Haynes Ford Focus Automotive Repair Manual 2000 thru 2005 1563925842, 9781563925849

Citation preview

Haynes Repair Manua Based on a complete teardown and rebuild

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ANTEDO,

Includes essential information for today’s more complex vehicles

Digitized by the Internet Archive

in 2022 with funding from Kahle/Austin Foundation

https://archive.org/details/fordfocusautomot0000stor

Ford Focus

Automotive Repair Manual

by Jay Storer and John H Haynes Member of the Guild of Motoring Writers

Models covered: Focus models 2000 through 2005 Does not include information specific to SVT and rear disc brake models

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A CESSORIES “EMBER Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

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Acknowledgements Wiring diagrams provided exclusively for Haynes North America, Inc. by Valley Forge Technical Information Services. Technical writers who contributed to this project include R.M. Jex and Peter T. Gill.

© Haynes North America, Inc. 2002, 2004, 2005 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 584 2 Library of Congress Control Number 2005929296 While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

“Ford” and the Ford logo are registered trademarks of Ford Motor Company. Ford Motor Company is not a sponsor or affiliate of Haynes Publishing Group or Haynes North America, Inc. and is not a contributor to the content of this manual. 05-336

Contents Introductory pages About this manual Introduction Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Booster battery (jump) starting Jacking and towing Automotive chemicals and lubricants Conversion factors Fraction/decimal/millimeter equivalents Safety first! Troubleshooting

0-5 0-5 0-6 0-7 0-7 0-13 0-14 0-15 0-16 0-17 0-18 0-19

Chapter 1 Tune-up and routine maintenance

1-1

2.0L SPI engine

Chapter2

2A-1

PartB

2.0L Zetec-E engine See ee ee ee Chapter 2 PartC 2.3L and 2005 2.0L engines

Chapter 2

2B-1 ee 2C-1

PartD

General engine overhaul procedures

2D-1

Chapter 3 Cooling, heating and air conditioning systems Pere Se ESE OE ee ee

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3-1

Chapter 4 PartA Fuel and exhaust systems ie ahs ge SST a Sia

as

4A-1 eS

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Chapter 4 Part B Emissions and engine control systems Mer ise Se es

4B-1

Sh

Chapter 5 PartA Starting and charging systems

5A-1

Chapter 5 Part B Ignition system

5B-1

Chapter 6 Clutch

6-1

Chapter 7

PartA

Manual transaxle

Chapter7

TA-1

PartB 7B-1 eee

Automatic transaxle

ee Chapter 8 Driveaxles iS EEE I a i a i

Chapter 9 Brakes ef Neither Chapter 10

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8-1

9-1

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Doce ab

10-1

Suspension and steering systems

Chapter 11 Body a AS a

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Chapter 12 Chassis electrical system

Wiring diagrams Index

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11-1

12-1

12-29 IND-1

Haynes mechanic, author and photographer with Focus

0-5

About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; ‘and it offers diagnostic and repair procedures to follow when trouble

occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop

must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual R

The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The ‘reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to

Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use” of the word “Chapter” apply to Sections and/or paragraphs in the same Chapter. For example, “see Section 8” means in the same Chapter. References to the left or right side of the vehicle assume you are sitting in the driver’s seat, facing forward. Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

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NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction The front-drive design features unitized construction and 4-wheel independent suspension. Models are available in 2-door, 4door and station wagon body styles.

The transversely mounted four-cylinder

engine drives the front wheels through a fivespeed manual, a six-speed manual or fourspeed automatic transaxle by way of unequal length driveaxles. The rack-and-pinion steering gear is mounted behind the engine and is

available with power assist. Brakes are discs at the front and drum-type at the rear with vacuum assist. Rear disc brakes are optional.

0-6

Vehicle identification numbers

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The Vehicle Identification Number (VIN) is visible from outside the vehicle through the driver’s side of the windshield

Modifications are a continuing and unpublicized process in vehicle manufacturing. Since spare parts lists and manuals are compiled on a numerical basis, the individual vehicle numbers are necessary to correctly identify the component required.

Vehicle Identification Number

(VIN) This very important identification number is stamped on a plate attached to the dashboard inside the windshield on the driver’s side of the vehicle (see illustration). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains information such as where and when the vehicle was manufactured, the model year and the body style.

The Certification label is located on the left front door post

VIN engine and model year codes Two particularly important pieces of information found in the VIN are the engine code and the model year code. Counting from the left, the engine code letter designation is the 8th digit and the model year code designation is the 10th digit. On the models covered by this manual the

engine codes are: Pog tiaetain concatenate 2.0L SPI

Ba ists thhecatnin Mtayianetees2003 AA ayshsthbe TARR Na ge 2004 Os aie Races yeas aaiae 2005

Vehicle Certification Label The Vehicle Certification Label is attached to the driver’s side door pillar (see illustration). Information on this label includes the name of the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and the certification statement.

Ro RVR PSI Seay reat Mp aT 2.0L Zetec COMP ch LOD Me eas SVT Duratec

Engine number

N STS ake ae ar cee 2005 2.0L Ze. ae iar HER nes ero

The engine number is stamped onto a machined pad on the external surface of the engine block. There’s also an identification label that’s usually on the timing belt cover.

On the models covered by this manual the model year codes are:

0-7

Buying parts Replacement parts are available from many sources, which generally fall into one of two categories - authorized dealer parts departments and independent retail auto

parts stores. Our advice concerning these parts is as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned

parts on an exchange basis, which can save a considerable amount of money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general accessories, have convenient hours, charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are

unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: \f the vehicle is still covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.

Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.

Most automotive machine shops can perform this task, as well as other repair procedures, such as the repair of threaded holes that have been stripped out.

Flat washers and lockwashers,

when

removed from an assembly, should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use a lockwasher on any soft metal surface (such

as aluminum), thin sheet metal or plastic.

Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type,

either a lockwasher, locknut, locking tab or thread adhesive. All threaded fasteners should be clean and straight, with undamaged threads and undamaged corners on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber inserts can only be used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts and bolts should be treated

with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpentine in a spout-type oil can, which works _ quite well. After applying the rust penetrant, let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores. If a bolt or stud breaks off in an assembly, it can be drilled and removed with a special tool commonly available for this purpose.

Grade 1 or 2

Grade 5

Bolt strength marking (standard/SAE/USS; bottom - metric)

Grade

_ Identification 6

Hex

Nut

Grade

Identification

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Hex Nut

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Property Class 9

3 Dots ~

Arabic 9

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6 Dots Standard hex nut strength markings

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Hex Nut Prope! Glace 2

Hex Nut Grade &

Class 10.9

Class 9.8

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Cla 8.8

Arabic 10 Metric hex nut strength markings

Metric stud strength markings | 00-1HAYNES HAYNES |

0-8

Maintenance techniques, tools and working facilities

Fastener sizes For a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners. Therefore, it is important to be able to tell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be inter-

Metric thread sizes

changed. All bolts, whether standard or metric, are sized according to diameter, thread pitch and length. For example, a standard 1/2 - 13 x 1 bolt is 1/2 inch in diameter, has 13 threads per inch and is 1 inch long. An M12 - 1.75 x 25 metric bolt is 12 mm in diameter, has a thread

pitch of 1.75 mm

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6 to9

9 to 12

ee fie peicelt Lee

14 28 50 80

Seeearte saatceet Aachen Stheee

5 to 8 12 to 18 22 to 33 25 to 35

7 to 10 17 to 24 30 to 44 34 to 47

vaste CORR Bee Seance

6 to9 12 to 14 to 22 to 27 to

18 20 32 38

9 to 12 17 to 24 19 to 27 30 to 43 37 to 51

shone

40 to 55

55 to 74

40 to 60 55 to 80

55 to 81 75 to 108

to to to to

21 40 71 140

19 to 28 38 to 54 68 to 96 109 to 154

(the distance between

threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable. In addition to the differences in diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the distance across the flats on a standard bolt head is measured in inches, while the same dimension on a metric bolt is sized in millimeters (the same is true for nuts). As a result, a standard wrench should not be used on a metric bolt anda metric wrench should not be used on a standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt, which is an indication of the amount of torque that can be applied to it. The greater the number of slashes, the greater the strength of the bolt. Grades 0 through 5 are commonly used on automobiles. Metric bolts have a property class (grade) number, rather than a slash, molded into their heads to indicate bolt strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9.8 and ’ 10.9 are commonly used on automobiles. Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped into one side, while metric nuts are marked with a number. The greater the number of dots, or the higher the number, the greater the strength of the nut. Metric studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade. It should be noted that many fasteners, especially Grades 0 through 2, have no distinguishing marks on them. When such is the case, the only way to determine whether it is standard or metric is to measure the thread

pitch or compare it to a known fastener of the same size. Standard fasteners are often referred to as SAE, as opposed to metric. However, it should be noted that SAE technically refers to a non-metric fine thread fastener only. Coarse thread non-metric fasteners are referred to as USS sizes. Since fasteners of the same size (both standard and metric) may have different

5 2

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Pee

Hetil

Standard (SAE and USS) bolt dimensions/grade marks

G_ L T D

Grade marks (bolt strength) Length (in inches) Thread pitch (number of threads per inch) Nominal diameter (in inches)

strength ratings, be sure to reinstall any bolts, studs or nuts removed from your vehicle in their original locations. Also, when replacing a fastener with a new one, make sure that the new one has a strength rating equal to or greater than the original.

Tightening sequences and procedures Most threaded fasteners should be tightened to a specific torque value (torque is the twisting force applied to a threaded component such as a nut or bolt). Overtightening the fastener can weaken it and cause it to break, while undertightening can cause it to eventually come loose. Bolts, screws and studs, depending on the material they are

Metric bolt dimensions/grade marks

P __ Property class (bolt strength) L__ Length (in millimeters) T _ Thread pitch (distance between threads in millimeters) D Diameter

made of and their thread diameters, have specific torque values, many of which are noted in the Specifications at the beginning of each Chapter. Be sure to follow the torque recommendations closely. For fasteners not assigned a specific torque, a general torque value chart is presented here as a guide. These torque values are for dry (unlubricated) fasteners threaded into steel or cast iron (not aluminum). As was previously mentioned, the size and grade of a fastener determine the amount of torque that can safely be applied to it. The figures listed here are approximate for Grade 2 and Grade 3 fasteners. Higher grades can tolerate higher torque values. Fasteners laid out in a pattern, such as cylinder head bolts, oil pan bolts, differential cover bolts, etc., must be loosened or tight-

Maintenance techniques, tools and working facilities

ONG Micrometer set

ened in sequence to avoid warping the component. This sequence will normally be shown in the appropriate Chapter. If a specific pattern is not given, the following procedures can be used to prevent warping. Initially, the bolts or nuts should be

assembled finger-tight only. Next, they should be tightened one full turn each, in a criss-cross or diagonal pattern. After each one has been tightened one full turn, return to the first one and tighten them all one-half turn, following the same pattern. Finally, tighten each of them one-quarter turn at a time until each fastener has been tightened to the proper torque. To loosen and remove the fasteners, the procedure would be reversed.

Component disassembly Component disassembly should be done with care and purpose to help ensure that the parts go back together properly. Always keep track of the sequence in which parts are removed. Make note of special characteristics or marks on parts that can be installed more than one way, such as a grooved thrust washer on a shaft. It is a good idea to lay the disassembled parts out on a clean surface in the order that they were removed. It may also be helpful to make sketches or take instant photos of components before removal. When removing fasteners from a component, keep track of their locations. Sometimes threading a bolt back in a part, or putting the washers and nut back on a stud, can prevent mix-ups later. If nuts and bolts cannot be returned to their original locations, they should be kept in a compartmented box or a series of small boxes. A cupcake or muffin tin is ideal for this purpose, since each cavity can hold the bolts and nuts from a particular area (i.e. oil pan bolts, valve cover bolts, engine mount bolts, etc.). A pan of this type is especially helpful when working on assemblies with very small parts, such as the carburetor, alternator, valve train or interior

dash and trim pieces. The cavities can be marked with paint or tape to identify the contents. Whenever wiring looms, harnesses or connectors are separated, it is a good idea to

~

Dial indicator set

identify the two halves with numbered pieces of masking tape so they can be easily reconnected.

Gasket sealing surfaces Throughout any vehicle, gaskets are used to seal the mating surfaces between two parts and keep lubricants, fluids, vacuum or pressure contained in an assembly. Many times these gaskets are coated with a liquid or paste-type gasket sealing compound before assembly. Age, heat and pressure can sometimes cause the two parts to stick together so tightly that they are very difficult to separate. Often, the assembly can be loosened by striking it with a soft-face hammer near the mating surfaces. A regular hammer can be used if a block of wood is placed between the hammer and the part. Do not hammer on cast parts or parts that could be easily damaged. With any particularly stubborn part, always recheck to make sure that every fastener has been removed. Avoid using a screwdriver or bar to pry apart an assembly, as they can easily mar the gasket sealing surfaces of the parts, which must remain smooth. If prying is absolutely necessary, use an old broom handle, but keep in mind that extra clean up will be necessary if the wood splinters. After the parts are separated, the old gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket material can be soaked with rust penetrant or treated with a special chemical to soften it so it can be easily scraped off. A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end. Copper is recommended because it is usually softer than the surfaces to be scraped, which reduces the chance of gouging the part. Some gaskets can be removed with a wire brush, but regardless of the method

used,

the mating surfaces must be left clean and smooth. If for some reason the gasket surface is gouged, then a gasket sealer thick enough to fill scratches will have to be used during reassembly of the components. For most applications, a non-drying (or semi-drying) gasket sealer should be used.

Hose removal tips Warning: /f the vehicle is equipped with air conditioning, do not disconnect any of the

A/C hoses without first having the system depressurized by a dealer service department or a service station. Hose removal precautions closely parallel gasket removal precautions. Avoid scratching or gouging the surface that the hose mates against or the connection may leak. This is especially true for radiator hoses. Because of various chemical reactions, the rubber in hoses can bond itself to the metal spigot that the hose fits over. To remove a hose, first loosen the hose clamps that secure it to the spigot. Then, with slip-joint pliers, grab the hose at the clamp and rotate it around the spigot. Work it back and forth until it is completely free, then pull it off. Silicone or other lubricants will ease removal if they can be applied between the hose and the outside of the spigot. Apply the same lubricant to the inside of the hose and the outside of the spigot to simplify installation. As a last resort (and if the hose is to be replaced with a new one anyway), the rubber can be slit with a knife and the hose peeled from the spigot. If this must be done, be careful that the metal connection is not damaged. If a hose clamp is broken or damaged,

do not reuse it. Wire-type clamps usually weaken with age, so it is a good idea to replace them with screw-type clamps whenever a hose is removed.

Tools A selection of good tools is a basic requirement for anyone who plans to maintain and repair his or her own vehicle. For the owner who has few tools, the initial investment might seem high, but when compared to the spiraling costs of professional auto maintenance and repair, it is a wise one. To help the owner decide which tools are needed to perform the tasks detailed in this manual, the following tool lists are offered: Maintenance and minor repair, Repair/overhaul and Special. The newcomer to practical mechanics

0-10

Maintenance techniques, tools and working facilities

Hand-operated vacuum pump

Timing light

Compression gauge with spark plug hole adapter

Valve spring compressor

Ridge reamer

Piston ring groove cleaning tool

Ring removal/installation tool

Maintenance techniques, tools and working facilities

0-11

Ring compressor

Cylinder hone

Brake cylinder hone

Clutch plate alignment tool

Tap and die set

should start off with the maintenance and minor repair tool kit, which is adequate for the simpler jobs performed on a vehicle. Then, as confidence and experience grow, the owner can tackle more difficult tasks, buying additional tools as they are needed. Eventually the basic kit will be expanded into the repair and overhaul tool set. Over a period of time, the experienced do-it-yourselfer will assemble a tool set complete enough for most repair and overhaul procedures and will add tools from the special category when it is felt that the expense is justified by the frequency of use.

Phillips screwdriver (No. 2 x 6 inch) Combination pliers - 6 inch Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush Battery post and cable cleaning tool Oil filter wrench Funnel (medium size) Safety goggles Jackstands (2) Drain pan Note: /f basic tune-ups are going to be part of

it has the capacity of accepting a very wide range of large sockets. Ideally, however, the mechanic should have a 3/8-inch drive set and a 1/2-inch drive set.

Maintenance and minor repair tool kit The tools in this list should be considered the minimum required for performance of routine maintenance, servicing and minor repair work. We recommend the purchase of combination wrenches (box-end and openend combined in one wrench). While more expensive than open end wrenches, they offer the advantages of both types of wrench.

Combination wrench set (1/4-inch to 1 inch or 6 mm to 19 mm) Adjustable wrench, 8 inch

Spark plug wrench with rubber insert Spark plug gap adjusting tool Feeler gauge set Brake bleeder wrench Standard screwdriver (5/16-inch x 6 inch)

routine maintenance,

it will be necessary to

purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because they are absolutely necessary for tuning most vehicles properly.

Repair and overhaul tool set These tools are essential for anyone who plans to perform major repairs and are in addition to those in the maintenance and minor repair tool kit. Included is a comprehensive set of sockets which, though expensive, are invaluable because of their versatility, especially when various extensions and drives are available. We recommend the 1/2inch drive over the 3/8-inch drive. Although the larger drive is bulky and more expensive,

Socket set(s) Reversible ratchet Extension - 10 inch Universal joint Torque wrench (same size drive as sockets) Ball peen hammer - 8 ounce Soft-face hammer (plastic/rubber) Standard screwdriver (1/4-inch x 6 inch) Standard screwdriver (stubby 5/16-inch) . Phillips screwdriver (No. 3 x 8 inch) Phillips screwdriver (stubby - No. 2) Pliers - vise grip Pliers - lineman’s Pliers - needle nose Pliers - snap-ring (internal and external) Cold chisel - 1/2-inch Scribe Scraper (made from flattened copper tubing) Centerpunch Pin punches (1/16, 1/8, 3/16-inch) Steel rule/straightedge - 12 inch Allen wrench set (1/8 to 3/8-inch or 4 mm to 10 mm) A selection of files Wire brush (large) Jackstands (second set) Jack (scissor or hydraulic type)

0-12

Maintenance techniques, tools and working facilities

Note: Another tool which is often useful is an electric drill with a chuck capacity of 3/8-inch and a set of good quality drill bits.

Special tools The tools in this list include those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturer’s instructions. Unless these tools will be used frequently, it is not very economical to purchase many of them. A consideration would be to split the cost and use between yourself and a friend or friends. In addition, most of these tools can be obtained from a tool rental shop on a temporary basis. This list primarily contains only those tools and instruments widely available to the public, and not those special tools produced by the vehicle manufacturer for distribution to dealer service departments. Occasionally, references to the manufacturer’s special tools are included in the text of this manual. Generally, an alternative method of doing the job without the special tool is offered. However, sometimes there is no alternative to their use. Where this is the case, and the tool cannot be purchased or borrowed, the work should be turned over to the dealer service department or an automotive repair shop. Valve spring compressor Piston ring groove cleaning tool Piston ring compressor Piston ring installation tool Cylinder compression gauge Cylinder ridge reamer Cylinder surfacing hone Cylinder bore gauge Micrometers and/or dial calipers Hydraulic lifter removal tool Balljoint separator Universal-type puller Impact screwdriver Dial indicator set Stroboscopic timing light (inductive pick-up) Hand operated vacuum/pressure pump Tachometer/dwell meter Universal electrical multimeter Cable hoist Brake spring removal and installation tools Floor jack

Buying tools For the do-it-yourselfer who is just starting to get involved in vehicle maintenance and repair, there are a number of options available when purchasing tools. If maintenance and minor repair is the extent of the work to be done, the purchase of individual tools is satisfactory. If, on the other hand, extensive work is planned, it would be a good idea to purchase a modest tool set from one

of the large retail chain stores. A set can usually be bought at a substantial savings over the individual tool prices, and they often

come with a tool box. As additional tools are needed, add-on sets, individual tools and a larger tool box can be purchased to expand the tool selection. Building a tool set gradually allows the cost of the tools to be spread over.a longer period of time and gives the mechanic the freedom to choose only those tools that will actually be used. Tool stores will often be the only source of some of the special tools that are needed, but regardless of where tools are bought, try to avoid cheap ones, especially when buying screwdrivers and sockets, because they won't last very long. The expense involved in replacing cheap tools will eventually be greater than the initial cost of quality tools.

Care and maintenance of tools Good tools are expensive, so it makes

sense to treat them with respect. Keep them clean and in usable condition and store them properly when not in use. Always wipe off any dirt, grease or metal chips before putting them away. Never leave tools lying around in the work area. Upon completion of a job, always check closely under the hood for tools that may have been left there so they won’t get lost during a test drive. Some tools, such as screwdrivers, pliers, wrenches and sockets, can be hung on a panel mounted on the garage or workshop wall, while others should be kept in a tool box or tray. Measuring instruments, gauges, meters, etc. must be carefully stored where they cannot be damaged by weather or impact from other tools. When tools are used with care and stored properly, they will last a very long time. Even with the best of care, though, tools will wear out if used frequently. When a tool is damaged or worn out, replace it. Subsequent jobs will be safer and more enjoyable if you do.

How to repair damaged threads Sometimes, the internal threads of a nut or bolt hole can become stripped, usually from overtightening. Stripping threads is an all-too-common occurrence, especially when working with aluminum parts, because aluminum is so soft that it easily strips out. Usually, external or internal threads are only partially stripped. After they’ve been cleaned up with a tap or die, they’ll still work. Sometimes, however, threads are badly dam-

aged. When this happens, you’ve got three choices:

1) Drill and tap the hole to the next suitable oversize and install a larger diameter bolt, screw or stud. 2) Drill and tap the hole to accept a threaded plug, then drill and tap the plug to the original screw size. You can also buy a plug already threaded to the original size. Then you simply drill a hole to the specified size, then run the threaded

plug into the hole with a bolt and jam nut.

Once

the plug

is fully seated,

remove the jam nut and bolt. 3) The third method uses a patented thread repair kit like Heli-Coil or Slimsert. These easy-to-use kits are designed to — repair damaged threads in_straightthrough holes and blind holes. Both are available as kits which can handle a variety of sizes and thread patterns. Drill the hole,

then

tap

it with

the

special

included tap. Install the Heli-Coil and the hole is back to its original diameter and thread pitch. Regardless of which method you use, be sure to proceed calmly and carefully. A little impatience or carelessness during one of these relatively simple procedures can ruin

your whole day’s work and cost you a bundle if you wreck an expensive part.

Working facilities Not to be overlooked when discussing tools is the workshop. If anything more than routine maintenance is to be carried out, some sort of suitable work area is essential. It is understood, and appreciated, that many home mechanics do not have a good workshop or garage available, and end up removing an engine or doing major repairs outside. It is recommended, however, that the overhaul or repair be completed under the cover of a roof. A clean, flat workbench or table of comfortable working height is an absolute necessity. The workbench should be equipped with a vise that has a jaw opening of at least four inches. As mentioned previously, some clean, dry storage space is also required for tools, as well as the lubricants, fluids, cleaning solvents, etc. which soon become necessary. Sometimes waste oil and fluids, drained from the engine or cooling system during normal maintenance or repairs, present a disposal problem. To avoid pouring them on the ground or into a sewage system, pour the used fluids into large containers, seal them with caps and take them to an authorized disposal site or recycling center. Plastic jugs, such as old antifreeze containers, are ideal for this purpose. Always keep a supply of old newspapers and clean rags available. Old towels are excellent for mopping up spills. Many mechanics use rolls of paper towels for most work because they are readily available and disposable. To help keep the area under the vehicle clean, a large cardboard box can be cut open and flattened to protect the garage or shop floor. Whenever working over a painted surface, such as when leaning over a fender to service something under the hood, always cover it with an old blanket or bedspread to protect the finish. Vinyl covered pads, made especially for this purpose, are available at auto parts stores.

0-13

Booster battery (jump) starting Booster battery (jump) starting

Dead battery

Booster battery

Observe these precautions when using a booster battery to start a vehicle: : a) Before connecting the booster battery, make sure the ignition switch is in the Off position. b) Turn off the lights, heater and other electrical loads. c) Your eyes should be shielded. Safety goggles are a good idea. d) Make sure the booster battery is the same voltage as the dead

one in the vehicle. e) The two vehicles MUST NOT TOUCH each other! f) Make sure the transaxle is in Neutral (manual) or Park (automatic). g) If the booster battery is not a maintenance-free type, remove the vent caps and lay a cloth over the vent holes.

OO0000

Connect the red jumper cable to the positive (+) terminals of each

battery (see illustration). Connect one end of the black jumper cable to the negative (-) terminal of the booster battery. The other end of this cable should be connected to a good ground on the vehicle to be started, such as a bolt or bracket on the body. Start the engine using the booster battery, then, with the engine running at idle speed, disconnect the jumper cables in the reverse order of connection.

ee

4

= Make the booster battery cable connections in the numerical order shown (note that the negative cable of the booster battery is NOT attached to the negative terminal of the dead battery)

0-14

Jacking and towing

Jacking and towing ‘

Jacking The jack supplied with the vehicle should be used only for raising the vehicle when changing a tire or placing jackstands under the frame. Warning: Never work under the vehicle or start the engine when this jack is being used as the only means of support. The vehicle should be on level ground with the wheels blocked and the transaxle in Park (automatic) or Neutral (manual). If a tire is being changed, loosen the lug nuts onehalf turn and leave them in place until the wheel is raised off the ground. Make sure no one is in the vehicle as it’s being raised off the ground. Place the jack under the side of the vehicle at the jacking point nearest the wheel to be changed (see illustration). Note: The jacking point has a notch for the jack. Caution: Never place the jack under the rear trailing arms. lf you’re using a floor jack, place it beneath the crossmember at the front or rear. Warning: Under the rear crossmember, place the jack only at the center of the crossmember, or the crossmember could be damaged. Operate the jack with a slow, smooth motion until the wheel is raised off the ground. If you’re using jackstands, position them beneath the support points along the front or

rear side sills. Remove the lug nuts, pull off the wheel, install the spare and thread the lug

nuts back on with the beveled sides facing in. Tighten snugly, but wait until the vehicle is lowered to tighten completely. Lower the vehicle, remove the jack and tighten the lug nuts (if loosened or removed) in a criss-cross pattern. If possible, tighten them with a torque wrench (see Chapter 1 for the torque figures). If you don’t have access to a torque wrench, have the nuts checked by a service station or repair shop as soon as possible. Retighten the lug nuts after 500 miles.

If the vehicle is equipped with a temporary spare tire, remember that it is intended only for temporary use until the regular tire can be repaired. Do not exceed the maximum speed that the tire is rated for.

The jack supplied with the vehicle fits over

Towing The vehicle must be towed with the front (drive) wheels off the ground to prevent damage to the transaxle. If the vehicle must be towed backward, place the front wheels on a dolly. Caution: Don’t use the hook loops under the vehicle for towing (they’re intended only for use as tie-downs). A wheel lift is recommended. A flatbed truck can also be used. In this case, pull the

vehicle onto the truck towards the front, using J-hooks at the front suspension control arms with the points turned down.

the rocker panel flange While towing, the parking brake must be released and the transaxle must be in Neutral.

The steering must be unlocked (ignition switch in the OFF position). Don’t exceed 50 mph (35 mph on rough roads). Safety is a major consideration while towing and all applicable state and local laws must be obeyed. A safety chain system must be used at all times. Remember that power ‘Steering and power brakes will not work with the engine off.

0-15

Automotive chemicals and lubricants A number of automotive chemicals and lubricants are available for use during vehicle maintenance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl.

Cleaners Carburetor cleaner and choke cleaner is a strong solvent for gum, varnish and carbon. Most carburetor cleaners leave a drytype lubricant film which will not harden or gum up. Because of this film it is not recommended for use on electrical components. Brake system cleaner is used to remove brake dust, grease and brake fluid from the brake system, where clean surfaces are absolutely necessary. It leaves no residue and often eliminates brake squeal caused by contaminants. ‘ Electrical cleaner removes oxidation, corrosion and carbon deposits from electrical contacts, restoring full current flow. It can also be used to clean spark plugs, carburetor jets, voltage regulators and other parts where an oil-free surface is desired. Demoisturants remove water and moisture from electrical components such as alternators, voltage regulators, electrical connectors and fuse blocks. They are non-conductive and non-corrosive. Degreasers are heavy-duty solvents used to remove grease from the outside of the engine and from chassis components. They can be sprayed or brushed on and, depending on the type, are rinsed off either with water or solvent.

Lubricants Motor oil is the tubricant formulated for use in engines. It normally contains a wide variety of additives to prevent corrosion and reduce foaming and wear. Motor oil comes in various weights (viscosity ratings) from 0 to 50. The recommended weight of the oil depends on the season, temperature and the demands on the engine. Light oil is used in cold cli-

mates and under light load conditions. Heavy oil is used in hot climates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number of weights from 5W-20 to 20W-50. Gear oil is designed to be used in differentials, manual transmissions and other areas where high-temperature lubrication is required. Chassis and wheel bearing grease is a heavy grease used where increased loads and friction are encountered, such as for wheel bearings, balljoints, tie-rod ends and universal joints. High-temperature wheel bearing grease is designed to withstand the extreme temperatures encountered by wheel bearings

in disc brake equipped vehicles. It usually _ contains molybdenum disulfide (moly), which is a dry-type lubricant. White grease is a heavy grease for metal-to-metal applications where water is a problem. White grease stays soft under both low and high temperatures (usually from -100 to +190-degrees F), and will not wash off or dilute in the presence of water.

Assembly lube is a special extreme pressure lubricant, usually containing moly, used to lubricate high-load parts (such as main and rod bearings and cam lobes) for initial start-up of a new engine. The assembly lube lubricates the parts without being squeezed out or washed away until the engine oiling system begins to function. Silicone lubricants are used to protect rubber, plastic, vinyl and nylon parts. Graphite lubricants are used where oils

cannot be used due to contamination problems, such as in locks. The dry graphite will lubricate metal parts while remaining uncontaminated by dirt, water, oil or acids. It is electrically conductive and will not foul electrical contacts in locks such as the ignition switch. Moly penetrants loosen and lubricate frozen, rusted and corroded fasteners and prevent future rusting or freezing. Heat-sink grease is a special electrically non-conductive grease that is used for

mounting electronic ignition modules where it is essential that heat is transferred away from the module.

Sealants RTV sealant is one of the most widely used gasket compounds. Made from silicone, RTV is air curing, it seals, bonds, waterproofs, fills surface irregularities, remains flexible, doesn’t shrink, is relatively easy to remove, and is used as a supplementary sealer with almost all low and medium temperature gaskets. Anaerobic sealant is much like RTV in that it can be used either to seal gaskets or to form gaskets by itself. It remains flexible, is solvent resistant and fills surface imperfections. The difference between an anaerobic sealant and an RTV-type sealant is in the cur-

ing. RTV cures when exposed to air, while an anaerobic sealant cures only in the absence of air. This means that an anaerobic sealant cures only after the assembly of parts, sealing them together. Thread and pipe sealant is used for sealing hydraulic and pneumatic fittings and vacuum lines. It is usually made from a Teflon compound, and comes in a spray, a paint-on liquid and as a wrap-around tape.

Chemicals Anti-seize compound prevents seizing, galling, cold welding, rust and corrosion in fasteners. High-temperature ant-seize, usu-

ally made with copper and graphite lubricants, is used for exhaust system and

exhaust manifold bolts. Anaerobic locking compounds are used to keep fasteners from vibrating or working loose and cure only after installation, in the absence of air. Medium strength locking compound is used for small nuts, bolts and screws that may be removed later. Highstrength locking compound is for large nuts, bolts and studs which aren’t removed on a regular basis. Oil additives range from viscosity index improvers to chemical treatments that claim to reduce internal engine friction. It should be noted that most oil manufacturers caution against using additives with their oils. Gas additives perform several functions, depending on their chemical makeup. They usually contain solvents that help dissolve gum and varnish that build up on carburetor, fuel injection and intake parts. They also serve to break down carbon deposits

that form on the inside surfaces of the combustion chambers. Some additives contain upper cylinder lubricants for valves and piston rings, and others contain chemicals to remove condensation from the gas tank.

Miscellaneous _ Brake fluid is “specially formulated hydraulic fluid that can withstand the heat and pressure encountered in brake systems. Care must be taken so this fluid does not come in contact with painted surfaces or plastics. An opened container should always be resealed to ‘prevent contamination by water or dirt. Weatherstrip adhesive is used to bond weatherstripping around doors, windows and trunk lids. It is sometimes used to attach trim pieces. Undercoating is a petroleum-based,

tar-like substance that is designed to protect metal surfaces on the underside of the vehicle from corrosion. It also acts as a sounddeadening agent by insulating the bottom of the vehicle. Waxes and polishes are used to help protect painted and plated surfaces from the weather. Different types of paint may require the use of different types of wax and polish. Some polishes utilize a chemical or abrasive cleaner to help remove the top layer of oxidized (dull) paint on older vehicles. In recent years many non-wax polishes that contain a wide variety of chemicals such as polymers and silicones have been introduced. These non-wax polishes are usually easier to apply and last longer than conventional waxes and polishes.

0-16

Conversion

factors

Length (distance) Inches (in) Feet (ft) Miles

25.4 0.305

=Millimeters (mm) =Meters (m)

1.609

=Kilometers (km)

0.0394 3.281 0.621

Volume (capacity) Cubic inches (cu in; in’) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (imp gal) Imperial gallons (Imp gal) US gallons (US gal)

16.387 0.568 1.137 1.201

= Cubic centimeters (cc; cm’) = Liters (I) =Liters (I) =US quarts (US qt)

0.946

= Liters (I)

4.546 1.201

= Liters (I) =US gallons (US gal)

X< xX KK KKK x x 3.785

= Liters (I)

0.061 1.76 0.88 0.833 1.057 0.22 0.833 KK KKK mK xX 0.264 x

= Inches (in)

= Feet (ft) = Miles

= Cubic inches (cu in; in’) Imperial pints (imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) = US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) = US gallons (US gal)

Mass (weight) 0.035 2.205

Ounces (oz)

28.35

Pounds (Ib)

xx 0.454

= Grams (g) = Kilograms (kg)

x

0.278 4.448 x xX 0.1

=Newtons (N) = Newtons (N) = Kilograms-force (kgf; kg)

3.6 0.225 xX x x 9.81

= Ounces (oz) = Pounds (Ib)

Force Ounces-force (ozf; oz) Pounds-force (Ibf; Ib) Newtons (N)

= Ounces-force (ozf; oz) = Pounds-force (Ibf; Ib)

= Newtons (N)

Pressure 0.070

= Kilograms-force per square

14.223

= Pounds-force per square inch

0.068

= Atmospheres (atm)

14.696

= Pounds-force per square inch

0.069

= Bars

14.5

= Pounds-force per square inch

6.895

= Kilopascals (kPa)

0.145

= Pounds-force per square inch

0.01

=Kilograms-force per square

inches

1.152

= Kilograms-force centimeter (kgf cm; kg cm)

inches

0.113

= Newton meters (Nm)

inches

0.083

= Pounds-force feet (Ibf ft; Ib ft)

feet (Ibf ft; Ib ft)

0.138

= Kilograms-force meters

Pounds-force feet (Ibf ft; Ib ft)

1.356 KX XK xx K 0.102

= Newton meters (Nm) = Kilograms-force meters (kgf m; kg m)

Pounds-force per square inch

(psi; Ibf/in?; Ib/in?) Pounds-force per square inch

(psi; Ibf/in?; tb/in?) Pounds-force per square inch

(psi; Ibf/in?; Ib/in?) Pounds-force per square inch

(psi; Ibf/in?; Ib/in?)

centimeter (kgf/cm?; kg/cm?)

(psi; Ibf/in?; Ib/in?) (psi; Ibf/in?; Ib/in?)

(psi; Ibf/in*; tb/in?)

(psi; Ibf/in?: Ib/in?)

Kilopascals (kPa)

KX xX x

centimeter (kgf/cm?; kg/cm?)

|

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98.1

= Kilopascals (kPa)

Torque (moment of force) Pounds-force (Ibf in; Ib in) Pounds-force (Ibf in; Ib in) Pounds-force (Ibf in; Ib in) Pounds-force

0.868

.

8.85

= Pounds-force inches (Ibf in; Ib in) = Pounds-force inches

12

= Pounds-force inches

(Ibf in; tb in)

7.233

(kgf m; kg m) Newton meters (Nm)

0.738 9.804

(Ibf in; Ib in) = Pounds-force feet (\bf ft; Ib ft)

= Pounds-force feet (Ibf ft; Ib ft) = Newton meters (Nm)

Vacuum Inches mercury (in. Hg) Inches mercury (in. Hg)

0.2961 0.0394

Inches mercury Inches mercury

=Watts (W)

0.0013

= Horsepower (hp)

1.609

= Kilometers per hour (km/hr; kph) x
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IND-1

Index A About this manual, 0-5 ABS hydraulic unit, removal and installation, 9-12 ABS wheel sensor, testing, removal and installation, 9-12 Accelerator cable, removal, installation and adjustment, 4A-5 pedal, removal and installation, 4A-5 Air cleaner assembly and air intake components, removal and installation, 4A-4 Air conditioning system components, removal and installation, 3-11 general information and precautions, 3-11 Air conditioning/heater controls, removal and installation, 3-10 Air filter replacement, 1-16 Airbag control module, removal and installation, 12-27 sliding contact, removal and installation, 12-27 units, removal and installation, 12-26 Alternator brushes and voltage regulator, replacement, 5A-5 removal and installation, 5A-3 Antifreeze, general information, 3-2 Anti-theft alarm system, general information, 12-21 Automatic transaxle, 7B-1 through 7B-6 fluid

and filter change, 1-23 cooler, removal and installation, 7B-4 level check, 1-9 pan, removal and installation, 7B-3 oil seals, replacement, 7B-3 overhaul, general information, 7B-5 removal and installation, 7B-4 selector

cable, removal, installation and adjustment, 7B-2 components, removal and installation, 7B-2 sensors, removal and installation, 7B-3 troubleshooting, general, 7B-2 Automotive chemicals and lubricants, 0-15 Auxiliary warning system, general information and component replacement, 12-21

Back-up light switch, removal and installation, 7A-6 Balljoint, front, replacement, 10-9 Battery check, maintenance and charging, 1-14 disconnection, 5A-1 removal, installation, testing and charging, 5A-2 Body damage, repair major, 11-6 minor, 11-2 Body side-trim moldings and adhesive emblems, removal and installation, 11-25 Body, 11-1 through 11-36 Booster battery (jump) starting, 0-13 Brakes, 9-1 through 9-14 ABS hydraulic unit, removal and installation, 9-12 ABS wheel sensor, testing, removal and installation, 9-12 booster, testing, removal and installation, 9-11 caliper, removal, overhaul and installation, 9-3 check, 1-19 disc, inspection, removal and installation, 9-4 drum, removal, inspection and installation, 9-5 electronic brake distribution (ABS models), general information, 9-12 hydraulic pipes and hoses, inspection, removal and installation, 9-10 hydraulic system, bleeding, 9-11 light switch, removal, installation and adjustment, 9-13 master cylinder, removal and installation, 9-8 pads, replacement, 9-2 parking brake cables, removal and installation, 9-13 lever, removal and installation, 9-13 pedal, removal and installation, 9-9 pressure-conscious regulator valve (non-ABS models), removal and installation, 9-12

rear wheel cylinders, removal, overhaul and installation, 9-7 shoes, replacement, 9-5 Traction control system, general information, 9-13 Traction control/AdvanceTrac control components, removal and installation, 9-13

IND-2

Index

vacuum booster unit vacuum hose and non-return valve, removal, testing and installation, 9-12 Bulb replacement exterior lights, 12-8 interior lights, 12-12 Bumper covers, removal and installation, 11-6 Buying parts, 0-7

C Cabin air filter replacement, 1-20 Caliper, front brake, removal, overhaul and installation, 9-3 Camshaft cover, removal and installation, 2C-5 Camshaft oil seal(s), replacement 2.0L SPI engine, 2A-5 2.0L Zetec-E engine, 2B-13 Camshaft position sensor, removal and installation, 4A-15 Camshaft(s), lifters and rocker arms, removal, inspection and installation, 2.0L SPI engine, 2A-6 Camshafts and cam followers, removal, inspection and installation, 2.0L Zetec-E engine, 2B-13 Camshafts and tappets, removal, inspection and installation, 2C-12 Capacities, 1-1 Catalytic converter, general information, removal and installation, 4B-4 Charging and starting systems, 5A-1 through 5A-6 Charging system general information and precautions, 5A-3 testing, 5A-3 Chassis electrical system, 12-1 through 12-28

CHECK ENGINE light, 4B-4 Chemicals and lubricants, 0-15 Cigarette lighter, removal and installation, 12-48 Clock, removal and installation, 12-17 Clutch, 6-1 through 6-6 check, 6-2 components, removal, inspection and installation, 6-4 hydraulic linkage inspection, 1-20 hydraulic system, bleeding, 6-6 master cylinder, removal and installation, 6-2 pedal position switch, removal and installation, 4A-16 removal and installation, 6-3 travel check, 1-11 release bearing (and slave cylinder), removal, inspection and installation, 6-5 Coil springs, rear, removal and installation, 10-12 Compact disc autochanger, removal and installation, 12-25 Compression test, description and interpretation, 2B-3, 2C-3 Console, removal and installation center, 11-32 overhead, 11-33 Conversion factors, 0-16 Cooling fan(s), testing, removal and installation, 3-4

Cooling system check, 1-17 hoses, disconnection and replacement, 3-3

servicing, 1-23

Cooling, heating and air conditioning systems, 3-1 through 3-12 Crankcase emission system, component replacement, 4B-2 Crankshaft inspection, 2D-15 installation and main bearing clearance check, 2D-17 pulley, removal and installation, 2B-7, 2C-8 removal, 2D-11 Crankshaft oil seals, replacement 2.0L SPI engine, 2A-11 2.0L Zetec-E engine, 2B-24 2.3L and 2005 2.0L engines, 2C-20 Crankshaft position sensor, removal and installation, 4A-15 Cruise control system, general information and component replacement, 12-22 Cylinder block/crankcase, cleaning and inspection, 2D-12 Cylinder head and valve components, cleaning and inspection, 2D-8 disassembly, 2D-7 reassembly, 2D-10 removal and installation 2.0L SPI engine, 2A-9 2.0L Zetec-E engine, 2B-16 2.3L and 2005 2.0L engines, 2C-15 Cylinder head temperature (CHT) sensor, removal and installation, 3-4, 4A-15

D Deck (trunk) lid lock components, removal and installation, 11-20 removal and installation, 11-19 Disc, front brake, inspection, removal and installation, 9-4 Door handle and lock components, removal and installation, 11-14 inner trim panel, removal and installation, 11-9 window glass, removal and installation, 11-11 window regulator, removal and installation, 11-13 removal and installation, 11-18 Driveaxles, 8-1 through 8-6 inner tripod joint boot, replacement, 8-4 inspection and joint replacement, 8-6 outer CV joint boot, replacement, 8-5 removal and installation, 8-2 Drivebelt check and replacement, 1-12 Drum, rear brake, removal, inspection and installation, 9-5

E Electric seat components, removal and installation, 12-28 Electrical troubleshooting, general information, 12-2 Electronic brake distribution (ABS models), general information, 9-12

Index See Emissions and engine control systems, 4B-1 through 4B-8 Engine camshaft cover, removal and installation, 2C-5 camshaft oil seal(s), replacement 2.0L SPI engine, 2A-5 2.0L Zetec-E engine, 2B-13 camshaft(s), lifters and rocker arms, removal, inspection and installation, 2.0L SPI engine, 2A-6 camshafts and cam followers, removal, inspection and installation, 2.0L Zetec-E engine, 2B-13 camshafts and tappets, removal, inspection and installation, 2C-12 compression test, description and interpretation, 2C-3 crankshaft inspection, 2D-15 installation and main bearing clearance check, 2D-17 pulley, removal and installation, 2B-7, 2C-8 removal, 2D-11

crankshaft oil seals, replacement 2.0L SPI engine, 2A-11 2.0L Zetec-E engine, 2B-24 2.3L and 2005 2.0L engine, 2C-20

cylinder block/crankcase, cleaning and inspection, 2D-12 cylinder head and valve components, cleaning and inspection, 2D-8 disassembly, 2D-7 reassembly, 2D-10 removal and installation 2.0L SPI engine, 2A-9

2.0L Zetec-E engine, 2B-16 2.3L and 2005 2.0L engines, 2C-15

engine/transaxle removal, methods and precautions, 2D-3 removal, separation and installation, 2D-4 exhaust manifold, removal and installation, 2C-7

flywheel/driveplate, removal and installation 2.0L SPI engine, 2A-11 2.0L Zetec-E engine, 2B-26 2.3L and 2005 2.0L engines, 2C-20 initial start-up after overhaul, 2D-20 intake manifold, removal and installation, 2C-6 main and connecting rod bearings, inspection, 2C-15 mounts, inspection and replacement, 2C-21 oil filter housing, removal and installation, 2C-19 oil pan, removal and installation

2.0L SPI engine, 2A-10 2.0L Zetec-E engine, 2B-21 2.3L and 2005 2.0L engines, 2C-16 oil pressure warning light switch, removal and installation, 2C-19 oil pump, removal and installation 2.0L SPI engine, 2A-11 2.0L Zetec-E engine, 2B-22 2.3L and 2005 2.0L engines, 2C-17 overhaul disassembly sequence, 2D-7 reassembly sequence, 2D-16 piston rings, installation, 2D-17 piston/connecting rod assemblies inspection, 2D-14 installation and bearing clearance check, 2D-18

removal, 2D-10

So

IND-3 ee

repair operations possible with the engine in the vehicle, 2C-3 timing belt covers, removal and installation, 2.0L Zetec-E engine, 2B-7 timing belt, removal, inspection and installation 2.0L SPI engine, 2A-3

2.0L Zetec-E engine, 2B-9 timing belt tensioner and sprockets, removal and installation, 2.0L Zetec-E engine, 2B-11 timing chain cover, removal and installation, 2C-8 timing chain tensioner and guides, removal, inspection and installation, 2C-10

Top Dead Center (TDC) for Number 1 piston, locating 2.0L SPI engine, 2A-2 2.0L Zetec-E engine, 2B-3 2.3L and 2005 2.0L engines, 2C-4 valve clearances, checking and adjustment

2.0L Zetec-E engine, 2B-6 2.3L and 2005 2.0L engines, 2C-14 valve cover, removal and installation 2.0L SPI engine, 2A-5 2.0L Zetec-E engine, 2B-5 valve lifter clearance checking, 2.0L SPI engine, 2A-3

valve springs, retainers and seals, replacement, 2A-7 Engine coolant (antifreeze), general information, 3-2 Engine mounts, check and replacement 2.0L SPI engine, 2A-14 2.0L Zetec-E engine, 2B-27 Engine oil and filter change, 1-10 Engine overhaul disassembly sequence, 2D-7 general information, 2D-2 reassembly sequence, 2D-16

Engine, 2.0L SPI, 2A-1 through 2A-12 Engine, 2.0L Zetec-E, 2B-1 through 2B-28 Engine, 2.3L and 2005 2.0L, 2C-1 through 2C-22 Engine/transaxle removal methods and precautions, 2D-3 removal, separation and replacement, 2D-4 Evaporative loss emission control system, component replacement, 4B-2 Exhaust Gas Recirculation (EGR) system, component replacement, 4B-3 Exhaust manifold, removal and installation, 2C-7 Exhaust system check, 1-17 general information, removal and installation, 4A-20 Expansion tank and radiator, removal, inspection and installation, 3-5 Exterior light units, removal and installation, 12-14 Exterior mirror and glass, removal and installation, 11-18

Fenderwell liner, removal and installation, 11-36 Filter replacement air, 1-16 engine oil, 1-10 interior ventilation, 1-20

PCV, 1-16 Fluid cooler, automatic transaxle, removal and installation, 7B-4 Fluid level checks, 1-6

IND-4

Index

Fluid pan, automatic transaxle, removal and installation, 7B-3 Flywheel/driveplate, removal and installation

2.0L SPI engine, 2A-11 2.0L Zetec-E engine, 2B-26 2.3L and 2005 2.0L engines, 2C-20 Fraction/decimal/millimeter equivalents, 0-17 Front brake caliper, removal, overhaul and installation, 9-3 disc, inspection, removal and installation, 9-4

pads, replacement, 9-2 Front crossmember/stabilizer bar and links, removal and installation, 10-7 Front hub and bearings, inspection and replacement, 10-4 Front suspension lower arm balljoint, replacement, 10-9 lower arm, removal, overhaul and installation, 10-9 strut assembly, removal and installation, 10-5 strut, overhaul, 10-6

Fuel and exhaust systems, 4A-1 through 4A-20 cut-off switch, removal and installation, 4A-11 filter replacement, 1-24 injection system check, 4A-11 components, removal and installation, 4A-12

lines and fittings, general information, 4A-3 pressure regulator, removal and installation, 4A-13 pump/fuel gauge sender unit, removal and installation, 4A-8 pump/fuel pressure, check, 4A-5 rail and injectors, removal and installation, 4A-12 system check, 1-16 system, depressurization, 4A-2 tank filler pipe, removal and installation, 4A-9 tank roll-over valves, removal and installation, 4A-9 tank, removal, inspection and installation, 4A-6 Fuel filler door and lock cylinder, removal and installation, 11-36 Fuel filter replacement, 1-24 Fuses, relays and timer module, testing and replacement, 12-3

G Gear lever and shift cables, removal and installation, 7A-3 General engine overhaul procedures, 2D-1 through 2D-20 Glovebox, removal and installation, 11-34

H

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Headlight and front foglight beam alignment, checking and adjustment, 12-15 Headlight leveling motor, removal and installation, 12-16 Heater/air conditioning controls, removal and installation, 3-9 Heater/ventilation components, removal and installation, 3-7 Hood lock, removal, installation and adjustment, 11-9 Hood, removal, installation and adjustment, 11-8 Horn, removal and installation, 12-18

Hub and bearings, inspection and replacement front, 10-5 rear, 10-9 Hydraulic pipes and hoses, inspection, removal and installation, 9-10 Hydraulic system, bleeding, 9-11

Idle speed control valve, removal and installation, 4A-13 Ignition system, 5B-1 through 5B-6 coils, removal, testing and installation, 5B-5 general information and precautions, 5B-1 sensors, removal and installation, 5B-5 testing, 5B-2

timing, checking and adjustment, 5B-6 troubleshooting, 5B-3 Initial start-up after overhaul, 2D-20 Instrument cluster components, removal and installation, 12-17 cluster, removal and installation, 12-17 panel, removal and installation, 11-34 Intake air temperature sensor, removal and installation, 4A-14 Interior mirror, removal and installation, 11-19 Interior trim panels, removal and installation, 11-31 Introduction, 0-5

J Jacking and towing, 0-13

Jump starting, 0-13

L Liftgate lock components, removal and installation, 11-22 removal and installation, 11-21 wiper motor assembly, removal and installation, 12-20 Lubricants and chemicals, 0-15 Lubricants, fluids and capacities, 1-1

M Main and connecting rod bearings, inspection, 2D-15 Maintenance schedule, 1-5 Maintenance techniques, tools and working facilities, 0-7 Major body damage, repair, 11-6 Malfunction indicator light, 4B-4 Manifolds, removal and installation, 4A-16 Manual transaxle, 7A-1 through 7A-10 back-up light switch, removal and installation, 7A-6 lubricant level check and change, 1-20 oil seals, replacement, 7A-6 oil, draining and refilling, 7A-7 removal and installation, 7A-7 shift cables and gear lever, removal and installation, 7A-3 shift cables, adjustment, 7A-2 Mass airflow sensor, removal and installation, 4A-14

IND-5

Index SS

S

Master cylinder, removal and installation, 9-8 Minor body damage, repair, 11-2 Mirror, removal and installation exterior, 11-18 interior, 11-19

O Oil and filter change, 1-10 Oil filter housing, removal and installation, 2C-19 Oil pan, removal and installation 2.0L SPI engine, 2A-10

2.0L Zetec-E engine, 2B-21 2.3L and 2005 2.0L engines, 2C-16 Oil pressure warning light switch, removal and installation, 2C-19 Oil pump, removal and installation 2.0L SPI engine, 2A-11 2.0L Zetec-E engine, 2B-22

Rear brake drum, removal, inspection and installation, 9-5 shoes, replacement, 9-5 Rear hub and bearings, inspection and replacement, 10-9 Rear suspension coil springs, removal and installation, 10-12 crossmember, removal and installation, 10-14 front lower arm, removal and installation, 10-13 rear lower arm, removal and installation, 10-12 shock absorber, removal, testing and installation, 10-10 stabilizer bar and links, removal and installation, 10-11 trailing arm, removal and installation, 10-13 upper arm, removal and installation, 10-13 Rear wheel cylinders, removal, overhaul and installation, 9-7 Recommended lubricants, fluids and capacities, 1-1 Relays, fuses and timer module, testing and replacement, 12-3 Routine maintenance schedule, 1-5

2.3L and 2005 2.0L engines, 2C-17 Oil seals, replacement, 7A-3 On-Board Diagnostic system (OBD-II) and diagnostic trouble codes, 4B-4 Oxygen sensors, removal and installation, 4B-4

p Parking brake cables, removal and installation, 9-13 lever, removal and installation, 9-13 PCV valve and filter replacement, 1-16

Piston rings, installation, 2D-17 Piston/connecting rod assemblies inspection, 2D-14 installation and bearing clearance check, 2D-18 removal, 2D-10 Power brake booster, testing, removal and installation, 9-11 Power door lock system components, testing, removal and installation, 11-25 Power steering fluid cooler, removal and installation, 10-19 fluid level check, 1-9 gear boots, replacement, 10-18 hydraulic system, bleeding, 10-18 pressure switch, removal and installation, 4A-16 pump, removal and installation, 10-18 rack, removal and installation, 10-17 Powertrain control module (PCM), removal and installation, 4A-14 Pressure-conscious regulator valve (non-ABS models), removal and installation, 9-12

R Radiator and expansion tank, removal, inspection and installation, 3-5 ;

electric cooling fan(s), testing, removal and installation, 3-4 grille, removal and installation, 11-8 Radio antenna, removal and installation, 12-25 Radio/cassette player (Audio Unit), removal and installation, 12-24

S Safety first!, 0-18 Seat belts, removal and installation, 11-28 Seats, removal and installation, 11-27 Selector cable, automatic transaxle, removal, installation and adjustment, 7B-2 Selector components, automatic transaxle, removal and installation, 7B-2 Shift cables adjustment, 7A-2 and gear lever, removal and installation, 7A-3 Shock absorber, rear, removal, testing and installation, 10-10 Shoes, rear brake, replacement, 9-5 Spark plug replacement, 1-21 type and gap, 1-2 wire check and replacement, 1-22 Speakers, removal and installation, 12-25 Stabilizer bar and links, removal and installation front, 10-7 rear, 10-11 Starter motor removal and installation, 5A-6 testing and overhaul, 5A-6 Starting and charging systems, 5A-1 through 5A-6 Starting system general information and precautions, 5A-5

testing, 5A-6 Steering angles and wheel alignment, general information, 10-20 Steering column, removal, inspection and installation, 10-15 fluid cooler, removal and installation, 10-19 gear boots, replacement, 10-18 gear, removal and installation, 10-17 hydraulic system, bleeding, 10-18 knuckle and hub assembly, removal and installation, 10-2 pump, removal and installation, 10-18 wheel, removal and installation, 10-14

IND-6 get ss

aE

Index eS

A

a

eG

ER

Sunroof, removal, installation and adjustment, 11-25 Support struts, removal and installation, 11-22 Suspension and steering check, 1-18 and steering systems, 10-1 through 10-20 crossmember, rear, removal and installation, 10-14 front lower arm, rear, removal and installation, 10-13 lower arm balljoint, front, replacement, 10-9 lower arm, front, removal, overhaul and installation, 10-9 rear lower arm, rear, removal and installation, 10-12

strut assembly, front overhaul, 10-6 removal and installation, 10-5 trailing arm, rear, removal and installation, 10-13 upper arm, rear, removal and installation, 10-13

Switches, removal and installation, 12-4

+ Thermostat, removal, testing and installation, 3-3 Throttle body housing, removal and installation, 4A-12 Throttle position sensor, removal and installation, 4A-16 Tie-rod ends, replacement, 10-19 Timer module, fuses and relays, testing and replacement, 12-3 Timing belt covers, removal and installation, 2.0L Zetec-E engine, 2B-7 Timing belt tensioner and sprockets, removal and installation, 2.0L Zetec-E engine, 2B-11 Timing belt, removal, inspection and installation 2.0L SPI engine, 2A-3 2.0L Zetec-E engine, 2B-9 Timing chain cover, removal and installation, 2C-8 Timing chain, tensioner and guides, removal, inspection and installation, 2C-10 Tire and tire pressure checks, 1-8 Tire rotation, 1-17 Top Dead Center (TDC) for Number 1 piston, locating 2.0L SPI engine, 2A-2

2.0L Zetec-E engine, 2B-3 2.3L and 2005 2.0L engines, 2C-4 Torque specifications Torque specifications can be found in the chapter that deals with the particular component being serviced Towing the vehicle, 0-13 Traction control system, general information, 9-13 Traction control/AdvanceTrac control components, removal and installation, 9-13 Trailing arm, rear suspension, removal and installation, 10-13 Transaxle, automatic, 7B-1 through 7B-8 fluid and filter change, 1-23 cooler, removal and installation, 7B-4 level check, 1-9 pan, removal and installation, 7B-3 oil seals, replacement, 7B-3 overhaul, general information, 7B-5 removal and installation, 7B-4 selector

RS

I A

I

OTE

TL

IEE

FEE

IEE NOS

DELETES

cable, removal, installation and adjustment, 7B-2 components, removal and installation, 7B-2 sensors, removal and installation, 7B-3

troubleshooting, general, 7B-2 Transaxle, manual 7A-1 through 7A-10 back-up light switch, removal and installation, 7A-6 lubricant level check and change, 1-20 oil seals, replacement, 7A-6 oil, draining and refilling, 7A-7 overhaul, general information, 7A-10 removal and installation, 7A-7 shift cables and gear lever, removal and installation, 7A-3 adjustment, 7A-2 Trouble codes, 4B-4 Troubleshooting, 0-19 Trunk lid lock components, removal and installation, 11-20 removal and installation, 11-19 Tune-up and routine maintenance, 1-1 through 1-24 Tune-up, general information, 1-6

U Underhood hose check and replacement, 1-11 Unleaded gasoline, general information and usage, 4A-3 Upholstery and carpets, maintenance, 11-2

V Vacuum booster unit vacuum hose and non-return valve, removal, testing and installation, 9-12 Valve clearances, checking and adjustment

2.0L Zetec-E engine, 2B-6 2.3L and 2005 2.0L engines, 2C-14 Valve cover, removal and installation 2.0L SPI engine, 2A-5 2.0L Zetec-E engine, 2B-5 Valve springs, retainers and seals, replacement, 2A-7 Valve lifter clearance checking, 2.0L SPI engine, 2A-3 Vehicle identification numbers, 0-6 Vehicle speed sensor, removal and installation, 7A-5 Voltage regulator and alternator brushes, installation, 5A-5

W Water pump, check, removal and installation, 3-6 Wheel alignment and steering angles, general information, 10-20 Wheel cylinders, removal, overhaul and installation, 9-7 Window regulator, removal and installation, 11-13 Windshield and fixed windows, removal and installation, 11-25 wiper blade check and replacement, 1-15 wiper motor and linkage, removal and installation, 12-18 Windshield/liftgate washer system components, removal and installation, 12-23 Wiper arms, removal and installation, 12-18 Wiring diagrams, general information, 12-28

Haynes Automotive Manuals NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.

HAYNES XTREME CUSTOMIZING 11101 11102 11410 11150 11213

Sport Sport In-car Sport Acura

11255 11314 11315 11373

GM Full-size Pick-ups Ford Focus Full-size Ford Pick-ups Honda Civic

12020 12021

Integra ’86 thru ’89 & Legend ’86 thru ’90 Integra ’90 thru 93 & Legend ’91 thru ’95

_ ACURA

Compact Customizing Compact Performance Entertainment Utility Vehicle Customizing

AMC 14020 14025

Jeep CJ - see JEEP (50020) Mid-size models '70 thru ’83 (Renault) Alliance & Encore ’83 thru ’87

AUDI 15020 15025 15026

4000 all models ’80 thru ’87 5000 all models ’77 thru ’83 5000 all models ’84 thru ’88

AUSTIN-HEALEY Sprite - see MG Midget (66015)

BMW 18020 ' 18021 18022

18025 18050

3/5 Series not including diesel or all-wheel drive models ’82 thru ’92 3-Series incl. Z3 models ’92 thru ’98 3-Series, E46 chassis ’99 thru ’05, Z4 models ’03 thru ’05 320i all 4 cyl models ’75 thru ’83 1500 thru 2002 except Turbo ’59 thru ’77

BUICK 19010 19020

19025

19030

Buick Century ’97 thru ’05 Century (front-wheel drive) - see GM (38005) Buick, Oldsmobile & Pontiac Full-size (Front-wheel drive) ’85 thru ’05 Buick Electra, LeSabre and Park Avenue; Oldsmobile Delta 88 Royale, Ninety Eight and Regency; Pontiac Bonneville Buick Oldsmobile & Pontiac Full-size (Rear wheel drive) Buick Estate ’70 thru ’90, Electra’70 thru ’84, LeSabre ’70 thru ’85, Limited ’74 thru ’79 Oldsmobile Custom Cruiser ’70 thru ’90, Delta 88 ’70 thru ’85,Ninety-eight ’70 thru ’84 Pontiac Bonneville ’70 thru ’81, Catalina ’70 thru ’81, Grandville ’70 thru ’75, Parisienne ’83 thru ’86 Mid-size Regal & Century all rear-drive models with V6, V8 and Turbo ’74 thru ’87 Regal - see GENERAL MOTORS (38010) Riviera - see GENERAL MOTORS (38030) Roadmaster - see CHEVROLET (24046) Skyhawk - see GENERAL MOTORS (38015) Skylark - see GM (38020, 38025) Somerset - see GENERAL MOTORS (38025)

CADILLAC 21030

Cadillac Rear Wheel Drive all gasoline models ’70 thru ’93 Cimarron - see GENERAL MOTORS (38015) DeVille - see GM (38031 & 38032) Eldorado - see GM (38030 & 38031) Fleetwood - see GM (38031) Seville - see GM (38030, 38031 & 38032)

CHEVROLET 24010 24015 24016 24017 24020 24024

24027 24032 24040 24041 10305 24045

24046

24048

Astro & GMC Safari Mini-vans ’85 thru ’03 Camaro V8 all models ’70 thru ’81 Camaro all models ’82 thru ’92 Camaro & Firebird ’93 thru 02 Cavalier - see GENERAL MOTORS (38016) Celebrity - see GENERAL MOTORS (38005) Chevelle, Malibu & El Camino ’69 thru ’87 Chevette & Pontiac T1000 ’76 thru ’87 Citation - see GENERAL MOTORS (38020) Colorado & GMC Canyon ’04 thru ’06 Corsica/Beretta all models ’87 thru ’96 Corvette all V8 models ’68 thru ’82 Corvette all models ’84 thru ’96 Chevrolet Engine Overhaul Manual Full-size Sedans Caprice, Impala, Biscayne, Bel Air & Wagons ’69 thru ’90 Impala SS & Caprice and Buick Roadmaster ’91 thru ’96 Impala - see LUMINA (24048) Lumina ’90 thru ’94 - see GM (38010) Lumina & Monte Carlo ’95 thru ’05 Lumina APV - see GM (38035)

24050

Luv Pick-up all 2WD & 4WD ’72 thru ’82 Malibu ’97 thru ’00 - see GM (38026) Monte Carlo all models '70 thru ’88 Monte Carlo ’95 thru ’01 - see LUMINA (24048) 24059 Nova all V8 models ’69 thru ’79 24060 Nova and Geo Prizm ’85 thru ’92 24064 Pick-ups ’67 thru ’87 - Chevrolet & GMC, all V8 & in-line 6 cyl, 2WD & 4WD ’67 thru ’87; Suburbans, Blazers & Jimmys ’67 thru ’91 24065 Pick-ups ’88 thru ’98 - Chevrolet & GMC, full-size pick-ups ’88 thru ’98, C/K Classic ’99 & ’00, Blazer & Jimmy '92 thru ’94; Suburban ’92 thru ’99; Tahoe & Yukon ’95 thru ’99 24066 Pick-ups ’99 thru ’03 - Chevrolet Silverado & GMC Sierra full-size pick-ups ’99 thru 05, Suburban/Tahoe/Yukon/Yukon XL ’00 thru ’05 24070 S-10 & S-15 Pick-ups ’82 thru ’93, Blazer & Jimmy ’83 thru 94, 24071 S-10 & Sonoma Pick-ups ’94 thru ’04, Blazer & Jimmy ’95 thru 04, Hombre ’96 thru ’01 24072 Chevrolet TrailBlazer & TrailBlazer EXT, GMC Envoy & Envoy XL, Oldsmobile Bravada 02 and ’03 24075 Sprint '85 thru ’88 & Geo Metro ’89 thru ’01 24080 Vans - Chevrolet & GMC ’68 thru ’96 24081 Chevrolet Express & GMC Savana Full-size Vans ’96 thru ’05

EAGLE

24055

CHRYSLER 25015

Chrysler Cirrus, Dodge Stratus, Plymouth Breeze 95 thru ’00 Chrysler Engine Overhaul Manual Full-size Front-Wheel Drive ’88 thru ’93 K-Cars - see DODGE Aries (30008) Laser - see DODGE Daytona (30030) Chrysler LHS, Concorde, New Yorker, Dodge Intrepid, Eagle Vision, '93 thru ’97 Chrysler LHS, Concorde, 300M, Dodge Intrepid, ’98 thru ’03 Chrysler 300 ’05 thru ’07 Chrysler & Plymouth Mid-size front wheel drive ’82 thru ’95 Rear-wheel Drive - see Dodge (30050) PT Cruiser all models ’01 thru ’03 Chrysler Sebring, Dodge Avenger ’95 thru ’05

10310 25020 25025 25026 25027 25030 25035 25040

DATSUN 28005 28007 28009 28012 28014

200SxX all models ’80 thru ’83 B-210 all models ’73 thru ’78 210 all models ’79 thru ’82 240Z, 260Z & 280Z Coupe ’70 thru ’78 280ZX Coupe & 2+2 ’79 thru ’83 300ZX - see NISSAN (72010) 510 & PL521 Pick-up ’68 thru ’73 510 all models ’78 thru ’81

28018 28020 28022

720 Series Pick-up - see NISSAN (72030) 810/Maxima all gasoline models, ’77 thru ’84

DODGE

30016 30020 30021 30022

30023 30025

30034 30035 30036 30040 30041 30042 30045 30050 30055 30060 30065

10355 36004 36006 36008 36012 10320 36016 36020 36022 36024 36025 36028 36030 36032 36034 36036 36044 36048 36049 36050 36051 36052 36054 36058 36059 36060 36061 36062 36066 36070 36071 36074 36075 36078 36082 36086 36090 36094 36097

Daytona & Chrysler Laser ’84 thru ’89

Intrepid - see CHRYSLER (25025, 25026) Neon all models ’95 thru ’99 Omni & Plymouth Horizon ’78 thru ’90 Dodge and Plymouth Neon ’00 thru’05 Pick-ups all full-size models ’74 thru ’93 Pick-ups all full-size models ’94 thru ’01 Dodge Full-size Pick-ups ’02 thru ’05 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups ’79 thru ’93 Dodge/Plymouth/Chrysler RWD ’71 thru ’89 Shadow & Plymouth Sundance ’87 thru ’94 Spirit & Plymouth Acclaim ’89 thru ’95 Vans - Dodge & Plymouth ’71 thru ’03

Ford Automatic Transmission Overhaul Aerostar Mini-vans all models ’86 thru ’97 Contour & Mercury Mystique ’95 thru ’00 Courier Pick-up all models ’72 thru ’82 Crown Victoria & Mercury Grand Marquis ’88 thru ’00 Ford Engine Overhaul Manual Escort/Mercury Lynx all models ’81 thru ’90 Escort/Mercury Tracer ’91 thru ’00 Ford Escape & Mazda Tribute ’01 thru ’03 Explorer & Mazda Navajo ’91 thru ’01 Ford Explorer & Mercury Mountaineer ’02 thru ’06 Fairmont & Mercury Zephyr ’78 thru ’83 Festiva & Aspire ’88 thru ’97 Fiesta all models ’77 thru ’80 Focus all models ’00 thru ’05 Ford & Mercury Full-size ’75 thru ’87 Ford & Mercury Mid-size ’75 thru ’86 Mustang V8 all models ’64-1/2 thru ’73 Mustang Mustang Mustang, Mustang Mustang Pick-ups Pick-ups

II 4 cyl, V6 & V8 models ’74 thru ’78

& Mercury Capri all models ’79 thru ’93; Capri, 79 thru ’86 all models ’94 thru ’03 ’05 thru ’07 & Bronco ’73 thru ’79 & Bronco ’80 thru ’96 F-150 & Expedition ’97 thru ’03, F-250 ’97 thru ’99 & Lincoln Navigator ’98 thru ’02 Super Duty Pick-ups, Excursion '99 thru ’06

F-150 full-size 04 thru ’06 Pinto & Mercury Bobcat ’75 thru ’80 Probe all models ’89 thru ’92 Ranger/Bronco Il gasoline models ’83 thru ’92 Ranger ’93 thru 05 & Mazda Pick-ups ’94 thru ’05 Taurus & Mercury Sable ’86 thru ’95 Taurus & Mercury Sable ’96 thru ’05 Tempo & Mercury Topaz ’84 thru ’94 Thunderbird/Mercury Cougar ’83 thru ’88 Thunderbird/Mercury Cougar ’89 and ’97 Vans all V8 Econoline models ’69 thru ’91

Vans full size ’92 thru ’05 Windstar Mini-van ’95 thru ’03

GENERAL MOTORS 10360 38005 38010 38015

Caravan & Plymouth Voyager ’84 thru ’95 Caravan & Plymouth Voyager ’96 thru ’02 Challenger/Plymouth Saporro ’78 thru ’83 Caravan, Chrysler Voyager, Town & Country ’03 thru ’06 Colt & Plymouth Champ ’78 thru ’87 Dakota Pick-ups all models ’87 thru ’96 Durango ’98 &’99, Dakota ’97 thru ’99 Dodge Durango models ’00 thru ’03 Dodge Dakota models ’00 thru ’03 Dodge Durango & Dakota ’04 thru ’06 Dart, Demon, Plymouth Barracuda,

124 Sport Coupe & Spider ’68 thru ’78 X1/9 all models ’74 thru ’80

FORD

400 & 600 - see CHRYSLER (25030) Aries & Plymouth Reliant ’81 thru ’89

Duster & Valiant 6 cyl models '67 thru ’76

30030

34010 34025

620 Series Pick-up all models ’73 thru ’79

28025

30008 30010 30011 30012 30013

FIAT

Talon - see MITSUBISHI (68030, 68031) Vision - see CHRYSLER (25025)

38016 38020 38025 38026 38027 38030 38031 38032 38035 38036

GEO

GM Automatic Transmission Overhaul Buick Century, Chevrolet Celebrity, Oldsmobile Cutlass Ciera & Pontiac 6000 all models ’82 thru ’96 Buick Regal, Chevrolet Lumina, Oldsmobile Cutlass Supreme & Pontiac Grand Prix (FWD) ’88 thru ’05 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza & Pontiac J-2000 & Sunbird ’82 thru ’94 Chevrolet Cavalier & Pontiac Sunfire ’95 thru ’04 Buick Skylark, Chevrolet Citation, Olds Omega, Pontiac Phoenix ’80 thru ’85 Buick Skylark & Somerset, Oldsmobile Achieva & Calais and Pontiac Grand Am all models ’85 thru ’98 Chevrolet Malibu, Olds Alero & Cutlass, Pontiac Grand Am ’97 thru ’03 Chevrolet Malibu ’04 thru ’07 Cadillac Eldorado ’71 thru ’85, Seville ’80 thru ’85, Oldsmobile Toronado ’71 thru ’85, Buick Riviera ’79 thru ’85 Cadillac Eldorado & Seville ’86 thru ’91, DeVille ’86 thru ’93, Fleetwood & Olds , Toronado ’86 thru '92, Buick Riviera ’86 thru ’93 Cadillac DeVille '94 thru '05 & Seville ’92 thru ’04 Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport all models ’90 thru ’96 Chevrolet Venture, Olds Silhouette, Pontiac Trans Sport & Montana ’97 thru ’05 General Motors Full-size

Rear-wheel Drive - see BUICK (19025) . Metro - see CHEVROLET Sprint (24075) Prizm - ’85 thru 92 see CHEVY (24060), ’93 thru '02 see TOYOTA Corolla (92036)

(Continued on other side)

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514 ¢ (805) 498-6703

e

AN

Haynes Automotive

Manuals (continued)

Le

Sawesg

40030

®

NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.

Storm all models ’90 thru ’93 Tracker - see SUZUKI Samurai (90010)

GMC Vans & Pick-ups - see CHEVROLET

68030 68031 68035 68040

Eclipse, Eagle Talon & Ply. Laser ’90 thru ’94 Eclipse ’95 thru ’01, Eagle Talon ’95 thru ’98 Mitsubishi Galant ’94 thru ’03 Pick-up ’83 thru ’96 & Montero ’83 thru ’93

HONDA

NISSAN

42010 42011 42012 42013 42014 42015 42020 42021 42022 42023 42024 42025

72010 72015 72020 72021 72030 72031

Accord CVCC all models ’76 thru ’83 Accord all models ’84 thru ’89 Accord all models ’90 thru 93 Accord all models ’94 thru ’97 Accord all models ’98 thru ’02 Honda Accord models ’03 thru '05 Civic 1200 all models ’73 thru ’79 Civic 1300 & 1500 CVCC ’80 thru ’83 Civic 1500 CVCC all models ’75 thru ’79 Civic all models ’84 thru ’91 Civic & del Sol ’92 thru ’95 Civic ’96 thru ’00, CR-V ’97 thru ’01, Acura Integra ’94 thru ’00 Civic ’01 thru ’04, CR-V ’02 thru ’04 Honda Odyssey all models ’99 thru ’04 Prelude CVCC all models ’79 thru ’89

42026 42035 42040

HYUNDAI 43010 43015

Elantra all models ’96 thru ’01 Excel & Accent all models ’86 thru ’98

300ZX all models including Turbo ’84 thru ’89 Altima all models ’93 thru ’04 Maxima all models ’85 thru ’92 Maxima all models ’93 thru ’04 Pick-ups ’80 thru ’97 Pathfinder ’87 thru ’95 Frontier Pick-up ’98 thru ’04, Xterra ’00 thru 04, Pathfinder ’96 thru ’04 Pulsar all models ’83 thru ’86 Quest - see MERCURY Villager (64200) Sentra all models ’82 thru ’94 Sentra & 200SX all models ’95 thru ’04 Stanza all models ’82 thru ’90

72040 72050 72051 72060

OLDSMOBILE 73015

Cutlass V6 & V8 gas models ’74 thru ’88 For other OLDSMOBILE titles, see BUICK, CHEVROLET or GENERAL MOTORS listing.

PLYMOUTH For PLYMOUTH titles, see DODGE listing.

PONTIAC

ISUZU 47017

Hombre - see CHEVROLET S-10 (24071) Rodeo ’91 thru ’02; Amigo ’89 thru ’94 and

47020

Trooper & Pick-up ’81 thru ’93

’98 thru ’02; Honda Passport ’95 thru ’02

XJ6 all 6 cyl models ’68 thru ’86 XJ6 all models ’88 thru ’94 XJ12 & XJS all 12 cyl models ’72 thru ’85

JEEP 50010

Cherokee, Comanche & Wagoneer Limited all models ’84 thru ’01 CJ all models ’49 thru ’86 Grand Cherokee all models ’93 thru 04 Grand Wagoneer & Pick-up ‘72 thru ’91 Grand Wagoneer ’84 thru ’91, Cherokee & Wagoneer ’72 thru ’83, Pick-up ’72 thru ’88 Wrangler all models ’87 thru ’03 Liberty ’02 thru ’04

50020 50025 50029 50030

50035

KIA 54070

Sephia ’94 thru ’01, Spectra ’00 thru ’04

LEXUS

ES 300 - see TOYOTA Camry (92007)

LINCOLN Navigator - see FORD Pick-up (36059) Rear-Wheel Drive all models ’70 thru 05

59010 61010 61011 61015 61016 61020

61030 61035 61036 61040 61041 61042

GLC Hatchback (rear-wheel drive) ’77 thru ’83 GLC (front-wheel drive) ’81 thru ’85 323 & Protogé ’90 thru ’00 MX-5 Miata ’90 thru ’97 MPV all models ’89 thru ’94 Navajo - see Ford Explorer (36024) Pick-ups ’72 thru ’93 Pick-ups ’94 thru ’00 - see Ford Ranger (36071) RX-7 all models ’79 thru ’85 RX-7 all models ’86 thru ’91 626 (rear-wheel drive) all models ’79 thru ’82 626/MX-6 (front-wheel drive) ’83 thru ’92

626 93 thru 01, MX-6/Ford Probe ’93 thru ’01

MERCEDES-BENZ 63012

123 Series Diesel '76 thru ’85

63015

190 Series four-cyl gas models, ’84 thru ’88 230/250/280 6 cyl sohc models ’68 thru ’72 280 123 Series gasoline models ’77 thru ’81 350 & 450 all models ’71 thru ’80

63020 63025 63030

MERCURY 64200

Villager & Nissan Quest ’93 thru ’01 All other titles, see FORD Listing.

MG 66010

MGB Roadster & GT Coupe ’62 thru ’80

66015

MG Midget, Austin Healey Sprite ’58 thru ’80

MITSUBISHI 68020

Cordia, Tredia, Galant, Precis & Mirage ’83 thru ’93

Spitfire all models 62 thru ’81 TR7 all models ’75 thru ’81

VW 96008 96009 96016

Beetle & Karmann Ghia '54 thru ’79 New Beetle ’98 thru ’00 Rabbit, Jetta, Scirocco & Pick-up gas models ’75 thru ’92 & Convertible ’80 thru ’92

96017

Golf, GTI & Jetta ’93 thru ’98 & Cabrio ’95 thru ’98 Golf, GTI, Jetta & Cabrio ’99 thru ’02 Rabbit, Jetta & Pick-up diesel '77 thru ’84 Passat 98 thru ’01, Audi A4 ’96 thru ’01 Transporter 1600 all models ’68 thru ’79 Transporter 1700, 1800 & 2000 ’72 thru ’7S Type 3 1500 & 1600 all models ’63 thru '73 Vanagon all air-cooled models ’80 thru ’83

96018 96020 96023 96030 96035 96040 96045

VOLVO 97010 97015 97020 97040 97050

120, 140 240 740 850

130 Series & 1800 Sports 61 thru ’73 Series all models ’66 thru ’74 Series all models ’76 thru ’93 & 760 Series all models ’82 thru ’88 Series all models ’93 thru ’97

TECHBOOK

MANUALS

79008

Fiero all models ’84 thru ’88

79018 79019 79040

Firebird V8 models except Turbo ’70 thru ’81 Firebird all models ’82 thru ’92 Mid-size Rear-wheel Drive ’70 thru ’87 For other PONTIAC titles, see BUICK,

10210 10215

Automotive Computer Codes OBD-II & Electronic Engine Management Systems Automotive Emissions Control Manual Fuel Injection Manual, 1978 thru 1985

10220 10225

Fuel Injection Manual, 1986 thru 1999 Holley Carburetor Manual

10230 10240 10305 10310 10320 10330 10340 10341 10345 10355 10360 10405 10410 10411 10415 10420 10425 10430 10435 10440 10445 10450 10452

Rochester Carburetor Manual Weber/Zenith/Stromberg/SU Carburetors Chevrolet Engine Overhaul Manual Chrysler Engine Overhaul Manual Ford Engine Overhaul Manual GM and Ford Diesel Engine Repair Manual Small Engine Repair Manual, 5 HP & Less Small Engine Repair Manual, 5.5 - 20 HP Suspension, Steering & Driveline Manual Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul Automotive Body Repair & Painting Automotive Brake Manual Automotive Anti-lock Brake (ABS) Systems Automotive Detaiing Manual Automotive Electrical Manual Automotive Heating & Air Conditioning Automotive Reference Manual & Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual

CHEVROLET or GENERAL MOTORS listing.

PORSCHE 80020 80025 80030 80035

911 914 924 944

except Turbo & Carrera 4 ’65 thru ’89 all 4 cyl models ’69 thru ’76 all models including Turbo ’76 thru ’82 all models including Turbo ’83 thru ’89

RENAULT Alliance & Encore - see AMC (14020)

SAAB 84010

900 all models including Turbo ’79 thru ’88

SATURN 87010 87011 87020

Saturn all models ’91 thru ’02 Saturn lon ’03 thru ’07 Saturn all L-series models ’00 thru ’04

SUBARU 89002 89003 89100

1100, 1300, 1400 & 1600 ’71 thru ’79 1600 & 1800 2WD & 4WD ’80 thru ’94 Legacy all models ’90 thru ’98

89101

Legacy & Forester ’00 thru 06

SUZUKI

MAZDA

94007 94010

10205 10206

JAGUAR 49010 49011 49015

TRIUMPH

90010

Samurai/Sidekick & Geo Tracker ’86 thru '01

TOYOTA 92005 92006 92007 92008 92015 92020 92025 92030 92032 92035

Camry all models ’83 thru ’91 Camry all models ’92 thru ’96 Camry, Avalon, Solara, Lexus ES 300 ’97 thru ’01 Toyota Camry, Avalon and Solara and Lexus ES 300/330 all models ’02 thru '05 Celica Rear Wheel Drive ’71 thru ’85 Celica Front Wheel Drive ’86 thru ’99 Celica Supra all models ’79 thru ’92 Corolla all models ’75 thru ’79 Corolla all rear wheel drive models ’80 thru ’87 Corolla all front wheel drive models ’84 thru ’92

92036

Corolla & Geo Prizm ’93 thru ’02

92037 92040 92045 92050

Corolla models ’03 thru ’05 Corolla Tercel all models ’80 thru ’82 Corona all models ’74 thru ’82 Cressida all models ’78 thru ’82

92055 92056 92065

Land Cruiser FJ40, 43, 45, 55 ’68 thru ’82 Land Cruiser FJ60, 62, 80, FZJ80 ’80 thru ’96 MR2 alli models ’85 thru ’87

92070 92075 92076

Pick-up all models ’69 thru ’78 Pick-up all models ’79 thru ’95 Tacoma ’95 thru ’04, 4Runner ’96 thru '02,

92078 92080 92082 92085 92090 92095

& T100 ’93 thru ’98 Tundra ’00 thru 02 & Sequoia ’01 thru ’02 Previa all models ’91 thru ’95 RAV4 all models ’96 thru ’02 Tercel all models ’87 thru ’94 Toyota Sienna all models ’98 thru ’02 Highlander & Lexus RX-330 ’99 thru ’06

ATV Basics Scooters, Automatic Transmission 50cc to 250cc

SPANISH MANUALS 98903 98904 98905 98910 98913 98915 99040

99041 99042

99055 99075 99077 99088 99091 99095 99100

99106

99110 99118

99125

Reparacién de Carroceria & Pintura Carburadores para los modelos Holley & Rochester Cédigos Automotrices de la Computador: Frenos Automotriz Electricidad Automotriz Inyeccién de Combustible 1986 al 1999 Chevrolet & GMC Camionetas ’67 al ’87

Incluye Suburban, Blazer & Jimmy ’67 al ’91 Chevrolet & GMC Camionetas ’88 al ’98 Incluye Suburban ’92 al ’98, Blazer & Jimmy ’92 al 94, Tahoe y Yukon ’95 al ’98 Chevrolet & GMC Camionetas Cerradas ’68 al 95 Dodge Caravan & Plymouth Voyager ’84 al 95 Ford Camionetas y Bronco ’80 al 94 Ford Camionetas Cerradas ’69 al ’91 Ford Modelos de Tamafio Mediano '75 al ’86 Ford Taurus & Mercury Sable ’86 al ’95

GM Modelos de Tamafio Grande ’70 al ’90 GM Modelos de Tamajfio Mediano

70 al ’88 Jeep Cherokee, Wagoneer & Comanche *84 al ’00 Nissan Camioneta ’80 al '96, Pathfinder ’87 al ’95 Nissan Sentra ’82 al ’94

Toyota Camionetas y 4Runner ’79 al ‘95 Over 100 Haynes motorcycle manuals also available

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514 e (805) 498-6703

10-06

Common

spark plug conditions NORMAL Symptoms: Brown to grayish-tan color and slight electrode wear. Correct heat range for engine and operating conditions. Recommendation: When new spark plugs are installed, replace with plugs of the same heat range.

WORN

TOO HOT

Symptoms: Rounded electrodes with a small amount of deposits on the firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy. Recommendation: Plugs have been left in the engine too long. Replace with new plugs of the same heat range. Follow the recommended maintenance schedule.

Symptoms: Blistered, white insulator, eroded electrode and absence of deposits. Results in shortened plug life. Recommendation: Check for the correct plug heat range, overadvanced ignition timing, lean fuel mixture, intake manifold vacuum leaks, sticking valves and insufficient engine cooling.

CARBON

DEPOSITS

Symptoms: Dry sooty deposits indicate a rich mixture or weak ignition. Causes misfiring, hard starting

and hesitation. Recommendation: Make sure the plug has the correct heat range. Check for a clogged air filter or problem in the fuel system or engine management system. Also check for ignition system problems.

ASH DEPOSITS Symptoms: Light brown deposits encrusted on the side or center electrodes or both. Derived from oil and/or fuel additives. Excessive amounts may mask the spark, causing misfiring and hesitation during acceleration. Recommendation: lf excessive deposits accumulate over a short time or low mileage, install new valve guide seals to prevent seepage of oil into the combustion chambers. Also try changing gasoline brands.

OIL DEPOSITS Symptoms: Oily coating caused by poor oil control. Oil is leaking past worn valve guides or piston rings into the combustion chamber. Causes hard starting, misfiring and hesitation. Recommendation: Correct the mechanical condition with necessary repairs and install new plugs.

PREIGNITION Symptoms: Melted electrodes. Insulators are white, but may be dirty due to misfiring or flying debris in the combustion chamber. Can lead to engine damage.

Recommendation:

Check for the

correct

range,

plug

heat

HIGH SPEED GLAZING Symptoms: Insulator has yellowish, glazed appearance. Indicates that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits

melt to form a conductive coating. Causes misfiring at high speeds. Recommendation: _ |nstall new plugs. Consider using a colder plug if driving habits warrant.

DETONATION Symptoms: Insulators may be cracked or chipped. Improper gap setting techniques can also result in a fractured insulator tip. Can lead to piston damage. Recommendation: Make sure the fuel anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine.

MECHANICAL GAP BRIDGING Symptoms: Combustion deposits lodge between the electrodes. Heavy deposits accumulate and bridge the electrode gap. The plug ceases to fire, resulting in a dead cylinder. Recommendation: Locate the faulty plug and remove the deposits from between the electrodes.

over-

advanced ignition timing, lean fuel mixture, insufficient engine cooling and lack of lubrication.

DAMAGE

Symptoms: May be caused by a foreign object in the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylinder and could result in piston damage. Recommendation: Repair the mechanical damage. Remove the foreign object from the engine and/or install the correct reach plug.

™Cooling andheating m Air conditioning m Fuel and exhaust aM taalixjle)aromere) ayice) | Blelaniireya!

= Brakes m Suspension and steering m Electrical systems Lila late melt-\e]¢-laats

Chapter 2 PartB

3.0L V6 engine

A 9.5b An exploded view of the distributor drive adapter assembly

@

Step-by-step procedures linked to hundreds of easy-to-follow photos and illustrations

d

Complete troubleshooting section helps a

:

3

Ko (=Yaltiavars) el=tel}i(em e)xe)e)(=\pats

&

9.5a To remove the distributor drive

adapter, remove the distributor hold-down nut (upper arrow), remove the distributor and remove the three adapter retaining bolts (arrows)

Written from hands-on experience

ring between

and the cylinder (see Chapter 5) and the ad tions). Note: /f you remove the adapter, skip the following Steps de: replacement. Pry out seal New seal with the ada;

g

h_ means the shallow recess

s i" sprocket holding tool to tighten the bolt to the torque in this Chapter’s Specifications 11 Installation of the remaining components is the revers moval 10

Rocker arm and hydraulic valve

lash adjusters - check, removal, inspection, and installation

seal installation tool as 9.6 To extract a camshaft seal, drill a couple of small holes in the old seal, thread a pair of sheetmetal screws into the holes and pry the seal out with a screwdriver and a claw hammer

y

=Check Refer to illustration 10.1

heck the hydraulic lash adjusters

fo

based on a vehicle teardown using commonly available tools

Haynes tips give valuable short cuts to make the job easier and:eliminate the need 1(0) ax)e=\e)[=| cele)[s)

rocker arm while lightly all down (see illustra-

Notes, Cautions and Warnings for idat=male)aalomanl=\ear-lalle Color spark plug diagnosis Moise winawes)

s 9.7a You can press a new seal into place with a section of pipe and a bolt of the proper size and thread pitch (don't let the camshaft turn as the bolt is tightened)

S 9.7b As a last resort, you can also drivea cam seal into place with a hammer and a large socket, but make sure you don't damage the sprocket positioning pin on the end of the camshaft

10.1 When performing the freeplay test, make sure the adjuster that’s being tested has the corresponding camshaft lobe pointing away from the rocker arm (closed valve)

ersts\VAN CO MUM Lile (=>4 ISBN-13: 978-1-56392-584-9

Models covered by this manual: ._.

Ford Focus models «2000 thru 2005

9"781563"925

{|

ISBN 1 56392 584 2 799-3077

ABCDEFGHI

Does not include information specific to SVT and rear disc brake models

OMNS8345"36034!

Ils