflections from the object).
Because the sensory impression of color is produced by all three of these components, it is
dependent on the type, quality and function of the individual components. Practical examples
make this clear:
If a particular article is subjected to artificial light, then it gives a different impression of color to
that which it gives in sunlight.
An object with uniform color but different surface textures appears to have different colors (grained
or ungrained dashboard).
A person with perception disorder (colorblindness) cannot recognize certain colors or distinguish
between them e.g. red-green weakness).
In turn the type of color is determined by the light absorption ability of an object. Light shines with all
color components (spectral colors) onto an object, certain components of the light are absorbed
(taken in) and other components are reflected (sent on). The components which are reflected produce
the specific color impression.
The colors as we see them are the result of a combination of reflected colors from the spectrum.
Physically speaking, these are electromagnetic waves with different wavelengths (and frequencies).
The healthy human eye can recognize wavelengths between 0.36 µm (violet) and 0.78 µm (red).
If all the perceptible wavelengths of the spectrum impinge on the human eye at the same time, the
impression of white light is produced.
Additive and subtractive color mixing
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Color%20Identification%20and%20Chromatics-… 1/7
2420/2430
Additive color mixing is the combination of light from different sources to give white. Different
intensities of the additive primary colors red, green and blue allow millions of different colors to be
represented (RGB colors).
Additive color mixing is always therefore used when light should enter the eye directly (without
reflection off an object). Such as in the case of computer monitors or overhead beamers.
Subtractive color mixing means mixing the primary colors cyan, magenta and yellow to form a
desired color (CMY colors).
Subtractive color mixing is used when light should enter the eye of an observer after reflection from
an object. Such as happens with painting or in printing.
Oswald color circle
The Oswald color circle is based on subtractive color mixing, and enables the behavior of paints when
they are mixed together to be represented.
Colors lying opposite each other are complementary colors and should not be mixed together as this
will produce a dull (i.e. grey) shade. If green is added to red, the red becomes greyer, not greener.
Color shades which are side by side are partner colors and produce a mixed color shade. For instance,
mixing red and blue produces a pure violet.
In addition, black and/or white may be necessary to produce a particular color shade.
White makes the color shade lighter.
Black makes the color shade darker.
With black and white the color shade becomes more dreary or greyer.
Metamerism
Metamerism is the name of the effect which occurs when two colors appear identical in a particular
light (e.g. artificial light), but the colors appear different under another light source (e.g. daylight).
2421/2430
The cause is the fact that the human brain, aided by the eyes, does not evaluate the wavelength,
instead it evaluates the spectral intensity of the reflected light.
It is for this reason that color matching in practice must only ever be performed in daylight, or under
special artificial light which is based on daylight.
Metallic and pearl pigments
Colored paints achieve their color effect by the addition of pigments. Pigments are colored, solid, very
fine organic and inorganic particles which are insoluble in the binding material.
Metallic pigments
Aluminum platelets are added as pigment to form metallic paint.
Depending on the size and shape of the aluminum platelets, different metallic effects can be
achieved:
Cornflake aluminum (1) causes very strong dispersion because of rough edges, low brilliance, very
low flop and produces grey-silver shades.
Dollar aluminum (2) causes hardly any dispersion because of the smooth surface, high brilliance,
produces very light, almost white silver shades.
With metallic paints however, only a light-dark light reflection effect occurs.
Colored metallic paints are produced by the extra addition of color pigments to the metallic paint.
Pearl pigments
The basis of pearl pigments is formed by mica, which is metallized with a silver or gold layer.
Depending on the angles of light and observation, the mica platelets reflect different proportions of
light. Because of this, the color of the paint appears to the observer to change.
Pearl pigments produce a colored and light-dark reflected light effect.
2422/2430
Color codes and their determination on Ford vehicles

It is necessary to determine the correct color shade of the original paintwork in order to perform a
professional and perfect paint repair.
The original paint color shade can be found by:

Inspection of the vehicle type plate with the color code stamped on it.
- Later design
- Earlier design
Color shade catalog or color shade system of the manufacturer.
The bare bodyshell plate with color designation.
Type plate
Type plate - location on Ford vehicles:
Right-hand B-pillar - door rebate

Left-hand B-pillar - door rebate
Hood lock panel
Left-hand vertical edge of inner front wing
Right-hand vertical edge of inner front wing
Right-hand engine compartment side member
Left-hand bulkhead
Right-hand bulkhead
Luggage compartment interior
Inner rear panel - luggage compartment
The type plate gives the color code in the last row.
2423/2430
On the newer type plates, the color code is given in the left-hand column, at the penultimate position.
Color shade catalog or color shade system of the repair paint manufacturer.
The repair paint manufacturers offer a variety of possible systems for the determining the production
color shade of motor vehicles. There are electronic systems, color card systems and manuals for the
determination of color shades.
Most repair paint manufacturers use the following systems:

A tabular system based on the following parameters:
- Color code
- Make
- Model
- Build year
- Color or color name
- Ancillary codes
A system with color cards based on the following parameters:
- Make
- Color shade
- Build year
2424/2430
Because of the many parameters used, in a tabular system the color shade can also be determined by
the lack of a parameter.
When using the color cards, emphasis is placed on matching of the original color shade with the color
shade samples. For this reason this method is very helpful when the other parameters are not
available.
Comparison of the results of both methods increases the certainty of using the correct original color
shade and its formulation.
Additional certainty can be achieved during color shade determination by making a color sample
plate. Here it is however important to apply the complete paint structure with base paint and clear
lacquer onto a sample plate (1) in order to carry out a color shade and color coverage test.
The color shade comparison is done by comparing the vehicle paintwork with the sample plate (1).
The color coverage test is possible by using the black test stripe (2): If the test stripe (2) is still
visible after test painting of the sample plate (1), the coverage is not good enough.
By using this determination of the original color shade, the formulation and information on any very
slight fine adjustments which may be necessary can be established.
Bare bodyshell plate
The bare bodyshell plate is located:

On the hood lock panel.
Near the type plate.
The color name is stamped on in the last row.
2425/2430
Matching tinted filler to the color code

NOTE: Color samples must always be made from the same materials as the subsequent repair
painting. Perform color shade matching in the fully hardened state, in natural light or under suitable
artificial light.
Various tinted fillers are used during factory painting. In order to achieve the exact color shade of the
factory applied paint, attention should be paid that the correctly matched fillers are used.
The repair paint manufacturers offer suitable precolored primers. The use of filler color cards allows
the matching color shade to be determined.
2426/2430
Paint - General Information - Tips and Tricks

Print
Comparing paint structures

It may happen that an area remains visible, especially when the area of the repair is small. The
reason for this is the structural variation in the paint surface at the repair location compared with the
original paint finish. The original paint finish has a slight orange peel effect while the repair areas is
extremely smooth.
This effect can be reduced by fine sanding using P3000 of the area around the repair location and
then polishing.
Etching substrate
If the substrate can be etched during the solvent test, suitable preparation must be done.
Job steps:
NOTE: Follow the manufacturer specific instructions.
Sand the damaged area extensively using an eccentric sander and P80 or P120 abrasive sheets.
Finish off sanding with P150 or P180.
Remove the sanding dust and clean the area of the damage using silicone remover.
Apply polyester stopper to the bare panel and to the damaged area.
Sand the dried polyester stopper to an even surface using P80 - P150. Finish sanding using P180 -
P240. If required apply more stopper, again only on the bare panel.
Wet sand the residual old paint finish using P600 - P800. Transitions with P400 - P600. Clean with
silicone remover.
Prime bare metal areas with acid primer.
After the acid primer has been left exposed to the air for the correct evaporation time, apply 2-
component primer filler in thin layers over the complete repair area, leaving enough air exposure
time in between coats.
After the filler has dried, sand wet with P800 or sand dry with P400. Sanded through areas must be
covered again with 2-component Nonstop filler primer.
Another possible method of preventing etching of the substrate is to use waterbased primer and filler
materials.
Masking the vehicle
Masking and covering work are among the most important preparations required to achieve a high
quality paint finish. Paint application onto neighboring components, paint mist and sharp paint
transitions are quality faults. For this reason it is extremely important to take special care and to use
suitable masking materials.
NOTE: When water based paints are used, all materials must be stable towards water.
Plan the masking work:
Determine the sequence of masking work. Sometimes after masking film has been applied, it is
difficult or impossible to reach certain areas.
Prepare the masking material.
Start with small difficult areas.
Pay special attention to the areas of profiled seals, edges, openings and paint transitions.
Masking tape
Masking tape is available in various widths for special application areas. In practice however, a wide
tape has proved best for almost all areas, also taking into account the time required for masking
work.
NOTE: Use of differing masking materials is often much more time-consuming.
Advantages
Good coverage. Narrower tapes must often be applied in several layers.
More resistant to tearing.
Wide tapes can be applied deep into joints and therefore protect from paint mist and contamination.
https://www.etis.ford.com/bodyRepairs.do?variantId=2677&language=en&country=USA&type=1#Tips%20and%20Tricks-G1538338 1/5
2427/2430
Removal is often easier.
Masking film
Transparent plastic film has become accepted as a practical method to mask large areas of a whole
vehicle. It can quickly and easily be applied to the vehicle from the roll.
NOTE: Only mask the vehicle when it is dry. Moisture under the film can lead to matt paint in the
drying process.
Using masking film

Clean the vehicle before masking it.
Pull the film over the vehicle. Because of the static charge, the film lies on the vehicle like a second
skin.
Cut out the repair area using the film knife and then mask it.
Other ways of masking a vehicle are:
Masking using masking paper.

Painting cloth (mostly used during filling work).
Profiled seals
If it is not possible to remove a profiled seal, then it must be masked in such a way that no edges can
form due to paint accumulation.
To do this, the seal is lifted slightly and masked. The following techniques are possible:

1 - Masking tape with plastic strips
2 - Sealing lip
3 - Sandpaper with masking tape
Laying a string or cord under the seal. Suitable for soft and elastic seal lips.
Special masking tape with plastic strips for hard seal lips.
Instead of using plastic strips, fine sandpaper cut into strips can be inserted and secured using
normal masking tape.
If the seal can be easily displaced, normal masking tape can also be used.
Edges/openings
Smooth paint transitions can be produced by positioning adhesive tapes.

NOTE: Pull the adhesive tapes away immediately after the paint has been applied and check the
paint transitions.
2428/2430

1 - Vehicle edge
2 - Adhesive surface
3 - Masking paper
Possible variations
At edges apply one strip of masking tape half on the area not to be painted and mask using a
second strip.
On surfaces, two masking strips can be attached, each affixed by half their adhesive surface. The
adhesive strip which arises is then applied with one half on the edge of the area to be painted. The
other half is aligned and fixed in addition in the curves.
Affix masking paper on one side over the area to be painted. Double back the masking paper and
secure it.
Affix round profiled foam at the edge of the area to be painted using masking tape.
Foam strips are suitable for affixing to openings such as door gaps.
NOTE: Choose a suitable profile diameter. A profile which is too thick will protrude from the
opening, one which is too thin will leave a gap.
Clean the door opening well and affix the matching shape.
Color shade problems
If a vehicle color shade is taken from a vehicle on a hot summer day and the mixed color applied, this
may cause color shade problems. Some colors change so much at higher temperatures that it can
lead to an incorrect result. Red color shades are particularly prone to this shade behavior.
This means that color determination should always be done on the bodywork when it is at about the
same temperature as the later working temperature will be. The best temperature of the item is
between 15° and 25° C.
2429/2430
Isopropanol and water

Painted surfaces are very easily cleaned using a mixture of 70% water and 30% isopropanol (can be
obtained through a laboratory supplies specialist or a pharmacist).
Temperature reduction spray
If finishing work must be performed on touched-up surfaces and newly painted plastic parts,
problems may arise. The paint and the transitions are not yet fully hardened.
NOTE: When working with the polishing machine, make certain that each operating run lasts no
longer than about 5 - 10 seconds, in order to prevent the paint becoming warm.
Even so, in order to be able to polish over transitions, temperature reduction spray must be applied to
the surface. The transition area is then alternately sprayed and polished until a perfect transition
surface is achieved.
Paint faults on soft plastic components where elasticizer additive has been used in painting must be
wet sanded using grade P2000 - P2500 paper.
In doing this the sanding location and the surroundings are sprayed with temperature reduction spray
and the paint faults sanded out by hand. Afterwards the location is polished as described above.
Paint plane
Dirt inclusions and paint runs can be removed with the sanding cylinder ("Finiball") and hand sanding
or eccentric sander in a wet sanding process.
Another practical tool for removal of paint faults which lie proud of the surface is the paint plane.
NOTE: Guide the tool carefully with the minimum of force. It must not tilt, otherwise more serious
damage may easily be caused.
This tool allows paint faults to be carefully removed in shavings. Afterwards the surface must be
polished using suitable materials.
Shading
Even when all the rules, steps and corresponding instructions have been followed concerning possible
shades, it may happen that the mixed color shade does not exactly match the vehicle color.
In these cases, shading must be done. Because there is no fixed formula for this, experience and a
trained eye are important. Some rules must be followed for shading.
NOTE: Self-made color sample plates of the current colors are very helpful for determining the color
shade. Refer to the chapter Color Determination and Color Theory.
When shading, if possible only use the paint mixture that is also allotted in the color shade formula.
Observe the rules concerning contrary colors (complementary colors) and partner colors according
to the Oswald color circle.
Complementary colors are not recommended during shading because they mutually inhibit and lead
to muddy mixtures.
Sanding marks
In certain circumstances, the recommended sanding methods up to now are no longer suitable for
light metallic color shades. Wet sanding with grade P1200 paper or a grey sanding pad can cause
sanding scratches which can become very visible under certain lights.
In order to achieve an excellent paint result on difficult color shades, follow these working rules:
2430/2430
Sand filler as before, rub down area to be painted with 3M ultra fine matting sponge and 3M
matting gel.
Sand filler as before, rub down area to be painted with soaked 3M wet sand paper P1500 - P2000.
Sand filler as before, rub down area to be painted with 3M 260 L P1000 eccentric (Interface Pad).
Improving touch-up work

During application of special effect base paints, the effect particles align themselves exactly parallel to
the surface in the paint layer while it is still liquid. This means a particular thickness of the paint layer
is required.
Because during painting the layer thickness in the transition zones reduces from normal to zero, the
effect particles can no longer align themselves. This leads to lighter, darker or cloudy zones.
If 1-component clear lacquer is sprayed before the base coat, this effect is prevented. An optically
perfect transition will result.
Welcome
FordEtis
Independent Operators
 Only individuals who have been allocated a registered account and authorised access to
this website should proceed beyond this point.
 Username
 Password
Login
LOGIN Register
REGISTER as anIOIO
AS AN
I forgot my password!
Ford Dealers and Staff
Dealers Login
DEALERS LOGIN Ford
FORDStaff Login
STAFF LOGIN
 No need to register, just login with Ford as normal.
Action took 0 ms. on eccvas1900e-eccvas1900e
https://www.etis.ford.com/...&proc-uid=G1381236&variantId=2677&uidselect=G1533736&guid=&type=1&displayNameId=0&displayName=[31.10.2018 16:08:24]
Welcome
© Ford Motor Company Ltd Privacy Policy / Terms and Conditions
https://www.etis.ford.com/...&proc-uid=G1381236&variantId=2677&uidselect=G1533736&guid=&type=1&displayNameId=0&displayName=[31.10.2018 16:08:24]

0.1.manual Reparatii Si Intretinere FORD FOCUS PDF

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

0.1.manual Reparatii Si Intretinere FORD FOCUS PDF

Transféré par

Droits d'auteur :

Formats disponibles

1/2430

General Information - Information - Overview

Description and Operation

General Information - About this Manual

Description and Operation

Item Part Number Description

Item Part Number Description

How to use Repair Procedures

NOTE: Removal steps in this procedure may contain installation details.

Reuse standard fasteners.

Types of self-locking nuts and bolts

Item Part Number Description

Item Part Number Description

GAS Service Action Icon

How to use Diagnosis and Testing procedures

General Information - Symbols Glossary

Description and Operation

Item Part Number Description

Item Part Number Description

Steering Wheel Symbols

Item Part Number Description

Item Part Number Description

Gearshift lever and selector lever position symbols

Item Part Number Description

17 - Set the gearshift lever to the neutral (N) position

Item Part Number Description

Item Part Number Description

Item Part Number Description

Cutting tool symbols

Item Part Number Description

Apply Chemical or load symbols

Item Part Number Description

17 - Handle the fluid using a syringe

Item Part Number Description

10 - The specified task requires the specified maximum temperature not to be

General equipment symbols

Item Part Number Description

6 - File with a specified size

Item Part Number Description

These symbols indicate the type of welding to be used.

Item Part Number Description

Drilling and grinding symbols

Item Part Number Description

Item Part Number Description

Item Part Number Description

16 - Area/component must be dry

Mandatory Protective equipment - Health and safety symbols

Item Part Number Description

Prohibition - Health and safety symbols and component damage

Item Part Number Description

Warning symbols - Health and safety and component damage

Item Part Number Description

Control Diagram symbols - Description and Operation procedures

Item Part Number Description

General Information - Health and Safety

Description and Operation

General Service Warnings

Follow manufacturers instructions.

Isocyanate (Polyurethane) Adhesives/Sealers

See also Resin-based Adhesives.

Chemical Materials - Do Nots

switch off the power supply before approaching the victim.

Highly flammable - observe No Smoking policy.