Engine Mechanical:
Detailed disassembly, inspection, assembly, and troubleshooting for all engine components.
Engine Electrical:
Wiring diagrams, component testing, ignition system, starting and charging systems.
Emission Control:
Evaporative emission control (EVAP), catalytic converter, oxygen sensors, exhaust gas recirculation (EGR).
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulator, fuel tank and lines.
Clutch System:
Clutch assembly, clutch pedal, master cylinder, slave cylinder, bleeding procedures.
Manual Transaxle:
Gearbox disassembly, inspection, repair, lubrication, shift linkage.
Automatic Transaxle:
Component identification, hydraulic control, electronic controls, fluid service, repair procedures.
Driveshaft Axle:
CV joints, drive axles, wheel bearings, hub assemblies.
Suspension System:
Front suspension (struts, control arms), rear suspension (torsion beam, shock absorbers), wheel alignment.
Steering System:
Power steering system, steering rack, tie rods, steering column, wheel alignment.
Restraint System:
Seat belts, airbag system (SRS) components, diagnostic procedures.
Brake System:
Front and rear disc/drum brakes, ABS system (if equipped), brake fluid, hydraulic lines.
Body Interior Exterior:
Body panel removal/installation, door mechanisms, interior trim, glass, seals.
Body Electrical:
Lighting systems, power windows, central locking, wipers, horn, instrument cluster.
HVAC:
Air conditioning system, heater core, blower motor, climate control, refrigerant.
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement.
Repair:
Complete engine rebuild, transmission overhaul, brake system repairs, suspension component replacement, electrical system diagnostics.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), component testing procedures.
Depth:
Expert-level, covering from basic DIY tasks to complex dealership-level repairs and diagnostics.
Engine Options:
Primarily 1.3L (4K) and 1.5L (5K) inline-four petrol engines. Some markets may have had the 1.8L Zetec-SE (ZETEC).
Typical Hp:
Ranges from approximately 60-75 hp for 1.3L and 70-90 hp for 1.5L, depending on exact engine code and market.
Typical Torque:
Approximate torque figures vary by engine, typically between 100-130 Nm.
Fuel Delivery:
Electronic Fuel Injection (EFI).
Common Codes 1.3L:
J4C, J4N
Common Codes 1.5L:
J5C, J5N
Common Codes 1.8L:
ZETEC-SE (Z5A)
Ignition Type:
Distributorless Ignition System (DIS) or Distributor-based depending on model year and market.
Cooling Type:
Pressurized liquid cooling system with thermostatic control.
Wheelbase Mm:
Approximately 2489 mm (98 in)
Length Mm:
Approximately 3975 mm (156.5 in)
Width Mm:
Approximately 1630 mm (64.2 in)
Height Mm:
Approximately 1380 mm (54.3 in)
Curb Weight Kg:
Ranges from approx. 900-1000 kg depending on engine and transmission.
Gross Vehicle Weight Rating Kg:
Typically around 1300-1400 kg.
Oil Change Interval Km:
Typically every 5,000 - 10,000 km or 6-12 months, depending on oil type and driving conditions.
Timing Belt Interval Km:
Recommended replacement every 80,000 - 100,000 km for engines using a timing belt.
Engine Oil Type:
API SG/SH or ACEA A2-96, viscosity typically 10W-30 or 5W-30, refer to manual for exact specification.
Coolant Type:
Ethylene glycol based coolant (e.g., Ford Super Premium Engine Coolant) mixed with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Ford MERCON or equivalent ATF fluid.
Common Problems:
Potential for minor electrical gremlins, wear on suspension components due to road conditions, clutch wear, and potential AC system issues over time.
Common Problems Detail:
Dashboard warning lights, power window regulators, door lock actuators, aging rubber seals and hoses are commonly reported.
