Powertrain:
Engine Service/Repair, Transmission Service/Repair, Fuel Injection/Fuel System, Cooling System, Emission System, Engine Control System, Differential/Drive, Axle
Chassis And Suspension:
Brake System, Suspension, Steering, Chassis/Body
Electrical And Body:
Wiring Diagram, Electrical System, Restraint System, Interior, Heater/Air Conditioning
Engine Management:
Covers ECU diagnosis, sensor testing (MAP, TPS, O2, ECT, CMP, CKP), ignition system (coil-on-plug or distributorless ignition), fuel system diagnostics and calibration.
Exhaust System:
Covers catalytic converter, mufflers, exhaust pipes, and oxygen sensors. Includes diagnostic and repair procedures.
Maintenance:
General Maintenance, Periodic Lubrication, Routine Service
Diagnostics And Repair:
Troubleshooting, Step-by-step repair procedures for all covered systems, Diagnostic fault code interpretation (implied)
Special Procedures:
Rebuilding, Refurbishing, Restoration (indicated by comprehensive nature)
Engine Rebuild:
Detailed procedures for cylinder head removal/installation, piston and connecting rod service, crankshaft service, bearing replacement, and engine timing procedures.
Suspension And Steering Repair:
Includes procedures for replacing struts, shock absorbers, control arms, ball joints, tie rod ends, power steering pump, rack and pinion, and wheel alignment specifications.
Brake System Overhaul:
Covers brake pad and disc replacement, caliper overhaul, master cylinder replacement, brake fluid flush and bleed procedures, and ABS component testing.
Body And Paint:
While not explicitly a paint manual, it will cover body panel alignment, dent repair principles, and preparation for painting.
Depth:
Comprehensive: From basic maintenance to advanced diagnostics and repair. Covers factory technician level information.
Wiring Diagrams:
Comprehensive wiring schematics for all electrical systems, including powertrain, lighting, accessories, HVAC, and safety systems. Allows for precise tracing and diagnosis of electrical faults.
Troubleshooting Guides:
Advanced troubleshooting sections that correlate symptoms with potential causes and diagnostic steps, often using flowcharts for efficient problem identification.
Body Panels:
Repair procedures for doors, hood, trunk lid, fenders, bumpers, body panels, and associated trim. Includes welding and panel replacement guidelines.
Interior Components:
Covers dashboard removal, seat removal, door panel replacement, headliner repair, and HVAC system internal components.
Airbags And Seatbelts:
Detailed procedures for airbag module diagnosis, replacement, SRS system checks, and seatbelt mechanism service.
Engine Options:
Likely covers 1.6L CVH, 1.8L DOHC (Zetec), 2.0L DOHC (Zetec), 2.5L V6 (Duratec/Cologne), and various Diesel engines (e.g., 1.8L TD) popular in the European market during this period. Specific engine codes would be detailed within the manual.
Performance Data:
The manual will contain specific horsepower, torque figures, and performance characteristics for each engine variant covered. (e.g., 1.8L Zetec typically produced around 115-130 PS, 2.0L Zetec around 130-145 PS, 2.5L V6 around 170 PS).
Fuel Delivery:
Electronic Fuel Injection (EFI) for petrol engines. Diesel engines would feature indirect or direct injection systems. Manual details component identification, testing, and repair for fuel pumps, injectors, sensors, and ECU.
Common Engine Codes:
Examples include L1 (1.6L CVH), N3A/N3B (1.8L Zetec-DOHC), N7A/N7B (2.0L Zetec-DOHC), PRB/PRM (2.5L V6). Diesel: RFM (1.8L TD). Manual will confirm all codes.
Crash Test Results:
The manual would contain information related to the vehicle's passive safety systems, but specific Euro NCAP or NHTSA ratings for this period would need external research. However, it will detail airbag systems, seatbelt pre-tensioners, and structural integrity points.
Active Safety:
Details on ABS (Anti-lock Braking System) operation and diagnostics, potentially traction control on higher trims.
Passive Safety:
Comprehensive coverage of airbags (driver, passenger), seatbelt systems, and body structure for occupant protection.
Infotainment Systems:
Basic radio/cassette or CD player systems, typically with rudimentary displays. Manual may cover radio removal/installation and speaker wiring.
Driver Assistance Features:
ABS, potentially cruise control on higher trims. Manual will detail the operation and repair of these systems.
Cruise Control System:
Detailed troubleshooting and repair for cruise control systems, including vacuum or electronic actuator diagnosis.
Connectivity Features:
Limited to basic diagnostic port (OBD-I or early OBD-II depending on specific year/market) for fault code retrieval.
Oil Change Interval:
Typically 15,000 km (9,300 miles) or 12 months, whichever comes first, depending on engine and oil type used. Manual will specify exact intervals and conditions.
Timing Belt Replacement:
Critical for Zetec engines; typically recommended every 60,000 - 100,000 km (37,000 - 62,000 miles) or 4-5 years. Manual will provide precise intervals and procedure, including tensioner replacement.
Engine Oil Specification:
Ford recommends specific grades like 5W-30 or 5W-40 Synthetic or Semi-Synthetic oil, meeting API SJ/CF or ACEA A3/B3 standards. Manual will list exact API/ACEA and Ford WSS specifications.
Coolant Specification:
Ford Super Plus coolant (blue) or equivalent Ethylene Glycol based antifreeze, mixed 50/50 with distilled water for -37°C freeze protection. Manual will detail capacity and type.
Transmission Fluid Specification:
Manual transmission oil: Gear oil, e.g., 75W-90 GL-4. Automatic transmission fluid: Mercon V or equivalent. Manual will list precise specifications and capacities.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid. Manual will specify the exact type and capacity for bleeding and flushing.
Power Steering Fluid:
Typically Dexron III ATF or a specific Ford power steering fluid. Manual will detail the correct type and procedure.
Common Issues:
Corrosion (especially wheel arches, sills), suspension component wear (bushings, ball joints), electrical gremlins (especially on early models), heater matrix leaks, window regulator failures, and potential catalytic converter issues. The manual will provide diagnostic and repair steps for these.
Common Diesel Issues:
Glow plug issues, injector pump problems, turbocharger maintenance (for TD models). Manual will provide specific diagnostic steps.
