Manual Coverage
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Systems Covered
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Engine Systems:
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Cooling, lubrication, fuel delivery, ignition, exhaust, engine mechanical (including timing, pistons, cylinders, crankshaft, camshafts), engine control unit (ECU) and sensors, emissions control.
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Transmission Systems:
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Manual transmission (clutch, gearbox, shift linkages), drivetrain (driveshafts, CV joints, differential).
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Brake Systems:
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Hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), disc and drum brake components, parking brake system.
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Suspension And Steering:
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Front and rear suspension components (struts, shocks, springs, control arms, bushings), steering rack, power steering system (if applicable), wheel alignment specifications.
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Electrical Systems:
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Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), ignition system wiring, instrument cluster, fuses and relays, body control modules, power windows, door locks, wipers, horn.
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Fuel And Emission Systems:
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Fuel tank, fuel pump, fuel injectors, fuel filter, evaporative emission control (EVAP) system, catalytic converter, oxygen sensors.
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Body And Chassis:
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Body panels, doors, hood, trunk, bumpers, interior trim, chassis components, structural integrity.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant checks and flushes, brake fluid checks and flushes, tire rotation and pressure checks, battery maintenance.
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Diagnostic Procedures:
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Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs), sensor testing, electrical circuit testing, component diagnostics.
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Repair And Rebuild:
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Engine component removal and installation (e.g., cylinder head, pistons, crankshaft), transmission overhaul, brake caliper and rotor replacement, suspension component replacement, exhaust system repair, electrical component replacement.
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Component Replacement:
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Detailed instructions for replacing wear items and major components such as alternators, starters, radiators, water pumps, clutches, CV joints, wheel bearings, and more.
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Wiring Diagrams:
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Comprehensive electrical wiring diagrams for all vehicle systems, aiding in diagnosing electrical faults and repairs.
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Technical Depth
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Depth:
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Comprehensive factory-level repair and maintenance information, suitable for professional technicians and advanced DIY enthusiasts.
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Engine Specifications
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Primary Engine
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Engine Type:
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Inline 4-cylinder, Petrol
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Displacement:
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1.2L (1242 cc) or 1.4L (1388 cc) Duratec (depending on market and specific model variant).
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Bore X Stroke:
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Specific values available in manual; typical for its class.
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Compression Ratio:
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Typically around 10.0:1 or higher for petrol variants.
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Performance
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Horsepower:
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Approx. 70-85 HP (for 1.2L) or 90-100 HP (for 1.4L), depending on tuning and market.
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Torque:
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Approx. 110-120 Nm (for 1.2L) or 125-140 Nm (for 1.4L), depending on tuning and market.
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Fuel System
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Fuel Delivery:
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Electronic Fuel Injection (EFI) with multi-point injection (MPI).
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Fuel Type:
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Unleaded Petrol (Gasoline)
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Engine Management
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ECU Type:
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Ford's proprietary ECU system, specific model variant details in manual.
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Maintenance
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Service Intervals
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Oil And Filter Change:
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Typically every 10,000 km or 12 months, whichever comes first (consult manual for precise recommendation and specific oil type).
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Air Filter Replacement:
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Recommended every 20,000 km or 24 months, or as needed based on driving conditions.
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Spark Plug Replacement:
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Typically around 40,000 km for standard spark plugs, or 80,000-100,000 km for iridium plugs (if equipped; manual will specify exact type and interval).
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Coolant Flush:
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First flush at 100,000 km, then every 50,000 km or 2-3 years (using correct Ford-approved coolant).
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Brake Fluid Flush:
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Typically every 2-3 years or 40,000-60,000 km.
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Fluid Specifications
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Engine Oil Type And Capacity:
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Refer to manual for specific API/ACEA specifications and viscosity grade (e.g., 5W-30, 5W-40) and capacity (approx. 3.5-4.0 liters).
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Coolant Type:
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Ford specification coolant (typically an ethylene glycol-based coolant, often pink or orange).
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Brake Fluid Type:
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DOT 3 or DOT 4 brake fluid (refer to manual for precise recommendation).
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Known Issues
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Engine Performance:
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Occasional reports of minor power delivery fluctuations or initial hesitation, often related to fuel quality or sensor calibration.
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Electrical Systems:
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Instances of minor electrical gremlins like interior light issues or window motor problems, typically solvable with wiring checks or component replacement.
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Suspension Wear:
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Bushing wear, particularly in control arms and sway bars, can occur over time with heavy use, leading to steering looseness or knocking sounds.
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Clutch Wear:
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As with most manual transmissions, clutch wear is a maintenance item that depends heavily on driving style. Symptoms include slipping or difficult engagement.
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