Manual Coverage
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Systems Covered
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Engine Mechanical:
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Engine overhaul, cylinder head, pistons, crankshaft, timing belt/chain, lubrication system, cooling system.
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Engine Electrical:
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Ignition system, fuel injection system, starter motor, alternator, battery, engine control module (ECM) diagnostics.
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Transmission Manual:
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Clutch system, gear shifter mechanism, gearbox disassembly and assembly, internal component inspection.
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Transmission Automatic Or Dct:
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PowerShift (if applicable): Gearbox operation, mechatronics, clutch pack replacement, control module diagnostics.
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Drivetrain:
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Front axle, drive shafts, wheel bearings, differential (if integrated).
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Brakes:
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Front and rear brake systems (disc/drum), brake calipers, master cylinder, brake booster, ABS system, parking brake.
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Electrical System:
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Wiring diagrams, lighting systems, instrument cluster, interior and exterior electrical components, fuses and relays.
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Body And Interior:
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Body panels, doors, latches, hinges, glass, interior trim, seats, airbags.
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HVAC:
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Heating, Ventilation, and Air Conditioning system diagnosis and repair, refrigerant handling.
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Fuel System:
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Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, evaporative emissions control (EVAP).
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Suspension And Steering
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Suspension And Steering:
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Front and rear suspension components (struts, shock absorbers, control arms, springs), power steering system (hydraulic or electric), steering rack, tie rods.
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Exhaust System
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Exhaust System:
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Exhaust manifold, catalytic converter, muffler, exhaust pipes, oxygen sensors.
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Procedures Included
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Maintenance:
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Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement, brake pad/shoe replacement, tire rotation.
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Diagnostics:
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Troubleshooting guides, fault code interpretation, diagnostic procedures for all major systems.
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Removal And Installation:
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Step-by-step procedures for removing and installing virtually all vehicle components.
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Disassembly And Assembly:
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Detailed instructions for dismantling and reassembling engine, transmission, and other major mechanical assemblies.
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Adjustments:
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Valve adjustments (if applicable), idle speed adjustments, parking brake adjustments, clutch pedal free play.
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Technical Depth
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Depth Of Coverage:
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Comprehensive, bumper-to-bumper coverage suitable for professional mechanics and experienced DIYers.
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Illustration Quality:
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Detailed illustrations, exploded diagrams, drawings, and photos.
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Special Tools:
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References to specific Ford special service tools with illustrations of their use.
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Wear Limits:
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Includes wear limits and allowable tolerances for various components.
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Torque Specifications:
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Precise tightening torque values for all critical fasteners.
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Completeness
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Completeness Statement:
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100% complete and intact, no missing or corrupt pages.
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Engine Specifications
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Primary Engine
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Engine 1 25L Duratec:
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Displacement: 1242 cc, Power: ~60-80 PS, Torque: ~115-120 Nm, Bore x Stroke: 79.0 x 62.0 mm.
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Engine 1 4L Duratec:
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Displacement: 1388 cc, Power: ~90-96 PS, Torque: ~125-130 Nm, Bore x Stroke: 82.0 x 69.6 mm.
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Engine 1 6L Duratec Ti Vct:
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Displacement: 1596 cc, Power: ~100-120 PS, Torque: ~150-160 Nm, Bore x Stroke: 82.0 x 79.5 mm, Variable Valve Timing.
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Engine 1 4L Tdci:
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Displacement: 1399 cc, Power: ~68 PS, Torque: ~160 Nm, Common Rail Diesel Injection.
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Engine 1 6L Tdci:
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Displacement: 1560 cc, Power: ~90-95 PS, Torque: ~215 Nm, Common Rail Diesel Injection, Turbocharged.
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Performance
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Performance Metrics:
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0-60 mph times vary by engine, typically between 10-14 seconds. Top speeds range from 100-120 mph.
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Fuel System
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Fuel Type:
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Unleaded Gasoline (petrol), Diesel
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Fuel Delivery:
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Electronic Fuel Injection (EFI), Common Rail Direct Injection (for diesel).
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Emission Controls:
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Catalytic converter, Oxygen sensors, EVAP system.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 12,500 miles (20,000 km) or 12 months, whichever comes first, for petrol engines. Diesel engines may vary slightly.
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Timing Belt Replacement:
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For 1.25L and 1.4L Duratec engines, typically every 10 years or 125,000 miles (200,000 km), but check manual for specific engine variant. 1.6 Ti-VCT may have a chain. TDCi diesels often use timing belts with similar intervals.
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Fluid Specifications
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Engine Oil:
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Ford specification WSS-M2C913-C or WSS-M2C913-D (typically 5W-30 synthetic).
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Coolant:
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Ford specification WSS-M97B44-D (Long Life Coolant, typically a 50/50 mix of antifreeze and distilled water).
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Brake Fluid:
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DOT 4 brake fluid.
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Transmission Fluid Manual:
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Ford specification WSS-M2C200-D2 (typically SAE 75W-85 GL-4 manual transmission fluid).
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Transmission Fluid Powershift:
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Specific PowerShift fluid, e.g., WSS-M2C200-D3 (often a synthetic automatic transmission fluid).
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Known Issues
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Common Issues Petrol:
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Occasional issues with ignition coils, throttle body problems, and minor oil leaks. Some models may experience gearbox synchro wear on higher mileage manual transmissions.
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Common Issues Diesel:
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Diesel Particulate Filter (DPF) regeneration issues (especially on short journeys), injector problems, turbocharger wear, and EGR valve issues can occur.
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Common Issues General:
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Water ingress into the boot, wear on suspension components (bushings, drop links), and occasional electrical gremlins.
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