Ford Cus 2007 PDF

2007.
50 Focus - Vietnam
Workshop Manual
Table of Contents
GROUP 1 General Information GROUP 3 Powertrain
Service Information Engine
General Information 100-00 Engine System - General
Identification Codes 100-01 Information 303-00
Jacking and Lifting 100-02 Engine - 2.0L Duratec-HE (MI4)/1.8L
Noise, Vibration and Duratec-HE (MI4) 303-01A
Harshness 100-04 Engine - 1.6L (Z6) 303-01B
Engine Cooling - 2.0L Duratec-HE
GROUP 2 Chassis (MI4)/1.8L Duratec-HE
(MI4) 303-03A
Engine Cooling - 1.6L (Z6) 303-03B
Suspension
Fuel Charging and Controls - 2.0L
Suspension System - General Duratec-HE (MI4)/1.8L Duratec-HE
Information 204-00 (MI4) 303-04A
Front Suspension 204-01 Fuel Charging and Controls - 1.6L
Rear Suspension 204-02 (Z6) 303-04B
Wheels and Tires 204-04 Accessory Drive 303-05
Driveline Starting System 303-06
Front Drive Halfshafts 205-04 Engine Ignition - 2.0L Duratec-HE
Brake System (MI4)/1.8L Duratec-HE
Brake System - General (MI4) 303-07A
Information 206-00 Engine Ignition - 1.6L (Z6) 303-07B
Drum Brake 206-02 Engine Emission Control - 2.0L
Front Disc Brake 206-03 Duratec-HE (MI4)/1.8L Duratec-HE
Rear Disc Brake 206-04 (MI4) 303-08A
Parking Brake and Actuation 206-05 Engine Emission Control - 1.6L
Hydraulic Brake Actuation 206-06 (Z6) 303-08B
Power Brake Actuation 206-07 Intake Air Distribution and
Anti-Lock Control 206-09A Filtering 303-12
Anti-Lock Control - Traction Evaporative Emissions 303-13
Control 206-09B Electronic Engine Controls 303-14
Anti-Lock Control - Stability Automatic Transmission/Transaxle
Assist 206-09C Automatic Transmission/Transaxle -
Steering System Vehicles With: 4-Speed Automatic
Steering System - General Transmission (4F27E) 307-01
Information 211-00 Transmission/Transaxle Cooling -
Power Steering 211-02 Vehicles With: 4-Speed Automatic
Steering Linkage 211-03 Transmission (4F27E) 307-02
Steering Column 211-04 Automatic Transmission/Transaxle
Steering Column Switches 211-05 External Controls - Vehicles With:
4-Speed Automatic Transmission
(4F27E) 307-05
2007.50 Focus
Manual Transmission/Transaxle, Clutch and Instrumentation and Warning Systems
Transfer Case Instrument Cluster and Panel
Manual Transmission/Transaxle and Illumination 413-00
Clutch - General Information 308-00 Instrument Cluster 413-01
Clutch - Vehicles With: 5-Speed Manual Horn 413-06
Transmission (iB5) 308-01A Clock 413-07
Clutch - Vehicles With: 5-Speed Manual Information and Message
Transmission (MTX-75) 308-01B Center 413-08
Clutch - Vehicles With: 5-Speed Manual Warning Devices 413-09
Transmission (F35M-R) 308-01C Parking Aid 413-13
Clutch Controls - Vehicles With: Battery and Charging System
5-Speed Manual Transmission Charging System - General
(iB5) 308-02A Information 414-00
Clutch Controls - Vehicles With: Battery, Mounting and Cables 414-01
5-Speed Manual Transmission Generator and Regulator 414-02
(MTX-75) 308-02B
Clutch Controls - Vehicles With: Information and Entertainment Systems
5-Speed Manual Transmission Information and Entertainment System
(F35M-R) 308-02C - General Information 415-00
Manual Transmission/Transaxle - Audio Unit 415-01A
Vehicles With: 5-Speed Manual Information and Entertainment
Transmission (iB5) 308-03A System 415-01B
Manual Transmission/Transaxle - Antenna 415-02
Vehicles With: 5-Speed Manual Speakers 415-03
Transmission (MTX-75) 308-03B Lighting
Manual Transmission/Transaxle - Exterior Lighting 417-01
Vehicles With: 5-Speed Manual Interior Lighting 417-02
Transmission (F35M-R) 308-03C Electrical Distribution
Manual Transmission/Transaxle
External Controls - Vehicles With: Module Communications
iB5/Manual Transaxle 308-06A Network 418-00
Manual Transmission/Transaxle Module Configuration 418-01
External Controls - Vehicles With: Electronic Feature Group
5-Speed Manual Transmission Anti-Theft - Active 419-01A
(MTX-75) 308-06B Anti-Theft - Passive 419-01B
Exhaust System Cellular Phone 419-08
Exhaust System 309-00 Multifunction Electronic
Modules 419-10
Fuel System
Fuel System - General GROUP 5 Body and Paint
Information 310-00
Fuel Tank and Lines 310-01
Acceleration Control 310-02 Body and Paint
Speed Control 310-03 Front End Body Panels 501-02
Body Closures 501-03
Interior Trim and
GROUP 4 Electrical Ornamentation 501-05
Exterior Trim and
Climate Control System Ornamentation 501-08
Climate Control System - General Rear View Mirrors 501-09
Information 412-00 Seating 501-10
Air Distribution and Filtering 412-01 Glass, Frames and
Heating and Ventilation 412-02 Mechanisms 501-11
Air Conditioning 412-03 Instrument Panel and Console 501-12
Control Components 412-04 Handles, Locks, Latches and Entry
Systems 501-14
2007.50 Focus
Wipers and Washers 501-16 Front End Sheet Metal Repairs 501-27
Roof Opening Panel 501-17 Roof Sheet Metal Repairs 501-28
Bumpers 501-19 Side Panel Sheet Metal
Safety Belt System 501-20A Repairs 501-29
Supplemental Restraint Rear End Sheet Metal Repairs 501-30
System 501-20B Paint - General Information 501-36
Body Repairs - General Frame and Mounting
Information 501-25 Uni-Body, Subframe and Mounting
Body Repairs - Vehicle Specific System 502-00
Information and Tolerance
Checks 501-26
To the best of our knowledge, the illustrations,
technical information, data and descriptions in
this issue were correct at the time of going to
print. The right to change prices, specifications,
equipment and maintenance instructions at
any time without notice is reserved as part of
FORD policy of continuous development and
improvement for the benefit of our customers.
No part of this publication may be reproduced,

stored in a data processing system or
transmitted in any form, electronic, mechanical,
photocopy, recording, translation or by any
other means without prior permission of
Ford-Werke Aktiengesellschaft. No liability can
be accepted for any inaccuracies in this
publication, although every possible care has
been taken to make it as complete and
accurate as possible.
Copyright ©
FORD-WERKE AKTIENGESELLSCHAFT
Service training programs D-F/GT-1
Printed in Germany - rewi druckhaus, Wissen

-
Printed on environmentally friendly

chlorine-free paper. (GB)
2007.50 Focus
GROUP
General Information 1
SECTION TITLE PAGE
Service Information
General Information.......................................................................................................100-00
Identification Codes.......................................................................................................100-01
Jacking and Lifting.........................................................................................................100-02
Noise, Vibration and Harshness....................................................................................100-04
2007.50 Focus
GROUP
Chassis 2
SECTION TITLE PAGE
Suspension
Suspension System - General Information....................................................................204-00
Front Suspension...........................................................................................................204-01
Rear Suspension...........................................................................................................204-02
Wheels and Tires...........................................................................................................204-04
Driveline
Front Drive Halfshafts....................................................................................................205-04
Brake System
Brake System - General Information..............................................................................206-00
Drum Brake....................................................................................................................206-02
Front Disc Brake............................................................................................................206-03
Rear Disc Brake.............................................................................................................206-04
Parking Brake and Actuation.........................................................................................206-05
Hydraulic Brake Actuation..............................................................................................206-06
Power Brake Actuation..................................................................................................206-07
Anti-Lock Control...........................................................................................................206-09A
Anti-Lock Control - Traction Control...............................................................................206-09B
Anti-Lock Control - Stability Assist.................................................................................206-09C
Steering System
Steering System - General Information..........................................................................211-00
Power Steering...............................................................................................................211-02
Steering Linkage............................................................................................................211-03
Steering Column............................................................................................................211-04
Steering Column Switches.............................................................................................211-05
2007.50 Focus
GROUP
Powertrain 3
SECTION TITLE PAGE
Engine
Engine System - General Information............................................................................303-00
Engine2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)..................................................303-01A
Engine1.6L (Z6).............................................................................................................303-01B
Engine Cooling2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4).....................................303-03A
Engine Cooling1.6L (Z6)................................................................................................303-03B
Fuel Charging and Controls2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4).................303-04A
Fuel Charging and Controls1.6L (Z6)............................................................................303-04B
Accessory Drive.............................................................................................................303-05
Starting System..............................................................................................................303-06
Engine Ignition2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)......................................303-07A
Engine Ignition1.6L (Z6).................................................................................................303-07B
Engine Emission Control2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)......................303-08A
Engine Emission Control1.6L (Z6).................................................................................303-08B
Intake Air Distribution and Filtering................................................................................303-12
Evaporative Emissions...................................................................................................303-13
Electronic Engine Controls.............................................................................................303-14
Automatic Transmission/Transaxle
Automatic Transmission/TransaxleVehicles With: 4-Speed Automatic Transmission
(4F27E)......................................................................................................................307-01
Transmission/Transaxle CoolingVehicles With: 4-Speed Automatic Transmission
(4F27E)......................................................................................................................307-02
Automatic Transmission/Transaxle External ControlsVehicles With: 4-Speed
Automatic Transmission (4F27E)...............................................................................307-05
Manual Transmission/Transaxle, Clutch and Transfer Case
Manual Transmission/Transaxle and Clutch - General Information...............................308-00
ClutchVehicles With: 5-Speed Manual Transmission (iB5)............................................308-01A
ClutchVehicles With: 5-Speed Manual Transmission (MTX-75)....................................308-01B
ClutchVehicles With: 5-Speed Manual Transmission (F35M-R)....................................308-01C
Clutch ControlsVehicles With: 5-Speed Manual Transmission (iB5).............................308-02A
Clutch ControlsVehicles With: 5-Speed Manual Transmission (MTX-75)......................308-02B
Clutch ControlsVehicles With: 5-Speed Manual Transmission (F35M-R).....................308-02C
Manual Transmission/TransaxleVehicles With: 5-Speed Manual Transmission
(iB5)............................................................................................................................308-03A
(MTX-75)....................................................................................................................308-03B
(F35M-R)....................................................................................................................308-03C
2007.50 Focus
Manual Transmission/Transaxle External ControlsVehicles With: iB5/Manual
Transaxle....................................................................................................................308-06A
Manual Transmission/Transaxle External ControlsVehicles With: 5-Speed Manual
Transmission (MTX-75)..............................................................................................308-06B
Exhaust System
Exhaust System.............................................................................................................309-00
Fuel System
Fuel System - General Information................................................................................310-00
Fuel Tank and Lines.......................................................................................................310-01
Acceleration Control.......................................................................................................310-02
Speed Control................................................................................................................310-03
2007.50 Focus
GROUP
Electrical 4
SECTION TITLE PAGE
Climate Control System

Climate Control System - General Information..............................................................412-00
Air Distribution and Filtering...........................................................................................412-01
Heating and Ventilation..................................................................................................412-02
Air Conditioning..............................................................................................................412-03
Control Components......................................................................................................412-04
Instrumentation and Warning Systems
Instrument Cluster and Panel Illumination.....................................................................413-00
Instrument Cluster..........................................................................................................413-01
Horn...............................................................................................................................413-06
Clock..............................................................................................................................413-07
Information and Message Center...................................................................................413-08
Warning Devices............................................................................................................413-09
Parking Aid.....................................................................................................................413-13
Battery and Charging System
Charging System - General Information........................................................................414-00
Battery, Mounting and Cables........................................................................................414-01
Generator and Regulator...............................................................................................414-02
Information and Entertainment Systems
Information and Entertainment System - General Information......................................415-00
Audio Unit......................................................................................................................415-01A
Information and Entertainment System.........................................................................415-01B
Antenna..........................................................................................................................415-02
Speakers........................................................................................................................415-03
Lighting
Exterior Lighting.............................................................................................................417-01
Interior Lighting..............................................................................................................417-02
Electrical Distribution
Module Communications Network.................................................................................418-00
Module Configuration.....................................................................................................418-01
Electronic Feature Group
Anti-Theft - Active..........................................................................................................419-01A
Anti-Theft - Passive........................................................................................................419-01B
Cellular Phone...............................................................................................................419-08
2007.50 Focus
Multifunction Electronic Modules...................................................................................419-10
2007.50 Focus
GROUP
Body and Paint 5

SECTION TITLE PAGE
Body and Paint

Front End Body Panels..................................................................................................501-02
Body Closures................................................................................................................501-03
Interior Trim and Ornamentation....................................................................................501-05
Exterior Trim and Ornamentation...................................................................................501-08
Rear View Mirrors..........................................................................................................501-09
Seating...........................................................................................................................501-10
Glass, Frames and Mechanisms....................................................................................501-11
Instrument Panel and Console.......................................................................................501-12
Handles, Locks, Latches and Entry Systems................................................................501-14
Wipers and Washers......................................................................................................501-16
Roof Opening Panel.......................................................................................................501-17
Bumpers.........................................................................................................................501-19
Safety Belt System.........................................................................................................501-20A
Supplemental Restraint System.....................................................................................501-20B
Body Repairs - General Information..............................................................................501-25
Body Repairs - Vehicle Specific Information and Tolerance Checks.............................501-26
Front End Sheet Metal Repairs......................................................................................501-27
Roof Sheet Metal Repairs..............................................................................................501-28
Side Panel Sheet Metal Repairs....................................................................................501-29
Rear End Sheet Metal Repairs......................................................................................501-30
Paint - General Information............................................................................................501-36
Frame and Mounting
Uni-Body, Subframe and Mounting System...................................................................502-00
2007.50 Focus
100-00-1 General Information 100-00-1
.
SECTION 100-00 General Information

VEHICLE APPLICATION:2007.50 Focus
CONTENTS PAGE
DESCRIPTION AND OPERATION

About This Manual.............................................................................................................. 100-00-3
Introduction......................................................................................................................... 100-00-3
Special Tools...................................................................................................................... 100-00-3
Important Safety Instructions.............................................................................................. 100-00-3
Warnings, Cautions and Notes in This Manual.................................................................. 100-00-3
Overview Procedures......................................................................................................... 100-00-3
Trustmark Authoring Standards (TAS) Removal and Installation Procedures.................... 100-00-4
How to Use This Manual.................................................................................................... 100-00-13
Health and Safety Precautions........................................................................................... 100-00-15
Introduction......................................................................................................................... 100-00-15
Acids and Alkalis................................................................................................................ 100-00-15
Air Bags.............................................................................................................................. 100-00-15
Air Conditioning Refrigerant............................................................................................... 100-00-15
Adhesives and Sealers....................................................................................................... 100-00-16
Antifreeze........................................................................................................................... 100-00-17
Asbestos............................................................................................................................. 100-00-17
Battery Acids...................................................................................................................... 100-00-17
Brake and Clutch Linings and Pads................................................................................... 100-00-17
Brake Fluids (Polyalkylene Glycols)................................................................................... 100-00-17
Brazing............................................................................................................................... 100-00-17
Chemical Materials............................................................................................................. 100-00-17
Chlorofluorocarbons (CFC)................................................................................................ 100-00-18
Clutch Fluids....................................................................................................................... 100-00-18
Clutch Linings and Pads..................................................................................................... 100-00-18
Corrosion Protection Materials........................................................................................... 100-00-18
Cutting................................................................................................................................ 100-00-18
Dewaxing............................................................................................................................ 100-00-19
Dusts.................................................................................................................................. 100-00-19
Electric Shock..................................................................................................................... 100-00-19
Engine Oils......................................................................................................................... 100-00-19
Exhaust Fumes................................................................................................................... 100-00-19
Fibre Insulation................................................................................................................... 100-00-19
Fire..................................................................................................................................... 100-00-19
First Aid.............................................................................................................................. 100-00-20
Fluoroelastomer.................................................................................................................. 100-00-20
Foams - Polyurethane........................................................................................................ 100-00-20
Freon.................................................................................................................................. 100-00-20
Fuels................................................................................................................................... 100-00-20
Gas Cylinders..................................................................................................................... 100-00-21
Gases................................................................................................................................. 100-00-21
Gaskets (Fluoroelastomer)................................................................................................. 100-00-21
General Workshop Tools and Equipment........................................................................... 100-00-21
High Pressure Air, Lubrication and Oil Test Equipment...................................................... 100-00-22
Halon.................................................................................................................................. 100-00-22
.
Legal Aspects..................................................................................................................... 100-00-22
Lubricants and Greases..................................................................................................... 100-00-22
Transmission Fluids............................................................................................................ 100-00-22
Noise.................................................................................................................................. 100-00-23
Noise Insulation Materials.................................................................................................. 100-00-23
O-Rings (Fluoroelastomer)................................................................................................. 100-00-23
Paints.................................................................................................................................. 100-00-23
Pressurized Equipment...................................................................................................... 100-00-24
Solder................................................................................................................................. 100-00-24
Solvents.............................................................................................................................. 100-00-24
Sound Insulation................................................................................................................. 100-00-24
Suspended Loads............................................................................................................... 100-00-24
Transmission Brake Bands................................................................................................. 100-00-25
Underseal........................................................................................................................... 100-00-25
Viton.................................................................................................................................... 100-00-25
Welding............................................................................................................................... 100-00-25
Warning Symbols on Vehicles............................................................................................ 100-00-26
White Spirit......................................................................................................................... 100-00-27
Standard Workshop Practices............................................................................................ 100-00-28
Vehicle in Workshop........................................................................................................... 100-00-28
Alternative Fuel................................................................................................................... 100-00-28
Alternative Fuel — Do's...................................................................................................... 100-00-28
Alternative Fuel — Do Nots................................................................................................ 100-00-28
Towing the Vehicle.............................................................................................................. 100-00-29
Connecting a Slave Battery Using Jumper Cables............................................................ 100-00-29
Component Cleaning.......................................................................................................... 100-00-30
Calibration of Essential Measuring Equipment................................................................... 100-00-30
Solvents, Sealants and Adhesives..................................................................................... 100-00-31
Introduction......................................................................................................................... 100-00-31
Road/Roller Testing............................................................................................................ 100-00-32
Pre-Test Checks................................................................................................................. 100-00-32
Starting the Engine............................................................................................................. 100-00-32
Road or Roller Testing........................................................................................................ 100-00-32
Brake Testing...................................................................................................................... 100-00-33
Air Conditioning (A/C) System Health and Safety Precautions.......................................... 100-00-34
Battery and Battery Charging Health and Safety Precautions............................................ 100-00-35
Engine Cooling System Health and Safety Precautions..................................................... 100-00-36
Petrol Fuel System Health and Safety Precautions............................................................ 100-00-37
Supplemental Restraint System (SRS) Health and Safety Precautions............................. 100-00-38
Window Glass Health and Safety Precautions................................................................... 100-00-39
About This Manual

Introduction CAUTION: Cautions are used to indicate
that failure to follow a procedure correctly
This manual has been written in a format that is may result in damage to the vehicle or
designed to meet the needs of technicians equipment being used.
worldwide. The objective is to use common formats
and include similar content in each manual. NOTE: Notes are used to provide additional
essential information required to carry out a
This manual provides general descriptions for complete and satisfactory repair.
accomplishing diagnosis and testing, service and
repair work with tested, effective techniques. As you read through this manual, you will come
Following them will help assure reliability. across WARNINGS, CAUTIONS and NOTES.
A warning, caution or note is placed at the
beginning of a series of steps if it applies to multiple
Special Tools steps. If the warning, caution or note only applies
to one step, it is placed at the beginning of the
The special tool(s) table provided at the beginning specific step (after the step number).
of each procedure shows all special tools required
to carry out a repair. Where possible, illustrations
are provided to assist in identifying the special tool Overview Procedures
required.
Overview procedures contain an exploded view
illustration(s). The numbered sequence within the
Important Safety Instructions illustration(s) indicate the order to be followed when
removing/disassembling or when
Appropriate service methods and correct repair installing/assembling a component. Additional
procedures are essential for the safe, reliable information, symbol(s) or a torque figure, may also
operation of all motor vehicles as well as the be shown alongside the component.
personal safety of the individual carrying out the
work. There are ten symbols used to give additional
information when removing/disassembling or when
This manual cannot possibly anticipate all such installing/assembling a component.
variations and provide advice or cautions as to
each. Anyone who departs from the instructions
provided in this manual must first establish that he
1 2 3 4 5 6 7 8 9 10
compromises neither his personal safety nor the
vehicle integrity by his choice of methods, tools or
components.
Warnings, Cautions and Notes in This

Manual
WARNING: Warnings are used to indicate
that failure to follow a procedure correctly TIE42918
may result in personal injury.
Item Designation Description

1 Special tool A special tool is required for this component. There will also
be a removal or installation symbol alongside the special
tool symbol.
2 Install new component Discard the old component and install a new component.
3 Inspect Check the component for damage.
2007.50 Focus 3/2007 G935689en

Item Designation Description

4 Apply sealant Apply sealant to the component as specified in the materials
table.
5 Apply petroleum jelly Apply petroleum jelly to the component as specified in the
materials table.
6 Apply oil Apply oil to the component as specified in the materials table.
7 Apply fluid Apply fluid to the component as specified in the materials
table.
8 Apply grease Apply grease to the component as specified in the materials
table.
9 Removal or Disassembly Go to the removal or disassembly detail for additional
detail information to remove or disassemble a component
10 Installation or Assembly Go to the installation or assembly detail for additional
detail information to install or assemble a component
Special Tools and Torque Figures NOTE: Removal steps in this procedure may
contain installation details.
Any requirement for special tools will picture the
tool, showing it in use and with its tool number Items such as O-ring seals, gaskets, seals,
shown. Torque settings will be given at the relevant self-locking nuts and bolts are to be discarded and
point in the procedure. new components installed unless otherwise stated
within the procedure. Coated nuts or bolts are to
be reused, unless damaged or otherwise stated
within the procedure.
59 Nm 23-045
Specification procedures will contain all technical
data that are not part of a repair procedure.
TAS Graphics
Colors used in the graphic are as follows:
• Blue - Indicates the target item, item to be
removed/installed or disassembled/assembled
TIA2301151 • Green and Brown - Indicates a secondary item
that needs to be detached, removed/installed
or disassembled/assembled prior to the target
Trustmark Authoring Standards (TAS) item
Removal and Installation Procedures • Magenta - Indicates electrical connectors and
fasteners such as nuts, bolts, clamps or clips
NOTE: TAS style procedures can be identified by • Pale Blue - is for the special tool(s) and general
steps that have no accompanying step text and equipment
the magenta color of the electrical connectors and
fasteners such as nuts, bolts, clamps or clips. There may be multiple steps assigned to one
illustration.
A TAS removal and installation procedure uses a
sequence of color illustrations to indicate the order Numbered pointers are used to indicate the number
to be followed when removing/disassembling or of electrical connectors and fasteners such as nuts,
installing/assembling a component. bolts, clamps or clips.
Many of the TAS procedures will have the Items in the illustration can be transparent or use
installation information within the removal steps. cutouts to show hidden detail(s).
These procedures will have the following note at
the beginning of the procedure:
2007.50 Focus 3/2007 G935689en

2 303-378 205-072
4
1
3 x3
E63828 E60043
TAS Symbols
Symbols are used inside the graphics and in the
text area to enhance the information display. The
following paragraphs describe the various types
and categories of symbols.
Prohibition symbols advise on prohibited actions
to either avoid damage or health and safety related
risks.
E85026
Health and Safety symbols recommend the use of

particular protection equipment to avoid or at least
reduce the risk or severity of possible injuries.
2007.50 Focus 3/2007 G935689en

E85027
Warning symbols are used to indicate potential

risks resulting from a certain component or area.
E85028
2007.50 Focus 3/2007 G935689en

Instruction symbols are used to apply sealer, component.
lubricant, weight, tape or cleaning detergent to a
E84834
Location symbols are used to show the location of

a component or system within the vehicle.
2007.50 Focus 3/2007 G935689en

E84835
Gearshift lever or selector lever position symbols

are used to show which gearshift lever or selector
lever position is to be set.
2007.50 Focus 3/2007 G935689en

308-640
E84836
Pointer symbols are used to draw the attention to located inside the circle. Numbers inside circles
components and give special instructions such as are also used to allocate special information such
a required sequence or number of components. as tightening torques or chemicals to a particular
The number of components is reflected by the component.
value inside the luty arrow. A sequence number is
2007.50 Focus 3/2007 G935689en

3
2
2
x12
E84837
Movement arrows are used to show three

dimensional or rotational movements. These
movements can include specific values inside the
symbol if required.
2007.50 Focus 3/2007 G935689en

E84839
The following graphic illustrates a set of symbols

that are used to provide detailed information on
where to apply a material.
2007.50 Focus 3/2007 G935689en

E84840
Measurement symbols provide detailed information

on where to carry out a specific measurement.
These symbols can include specific values if
required.
2007.50 Focus 3/2007 G935689en

E84841
Special Tools and Torque Figure(s) If components need to be removed or

disassembled in sequence, the sequence will be
Special tools will be shown with the tool number
identified numerically in a graphic and the
in the illustration. The special tool number(s),
corresponding text will be numbered accordingly.
general equipment, material(s) and torque figure(s)
used for the procedure step will be shown in the All left and right-hand references to the vehicle are
text column. taken from a position sitting in the driver seat
looking forward.
How to Use This Manual All left and right-hand references to the engine are
taken from a position at the flywheel looking
This manual covers diagnosis and testing, service towards the front camshaft pulley.
and repair procedures. Where appropriate, instructions will be given for
This manual is structured into groups and sections, the use of the diagnostic tool.
with specific system sections collected together
Inspection and Verification
under their relevant group.
A group covers a specific portion of the vehicle. Visual Inspection Charts, Symptom Charts and
The manual is divided into five groups, General other information charts (such as diagnostic
Information, Chassis, Powertrain, Electrical and routines) or supplement test procedures with
Body and Paint. The number of the group is the technical specifications will navigate the user to a
first number of a section number. specific test procedure.
Pages at the start of the manual list all sections Symptom Chart
available. Each section has a contents list detailing The symptom chart indicates symptoms, sources
Specifications, Description and Operation, and actions to address a condition.
Diagnosis and Testing, In Vehicle Repairs,
Disassembly and Assembly, Removal and
Installation.
2007.50 Focus 3/2007 G935689en

Pinpoint Tests
For electrical systems, pinpoint test steps are used
to identify the source of a concern in a logical,
step-by-step manner. pinpoint tests have two
columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is used exclusively for
graphics and icons (with or without captions) and
the DETAILS/RESULTS/ACTIONS column
provides direction to another test step or specific
corrective actions.
The boxed numbers indicate the order in which the
described action is to be performed.
Component Tests
A component test is used when a component is
tested in multiple pinpoint tests, or if a procedure
is too complicated to be formatted within a single
page of the pinpoint test.
Graphics
Test graphics show the measurement or test to be
performed in a test step.
A representative tester graphic is used for
voltmeters and ohmmeters.
If multiple measurements are made in a single
graphic, the test leads are drawn with a solid line
until the test lead splits to indicate the multiple
measurements, at which point dashed lines are
used.
Breakout box-type testers are represented by a
double circle test pin. Test pins are labeled with
the pin number.
2007.50 Focus 3/2007 G935689en

Health and Safety Precautions

Introduction inflator as this will lead to the risk of exposure to
Sodium Azide. If a gas generator is ruptured, full
Many of the procedures associated with vehicle protective clothing should be worn when dealing
maintenance and repair involve physical hazards with the spillage.
or other risks to health. This subsection lists, After normal deployment, gloves and safety
alphabetically, some of these hazardous operations goggles must be worn during the handling process.
and the materials and equipment associated with
them. Precautions necessary to avoid these Deployed air bags should be disposed of in a
hazards are identified. plastic bag in accordance with local regulations at
an approved chemical waste site.
The list is not exhaustive and all operations and
procedures, and the handling of materials, should Following any direct contact with gas generant.
be carried out with health and safety in mind. – wash affected areas thoroughly with water.
Before using any product the Materials Safety Data – seek medical assistance if necessary.
Sheet supplied by the manufacturer or supplier
Air Bags - Do's
should be consulted.
– Do store modules in an upright position.
– Do keep modules dry.
Acids and Alkalis
– Do carry modules with the cover side pointing
See also Battery Acids. away from the body.
– Do place modules with their cover side upwards.
For example caustic soda, sulphuric acid.
– Do carefully inspect modules for damage.
Used in batteries and cleaning materials.
– Do stand to one side when connecting modules.
Irritant and corrosive to the skin, eyes, nose and – Do make sure all test equipment is properly
throat. Cause burns. Can destroy ordinary calibrated and maintained.
protective clothing.
– Do wash hands after handling deployed air
Avoid splashes to the skin, eyes and clothing. Wear bags.
suitable protective impervious apron, gloves and
Air Bags - Do Nots
goggles. Do not breath mists.
– Do not store highly flammable material together
Make sure access to eye wash bottles, shower and
with modules or gas generators.
soap are readily available for splashing accidents.
– Do not store gas generators at temperatures
Display Eye Hazard sign. exceeding 80°C.
– Do not store modules upside down.
Air Bags – Do not attempt to open a gas generator housing.
– Do not expose gas generators to open flame or
See also Fire, Chemical Materials. sources of heat.
Highly flammable, explosive – observe No Smoking – Do not place anything on top of a module cover.
policy. – Do not use damaged modules.
Used as a safety restraint system mounted in the – Do not touch a fired module or gas generator
steering wheel and passenger side of the for at least 10 minutes.
instrument panel. – Do not use any electrical probes on the wiring
The inflator contains a high-energetic propellant circuit.
which, when ignited, produces a VERY HOT GAS
(2500°C).
Air Conditioning Refrigerant
The gas generant used in air bags is Sodium Azide.
This material is hermetically sealed in the module See also Chlorofluorocarbon, Chemical Materials
and is completely consumed during deployment.
No attempt should be made to open an air bag Highly flammable, combustible – observe No
Smoking policy.
2007.50 Focus 3/2007 G17372en

Skin contact may result in frostbite. Hot Melt Adhesives
Instructions given by the manufacturer must be
In the solid state, they are safe. In the molten state
followed. Avoid naked lights, wear suitable
they may cause burns and health hazards may
protective gloves and goggles.
arise from the inhalation of toxic fumes.
If refrigerant comes into contact with the skin or
Use appropriate protective clothing and a
eyes, immediately rinse the affected areas with
thermostatically controlled heater with a thermal
water. Eyes should also be rinsed with an
cut-out and adequate extraction.
appropriate irrigation solution and should not be
rubbed. SEEK MEDICAL ASSISTANCE IF
NECESSARY.
Resin-based Adhesives/Sealers, for
example Epoxide and Formaldehyde
Air Conditioning Refrigerant - Do Nots Resin-based
Mixing should be carried out in well ventilated

– Do not expose refrigerant bottles to sunlight or
areas, as harmful or toxic volatile chemicals may
heat.
be released.
– Do not stand refrigerant bottles upright; when
filling, hold them with the valve downwards. Skin contact with uncured resins and hardeners
can result in irritation, dermatitis, and absorption
– Do not expose refrigerant bottles to frost.
of toxic or harmful chemicals through the skin.
– Do not drop refrigerant bottles. Splashes can damage the eyes.
– Do not vent refrigerant to atmosphere under any
Provide adequate ventilation and avoid skin and
circumstance.
eye contact.
– Do not mix refrigerants, for example R12 (Freon)
and R134a.
Anaerobic, Cyanoacrylate (super-glues)
Adhesives and Sealers and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin

See also Fire, Chemical Materials.
and respiratory tract. Some are eye irritants.
Highly flammable, flammable, combustible –
Skin and eye contact should be avoided and the
observe No Smoking policy.
manufacturers instructions followed.
Generally should be stored in No Smoking areas.
Cyanoacrylate adhesives (super-glues) MUST NOT
Cleanliness and tidiness in use should be
contact the skin or eyes. If skin or eye tissue is
observed, for example disposable paper covering
bonded, cover with a clean moist pad and SEEK
benches; should be dispensed from applicators
IMMEDIATE MEDICAL ATTENTION. Do not
where possible; containers, including secondary
attempt to pull tissue apart. Use in well ventilated
containers, should be labeled appropriately.
areas as vapors can cause irritation to the nose
and eyes.
Solvent-based Adhesives/Sealers - See For two-pack systems see Resin-based and
Solvents Isocyanate Adhesives/Sealers.
Follow manufacturers instructions.

Isocyanate (Polyurethane)
Adhesives/Sealers
Water-based Adhesives/Sealers
See also Resin-based Adhesives.
Those based on polymer emulsions and rubber
Individuals suffering from asthma or respiratory
latexes may contain small amounts of volatile toxic
allergies should not work with or near these
and harmful chemicals. Skin and eye contact
materials as sensitivity reactions can occur.
should be avoided and adequate ventilation
provided during use. Over exposure is irritating to the eyes and
respiratory system. Excessive concentrations may
produce effects on the nervous system including
2007.50 Focus 3/2007 G17372en

drowsiness. In extreme cases, loss of Asbestos dust waste should be dampened, placed
consciousness may result. Long term exposure to in a sealed container and marked for safe disposal.
vapor concentrations may result in adverse health If any cutting or drilling is attempted on materials
effects. containing asbestos the item should be dampened
Prolonged contact with the skin may have a and only hand tools or low speed power tools used.
defatting effect which may lead to skin irritation
and in some cases, dermatitis. Battery Acids
Splashes entering the eye will cause discomfort
and possible damage. See also Acids and Alkalis.
Any spraying should preferably be carried out in Gases released during charging are explosive.
exhaust ventilated booths, removing vapors and Never use naked flames or allow sparks near
spray droplets from the breathing zone. charging or recently charged batteries.
Wear appropriate gloves, eye and respiratory Make sure there is adequate ventilation.
protection.
Brake and Clutch Linings and Pads
Antifreeze
See Asbestos.
See also Fire, Solvents.
For example isopropanol, ethylene glycol, Brake Fluids (Polyalkylene Glycols)
methanol.
See also Fire.
Highly flammable, flammable, combustible.
Splashes to the skin and eyes are slightly irritating.
Used in vehicle coolant systems, brake air pressure
Avoid skin and eye contact as far as possible.
systems, screenwash solutions.
Inhalation vapor hazards do not arise at ambient
Vapors may be given off from coolant antifreeze temperatures because of the very low vapor
(glycol) when heated. Avoid breathing these pressure.
vapors.
Antifreeze may be absorbed through the skin in Brazing
toxic or harmful quantities. Antifreeze, if swallowed,
can be fatal and MEDICAL ATTENTION SHOULD See Welding.
BE SOUGHT IMMEDIATELY.
These products must not be used in any cooling
Chemical Materials
or industrial water system that is connected or
linked to general, food preparation or drinking water
See also Legal Aspects.
supplies.
Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids,
Asbestos antifreeze, brake fluids, fuels, oils and grease
should always be used with caution and stored and
See also Warning Symbols on Vehicles at the end handled with care. They may be toxic, harmful,
of this subsection. corrosive, irritant or highly flammable and give rise
Breathing asbestos dust may cause lung damage to hazardous fumes and dusts.
or, in some cases, cancer. The effects of excessive exposure to chemicals
Used in brake and clutch linings, transmission may be immediate or delayed; briefly experienced
brake bands and gaskets. or permanent; cumulative; superficial; life
threatening; or may reduce life expectancy.
The use of drum cleaning units, vacuum cleaning
or damp wiping is preferred.
2007.50 Focus 3/2007 G17372en

Chemical Materials - Do's – Do not clean hands or clothing with chemicals.
Chemicals, particularly solvents and fuels, will
– Do carefully read and observe hazard and dry the skin and may cause irritation leading to
precaution warnings given on material dermatitis or be absorbed through the skin in
containers (labels) and in any accompanying toxic or harmful quantities.
leaflets, posters or other instructions. Material – Do not use emptied containers for other
health and safety data sheets can be obtained materials except when they have been cleaned
from manufacturers. under supervised conditions.
– Do remove chemical materials from the skin – Do not sniff or smell chemical materials. Brief
and clothing as soon as practicable after soiling. exposure to high concentrations of fumes can
Change heavily soiled clothing and have it be toxic or harmful.
cleaned.
– Do organize work practices and protective
clothing to avoid soiling of the skin and eyes; Chlorofluorocarbons (CFC)
breathing vapors, aerosols, dusts or fumes;
inadequate container labeling; fire and explosion There is concern in the scientific community that
hazards. CFCs and Halons are depleting the upper ozone
layer which filters out harmful ultraviolet radiation.
– Do wash before job breaks, before eating,
Decreased filtration of ultraviolet radiation may
smoking, drinking or using toilet facilities when
result in increases in skin cancer, cataracts and
handling chemical materials.
immune system suppression in humans, as well
– Do keep work areas clean, uncluttered and free as decreased productivity of crops and aquatic
of spills. systems.
– Do store chemical materials according to CFCs are used primarily as refrigerants in vehicle
national and local regulations. air conditioning systems and as aerosol
– Do keep chemical materials out of the reach of propellants. Halons are used as fire extinguishants.
children.
Clutch Fluids
Chemical Materials - Do Nots
See Brake fluids.
– Do not mix chemical materials except under the
manufacturers instructions; some chemicals can
form other toxic or harmful chemicals, give off Clutch Linings and Pads
toxic or harmful fumes or become explosive
when mixed together. See Asbestos.
– Do not spray chemical materials, particularly
those based on solvents, in confined spaces, Corrosion Protection Materials
for example when people are inside a vehicle.
– Do not apply heat or flame to chemical materials See also Solvents, Fire.
except under the manufacturers instructions. Highly flammable, flammable – observe No
Some are highly flammable and some may Smoking policy.
release toxic or harmful fumes.
These materials are varied and the manufacturers
– Do not leave containers open. Fumes given off instructions must be followed. They may contain
can build up to toxic, harmful or explosive solvents, resins or petroleum products. Skin and
concentrations. Some fumes are heavier than eye contact should be avoided. They should only
air and will accumulate in confined areas such be sprayed in conditions of adequate ventilation
as pits. and not in confined spaces.
– Do not transfer chemical materials to unlabelled
containers.
Cutting
See Welding.
2007.50 Focus 3/2007 G17372en

Dewaxing Engine Oils
See Solvents and Fuels (Kerosene). See Lubricants and Grease.
Dusts Exhaust Fumes

Powder, dusts or clouds may be irritant, harmful These contain asphyxiating, harmful and toxic
or toxic. Avoid breathing dusts from powdery chemicals and particles such as carbon oxides,
chemical materials or those arising from dry nitrogen oxides, aldehydes, lead and aromatic
abrasion operations. Wear respiratory protection hydrocarbons. Engines should be run only under
if ventilation is inadequate. conditions of adequate exhaust extraction or
Fine dusts of combustible material can present an general ventilation and not in confined spaces.
explosion hazard. Avoid explosive limits and
sources of ignition.
Gasoline (petrol) engine
Electric Shock There may not be adequate warning of odor or of

irritation before toxic or harmful effects arise. These
Electric shock can result from the use of faulty may be immediate or delayed.
electrical equipment or from the misuse of
equipment in good condition.
Diesel engine
Make sure that electrical equipment is maintained
in good condition and frequently tested. Faulty Soot, discomfort and irritation usually give
equipment should be labeled and preferably adequate warning of hazardous fume
removed from the workstation. concentrations.
Make sure that flexes, cables, plugs and sockets
are not frayed, kinked, cut, cracked or otherwise
damaged.
Fibre Insulation
Make sure that electrical equipment and flexes do See also Dusts.
not come into contact with water.
Used in noise and sound insulation.
Make sure that electrical equipment is protected
The fibrous nature of surfaces and cut edges can
by the correct rated fuse.
cause skin irritation. This is usually a physical and
Never misuse electrical equipment and never use not a chemical effect.
equipment that is in any way faulty. The results
Precautions should be taken to avoid excessive
could be fatal.
skin contact through careful organization of work
Make sure that the cables of mobile electrical practices and the use of gloves.
equipment cannot get trapped and damaged, such
as in a vehicle hoist.
Fire
Make sure that the designated electrical workers
are trained in basic First Aid. See also Welding, Foams, Legal Aspects.
In cases of electrocution: Many of the materials found on or associated with
– switch off the power supply before approaching the repair of vehicles are highly flammable. Some
the victim. give off toxic or harmful fumes if burnt.
– if this is not possible push or drag the victim Observe strict fire safety when storing and handling
from the source of electricity using dry flammable materials or solvents, particularly near
non-conductive material. electrical equipment or welding processes.
– commence resuscitation if trained to do so. Make sure, before using electrical or welding
– SUMMON MEDICAL ASSISTANCE. equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when
using welding or heating equipment.
2007.50 Focus 3/2007 G17372en

First Aid foams should be conducted with extraction
ventilation. See also the vehicle Body Repair
Apart from meeting any legal requirements it is Manual.
desirable for someone in the workshop to be
trained in First Aid procedures.
Freon
Splashes in the eye should be flushed carefully
with clean water for at least ten minutes. See Air Conditioning Refrigerant.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place Fuels
affected area in cool to cold water.
See also, Fire, Legal Aspects, Chemicals and
Individuals affected by inhalation of gases and
Solvents.
fumes should be removed to fresh air immediately.
If effects persist, consult a doctor. Avoid skin contact with fuel where possible. Should
contact occur, wash the affected skin with soap
If liquids are swallowed inadvertently, consult a
and water.
doctor giving him the information on the container
or label. Do not induce vomiting unless this action
is indicated on the label. Gasoline (Petrol)
Fluoroelastomer Highly flammable - observe No Smoking policy.

Swallowing can result in mouth and throat irritation
See Viton. and absorption from the stomach can result in
drowsiness and unconsciousness. Small amounts
can be fatal to children. Aspiration of liquid into the
Foams - Polyurethane
lungs, through vomiting, is a very serious hazard.
See also Fire. Gasoline dries the skin and can cause irritation
and dermatitis on prolonged or repeated contact.
Used in sound and noise insulation. Cured foams
Liquid in the eye causes severe smarting.
used in seat and trim cushioning.
Motor gasoline may contain appreciable quantities
Follow manufacturers instructions.
of benzene, which is toxic upon inhalation, and the
Unreacted components are irritating and may be concentration of gasoline vapors must be kept very
harmful to the skin and eyes. Wear gloves and low. High concentrations will cause eye, nose and
goggles. throat irritation, nausea, headache, depression and
Individuals with chronic respiratory diseases, symptoms of drunkenness. Very high
asthma, bronchial medical problems, or histories concentrations will result in rapid loss of
of allergic diseases should not work in or near consciousness.
uncured materials. Make sure there is adequate ventilation when
The components, vapors or spray mists can cause handling and using gasoline. Great care must be
direct irritation, sensitivity reactions and may be taken to avoid the serious consequences of
toxic or harmful. inhalation in the event of vapor build up arising
from spillages in confined spaces.
Vapors and spray mists must not be inhaled. These
materials must be applied with adequate ventilation Special precautions apply to cleaning and
and respiratory protection. Do not remove the maintenance operations on gasoline storage tanks.
respirator immediately after spraying; wait until the Gasoline should not be used as a cleaning agent.
vapors/mists have cleared. It must not be siphoned by mouth. See First Aid.
Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical Gas-oil (Diesel Fuel)
equipment during foaming operations and until
Combustible.
vapors/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
2007.50 Focus 3/2007 G17372en

Gross or prolonged skin contact with high boiling If the fuel tank is to be removed for service or repair
point gas oils may also cause serious skin the fuel must be evacuated using dedicated
disorders including skin cancer. equipment and following the specified procedures.
Kerosene (Paraffin) Gas Cylinders
Used also as heating fuel, solvent and cleaning See also Fire.
agent. Gases such as oxygen, acetylene, argon and
Flammable - observe No Smoking policy. propane are normally stored in cylinders at
pressures of up to 138 bar (2000 psi) and great
Irritation of the mouth and throat may result from care should be taken in handling these cylinders
swallowing. The main hazard from swallowing to avoid mechanical damage to them or to the valve
arises if liquid aspiration into the lungs occurs. gear attached. The contents of each cylinder
Liquid contact dries the skin and can cause should be clearly identified by appropriate
irritation or dermatitis. Splashes in the eye may be markings.
slightly irritating. Cylinders should be stored in well-ventilated
In normal circumstances the low volatility does not enclosures, and protected from ice and snow, or
give rise to harmful vapors. Exposure to mists and direct sunlight. Fuel gases, for example acetylene
vapors from kerosene at elevated temperature and propane, should not be stored in close
should be avoided (mists may arise in dewaxing). proximity to oxygen cylinders.
Avoid skin and eye contact and make sure there Care should be exercised to prevent leaks from
is adequate ventilation. gas cylinders and lines, and to avoid sources of
ignition.
Alternative Fuel Only trained personnel should undertake work
involving gas cylinders.
Highly flammable. Observe ``NO SMOKING" signs.
Make sure there is adequate ventilation when Gases
working on alternative fuelled vehicles. Great care
must be taken to avoid the serious consequences See Gas Cylinders.
of inhalation in the event of vapor build up in
confined spaces.
Gaskets (Fluoroelastomer)
Inhalation in high concentrations may cause
dizziness, headache, nausea and loss of See Viton.
co-ordination. Very high concentrations may result
in loss of consciousness.
General Workshop Tools and
Contact with liquefied petroleum gas (LPG) or Equipment
compressed natural gas (CNG) to the skin may
cause cold burns and frost bite. It is essential that all tools and equipment are
Long sleeved cotton overalls, steel toe capped maintained in good condition and that the correct
safety boots and rubber neoprene gloves should safety equipment is used where required.
be worn during removal and installation of Never use tools or equipment for any purpose other
LPG/CNG fuel system components. than that for which they were designed. Never
LPG/CNG fuel leaks could cause a fire and be a overload equipment such as hoists, jacks, axle and
hazard to health that can lead to personal injury, chassis stands or lifting slings. Damage caused by
illness or even death. overloading is not always immediately apparent
and may result in a fatal failure the next time that
If a leak is detected, under no circumstances
the equipment is used.
attempt to seal the leak by tightening the
union/connection until the fuel in the system or
component is depressurized. Once tightened the
system should be checked for integrity following
the specified procedures.
2007.50 Focus 3/2007 G17372en

Do not use damaged or defective tools or Transmission Fluids
equipment, particularly high-speed equipment such
as grinding wheels. A damaged grinding wheel can
disintegrate without warning and cause serious Safety instructions
injury.
Certain Transmission and Power Steering fluids
Wear suitable eye protection when using grinding,
supplied to Ford may contain additives which have
chiseling or sand blasting equipment.
the potential to cause skin disease (dermatitis) to
Wear a suitable breathing mask when using exposed persons. The dermatitis may be irritant
abrasive blasting equipment, working with or allergic in nature. Risks are higher where
asbestos-based materials or using spraying prolonged or repeated skin contact with a fluid may
equipment. occur. These fluids are used for vehicle initial fill
Make sure there is adequate ventilation to control and service purposes. This sub-section is to:
dusts, mists and fumes. • Inform Service personnel who may come into
contact with these vehicle fluids (hazard
communication).
High Pressure Air, Lubrication and Oil
Test Equipment • Summarise appropriate workplace control
measures and personal protective equipment
See also Lubricants and Greases. requirements.
• Draw attention to the existence of Material
Always keep high-pressure equipment in good Safety Datasheets (MSDS's) for the fluids
condition, and regularly maintained, particularly at (available from Ford Customer Service Division).
joints and unions. These MSDS's contain detailed information on
Never direct a high-pressure nozzle, for example hazards and appropriate controls.
diesel injector, at the skin as the fluid may
penetrate to the underlying tissue, and cause
serious injury. Control measures
Workplace risk assessments made under national

Halon chemical control regulations should identify
operations involving the fluids as potentially
See CFCs. hazardous and specify workplace control and
worker awareness measures. In such
Legal Aspects circumstances, the relevant Material Safety
Datasheet (see the details specified below) which
There are many laws and regulations relating to specifies hazards and control measures in detail
health and safety in the use and disposal of should be made available for guidance.
materials and equipment in a workshop. Avoid unprotected skin contact with the fluids, and
For a safe working environment and to avoid in particular, avoid prolonged or repeated skin
environmental pollution, workshops should be contact. Work practices should be organised so as
familiar, in detail, with the many health and safety to minimise the potential for skin contact. This may
laws and regulations within their country, published include the use of drip trays, absorbents, correct
by both national and local authorities. fluid handling equipment (funnels etc), and
workplace housekeeping measures such as the
cleaning of contaminated surfaces.
Lubricants and Greases Personnel engaged in operations where skin
contact could occur (such as fluid draining or filling)
Avoid all prolonged and repeated contact with should wear impervious gloves made from nitrile
mineral oils. All lubricants and greases may be rubber, certified to a chemical protection standard,
irritating to the eyes and skin. e.g. Europe Standard EN374. This glove type is
widely available from reputable suppliers of gloves
for chemical protection [including the manufacturers
Ansell-Admont (Solvex Range), North Safety
products (North Nitrile Latex Gloves range), and
2007.50 Focus 3/2007 G17372en

Marigold Industrial (Blue Nitrile range)]. If gloves Do not employ used engine oils as lubricants or
become torn or contaminated on the inside they for any application where appreciable skin contact
should be replaced. Eye protection with safety is likely to occur.
glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more
extensive exposure is possible. Use of skin barrier Environmental Precautions
creams suitable for work with mineral oil products
may offer some supplementary protection, but such Burning used engine oil in small space heaters or
barrier creams should not be used in place of boilers can be recommended only for units of
protective clothing. approved design. If in doubt check with the
appropriate local authority and manufacturer of
If accidental skin contact occurs with the fluids,
approved appliances.
wash the area thoroughly with soap or skin
cleanser and water. Dispose of used oil and used oil filters through
authorized waste disposal contractors or licensed
Accidental eye contact should be dealt with as per
waste disposal sites, or to the waste oil reclamation
normal first aid practices, by flushing the eyes with
trade. If in doubt, contact the relevant local
an eye wash or clean cool water for 10 minutes,
authority for advice on disposal facilities.
after which medical attention should be obtained.
It is illegal to pour used oil on to the ground, down
Remove and launder clothing which becomes
sewers or drains, or into watercourses.
contaminated with the fluids. Do not place rags
contaminated with fluid in clothing pockets.
Wash thoroughly after completing operations where Noise
skin exposure may have occurred.
Some operations may produce high noise levels,
It is important that personnel do not smoke, eat or which could, in time, damage hearing. In these
drink whilst handling the fluids or affected cases, suitable ear protection must be worn.
transmissions. These measures are designed to
limit the risk from accidental ingestion.
Noise Insulation Materials
Label any decanted fluid properly/use an equivalent
label to that on original product containers. See Foams, Fibre Insulation.
Clean up any spills promptly using an inert
absorbent and wash down contaminated surfaces
with detergent and water. O-Rings (Fluoroelastomer)
Dispose of any waste fluids safely as hazardous See Viton.
waste.
Paints
Safety Data Sheets
See also Solvents, Chemical Materials.
Safety Data Sheets, which detail specific material Highly flammable, flammable - observe No
handling instructions and precautions are available Smoking policy
from the respective national sales company, and
via internet www.msds.ford.com.
One Pack
Used Engine Oil Can contain harmful or toxic pigments, driers and
other components as well as solvents. Spraying
Prolonged and repeated contact with mineral oil should be carried out only with adequate
will result in the removal of natural fats from the ventilation.
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants, which may cause skin
cancer. Adequate means of skin protection and
washing facilities must be provided.
2007.50 Focus 3/2007 G17372en

Two Pack Used in cleaning and dewaxing materials, paints,
plastics, resins and thinners.
Can also contain harmful and toxic unreacted
Some may be highly flammable or flammable.
resins and resin hardening agents. The
manufacturers instructions should be followed. See Skin contact will degrease the skin and may result
also Resin-based Adhesives and Isocyanate in irritation and dermatitis following repeated or
Adhesives and Sealers under Adhesives and prolonged contact. Some can be absorbed through
Sealers. the skin in toxic or harmful quantities.
Spraying should preferably be carried out in Splashes in the eye may cause severe irritation
exhausted ventilated booths removing vapor and and could lead to loss of vision.
spray mists from the breathing zone. Individuals Brief exposure of high concentrations of vapors or
working in booths should wear appropriate mists will cause eye and throat irritation,
respiratory protection. Those doing small-scale drowsiness, dizziness, headaches and, in the worst
repair work in the open workshop should wear circumstances, unconsciousness.
air-fed respirators.
Repeated or prolonged exposure to excessive but
lower concentrations of vapors or mists, for which
Pressurized Equipment there might not be adequate warning indications,
can cause more serious toxic or harmful effects.
See High Pressure Air, Lubrication and Oil Test
Equipment. Aspiration into the lungs, for example through
vomiting, is the most serious consequence of
swallowing.
Solder Avoid splashes to the skin, eyes and clothing. Wear
protective gloves, goggles and clothing if
Solders are mixtures of metals such that the necessary.
melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder Make sure there is good ventilation when in use,
application does not normally give rise to toxic lead avoid breathing fumes, vapors and spray mists and
fumes, provided a gas/air flame is used. keep containers tightly sealed. Do not use in
Oxy-acetylene flames should not be used, as they confined spaces.
are much hotter and will cause lead fumes to be When spraying materials containing solvents, for
produced. example paints, adhesive, coatings, use extraction
Some fumes may be produced by the application ventilation or personal respiratory protection in the
of any flame to surfaces coated with grease, and absence of adequate general ventilation.
inhalation of these should be avoided. Do not apply heat or flame except under specific
Removal of excess solder should be undertaken and detailed manufacturers instructions.
with care, to make sure that fine lead dust is not
produced, which can give toxic effects if inhaled.
Sound Insulation
Respiratory protection may be necessary.
Solder spillage and filings should be collected and See Fibre Insulation, Foams.
removed promptly to prevent general air
contamination by lead.
Suspended Loads
High standards of personal hygiene are necessary
in order to avoid ingestion of lead or inhalation of CAUTION: Never improvise lifting tackle.
solder dust from clothing.
There is always a danger when loads are lifted or
suspended. Never work under an unsupported,
Solvents suspended or raised load, for example a
suspended engine.
See also Chemical Materials, Fuels (Kerosene),
Fire. Always make sure that lifting equipment such as
jacks, hoists, axle stands and slings are adequate
For example acetone, white spirit, toluene, xylene,
and suitable for the job, in good condition and
trichloroethane.
regularly maintained.
2007.50 Focus 3/2007 G17372en

Transmission Brake Bands Welding
See Asbestos. See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding
Underseal (Spot Welding), Arc Welding and Gas Welding.
See Corrosion Protection.

Resistance Welding
Viton This process may cause particles of molten metal
to be emitted at a high velocity, and the eyes and
In common with many other manufacturers skin must be protected.
vehicles, some components have O-rings, seals
or gaskets, which contain a material known as
`Viton'. Arc Welding
Viton is a fluoroelastomer, that is a synthetic rubber
This process emits a high level of ultra-violet
type material, which contains Fluorine. It is
radiation, which may cause arc-eye, and skin burns
commonly used for O-rings, gaskets and seals of
to the operator and to other persons nearby.
all types. Although Viton is the most well known
Gas-shielded welding processes are particularly
fluoroelastomer, there are others, including Fluorel
hazardous in this respect. Personal protection must
and Tecmoflon.
be worn, and screens used to shield other people.
When used under design conditions
CONTACT LENS WEARERS ARE ADVISED TO
fluoroelastomers are perfectly safe. If, however,
REVERT TO ORDINARY SPECTACLES WHEN
they are exposed to temperatures in excess of
ARC WELDING as the arc spectrum is believed to
400°C, the material will not burn, but will
emit microwaves which dry out the fluid between
decompose, and one of the products formed is
the lens and the eye. This may result in blindness
hydrofluoric acid.
when the lens is removed from the eye.
This acid is extremely corrosive and may be
Metal spatter will also occur, and appropriate eye
absorbed directly, through contact, into the general
and skin protection is necessary.
body system.
The heat of the welding arc will produce fumes and
O-rings, seals or gaskets which have been exposed
gases from the metals being welded, the rods and
to very high temperatures will appear charred or
from any applied coatings or contamination on the
as a black sticky substance.
surfaces being worked on. These gases and fumes
DO NOT; under any circumstances touch them or may be toxic and inhalation of these should be
the attached components. avoided. The use of extraction ventilation to remove
Enquiries should be made to determine whether the fumes from the working area may be necessary
Viton or any other fluoroelastomer has been used particularly in cases where the general ventilation
in the affected O-ring, seal or gasket. If they are of is poor, or where considerable welding work is
natural rubber or nitrile there is no hazard. If in anticipated. In extreme cases or confined spaces
doubt, be cautious, as the material may be Viton where adequate ventilation cannot be provided,
or any fluoroelastomer. air-fed respirators may be necessary.
If Viton or any other fluoroelastomers have been

used, the affected area should be decontaminated Gas Welding (and Cutting)
before the commencement of work.
Disposable heavy duty plastic gloves should be Oxy-acetylene torches may be used for welding
worn at all times, and the affected area washed and cutting, and special care must be taken to
down using wire wool and a limewater (calcium prevent leakage of these gases, with consequent
hydroxide) solution to neutralize the acid before risk of fire and explosion.
disposing of the decomposed Viton residue and The process will produce metal spatter and eye
final cleaning of the area. After use, the plastic and skin protection is necessary.
gloves should be discarded carefully and safely.
2007.50 Focus 3/2007 G17372en

The flame is bright, and eye protection should be
used, but the ultra-violet emission is much less
than that from arc welding, and lighter filters may
be used.
The process itself produces few toxic fumes, but
such fumes and gases may be produced from
coatings on the work, particularly during cutting
away of damaged body parts, and inhalation of the
fumes should be avoided.
In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard TIM0101002
may arise if brazing rods containing cadmium are
used. In this event particular care must be taken 2. Components or assemblies displaying the
to avoid inhalation of fumes and expert advice may warning triangle with the `electrified' arrow and
be required. open book symbol give warning of inherent high
SPECIAL PRECAUTIONS MUST BE TAKEN voltages. Never touch these with the engine
BEFORE ANY WELDING OR CUTTING TAKES running or the ignition switched on. See Electric
PLACE ON VESSELS, WHICH HAVE Shock in this subsection.
CONTAINED COMBUSTIBLE MATERIALS, FOR
EXAMPLE BOILING OR STEAMING OUT OF
FUEL TANKS.
Warning Symbols on Vehicles

Decals showing warning symbols will be found on
various vehicle components.
These decals must not be removed. The warnings
are for the attention of owners/operators and
persons carrying out service or repair operations TIM0101003
on the vehicle.
3. Vehicles and replacement components which
The most commonly found decals are reproduced contain asbestos are identified by this symbol.
below together with an explanation of the warnings. See Asbestos in this subsection.
TIM0101001 TIM0101004
1. Components or assemblies displaying the 4. Components or assemblies displaying this

caution triangle and open book symbol advise symbol give warning that the component
consultation of the relevant section of the owner contains a corrosive substance. See Acids and
literature before touching or attempting Alkalis in this subsection.
adjustments of any kind.
2007.50 Focus 3/2007 G17372en

TIM0101005
5. Displaying the caution circle with a deleted

lighted match symbol, caution against the use
of naked lights or flames within the immediate
vicinity due to the presence of highly flammable
or explosive liquids or vapors. See Fire in this
subsection.
TIM0101006
6. Displaying this symbol (normally in conjunction

with 5 above) warn of the presence of potentially
explosive matter within the immediate vicinity.
TIM0101008
7. Displaying this symbol warn that children should

not be allowed in the immediate vicinity
unsupervised.
White Spirit
See Solvents.
2007.50 Focus 3/2007 G17372en

Standard Workshop Practices
Vehicle in Workshop Alternative Fuel — Do's
When working on a vehicle in the workshop always – Do work on the vehicle in a designated area,
make sure that: that is well ventilated and with access restricted
to qualified personnel only.
– the parking brake is applied or the wheels are – Install new warning labels to their original
securely chocked to prevent the vehicle moving locations.
forwards or backwards.
– If possible always isolate the alternative fuel
– the key is removed from key operated hood tank, and run the vehicle on the alternative fuel
locks before any work is carried out around the until it automatically switches to its normal fuel
front of the vehicle. prior to taking the vehicle into the workshop
– if the engine is to be run, there is adequate service area.
ventilation, or an extraction hose to remove – Only use tested and approved components and
exhaust fumes. pipes when repairing or servicing LPG and CNG
– there is adequate room to raise the vehicle and systems.
remove the wheels, if necessary.
– fender covers are always fitted if any work is to
be carried out in the engine compartment.
Alternative Fuel — Do Nots
– the battery is disconnected if working on the – Do not vent off LPG fuel.
engine, underneath the vehicle, or if the vehicle
– Do not use shop air pressure to force LPG fuel
is raised.
from the fuel tank.
CAUTION: When electric arc welding on a – Do not use paint drying ovens above 40°C for
vehicle, always disconnect the generator any alternative fuel vehicle. LPG and CNG fuel
wiring to prevent the possibility of a surge tanks must be removed from the vehicle prior
of current causing damage to the internal to being put into paint drying ovens above 40°C.
components of the generator.
– Do not modify the system or install new
– if using welding equipment on the vehicle, a components that are not designed for gas
suitable fire extinguisher is readily available. vehicles.
– Do not evacuate fuel tanks unless there is repair
Alternative Fuel that requires the removal of the fuel tank.
– Do not work on the fuel lines or system
WARNING: When servicing the fuel system components unless the alternative fuel has been
always follow the recommended evacuated and the pressure in the system
procedures. Failure to follow these reduced to atmospheric or less.
instructions may result in personal injury. – Do not use anything other than the specified
If the odor of liquefied petroleum gas (LPG) or leak detector fluid to trace fuel leaks.
compressed natural gas (CNG) is present in the Be aware of situations that may cause the LPG or
air in the workshop, warn all persons in the area CNG fuel system to vent off fuel, such as:
to:
– extremely hot days.
– extinguish all flames and lighted tobacco.
– parking by a space heater.
– shut off electrical and air powered equipment.
– hoisting a vehicle up near a ceiling heater.
– evacuate the area.
– ventilate the area. Only fully trained personnel, who are conversant
with local standards, are to work on alternative fuel
– contact the fire control authorities. vehicles.
– remove the vehicle to a dedicated, ventilated
area.
2007.50 Focus 3/2007 G17373en

Towing the Vehicle an instance, the discharged battery must
be recharged immediately after jump
WARNING: When the vehicle is being starting to avoid permanent damage.
towed, the ignition switch must be in – Always make sure that the jumper cables are
position II (steering lock released and adequate for the task. Heavy duty cables must
warning lamps illuminated). Only then will be used.
the steering, turn signal lamps, horn and – Always make sure that the slave battery is of
stop lamps be operational. Failure to follow the same voltage as the vehicle battery. The
these instructions may result in personal batteries must be connected in parallel.
injury.
– Always make sure that switched electric circuits
NOTE: The removable towing eye (if equipped), are switched off before connecting jumper
has a left-hand thread and must be fully tightened cables. This reduces the risk of arcing occurring
before towing can commence. when the final connection is made.
When towing is necessary, the vehicle towing eyes
should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will
not foul the bodywork.
When a vehicle with automatic transmission is
towed, the gear selector must be in position N
(Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off TIM0103001
the ground.
WARNING: Make sure that the ends of the
Alternatively the vehicle can be transported on a jumper cables do not touch each other or
low loader or a trailer. ground against the vehicle body at any
time while the cables are attached to the
Connecting a Slave Battery Using battery. A fully charged battery, if shorted
Jumper Cables through jumper cables, can discharge at
a rate well above 1000 amps causing
WARNING: If the slave battery has recently violent arcing and very rapid heating of the
been charged and is gassing, cover the jumper cables and terminals, and can even
vent plugs or covers with a damp cloth to cause the battery to explode. Failure to
reduce the risk of explosion should arcing follow these instructions may result in
occur when connecting the jumper cables. personal injury.
Failure to follow these instructions may Always connect the jumper cables in the following
result in personal injury. sequence:
CAUTIONS: – Slave battery positive first and then vehicle

battery positive.
A discharged battery condition may have – Slave battery negative next and then vehicle
been caused by an electrical short circuit. ground at least 12 inches (300 mm) from the
If this condition exists there will be an battery terminal, for example engine lifting eye.
apparently live circuit on the vehicle even
when all normal circuits are switched off. Always reduce the engine speed to idle before
This can cause arcing when the jumper disconnecting the jumper cables.
cables are connected. Before removing the jumper cables from the vehicle
While it is not recommended that the that had the discharged battery, switch on the
vehicle is jump started, it is recognized heater blower (high) or the heated rear window, to
that this may occasionally be the only reduce the voltage peak when the cables are
practical way to mobilize a vehicle. In such removed.
2007.50 Focus 3/2007 G17373en

Always disconnect the jumper cables in the reverse Various solvents are available which are suitable
order to the connecting sequence and do not short for component cleaning. Some components, such
the ends of the cables. as brake hydraulic parts and electrical assemblies
should be cleaned only with recommended solvents
Do not rely on the generator to restore a
— refer to Solvents, Sealers and Adhesives or to
discharged battery. For a generator to recharge a
the section of the manual relevant to the
battery, it would take in excess of eight hours
component.
continuous driving with no additional loads placed
on the battery.
Calibration of Essential Measuring
Component Cleaning Equipment
To prevent the ingress of dirt, accumulations of WARNING: Equipment, which requires

loose dirt and greasy deposits should be removed regular calibration, must be calibrated in
before disconnecting or dismantling components accordance with the manufacturers
or assemblies. instructions. Failure to follow this
instruction may result in personal injury
Components should be thoroughly cleaned before or damage to components.
inspection prior to reassembly.
It is of fundamental importance that certain
essential equipment, for example torque wrenches,
Cleaning Methods: multimeters, exhaust gas analyzers or rolling roads,
are regularly calibrated in accordance with the
– Dry cleaning. manufacturers instructions.
– Removal of loose dirt with soft or cable brushes.
– Scraping dirt off with a piece of metal or wood.
– Wiping off with a rag.
WARNING: Wear eye protection when
cleaning vehicle components with
compressed air, a steam cleaner or a
power washer. Failure to follow this
instruction may result in personal injury.
CAUTIONS:
Compressed air is sometimes 'wet' so use
with caution, especially on hydraulic
systems.
To prevent damage to the electrical
connectors in the engine compartment, do
not use a steam cleaner or a power washer
to clean the engine compartment.
– Blowing dirt off with compressed air.
– Removal of dry dust using vacuum equipment.
This method must always be used to remove
friction lining material dust (asbestos particles).
– Steam cleaning.
WARNING: Most solvents require careful
handling and some are harmful. Refer to
Health and Safety Precautions and to the
manufacturers literature for the relevant
safety precautions. Failure to follow these
instructions may result in personal injury.
2007.50 Focus 3/2007 G17373en

Solvents, Sealants and Adhesives

Introduction
WARNING: Always handle all solvents,
sealers and adhesives with extreme care.
Some contain chemicals or give off fumes
which can be dangerous to health. Always
follow the manufacturers instructions. If in
doubt about any substance, particularly a
solvent, DO NOT use it.
CAUTION: If in doubt about the suitability
of any proprietary solvent or sealer for a
particular application, contact the
manufacturer of the product for
information regarding storage, handling
and application.
The Health and Safety Precautions subsection
refers to some commonly used chemicals and
materials, hazards associated with their use, and
safety measures to be taken.
2007.50 Focus 3/2007 G17374en

Road/Roller Testing
Road or roller testing may be carried out for various – that the parking brake is applied.
reasons and a procedure detailing pre-test checks, – that the gear lever is in the neutral position.
engine starting and stopping, pre-driving checks,
– that all instrument gauges (except fuel gauge)
on-test checks and final checks to be completed
read zero.
on completion of the test is given below.
With the ignition switched on, check:
Unless complete vehicle performance is being
checked, the full road test procedure need not be – that the ignition controlled warning lamps are
carried out. Instead, those items particularly illuminated.
relevant to the system(s) being checked can be – that the engine temperature gauge registers a
extracted. reading compatible with the engine temperature.
– that the fuel gauge registers a reading
Pre-Test Checks appropriate to the fuel level in the tank.
– the operation of the parking brake warning lamp
WARNING: If the brake system hydraulic and fluid level warning indicator.
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for Road or Roller Testing
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified. CAUTION: If road testing, check the brake
operation while still traveling at low speed
It is suggested that pre-test checks and functional before continuing with the test. If the
tests of those systems and circuits which affect the brakes pull to one side, or appear to be
safe and legal operations of the vehicle, such as otherwise faulty, do not continue with the
brakes, lights and steering, should always be road test until the fault has been found and
carried out before the road or roller test. rectified.
With the ignition switched off, check: During the road or roller test, check:
– the engine oil level. – that the clutch pedal operation is not stiff or
– the engine coolant level. heavy.
– the tires, for correct pressure, compatible types – that the initial gear engagement is smooth and
and tread patterns, and wear within limits. there is no evidence of clutch drag.
– that there is sufficient fuel in the tank to – that the parking brake control operates smoothly
complete the test. and releases quickly and completely.
– all around the engine, transmission and under – that the clutch takes up the drive smoothly,
the vehicle for oil, coolant, hydraulic and fuel without slip or judder.
leaks. Make a note of any apparent leaks and – that gear changing is smooth with no abnormal
wipe off the surrounding areas to make it easier noises or vibrations from the transmission.
to identify the extent of the leak on completion – the engine power output is satisfactory, full
of the test. power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
Starting the Engine speed returns to idle correctly.
– there is no excessive or abnormally colored
NOTE: On initial drive away from cold and within smoke from the engine under normal driving,
the first 1.5 km (1 mile), do not depress the heavy load or overrun conditions.
accelerator pedal beyond half travel until the – that steering operation, including power steering
vehicle has attained a minimum speed of 25 km/h (if equipped), is smooth, accurate, not
(15 miles/h). Never operate at high engine speed excessively heavy or with excessive free play
or with the accelerator pedal at full travel whilst the or vibration.
engine is cold. – that the steering does not pull to one side and
With the ignition switched off, check: self centers smoothly after cornering.
2007.50 Focus 3/2007 G17375en

– that the speedometer, coolant temperature – oil, coolant, hydraulic, air and fuel leaks.
gauge and tachometer (if equipped) register the – abnormal temperature of any moving
correct readings and operate correctly. components or assemblies, for example wheel
– that the switches and controls operate smoothly hubs, transmission and axle, which might
and positively, warning and indicator lamps indicate over tightness or lack of lubrication.
operate correctly and the direction indicator
control self cancels when the steering is
returned to the straight ahead position.
– that the heating and ventilation systems operate
correctly and effectively.
– the brake operation and efficiency.
Brake Testing
WARNING: When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
For additional information, refer to: Health
and Safety Precautions (100-00 General
Information, Description and Operation).
CAUTIONS:
Avoid brake testing on busy roads where
it may cause inconvenience or danger to
other road users.
Brake testing which includes heavy brake
applications should not be carried out with
new brake pads/discs or linings/drums
until the components have bedded-in. New
brake friction components will not reach
full efficiency until the bedding-in process
is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or
drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature. A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for:
2007.50 Focus 3/2007 G17375en

Air Conditioning (A/C) System Health and Safety Precautions

WARNINGS: Provide adequate ventilation when
Only qualified technicians are allowed to handling refrigerant.
work on air conditioning (A/C) systems. Never release refrigerant into the
Air conditioning (A/C) system components atmosphere.
can become particularly hot or cold. Only use special tools, equipment and
When handling refrigerants, always wear lubricants that are approved for the type
protective goggles and gloves made of of refrigerant being used.
fluoroelastomer. Leather or fabric gloves The pressurized container in the servicing
are not suitable. unit must never be over-filled. The
Make sure that the air conditioning (A/C) refrigerant must have sufficient room to
system is at ambient temperature before expand if the temperature rises.
carrying out any repair. Always follow the manufacturer’s
If liquid refrigerant comes into contact with instructions for the correct servicing unit
the skin, it produces severe frostbite. operating procedure.
Immediately rinse the affected areas with
water for 15 minutes. Seek medical CAUTIONS:
attention. Do not mix refrigerant oils for different
If refrigerant comes into contact with the types of refrigerant.
eyes, immediately rinse the eyes with Never mix different types of refrigerant or
plenty of water for 15 minutes. Seek equipment intended for them.
medical attention.
Only use refrigerant in gas form when
If refrigerant comes into contact with naked filling the system through the low-pressure
flames or hot surfaces, it produces toxic connection.
gases (fluorine and phosgene). The toxic
gases formed are readily recognizable by Only use refrigerant in liquid form when
their pungent smell at tiny concentrations. filling the system through the
high-pressure connection.
Refrigerant is flammable and explosive.
Refrigerant attacks certain plastics. Only
Make sure that the local regulations use seals suitable for refrigerant.
regarding work on air conditioning (A/C) If the air conditioning (A/C) compressor is
systems are adhered to. damaged, the fixed orifice tube can
Make sure that refrigerant bottles are not become blocked with metal particles.
exposed to temperatures greater than 45°C. Any sort of blockage in the refrigerant
Make sure that refrigerant bottles are circuit will damage the air conditioning
closed properly. (A/C) compressor irreparably.
Toxic gases generated when refrigerant is If the air conditioning (A/C) system has
heated are hazardous to health. The gases been opened for a period greater than 2
have an irritating smell and can cause lung hours, a new receiver drier must be
damage. The symptoms can continue for installed and the evacuating time to be
a long time after having been in contact increased by a minimum of 2 hours.
with the gases. The gases can cause lung NOTE: New air conditioning (A/C) compressors
damage even if the amount of gas in the are delivered prefilled.
air is too small to smell.
NOTE: Refrigerant oil in new air conditioning (A/C)
Gaseous refrigerant has a higher density compressors can contain Teflon, visible as white
than air. There is a danger of suffocation particles, which will not harm the system.
when working close to the ground or in
workshop pits.
2007.50 Focus 3/2007 G548993en

Battery and Battery Charging Health and Safety Precautions

WARNINGS:
Batteries contain sulphuric acid, avoid
contact with skin, eyes or clothing. Wear
safety goggles when working near the
battery to protect against possible
splashing of the acid solution. In cases of
acid contact with the skin or eyes, flush
immediately with water for a minimum of
15 minutes and seek prompt medical
attention. If swallowed, seek immediate
medical attention.
Batteries normally produce explosive
gases. Do not allow naked flames, sparks
or lighted substances to come near the
battery.
When charging the battery shield your face
and wear safety goggles. Provide adequate
ventilation.
CAUTION: Boost charging with excessive
current or voltage above 16 volts will
damage the battery.
2007.50 Focus 3/2007 G548994en

Engine Cooling System Health and Safety Precautions

WARNINGS:
Extreme care must be exercised when
handling hot fluids. Always wash off spilled
fluids from exposed skin immediately.
Vapors may be given off from antifreeze
when heated. Avoid breathing these
vapors.
Antifreeze may be absorbed through the
skin in toxic or harmful quantities. If taken
internally, drink water and induce vomiting.
Seek medical attention immediately.
Antifreeze must not be used in any cooling
or industrial water system that is
connected or linked to general water
supplies.
2007.50 Focus 3/2007 G548995en

Petrol Fuel System Health and Safety Precautions

WARNINGS:
CAUTIONS:
Extreme care must be exercised when
handling hot fluids. Always wash off spilled Fuel injection equipment is manufactured
fluids from exposed skin immediately. to very precise tolerances and fine
clearances. It is essential that absolute
Highly flammable mixtures are always cleanliness is observed when working with
present and may ignite when working on these components.
fuel systems. Do not allow naked flames,
sparks or lighted substances to come near Make sure that the workshop area in which
fuel related components. the vehicle is being worked on is as clean
and as dust free as possible.
There may not be adequate warning of
odor or of irritation before toxic or harmful
effects arise. These may be immediate or
delayed.
Swallowing can result in mouth and throat
irritation and absorption from the stomach
can result in drowsiness and
unconsciousness. Small amounts can be
fatal to children. Aspiration of liquid into
the lungs, through vomiting, is a very
serious hazard.
Gasoline dries the skin and can cause
irritation and dermatitis on prolonged or
repeated contact. Liquid in the eye causes
severe smarting.
Motor gasoline may contain appreciable
quantities of benzene, which is toxic upon
inhalation, and the concentration of
gasoline vapors must be kept very low.
High concentrations will cause eye, nose
and throat irritation, nausea, headache,
depression and symptoms of drunkenness.
Very high concentrations will result in
rapid loss of consciousness.
Make sure there is adequate ventilation
when handling and using gasoline. Great
care must be taken to avoid the serious
consequences of inhalation in the event of
vapor build up arising from spillages in
confined spaces.
Special procedures apply to cleaning and
maintenance operations on gasoline
storage tanks.
Gasoline should not be used as a cleaning
agent. It must not be siphoned by mouth.
See First Aid.
2007.50 Focus 3/2007 G548996en

Supplemental Restraint System (SRS) Health and Safety

Precautions
WARNINGS:
Undeployed pyrotechnic supplemental
restraint system (SRS) components must
not be deployed in the vehicle.
Never carry out any electrical measurement
on disconnected, undeployed
supplemental restraint system (SRS)
pyrotechnic components.
Pyrotechnic components must not be
disassembled.
Pyrotechnic components are not
interchangeable between vehicles.
Always carry a live air bag module away
from the body with the air bag or trim cover
pointing upwards.
Live air bag modules must be placed in a
suitable cage when removed from the
vehicle. The air bag or trim cover must be
facing upwards.
CAUTIONS:
Supplemental restraint system (SRS)
components must not be subjected to
temperatures higher than 110°C.
Never install aftermarket accessories to
the vehicle on or adjacent to the
supplemental restraint system (SRS)
module.
2007.50 Focus 3/2007 G548998en

Window Glass Health and Safety Precautions

WARNINGS:
Cured polyurethane (PU) adhesive can
degrade if subjected to high temperatures.
Isocyanide compounds can be released
when grinding or welding in close
proximity to cured PU adhesive.
Polyurethane (PU) adhesive can cause
asthma like symptoms. Isocyanate vapor
from primer or PU adhesive can cause
allergies in the respiratory tract.
Wear gloves and eye protection when
working with the direct glazing cutter for
bonded glass as the cutting operation may
produce splinters. When using the direct
glazing cutter for bonded glass wear ear
protectors. Failure to follow these
CAUTIONS:
Make sure that the direct glazing for
bonded glass cutting blades are changed
where the cutting depth changes to avoid
damage to the body and trim panels.
During the curing period of the PU
adhesive, the door windows must be left
open to avoid a build up of pressure when
the doors are opened and closed.
2007.50 Focus 3/2007 G548999en

100-01-1 Identification Codes 100-01-1
.
SECTION 100-01 Identification Codes

CONTENTS PAGE

Identification Codes............................................................................................................ 100-01-2
Identification Codes............................................................................................................ 100-01-2
VIN (an example of VIN shown)......................................................................................... 100-01-3
Vehicle Certification Label (Typical) or VIN Plate............................................................... 100-01-5
Identification Codes
Identification Codes build specification to be established. The vehicle
identification number (VIN) may also be viewed
The vehicle identification plate (VIN plate) is through the windshield or in the drivers
located on the right-hand B-pillar. The codes compartment where it is stamped into the floor
stamped or printed on the VIN plate during panel.
production enable the precise details of the vehicle
E56807
Item Description
1 Visible VIN
2 VIN on the floor panel
3 VIN plate
2007.50 Focus 3/2007 G371114en

VIN (an example of VIN shown)
1 2 3 4 5 6 7
E0025438
Item Description Item Description
1 VIN Position 1, 2 and 3 - World 5 VIN Position 11 - Year of manufacture

manufacturer identifier 6 VIN Position 12 - Month of manufacture
2 VIN Position 5 and 6 - Constant X 7 VIN Positions 13 to 17 - Vehicle serial
3 VIN Position 7 and 8 - Product source number
company and assembly plant 8 VIN Position 4 and 10 - Body type
4 VIN Position 9 - Model
VIN Position 1, 2 and 3 - World Manufacturer Identifier

Codes World Manufacturer
WF0 Ford-Werke AG Germany (European vehicles)
VIN Position 4 and 10 - Body Type

Code Body Type
W Wagon
X Convertible
3 3-door
4 4-door
5 5-door
2007.50 Focus 3/2007 G371114en

VIN Position 5 and 6 - Constant X
VIN Position 7 and 8 - Product Source Company and Assembly Plant
Code Product Source Company and Assembly Plant
GC Saarlouis/Germany
LU Turin/Italy
WP Valencia/Spain
VIN Position 9 - Model

Code Model
D Focus
VIN Position 11 - Year of Manufacture

Code Year of Manufacture
4 2004
5 2005
6 2006
7 2007
8 2008
9 2009
VIN Position 12 - Month of Manufacture

Month 2004 2005 2006 2007 2008 2009
January B J L C B J
February R U Y K R U
March A M S D A M
April G P T E G P
May C B J L C B
June K R U Y K R
July D A M S D A
August E G P T E G
September L C B J L C
October Y K R U Y K
November S D A M S D
December T E G P T E
VIN Positions 13 to 17 - Vehicle Serial Number

Five Digit Number
2007.50 Focus 3/2007 G371114en

Vehicle Certification Label (Typical) or VIN Plate
1 2 3
18
17
4
16
15
5
14
6
13
12
11 10 9 8 7
TIE0027423
1 National or whole vehicle type approval 10 Door combination code
2 VIN 11 Exhaust emission level codes
3 Gross vehicle mass (GVM) 12 Body color codes
4 Gross train mass (GTM) 13 Interior trim codes
5 Maximum permissible front axle mass 14 Transaxle final drive ratio codes
6 Maximum permissible rear axle mass 15 Transaxle codes
7 Smoke value (diesel only) 16 Engine codes
8 Model body or type codes 17 Hand of drive
9 Model type code 18 Axle mounting (Transit only)
Items 1 to 6: Vehicle Certification Label

Item Details
Item 1: National or whole vehicle type approval A unique code required by legislation in certain
territories.
Item 2: VIN Vehicle identification number.
Item 3: GVM Indicates the maximum legal laden mass, in territ-
ories where this is required.
2007.50 Focus 3/2007 G371114en

Item Details
Item 4: GTM Indicates the maximum combined mass of vehicle
and trailer or caravan.
Item 5: Maximum permissible front axle mass Maximum permissible loading on the front wheels
of the vehicle.
Item 6: Maximum permissible rear axle mass Maximum permissible loading on the rear wheels
of the vehicle.
Item 7: Smoke Value (diesel only)

Number Smoke Value
Per meter
Item 8: Model Body or Type Codes

Code Model Body or Type
DA3 3-door
DB3 4-door
DA3 5-door
DA3 Wagon
DB3 2-door convertible
Item 9: Model Type Code

Code Model Type
- -
Item 10: Door Combination Code

Code Door Combination
- -
Item 11: Exhaust Emission Level Codes

Code Exhaust Emissions
K Stage V
S 2000 EEC (Stage III)
V Stage IV + Diesel Particulate Filter (DPF)
7 Stage IV
Item 12: Body Color Codes

Code Body Color
A Tango (Orange)
B Mandarin Orange
C Colorado Red or Pitch Black
D Machine Silver
F Panther Black
2007.50 Focus 3/2007 G371114en

Code Body Color

G Aquarius (Blue)
H Sea Grey or Red Hot (Bright Red)
I Ink Blue
J Performance Blue
K Magnum Grey or Limoncello (Yellow)
L Flare
N Diamond White or Grenadine (Dark Red)
O Moondust Silver
Q Luna
R Blue Di Cina Pearl (Dark Blue)
S Iris (Purple)
U Vitro or Argentino (Silver)
V Deep Navy (Blue)
W Honor Green
X Neptune Green
Z Tonic (Blue)
1 Sublime (Green)
2 Jeans (Blue)
3 Stirling Silver
9 Deep Rosso Red
For vehicles built in continental plants, the second digit of the paint code, on the VIN label, denotes the original model year of
the color’s introduction, (‘0’=color introduction in 2000 model year).
Item 13: Interior Trim Codes

Code Interior Trim
AE Humy - Dark Flint
AF Louis Leather - Dark Flint
AN Rack - Dark Flint
AP Cubical - Dark Flint
AR Span - Dark Flint
AU Stripy/Gene - Dark Flint
AV Stripy - Dark Flint
BF Louis Leather - Ebony
CL Louis Leather - Vernon Camel
EL Louis Leather - Vernon Ebony
ES Span Turquiose - Mondus Ebony
2007.50 Focus 3/2007 G371114en

Code Interior Trim

EX Volume - Anthracite
FL Span - Vernon Ebony
GX Volume - Yellow
IP Piega Iris - Iris Ebony
LF Louis Leather - Medium Light Stone Blue
LN Rack - Medium Light Stone Blue
LR Span - Medium Light Stone Blue
MP Piega Grey - Mondus Ebony
RS Span Red - Mondus Ebony
SL Louis Leather - Veronon Saddle
VE Humy - Medium Light Stone
VF Louis Leather - Medium Light Stone
VP Cubical - Medium Light Stone
YA Louis Leather - Vernon Camel
YB Louis Leather - Vernon Ebony
YC Span - Vernon Ebony
YD Piega - Mondus Iris
YE Piega - Mondus Generic Grey
YF Span - Mondus Generic Red
YG Louis Leather - Veronon Saddle
YH Span - Mondus
YJ Span - Mondus Generic Grey
YL Span - Mondus Ebony
1X Volume - Blue
2X Volume - Blue
3X Volume - Red
12 Blue Ditto - Blue
32 Blue Ditto - Red
51 Cuboid - Grey
Item 14: Transaxle Final Drive Ratio Codes

Code Transaxle Final Drive Ratio
AW 4.06
BW 4.06
B2 4.203
CW 4.06
2007.50 Focus 3/2007 G371114en

Code Transaxle Final Drive Ratio

EQ 4.07
E2 4.203
JV 4.00
1Q 3.41
1R 4.33
2Q 3.41
4Q 4.06
36 4.071/2.85 (a)
a) The 6-speed manual transaxle (MMT6) has two output shafts. First, second, third and fourth gears have the higher final drove
ratio. Fifth, sixth and reverse gears have the lower final drive ratio.
Item 15: Transaxle Codes

Code Transaxle
Q 5-Speed Manual Transaxle (MTX-75)
R Automatic Transaxle (CFT23)
V 6-Speed Manual Transaxle (M66)
W 5-Speed Manual Transaxle (iB5)
2 4-Speed Automatic Transaxle (4F27 E)
6 6-Speed Manual Transaxle (MMT6)
Item 16: Engine Codes

Code Engine
A 1.4L Duratec-16V (Sigma) (75 PS)
B 1.6L Duratec-16V (Sigma) (100 PS)
C 1.6L Duratec-16V Ti-VCT (Sigma) (115 PS)
E 2.0L Duratec-HE (MI4) (145 PS)
F 1.8L Duratec-HE (MI4) - Flexible Fuel (125 PS)
H 1.8L Duratec-HE (MI4) (125 PS)
J 2.5L Duratec-ST (VI5)
1 1.6L Duratorq-TDCi (DV) Diesel (110 PS)
2 1.6L Duratorq-TDCi (DV) Diesel (90 PS)
3 2.0L Duratorq-TDCi (DW) Diesel (136 PS)
4 1.8L Duratorq-TDCi (Kent) Diesel
Item 17: Hand of Drive

Code Drive
E Left-hand drive
2007.50 Focus 3/2007 G371114en

Code Drive
F Right-hand drive
I Left-hand drive
J Right-hand drive
M Left-hand drive
N Right-hand drive
Q Left-hand drive
R Right-hand drive
U Left-hand drive
V Right-hand drive
1 Left-hand drive
2 Right-hand drive
5 Left-hand drive
6 Right-hand drive
2007.50 Focus 3/2007 G371114en

100-02-1 Jacking and Lifting 100-02-1
.
SECTION 100-02 Jacking and Lifting

CONTENTS PAGE

Jacking................................................................................................................................ 100-02-2
Lifting.................................................................................................................................. 100-02-3
Jacking
WARNING: Always position the vehicle on CAUTIONS:
a hard level surface. If the vehicle must be
jacked up on a soft surface use load It is important that only the correct jacking
spreading blocks under the jack. Always and support locations are used at all times.
chock the wheel diagonally opposite the The convertible top must not be operated
jacking point. Failure to follow these while the vehicle is lifted by a single jack.
NOTE: When using the vehicle jack, refer to the
owner guide for correct operating instructions.
E57513
2007.50 Focus 3/2007 G420743en

Lifting
CAUTIONS: When lifting the vehicle with a two post lift,
When lifting the vehicle with a two post lift, the maximum curb weight must not be
vehicle lift arm adapters must be used exceeded.
under the lifting points. It is important that only the correct lifting
and support locations are used at all times.
E57512
2007.50 Focus 3/2007 G420744en

100-04-1 Noise, Vibration and Harshness 100-04-1
.
SECTION 100-04 Noise, Vibration and Harshness

CONTENTS PAGE

Noise, Vibration and Harshness (NVH).............................................................................. 100-04-2
Diagnostic Theory............................................................................................................... 100-04-2
Know the System................................................................................................................ 100-04-2
Know the History of the System......................................................................................... 100-04-2
Know the History of the Condition...................................................................................... 100-04-2
Know the Probability of Certain Conditions Developing..................................................... 100-04-2
Do Not Cure the Symptom and Leave the Cause.............................................................. 100-04-2
Be Positive the Cause is Found......................................................................................... 100-04-2
Diagnostic Charts............................................................................................................... 100-04-2
DIAGNOSIS AND TESTING

Noise, Vibration and Harshness (NVH).............................................................................. 100-04-4
Inspection and Verification.................................................................................................. 100-04-4
Noise Diagnostic Procedure............................................................................................... 100-04-4
Road Test........................................................................................................................... 100-04-5
Road Test Quick Checks.................................................................................................... 100-04-5
Road Conditions................................................................................................................. 100-04-6
Vehicle Preparation............................................................................................................ 100-04-6
Power Steering Conditions................................................................................................. 100-04-6
Power Steering Operation Noise Check............................................................................. 100-04-6
Symptom Chart................................................................................................................... 100-04-9
Pinpoint Tests..................................................................................................................... 100-04-16
GENERAL PROCEDURES
Powertrain/Drivetrain Mount Neutralizing....................................................... (14 001 0) 100-04-23
Noise, Vibration and Harshness (NVH)

Noise, vibration and harshness (NVH) is becoming
more important as vehicles become more Know the History of the Condition
sophisticated and passenger comfort levels
increase. This section is designed to aid in the – Did it start suddenly or appear gradually?
diagnosis and testing and repair of NVH concerns. – Was it related to some other occurrence such
– Noise is defined as sounds not associated with as a collision or previous part replacement?
the operation of passenger compartment – Know how the condition made itself known; it
equipment that interface with customer may be an important clue to the cause.
satisfaction.
– Vibration is defined as impulses felt by the
customer that are not caused by road surface Know the Probability of Certain
changes. Conditions Developing
– Harshness is a ride quality issue where the – Look for the simple rather than the complex.
customer feels that the vehicle response to the
road surface is sharply transmitted to the – For example:
customer. – Electrical conditions usually occur at
connections rather than components.
– An engine no-start is more likely to be caused
Diagnostic Theory by a loose wire or small adjustment rather
than a sheared-off camshaft.
Diagnosis is more than just following a series of
interrelated steps in order to find the solution to the – Know the difference between impossible and
specific condition. It is a way of looking at systems improbable. Certain failures in a system can be
that are not functioning the way they should and improbable but still happen.
finding out why. Also it is knowing how the system – New parts are just that, new. It does not mean
should work and whether it is working correctly. they are always good functioning parts.
There are basic rules for diagnosis. If these rules
are followed, the cause of the condition is usually Do Not Cure the Symptom and Leave
found the first time through the system. the Cause
Lowering the pressure in a front tire may correct
Know the System the condition of a vehicle leaning to one side, but
it does not correct the original condition.
– Know how the parts go together.
– Know how the system operates as well as its
limits and what happens when the system goes Be Positive the Cause is Found
wrong.
– Sometimes this means checking the system – Double check findings.
against one that is known to be working – What caused a worn component?
correctly. – A loose transmission or engine mount could
indicate that other mounts are also loose.
Know the History of the System
Diagnostic Charts
A clue in any one of these areas may save time:
– How old or new is the system? Charts are a simple way of expressing the
relationship between basic logic and a physical
– What kind of treatment has it had? system of components. They help discover the
– Has it been serviced in the past in such a cause of a condition in the least time. Diagnostic
manner that might relate to the present charts combine many areas of diagnosis into one
condition? visual display:
– What is the service history?
2007.50 Focus 3/2007 G28448en

– Probability of certain things occurring in a
system.
– Speed of checking certain components or
functions before others.
– Simplicity of performing certain tests before
others.
– Elimination of checking huge portions of a
system by performing simple tests.
– Certainty of narrowing down the search to a
small portion before performing in-depth testing.
The fastest way to find a condition is to work with
the tools that are available. This means working
with proven diagnostic charts and the correct
special equipment for the system.
2007.50 Focus 3/2007 G28448en

Noise, Vibration and Harshness (NVH)

Identify the Condition
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical NVH usually occur in four areas:
or electrical damage.
• tires
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible) • engine accessories
before proceeding to the next step. • suspension
4. If the concern is not visually evident, verify the • driveline
symptom and REFER to the Symptom Chart. It is important, therefore, that an NVH concern be
isolated into its specific area(s) as soon as
possible. The easiest and quickest way to do this
How to Use this Diagnostic Procedure is to carry out the Road Test as outlined. To assist
Section in the diagnosis and testing procedure(s), use a
suitable approved NVH diagnosis tester.
• Noise, vibration and harshness (NVH) concerns
have become more important as vehicles have
become more sensitive to these vibrations. This Noise Diagnostic Procedure
section is designed to aid in identifying these
concerns.
• The section provides diagnostic procedures Non-Axle Noise
based on symptom. If the condition occurs at
high speed, for instance, the most likely place The five most common sources of non-axle noise
to start is under Shake and Vibration While are exhaust, tires, roof racks, trim panels and
Driving. transmission.
• The road test procedure will tell how to sort the Therefore, make sure that none of the following
conditions into categories and how to tell a conditions are the cause of the noise before
vibration from a shake. proceeding with a driveline teardown and
• A series of Road Test Quick Checks are diagnosis.
provided to make sure that a cause is either • In certain conditions, the pitch of the exhaust
pinpointed or eliminated. may sound very much like gear noise. At other
• Name the condition, proceed to the appropriate times, it can be mistaken for a wheel bearing
section and locate the correct diagnosis. When rumble.
the condition is identified, the job is partly done. • Tires, especially snow tires, can have a high
• Follow the diagnostic procedure as outlined. pitched tread whine or roar, similar to gear
• Quick Checks are described within the step, noise. Radial tires may have this characteristic.
while more involved tests and adjustments are Also, any non-standard tire with an unusual
outlined in General Procedures. tread construction may emit a roar or whine
noise.
• Always follow each step exactly and make notes
to recall important findings later. • Trim panels can also cause whistling or whining
noise.
• Clunk may be a metallic noise heard when the
Customer Interview automatic transaxle is engaged in "R"
(REVERSE) or "D" (DRIVE) or it may occur
The road test and customer interview (if available) when the throttle is applied or released. It is
provide information that will help identify the caused by backlash somewhere in the driveline.
concern and will provide direction to the correct • Bearing rumble sounds like marbles being
starting point for diagnosis. tumbled. This condition is usually caused by a
damaged wheel bearing.
2007.50 Focus 3/2007 G37349en

Noise Conditions conditions, as on a newly paved asphalt road. The
slight noise is in no way detrimental and must be
• Gear noise is typically a howling or whining due considered normal.
to gear damage or incorrect bearing preload. It
The road test and customer interview (if available)
can occur at various speeds and driving
provide information needed to identify the condition
conditions, or it can be continuous.
and give direction to the correct starting point for
• Chuckle is a particular rattling noise that sounds diagnosis.
like a stick against the spokes of a spinning
bicycle wheel. It occurs while decelerating from 1. Make notes throughout the diagnosis routine.
64 km/h (40 mph) and can usually be heard all Make sure to write down even the smallest bit
the way to a stop. The frequency varies with of information, because it may turn out to be the
vehicle speed. most important.
• Knock is very similar to chuckle, though it may 2. Do not touch anything until a road test and a
be louder and occurs on acceleration or thorough visual inspection of the vehicle have
deceleration. The teardown will disclose what been carried out. Leave the tire pressures and
has to be corrected. vehicle load just where they were when the
condition was first observed. Adjusting tire
Clicking, popping or grinding noises may be caused pressures, vehicle load or making other
by the following: adjustments may reduce the condition(s)
• worn, damaged or incorrectly installed wheel intensity to a point where it cannot be identified
bearing, suspension or brake component. clearly. It may also inject something new into
the system, preventing correct diagnosis.
Check and rule out tires, exhaust and trim items
before disassembling the transmission to diagnose 3. Make a visual inspection as part of the
and correct gear noise. preliminary diagnosis routine, writing down
anything that does not look right. Note tire
The noises described under Road Test usually pressures, but do not adjust them yet. Note
have specific causes that can be diagnosed by leaking fluids, loose nuts and bolts, or bright
observation as the unit is disassembled. The initial spots where components may be rubbing
clues are the type of noise heard on the road test against each other. Check the load space for
and driving conditions. unusual loads.
4. Road test the vehicle and define the condition
by reproducing it several times during the road
Vibration Conditions test.
Vibration at highway speeds may be caused by 5. Carry out the Road Test Quick Checks as soon
the following: as the condition is reproduced. This will identify
the correct diagnostic procedure. Carry out the
• out-of-balance front or rear wheels. Road Test Quick Checks more than once to
• out-of-round tires. verify they are providing a valid result.
Shudder or vibration during acceleration may be Remember, the Road Test Quick Checks may
caused by the following: not tell where the concern is, but they will tell
where it is not.
• damaged powertrain/drivetrain mounts.
• excessively high constant velocity (CV) joint
operating angles caused by incorrect ride height.
Road Test Quick Checks
Check ride height, verify correct spring rate and
check items under inoperative conditions. 1. 24-80 km/h (15-50 mph): with light acceleration,
a moaning noise is heard and possibly a
vibration felt in the front floor panel. It is usually
Road Test worse at a particular engine speed and at a
particular throttle setting during acceleration at
A gear-driven unit will produce a certain amount that speed. It may also produce a moaning
of noise. Some noise is acceptable and may be sound, depending on what component is
audible at certain speeds or under various driving causing it. REFER to Tip-in Moan in the
Driveline Noise and Vibration Symptom Chart.
2007.50 Focus 3/2007 G37349en

2. Acceleration/Deceleration: With slow produced. Once the route is established and
acceleration and deceleration, a shake is consistently used, the road noise variable is
sometimes noticed in the steering wheel/column, eliminated from the test results.
seats, front floor panel, front door trim panel or
NOTE: Some concerns may be apparent only on
front end sheet metal. It is a low frequency
smooth asphalt roads.
vibration (around 9-15 cycles per second). It
may or may not be increased by applying the If a customer complains of a noise or vibration on
brakes lightly. REFER to Idle a particular road and only on a particular road, the
Boom/Shake/Vibration in the Driveline Noise source of the concern may be the road surface. If
and Vibration Symptom Chart. possible, try to test the vehicle on the same type
3. High Speed: A vibration is felt in the front floor of road.
panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum, Vehicle Preparation
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift Carry out a thorough visual inspection of the
control selector lever in "N" (NEUTRAL) vehicle before carrying out the road test. Note
(automatic transmission) and engine idling. If anything which is unusual. Do not repair or adjust
vibration is still evident, it may be related to any condition until the road test is carried out,
wheels, tires, front brake discs, wheel hubs or unless the vehicle is inoperative or the condition
front wheel bearings. REFER to Shake and could pose a hazard to the technician. After
Vibration While Driving in the Driveline Noise verifying that the condition has been corrected,
and Vibration Symptom Chart. make sure all components removed have been
4. Engine rpm Sensitive: A vibration is felt installed.
whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at Power Steering Conditions
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the Check for the noise in the following conditions to
accessory drive belt to the clutch or torque verify the customer concern.
converter which turns at engine speed when the • Check for the noise in several temperature
vehicle is stopped. REFER to Shake and conditions.
Vibration While Driving in the Driveline Noise • Is the noise from when the vehicle was new?
and Vibration Symptom Chart.
• Can the noise be repeated constantly or is it
5. Noise and Vibration While Turning: Clicking, random?
popping or grinding noises may be due to the
following: • Check the condition of the vehicle age, mileage
and service record.
• worn, damaged or incorrectly installed front
wheel bearing. • Interview the customer to find the operating
condition in which the noise will occur. Test the
• damaged powertrain/drivetrain mounts. vehicle based on the detail(s) from the customer
interview.
Road Conditions • Follow the power steering operation noise
condition tables below, to find which condition
An experienced technician will always establish a the noise will occur.
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a Power Steering Operation Noise Check
particular condition needs to be identified). A
smooth asphalt road that allows driving over a Step 1: Check for NVH concerns from non-steering
range of speeds is best. Gravel or bumpy roads components, which may sound like noises coming
are unsuitable because of the additional road noise from the steering system.
2007.50 Focus 3/2007 G37349en

Power assisted steering operating condition

Parking Driving
Steering central/slightly Steering at a steering Driving straight ahead Cornering condition
off center lock stop
REFER to NVH concerns REFER to NVH concerns REFER to NVH concerns REFER to NVH concerns
from other components from other components from other components from other components
column A column B column C column D
NVH concerns from other components

NVH concerns from other condition (column A to D)
Noise Driving Condition A B C D
Pedal box knocking Drive off, stop driving and slow cornering X X O X
over uneven roads
Stabilizer bar link Drive off, driving and cornering X O O X
knocking
Engine support insu- Drive off, driving, acceleration and decel- X X
lator knocking eration
Air conditioning Engine on, activate switch for air condi- X X O O
knocking tioning
Suspension knocking Drive off, driving, cornering, acceleration X O X
(Subframe, Springs) and deceleration
Constant velocity (CV) Drive off, driving, cornering, acceleration X O X
joint knocking and deceleration
Washer bottle Deceleration, acceleration and single O X
impact
Loose suspension All driving conditions O O X
bolts
Instrument panel rattle/ All driving conditions. Engine rpm X X X X
squeak dependant
• X = Noise will most likely occur in this operating condition.
• O = Noise can possibly occur in this operating condition.
• Blank = Noise is unlikely to occur in this operating condition.
Step 2: Check for steering system NVH concerns

according to operation condition described at the
customer interview.

Parking Driving Vehicle stationary with engine off
Steering Steering at a Steering Steering at a Steering central/ Steering at a
central/ steering lock central/slightly steering lock slightly off centre steering lock stop
slightly off stop off center stop
center
2007.50 Focus 3/2007 G37349en


Parking Driving Vehicle stationary with engine off
REFER to REFER to REFER to REFER to REFER to steering REFER to steering
steering steering steering steering system system NVH system NVH
system NVH system NVH system NVH NVH concerns concerns column E concerns column F
concerns concerns concerns column D
column A column B column C
Steering system NVH concerns

Steering System operation condition (column A to F)
Noise Driving condition A B C D E F
Moan Parking between lock stops, at engine idle and X O
also increased engine speed
Whine Driving, high engine rpm. Must be present from O O X X
new
Hiss a) Parking between lock stops. Must be present X X O O
from new
b) Holding steering wheel against lock stops. Must X
be present from new
Lock stop impact a) Parking at lock stop. Must be present from new X X
knock
Mechanical knock b) Parking between lock stops, engine OFF. Must X
(power assisted be present from new
steering (PAS) off)
Mechanical Knock c) Parking between lock stops, engine ON (ball X
(PAS on) joint knock)
Hammer knock d) Parking into lock stop and release (vehicle with X
hydraulic power assisted steering (HPAS) only,
not for vehicles with electro-hydraulic power
assisted steering (EHPAS))
Hydraulic knock e) Driving, cobble stones, rough road (clonk). Must O X
(clonk) be present from new
Column knock f) Parking, driving. cobble stones and rough roads X X O X X X
Column rattle Mainly driving on rough roads O X X O
Toc-toc Steering left and right at high frequency. Must be X
present from new
Grinding When turning steering wheel X O X
Zip At engine start, low temperatures below -10°C only X O
• X = Noise will most likely occur in this operating condition.
• O = Noise can possibly occur in this operating condition.
• Blank = Noise is unlikely to occur in this operating condition.
2007.50 Focus 3/2007 G37349en

Step 3: According to each identified operating Symptom Chart
condition (Column A, B, C, D, E, F), check each
possible Steering System NVH concern with the
detail symptom charts below. Power Steering Moan Noise
Before conducting a vehicle test to identify a NVH
Test Condition
concern carry out the following checks.
Listen for steering moan noise with the vehicle
1. Check the tire pressures and adjust to
parked, transmission in neutral and all windows
specification, as necessary.
closed in the following test conditions.
2. Make sure the steering system fluid is correct,
the system is free of leaks and is operating 1. Engine speed at idle with no steering action.
correctly. 2. Engine speed at idle with slow 90 degrees per
3. Make sure the vehicle steering system second turning of the steering wheel.
temperature is the same as described at the 3. Engine speed at 1250 +/- 50 rpm with no
customer interview. steering action.
4. All evaluations must take place in a relatively 4. Engine speed at 1250 +/- 50 rpm with slow 90
quiet location. degrees per second turning of the steering
5. The heating - air conditioning (A/C) fan and wheel.
radio must be turned off during evaluations and
the windows closed.
2007.50 Focus 3/2007 G37349en

Symptom Possible Sources Action

• CHECK the routing of the
power steering lines.
• CHECK the power steering line
clamps are secure.
Power steering lines.
• CHECK the power steering
lines for clearance from the
vehicle body, front axle cross-
member and steering gear.
FLUSH the power steering

system. REFER to: (211-00 )
Power Steering System
Power steering system moan Flushing - 1.8L Duratec-HE
noise – A continuous low pitched (MI4)/1.8L Duratec-SCi
humming noise occurs when the (MI4)/2.0L Duratec-HE (MI4)
steering wheel is turned and the (General Procedures),
steering system is loaded. Noise Power Steering System
frequency changes with engine Flushing - 3.0L Duratec-SE
rpm changes. Particularly Incorrect power steering fluid. (VE6)/2.5L Duratec-VE
annoying at lower engine speed. (VE6)/3.0L Duratec-ST (VE6)
(General Procedures),
Flushing - 2.0L Duratorq-
Di/TDDi (Puma) Diesel/2.0L
Duratorq-TDCi (Puma)
Diesel/2.2L Duratorq-TDCi
(Puma) Diesel (General
Procedures).
Pressure pulses from the power
steering pump. Certain amount of
Power steering pump.
noise level acceptable, not a
safety critical item.
Power Steering Whine Noise 2. Engine speed at 1800 +/- 50 rpm with slow 90
degrees turning of the steering wheel.
Test Condition 3. Engine speed at 3000 +/- 50 rpm with no
Listen for steering whine noise with the vehicle steering action.
parked, transmission in neutral and all windows 4. Engine speed at 3000 +/- 50 rpm with slow 90
closed in the following test conditions. degrees turning of the steering wheel.
1. Engine speed at 1800 +/- 50 rpm with no
steering action.
2007.50 Focus 3/2007 G37349en


BLEED the power steering system.
REFER to: Power Steering System
Power steering fluid aeration. Bleeding - 1.6L Duratec-16V
(Sigma) (211-00 Steering
System - General Information,
General Procedures).
FLUSH the power steering system.
REFER to: (211-00 )
Flushing - 1.8L Duratec-HE
(MI4)/1.8L Duratec-SCi
(MI4)/2.0L Duratec-HE (MI4)
Flushing - 3.0L Duratec-SE
Incorrect power steering fluid. (VE6)/2.5L Duratec-VE
(VE6)/3.0L Duratec-ST (VE6)
Power steering system whine Di/TDDi (Puma) Diesel/2.0L
noise – a high pitched buzzing Duratorq-TDCi (Puma)
sound like an electric motor or Diesel/2.2L Duratorq-TDCi
drill. Whine occurs at the higher (Puma) Diesel (General
engine rpm, 1500 - 5000 rpm, Procedures).
frequency does not change if
FLUSH the power steering system.
system is loaded or not loaded.
REFER to: (211-00 )
Flushing - 1.8L Duratec-HE
(MI4)/1.8L Duratec-SCi
Flushing - 3.0L Duratec-SE
Overheated power steering fluid. (VE6)/2.5L Duratec-VE
(VE6)/3.0L Duratec-ST (VE6)
Di/TDDi (Puma) Diesel/2.0L
Duratorq-TDCi (Puma)
(Puma) Diesel (General
Procedures).
Certain amount of noise level
Hydraulic operating condition of
acceptable, not a safety critical
the power steering pump.
item.
2007.50 Focus 3/2007 G37349en

Power Steering Hiss Noise Listen for steering hiss noise with the vehicle
parked, transmission in neutral and all windows
Test Condition closed in the following test conditions.

NOTE: Engine speed at idle CHECK the installation and
Floor seal.
turning the steering wheel slowly potential damage of the floor seal.
lock to lock.
Power steering system hiss noise Power steering gear valve design. acceptable, not a safety critical
– a high frequency, continuous item.
rush or swish noise like escaping
air from a balloon. Hiss occurs
while turning between the steering Certain amount of noise level
lock stops, all steering angles. Power steering system hydraulic
Noise does not change with design.
item.
engine rpm and is worse at high
operating temperatures.
NOTE: Engine speed at idle
holding the steering wheel against
a steering lock for three seconds.
Do not hold for more than five
seconds. Certain amount of noise level
Power steering pump pressure
Power steering system hiss noise relief valve. item.
– a continuous noise like escaping
air occurs while holding the
steering against a steering lock
stop.
Power Steering Lock Stop Impact Knock 1. Turn the steering wheel to the left-hand and
Noise right-hand steering locks and listen for the
impact noise.
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (noise
also apparent with engine off).

Power steering system knock
noise – a heavy loud sound like a Power steering gear mechanical Certain amount of noise level
knock on a door that occurs in noise, metal to metal at end of acceptable, not a safety critical
parking condition when hitting the steering travel. item.
lock stop.
Power Steering Mechanical Knock Noise 1. Turn the steering wheel 90 degrees to the right,
(PAS off) hold and then quickly release.
2. Turn the steering wheel 90 degrees to the left,
Test Condition hold and then quickly release.
Listen for steering knock noise with the engine off
in the following test conditions (no power assist).
2007.50 Focus 3/2007 G37349en


noise – a damped, metallic knock Certain amount of noise level
Power steering system knock noise which only occurs at acceptable, not a safety critical
noise – a heavy loud repeating steering condition with engine off item.
sound like a knock on a door that (very high efforts).
occurs in several driving and
steering conditions. Certain amount of noise level
Tolerances in the steering gear
components.
item.
Power Steering Mechanical Knock Noise 1. Turn the steering wheel to a steering lock and
(PAS on) return to center quickly.
2. Turn the steering wheel 90 degrees to the left
Test Condition and then 90 degrees to the right quickly.
speed at idle in the following test conditions (power
assist).

Power steering system knock REFER to Steering System.
noise – clear knock noise from Worn tie-rod ball joints (inner and
outer ball joints). REFER to: Steering System (211-
steering gear linkage area. 00, Diagnosis and Testing).
Power Steering Hammer Knock (Hydraulic) 1. Turn the steering wheel to a steering lock
Noise position and return quickly.
Test Condition
speed at idle in the following test conditions (for
vehicles with hydraulic power assisted steering
only, not electro-hydraulic power steering).

noise – loud, metallic sound if
hitting the suspension cross- Certain amount of noise level
Hydraulic noise created by pres-
member with a hammer (sounds acceptable, not a safety critical
sure impulses.
like metallic noise but is created item.
by pressure impulse in gear and
return line).
Power Steering Hydraulic Knock/Clonk 1. Drive over cobbled roads at low speed 10-30
Noise km/h (6-20 mph) with and without turning.
2. Drive over straight tar strips road rails or 25 mm
Test Condition tall harshness strips at low speed 10-30 km/h
Listen for steering knock/clonk noise in the (6-20 mph) both driving straight and with
following test conditions with the windows closed. moderate turning.
2007.50 Focus 3/2007 G37349en


Power steering system knock/ Certain amount of noise level
clonk noise – sounds almost Power steering return lines. acceptable, not a safety critical
identical to column knock that item.
occurs when driving and cornering
over cobbled stones or rough High power assist gain of power Certain amount of noise level
roads. Noise may appear to steering gear valve (steering gear acceptable, not a safety critical
emanate from a location closer to design - no quality issue). item.
the floor than that for column
knock (Sounds like metallic noise
but is created by pressure impulse Certain amount of noise level
High power steering pump flow
in gear and return line – similar to acceptable, not a safety critical
rate (by design).
a sound like quickly turning off a item.
water tap).
Power Steering Column Knock Noise 1. Drive over cobbled stones at low speed 16-40
km/h (10-25 mph) with and without steering
Test Condition input carefully listening for knock sounds.
Listen for steering knock noise in the following test 2. Drive over straight tar strips, road rails or 25 mm
conditions with windows closed. tall harshness strips at low speed 16-40 km/h
(10-25 mph) both driving straight and with
moderate cornering.

CHECK the steering column
retaining bolts and attachments
to the steering column and secure
if necessary.
Power steering system column
knock noise – a loose sounding REFER to: Specifications (211-
Steering column or steering 04, Specifications).
rattle or vibration coming from the
column shaft.
column. Noticeable by hearing Check steering column and inter-
and touch. mediate shaft for free play or
loose components.
REFER to: Steering System (211-
00, Diagnosis and Testing).
Power Steering Toc-Toc Noise 1. Turn the steering wheel from left to right abruptly
changing direction.
Test Condition 2. Drive the vehicle for low speed parking
Listen for steering toc-toc noise with the engine manoeuvres constantly changing steering
speed at idle and the vehicle parked, automatic direction.
transmission in "P" (PARK) or manual transmission
in neutral and the windows closed.
2007.50 Focus 3/2007 G37349en


Power steering system toc-toc
noise – a metallic noise created
when changing direction of Steering gear (design tolerance
steering wheel rotation during in steering rack).
item.
parking manoeuvre or at stand-
still.
Power Steering Grinding Noise 1. Slowly turn the steering wheel from lock to lock.
2. Tilt and extend the steering column in various
Test Condition positions and slowly turn the steering wheel
Listen for steering grinding noise with the engine from lock to lock.
speed at idle and the vehicle parked, automatic
transmission in "P" (PARK) or manual transmission
in neutral and the windows closed.

Steering wheel to shroud interfer-
ence.
item.
Steering column bearing. acceptable, not a safety critical
Power steering system grinding item.
noise – an abrasive noise (like CHECK if floor covering is
sand paper rubbing against wood) obstructing the steering gear
occurs between moving compon- Foreign material in contact with pinion.
ents such as steering wheel and the steering column shaft.
the steering column shroud. CHECK the installation of the floor
seal.
CHECK the clockspring and
secure if necessary.
Clockspring.
REFER to: Clockspring (501-20B,
Removal and Installation).
Power Steering Zip Noise

High viscosity of power steering
Power steering system zip noise fluid at low temperature.
item.
– occurs when hydraulic fluid
does not flow freely through the BLEED the power steering
power steering pump supply hose system.
from steering fluid reservoir to
REFER to: Power Steering
power steering pump causing Aeration of the power steering System Bleeding - 1.6L
cavitation at the pump. Zip is fluid. Duratec-16V (Sigma) (211-00
primarily a cold weather start-up
Steering System - General
phenomenon (below -10°C).
Information, General Proced-
ures).
2007.50 Focus 3/2007 G37349en

Driveline Noise and Vibration

• Wheel end vibration.
Shake and vibration while driving • Engine/transmission. GO to Pinpoint Test A.
• Air cleaner.
• Power assisted steering.
Tip-in moan • Powertrain. GO to Pinpoint Test B.
• Powertrain/drivetrain mounts.
• Exhaust system.
• Cable(s)/hose(s).
Idle boom/shake/vibration/ • Powertrain/drivetrain mounts.
• Exhaust system. GO to Pinpoint Test C.
shudder
• Belt/pulleys.
Suspension Noise and Vibration

• Suspension.
Wheel end vibration analysis • Wheel bearings. GO to Pinpoint Test D.
• Trim panels.
Non-axle noise • Air conditioning (A/C) system. GO to Pinpoint Test E.
• Accessories.
Pinpoint Tests steps necessary to correct the condition. Then

check the operation of the system to make sure
NOTE: These Pinpoint Tests are designed to take the condition has been corrected.
the technician through a step-by-step diagnosis After verifying that the condition has been
procedure to determine the cause of a condition. corrected, make sure all components removed
It may not always be necessary to follow the chart have been installed.
to its conclusion. Carry out only the pinpoint test
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
• Does the vibration disappear during the neutral
coast test?
→ Yes
GO to A2.
→ No
GO to Pinpoint Test D.
2007.50 Focus 3/2007 G37349en


A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the mounts OK?
→ Yes
Vehicle condition corrected. ROAD TEST as
necessary.
→ No
INSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST B : TIP-IN MOAN

B1: CHECK THE AIR CLEANER
1 Check the condition of the air cleaner mounts,
inlet tube, outlet tube, resonators and all other
components associated with the air induction
system for correct installation and tightness of
all connections.
• Are the components OK?
→ Yes
GO to B2.
→ No
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
REFER to: Exhaust System Neutralizing (100-
04, General Procedures).
• Is the exhaust system OK?
→ Yes
GO to B3.
→ No
REPAIR as necessary. ROAD TEST as
necessary.
2007.50 Focus 3/2007 G37349en


B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for
tip-in moan. REFER to: (303-05 Accessory
Drive)
Accessory Drive Belt - 1.8L Duratec-HE
(MI4)/1.8L Duratec-SCi (MI4)/2.0L Duratec-HE
(MI4) (Removal and Installation),
Accessory Drive Belt - 3.0L Duratec-SE
(VE6)/2.5L Duratec-VE (VE6)/3.0L Duratec-ST
(VE6) (Removal and Installation),
Accessory Drive Belt - 2.0L Duratorq-Di/TDDi
(Puma) Diesel/2.0L Duratorq-TDCi (Puma)
Diesel/2.2L Duratorq-TDCi (Puma) Diesel
(Removal and Installation).
• Is the tip-in moan OK?
→ Yes
REPAIR the power steering as necessary.
REFER to: Steering System (211-00 Steering
System - General Information, Diagnosis
and Testing).
→ No
GO to B4.
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
ralizing procedure
• Are the powertrain/drivetrain mounts OK?
→ Yes
necessary.
→ No
2007.50 Focus 3/2007 G37349en

PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER
C1: CHECK THE CABLE/HOSES
1 Check the engine compartment for any
component that may have a touch condition
between the engine and body or chassis. For
example: control cable, air conditioning (A/C)
hoses, acceleration cable.
• Are the components OK?
→ Yes
GO to C2.
→ No
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings
and bushings for security and condition. Check
the radiator installation for any component that
may have a touch condition.
• Is the installation and bushings OK?
→ Yes
GO to C3.
→ No
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
REFER to: Exhaust System Neutralizing (100-
04, General Procedures).
• Is the exhaust system OK?
→ Yes
GO to C4.
→ No
REPAIR as necessary. ROAD TEST as
necessary.
2007.50 Focus 3/2007 G37349en


C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
ralizing procedure
• Are the powertrain/drivetrain mounts OK?
→ Yes
necessary.
→ No
PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS

D1: INSPECT THE WHEELS AND TIRES
1 Inspect the wheels and tires.
REFER to: Wheels and Tires (204-04 Wheels
and Tires, Diagnosis and Testing).
• Are the wheels and tires OK?
→ Yes
GO to D2.
→ No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
2007.50 Focus 3/2007 G37349en


D2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
REFER to: Wheel Bearing Inspection (204-00
Suspension System - General Information,
• Are the wheel bearings OK?
→ Yes
GO to D3.
→ No
INSTALL new wheel bearings as necessary.
REFER to:
Wheel Bearing (204-01 Front Suspension,
Removal and Installation),
Wheel Bearing - 2.0L Duratorq-Di/TDDi (Puma)
Diesel/2.0L Duratorq-TDCi (Puma) Diesel,
Vehicles With: 5-Speed Automatic Transaxle
(5F31J) (204-01 Front Suspension, Removal
and Installation),
Wheel Hub (204-02 Rear Suspension, Removal
and Installation).
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
• Is the wheel and tire runout OK?
→ Yes
Balance the wheels and tires. Refer to the
wheel balance equipment manufacturer's
instructions. ROAD TEST as necessary.
→ No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
2007.50 Focus 3/2007 G37349en

PINPOINT TEST E : NON-AXLE NOISE
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see
if they are the source of the noise.
• Are the vehicle trim components causing the
noise?
→ Yes
INSTALL new trim components or REPAIR
→ No
GO to E2.
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Ignition switch in position III.
2 Ignition switch in position II.
3 Check the A/C system components for noise by
turning the A/C system on and off.
• Is the A/C system causing the noise?
→ Yes
INSPECT the A/C system. REFER to: (412-
00 Climate Control System - General Informa-
tion)
Climate Control System (Diagnosis and Testing),
Climate Control System (Diagnosis and Testing).
→ No
GO to E3.
E3: CHECK NON-FACTORY FITTED ACCESSORIES
1 Check any non-factory installed accessories for
being the source of the noise. For example:
touch condition body-to-frame, antennas,
deflectors and fog lights.
• Are the accessories the cause of the noise?
→ Yes
ADJUST, REPAIR, or INSTALL new
accessories or fasteners as required. ROAD
TEST as necessary.
→ No
VERIFY the customer concern.
2007.50 Focus 3/2007 G37349en

GENERAL PROCEDURES
Powertrain/Drivetrain Mount Neutralizing(14 001 0)

NOTE: There is no procedure for neutralizing the
powertrain/drivetrain mounts. To check the
alignment of the powertrain mounts visually,
proceed as follows.
1. Loosen the rear support insulator retaining
bolts (if equipped).
2. Loosen the powertrain/drivetrain mount
retaining bolts.
3. NOTE: Support the powertrain/drivetrain in
an approximate position and height.
NOTE: Make sure that the right-hand mount and
left-hand insulator align over the studs on the
powertrain and drivetrain to allow the fixings to be
assembled through the large holes in the support
insulator bracket without overstraining.
Check the powertrain/drivetrain mount
alignment.
4. Tighten the powertrain/drivetrain mount to
powertrain/drivetrain mount bracket retaining
bolts.
5. Tighten the powertrain/drivetrain mount to
body retaining bolts.
6. Tighten the rear support insulator retaining
bolts (if equipped).
2007.50 Focus 3/2007 G17382en

204-00-1 Suspension System - General Information 204-00-1
.
SECTION 204-00 Suspension System - General

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 204-00-2

Suspension System............................................................................................................ 204-00-4
Symptom Chart................................................................................................................... 204-00-4
Pinpoint Tests..................................................................................................................... 204-00-9
Component Tests................................................................................................................ 204-00-17
GENERAL PROCEDURES
Front Toe Adjustment..................................................................................... (14 117 3) 204-00-19
Rear Toe Adjustment...................................................................................... (15 211 3) 204-00-20
SPECIFICATIONS
Front Wheel Alignment (at curb weight) – Vehicles with standard suspension
Description Tolerance Range Setting or Maximum Vari-
Nominal ance Left or Right
Caster angle Degrees and 4°13’ to 2°09’ 3°11’ 1°00'
minutes
Decimal degrees 4.21° to 2.15° 3.18° 1.00°
Camber angle Degrees and 0°36’ to -1°58’ -0°41’ 1°15'
minutes
Decimal degrees 0.60° to -1.96° -0.68° 1.25°
Total toe mm 0.7 Toe in ± 1.7 0.7 Toe in ± 1.0 -
Degrees and 0°06' Toe in ± 0°15' 0°06' Toe in ± 0°09' -
minutes
Decimal degrees 0.10° Toe in ± 0.25° 0.10° Toe in ± 0.15° -
Front Wheel Alignment (at curb weight) – Vehicles with sport suspension
Caster angle Degrees and 4°14’ to 2°13’ 3°14’ 1°00'
minutes
Decimal degrees 4.24° to 2.22° 3.23° 1.00°
Camber angle Degrees and 0°25’ to -2°07’ -0°51’ 1°15'
minutes
Decimal degrees 0.41° to -2.11° -0.85° 1.25°
Total toe mm 0.7 Toe in ± 1.7 0.7 Toe in ± 1.0 -
Degrees and 0°06' Toe in ± 0°15' 0°06' Toe in ± 0°09' -
minutes
Decimal degrees 0.10° Toe in ± 0.25° 0.10° Toe in ± 0.15° -
Rear Wheel Alignment (at curb weight) – Vehicles with standard suspension
Camber angle Degrees and 0 Toe to -2°35’ -1°17’ 1°15'
minutes
Decimal degrees 0 Toe to -2.58° -1.29° 1.25°
Total toe mm 4.2 to 0.9 2.5 Toe in ± 1.0 -
Degrees and 0°38’ to 0°08' 0°23’ Toe in ± 0°09' -
minutes
Decimal degrees 0.63° to 0.13° 0.38° Toe in ± 0.15° -
2007.50 Focus 3/2007 G410646en

SPECIFICATIONS
Rear Wheel Alignment (at curb weight) – Vehicles with sport suspension
Camber angle Degrees and -0°08’ to -2°38’ -1°23’ 1°15'
minutes
Decimal degrees -0.14° to -2.64° -1.39° 1.25°
Total toe mm 4.2 to 0.9 2.5 Toe in ± 1.0 -
Degrees and 0°38’ to 0°08' 0°23’ Toe in ± 0°09' -
minutes
Decimal degrees 0.63° to 0.13° 0.38° Toe in ± 0.15° -
Torque Specifications
Item Nm lb-ft lb-in
Tie-rod end locknut 62 46 -
Rear lower arm adjustment cam nut 90 66 -
2007.50 Focus 3/2007 G410646en

Suspension System
Special Tool(s) Mechanical
Alignment Pins, Subframe - Wheel knuckles
205-316 (15-097A)
- Tie-rod ends
- Front suspension lower arm ball joints
- Front suspension lower arm bushings
15097A
- Front strut and spring assemblies
Front and rear stabilizer bar and connecting links
Inspection and Verification - Rear springs
1. Verify the customer concern. - Rear shock absorbers

2. Visually inspect for obvious signs of mechanical - Rear suspension lower arms
damage.
Visual Inspection Chart concern is found, correct the cause (if possible)
Mechanical before proceeding to the next step.
- Tire pressure(s) 4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
- Wheel and tires
Symptom Chart
Symptom Chart
• Drift left or right • Vehicle attitude incorrect (front • Vehicles without load levelling
or rear is high or low). shock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
• Vehicles with load levelling
shock absorbers, GO to
Pinpoint Test C.
• Steering gear or linkage worn • CHECK the steering system.
or damaged. REFER to: (211-00 Steering
System - General Information)
Steering System - 1.6L
Duratec-16V (Sigma)
(Diagnosis and Testing),
Steering System (Diagnosis
and Testing).
• Brake system. • CHECK the brake system.
REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
2007.50 Focus 3/2007 G163120en


• Incorrect wheel alignment. • ADJUST the wheel alignment.
REFER to: Specifications - 3-
Door (204-00 Suspension
System - General Informa-
tion, Specifications).
• Incorrect front crossmember • Using the special tool, CHECK
alignment. the front subframe alignment..
• Worn front wheel bearings. • CHECK the wheel bearings.
• Wheel and tires. • GO to Pinpoint Test A.
• Steering wheel off center • Vehicle attitude incorrect (front • Vehicles without load levelling
or rear is high or low). shock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
• Vehicles with load levelling
shock absorbers, GO to
Pinpoint Test C.
Duratec-16V (Sigma)
and Testing).
• Suspension lower arm ball • CARRY OUT the Ball Joint
joint. Inspection Component Test in
this procedure.
• Tracks incorrectly • Incorrect front suspension toe • ADJUST the wheel alignment.
castor or camber angles. REFER to: Specifications - 3-
CHECK and INSTALL new
suspension components as
necessary.
2007.50 Focus 3/2007 G163120en


• Incorrect rear suspension toe • CHECK the wheel alignment.
or camber angles. REFER to: Specifications - 3-
CHECK and INSTALL new
necessary.
• Front or rear suspension • CHECK and INSTALL new
damage. suspension components as
necessary.
• Rough ride • Front strut and spring assem- • CARRY OUT the Strut or
blies. Shock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new
necessary.
REFER to: Strut and Spring
Assembly (204-01 Front
Suspension, Disassembly
and Assembly).
• Front or rear stabilizer bar • CHECK and INSTALL new
connecting links or bushings. suspension components as
necessary. REFER to:
Front Stabilizer Bar - 3-Door
(204-01 Front Suspension,
Stabilizer Bar - Wagon,
Vehicles With: Solid Stabilizer
Bar Link (204-02 Rear
Suspension, Removal and
Installation),
Stabilizer Bar - Vehicles With:
Solid Stabilizer Bar Link (204-
02 Rear Suspension,
Ball Joint Stabilizer Bar Link
(204-02 Rear Suspension,
• Front suspension lower arm • INSTALL a new lower arm.
bushings. REFER to: Lower Arm - 3-Door
2007.50 Focus 3/2007 G163120en


• Rear suspension arm bushings. • CHECK and INSTALL new
components as necessary.
REFER to: (204-02 Rear
Suspension)
Upper Arm (Removal and
Installation),
Upper Arm - Wagon (Removal
and Installation),
Front Lower Arm (Removal and
Installation),
Front Lower Arm - Wagon
(Removal and Installation),
Rear Lower Arm - Vehicles
With: Solid Stabilizer Bar Link
Rear Lower Arm - Wagon,
Bar Link (Removal and
Installation),
Rear Lower Arm - Vehicles
With: Ball Joint Stabilizer Bar
Link (Removal and Installa-
tion),
Stabilizer Bar - Wagon,
Bar Link (Removal and
Installation),
Solid Stabilizer Bar Link
Ball Joint Stabilizer Bar Link
• Rear shock absorbers. • CARRY OUT the Strut or
Shock Absorber Testing
procedure.
necessary.
• Excessive noise • Front strut and spring assembly • GO to Pinpoint Test B.
or rear shock absorber and
spring upper mounting bolts or
nuts loose or broken.
• Shock absorbers leaking. • GO to Pinpoint Test B.
• Shock absorbers performance • GO to Pinpoint Test B.
incorrect.
• Stabilizer bar components. • GO to Pinpoint Test B.
• Strut and spring assembly and • GO to Pinpoint Test B.
springs.
2007.50 Focus 3/2007 G163120en


• Springs moving on springs • GO to Pinpoint Test B.
upper or lower seats.
• Suspension bushings. • GO to Pinpoint Test B.
• Lower arm ball joint. • GO to Pinpoint Test B.
• Worn front wheel bearings • GO to Pinpoint Test B.
• Wheels and tires. • GO to Pinpoint Test B.
• Incorrect tire wear • Front or rear suspension • CHECK and INSTALL new
damage. suspension components as
necessary.
• Vibration • Damaged or worn front wheel • CHECK the front wheel bear-
bearings. ings.
• Wheels and tires. • CHECK the tires. BALANCE or
INSTALL new tires as neces-
sary.
Duratec-16V (Sigma)
and Testing).
• Front strut and spring assem- • CARRY OUT the Strut or
blies. Shock Absorber Testing
procedure.
necessary.
REFER to: Strut and Spring
Assembly (204-01 Front
Suspension, Disassembly
and Assembly).
2007.50 Focus 3/2007 G163120en


• Damaged front suspension • CHECK and INSTALL new
lower arm(s). suspension components as
necessary.
REFER to: Lower Arm - 3-Door
• Vehicle lean • Load-levelling shock absorbers. • GO to Pinpoint Test C.
Pinpoint Tests
PINPOINT TEST A : DRIFT LEFT OR RIGHT
WARNING: To avoid personal injury due to the loss of vehicle control, the inspection should
be carried out by two people to maintain safe driving conditions. Adequate grip should
always be maintained on the steering wheel. Failure to follow these instructions may result
in personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
NOTE: The tire swapping procedures are for bi-directional rotating tires only.
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES

1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front left-hand wheel and tire
assembly with the front right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
→ Yes
GO to A2.
→ No
The concern has been corrected.
2007.50 Focus 3/2007 G163120en


A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
– Swap the rear left-hand wheel and tire
assembly with the rear right-hand wheel and
tire assembly.
→ Yes
GO to A3.
→ No
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
assembly with the rear left-hand wheel and
tire assembly.
→ Yes
GO to A4.
→ No
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
– Swap the front right-hand wheel and tire
tire assembly.
→ Yes
GO to A5.
→ No
2007.50 Focus 3/2007 G163120en


A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY
tire assembly.
→ Yes
GO to A6.
→ No
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
– Swap the front right-hand wheel and tire
assembly with the rear left-hand wheel and
tire assembly.
→ Yes
GO to A7.
→ No
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1 Install new tires to the four road wheels. TEST

the system for normal operation.
→ Yes
Verify possible sources, refer to the Symptom
Chart.
→ No
2007.50 Focus 3/2007 G163120en

PINPOINT TEST B : EXCESSIVE NOISE
B1: INSPECT ALL STRUT AND SPRING ASSEMBLY AND SHOCK ABSORBER MOUNTING BOLTS
AND NUTS
1 Inspect the strut and spring assembly and shock
absorber mounting bolts and nuts.
• Are the mounting bolts or nuts loose or
broken?
→ Yes
TIGHTEN or INSTALL new suspension
mounting bolts. REFER to:
Specifications - 3-Door (204-01 Front Suspen-
sion, Specifications),
Specifications (204-02 Rear Suspension,
Specifications).
→ No
GO to B2.
B2: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBERS FOR LEAKS
NOTE: Make sure that the oil is not from another

source.
1 Inspect the strut and spring assemblies and
shock absorbers for signs of oil weepage or
leaks. Refer to weepage and leakage conditions
in the Strut or Shock Absorber Testing
component test in this procedure.
• Are the struts or shock absorbers leaking?
→ Yes
INSTALL new struts or shock absorbers as
necessary. REFER to:
Strut and Spring Assembly (204-01 Front
Suspension, Removal and Installation),
Rear Shock Absorber - Wagon (204-02 Rear
Suspension, Removal and Installation).
→ No
GO to B3.
2007.50 Focus 3/2007 G163120en


B3: INSPECT THE SPRINGS AND STABILIZER BAR(S)
1 Inspect the springs and stabilizer bar(s) for
damage.
• Are the springs or stabilizer bar(s) damaged?
→ Yes
INSTALL new springs or stabilzer bar(s).
REFER to:
Front Stabilizer Bar - 3-Door (204-01 Front
Stabilizer Bar - Wagon, Vehicles With: Solid
Stabilizer Bar Link (204-02 Rear Suspension,
Stabilizer Bar - Vehicles With: Solid Stabilizer
Bar Link (204-02 Rear Suspension, Removal
and Installation),
Stabilizer Bar - Vehicles With: Ball Joint Stabil-
izer Bar Link (204-02 Rear Suspension,
Spring (204-02 Rear Suspension, Removal and
Installation),
Spring - Wagon (204-02 Rear Suspension,
→ No
GO to B4.
2007.50 Focus 3/2007 G163120en


B4: INSPECT THE SUSPENSION BUSHINGS
1 Inspect the suspension bushings for excessive
wear or damage.
• Are the bushings worn or damaged?
→ Yes
INSTALL new components as necessary.
REFER to:
Lower Arm - 3-Door (204-01 Front Suspension,
Front Stabilizer Bar - 3-Door (204-01 Front
Upper Arm (204-02 Rear Suspension, Removal
and Installation),
Upper Arm - Wagon (204-02 Rear Suspension,
Front Lower Arm (204-02 Rear Suspension,
Front Lower Arm - Wagon (204-02 Rear
Rear Lower Arm - Vehicles With: Solid Stabilizer
and Installation),
Rear Lower Arm - Wagon, Vehicles With: Solid
Rear Lower Arm - Vehicles With: Ball Joint
Stabilizer Bar - Wagon, Vehicles With: Solid
Stabilizer Bar - Vehicles With: Solid Stabilizer
and Installation),
Stabilizer Bar - Vehicles With: Ball Joint Stabil-
izer Bar Link (204-02 Rear Suspension,
→ No
GO to B5.
2007.50 Focus 3/2007 G163120en


B5: INSPECT THE SUSPENSIONS LOWER ARM BALL JOINTS
1 Carry out the Ball Joint Inspection component
test in this procedure.
• Is the lower arm ball joint or gaiter damaged?
→ Yes
INSTALL new lower arm.
REFER to: Lower Arm - 3-Door (204-01 Front
TEST the system for normal operation.
→ No
GO to B6.
B6: INSPECT THE WHEEL BEARINGS
1 Check the wheel bearings.
• Are the wheel bearings damaged?
→ Yes
INSTALL a new wheel hub(s). REFER to:
Wheel Hub (204-01 Front Suspension, Removal
and Installation),
Wheel Hub - Vehicles With: Rear Drum Brakes
(204-02 Rear Suspension, Removal and
Installation),
Wheel Hub - Vehicles With: Rear Disc Brakes
Installation).
→ No
GO to B7.
B7: INSPECT THE WHEEL AND TIRES
1 Inspect the tires for uneven wear.
• Is there uneven wear?
→ Yes
REFER to the symptom chart.
→ No
GO to B8.
2007.50 Focus 3/2007 G163120en


B8: INSPECT THE STRUT AND SPRING ASSEMBLY AND REAR SUSPENSION SPRING INTERFACE
1 Loosen the strut and spring assemblies and
shock absorbers top and bottom mounting bolts
and nuts. Tighten the mounting bolts and nuts.
REFER to:
Specifications - 3-Door (204-01 Front Suspen-
sion, Specifications),
Specifications (204-02 Rear Suspension,
Specifications).
– Carry out a road test.
REFER to: Road/Roller Testing (100-00
General Information, Description and Oper-
ation).
• Is the concern still evident?
→ Yes
GO to B9.
→ No
Vehicle condition corrected.
B9: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBER COMPONENTS
1 Check that the spring is correctly located on the
spring seat and has not moved.
2 Disassemble the strut and spring and assembly
and inspect the individual components.
REFER to: Strut and Spring Assembly (204-01
Front Suspension, Disassembly and
Assembly).
3 Inspect the shock absorber top mount for wear
or damage.
4 Carry out the Strut or Shock Absorber Testing
component test in this procedure.
• Are any of the strut and spring assemblies or
shock absorber components damaged?
→ Yes
REFER to:
Suspension, Disassembly and Assembly),
Rear Shock Absorber - Wagon (204-02 Rear
→ No
REINSTALL the strut and spring assemblies
or shock absorbers. GO to B10.
2007.50 Focus 3/2007 G163120en


B10: CARRY OUT A ROAD TEST
1 Carry out a road test.
REFER to: Road/Roller Testing (100-00 General
• Is the concern still evident?
→ Yes
REFER to: Noise, Vibration and Harshness
(NVH) (100-04 Noise, Vibration and Harsh-
ness, Diagnosis and Testing).
→ No
Vehicle condition corrected.
PINPOINT TEST C : VEHICLE LEAN

C1: VEHICLE LEAN
1 Detach the load levelling shock absorbers from
the wheel knuckles.
• Does the vehicle lean?
→ Yes
Install new rear springs. REFER to: (204-02
Rear Suspension)
Spring (Removal and Installation),
Spring - Wagon (Removal and Installation).
→ No
CARRY OUT the Load-Levelling Shock
Absorber Component Test in this section.
Component Tests 2. If there is any free movement install a new lower

arm.
Raise and support the vehicle. REFER to: (100-02 REFER to: Lower Arm - 3-Door (204-01 Front
Jacking and Lifting) Suspension, Removal and Installation).
Jacking (Description and Operation), 3. If a new lower arm is installed it will be
Lifting (Description and Operation). necessary to check and adjust the front wheel
alignment.
Ball Joint Inspection REFER to: Specifications - 3-Door (204-00

1. Firmly grasp the outer end of the suspension Specifications).
lower arm and try to move it up and down,
watching and feeling for any movement. Free
movement will usually be accompanied by an Strut or Shock Absorber Inspection
audible "click''. There should be no free
movement. NOTE: Inspect the struts or shock absorber for
signs of oil weepage or leaks. Make sure that the
oil is not from another source.
2007.50 Focus 3/2007 G163120en

Weepage: • The measurements on both sides should be
• deposits a thin film of oil on the strut and spring approximately equal.
assembly or shock absorber. 2. With a load of 4 average size adults and a 100
• is normally noticed due to a collection of dust kg weight, measure and note the dimensions
on the strut and spring assembly or shock between the base of the wheel rim and the top
absorber. of the rear fender on both sides.
• occurs during the normal running-in period of 3. NOTE: Due to the internal ratchet mechanism
4800 - 8050 km. After this period no new signs of the suspension components, the height
of oil should be visible. of the rear of the vehicle should rise during
• does not require new struts or shock absorbers the road test.
to be installed. With a load of 4 average size adults and a 100
Leakage: kg weight, drive the vehicle for 3 km on a road
of normal condition.
• covers the entire strut and spring assembly or
shock absorber with oil. 4. With a load of 4 average size adults and a 100
kg weight, measure and note the dimensions
• will drip oil onto the surrounding suspension
between the base of the wheel rim and the top
components.
of the rear fender on both sides.
• requires new struts or shock absorbers to be 5. If the dimensions on both sides are no longer
installed. approximately equal, install new load levelling
shock absorbers.
Strut or Shock Absorber Testing REFER to: Rear Shock Absorber - Wagon
NOTE: Struts or shock absorbers must be tested Installation).
in the vertical position. 6. NOTE: Due to the internal ratchet mechanism
1. Remove both strut and spring assemblies or of the suspension components, the height
shock absorbers. The piston rods should extend. of the rear of the vehicle should rise during
• Disassemble the strut and spring assemblies. the road test.
REFER to: Strut and Spring Assembly If the dimensions are approximately equal,
(204-01 Front Suspension, Disassembly unload the vehicle and drive the vehicle for 3
and Assembly). km on a road of normal condition.
2. Compress the piston rods. Both piston rods 7. With the vehicle unladen, measure and note the
should offer the same resistance when dimensions between the base of the wheel rim
compressing. and the top of the rear fender on both sides.
Check the final dimensions with the original
3. Compress and release the piston rods. The
dimensions taken in the unladen condition.
piston rods should extent equally.
8. If the final dimensions do not approximately
4. Compress and pull the piston rod in the vertical
equal the original dimensions, install new load
position. Feel if the resistance force at the point
levelling shock absorbers.
of direction change-over is perceptible without
a lag. If a lag is perceptible it is an indication of REFER to: Rear Shock Absorber - Wagon
damper valve damage and new struts or shock (204-02 Rear Suspension, Removal and
absorbers must be installed. REFER to: Installation).
Strut and Spring Assembly (204-01 Front 9. If the final dimensions approximately equal the
Suspension, Removal and Installation), original dimensions, verify the customer
Rear Shock Absorber - Wagon (204-02 Rear concern.
Load-Levelling Shock Absorber
1. With the vehicle unladen, measure and note the

dimensions between the base of the wheel rim
and the top of the rear fender on both sides.
2007.50 Focus 3/2007 G163120en

GENERAL PROCEDURES
Front Toe Adjustment(14 117 3)

NOTE: Make sure that the vehicle is standing on 4. Rotate the tie-rods an equal amount in either
a level surface. a clockwise or a counterclockwise direction
to adjust the toe setting.
1. Centralize the steering and lock it in position.
For additional information, refer to:
Specifications (204-00, Specifications).
TIE0016000
TIE0016002
2. Loosen the tie-rod end locknuts.
5. Tighten the tie-rod end locknuts.

For additional information, refer to: Tie Rod
End (211-03 Steering Linkage, Removal and
Installation).
TIE0016003
3. Remove the steering gear boot outer clamps.
TIE0016003
6. Install the steering gear boot outer clamps.
TIE0016001
TIE0016001
2007.50 Focus 3/2007 G17387en

GENERAL PROCEDURES
Rear Toe Adjustment(15 211 3)

General Equipment Tighten the rear lower arm adjustment cam
nut.
Four wheel alignment equipment
NOTE: The checking and subsequent adjustment
of the rear toe setting should be carried out on a
flat surface and in accordance with the
manufacturers instructions for the particular wheel
alignment equipment being used.
1. NOTE: Final tightening of the rear
suspension components should be carried 8 Nm
out when the vehicle weight is on the road
wheels.
Using suitable four wheel alignment TIE0014073
equipment, check the toe setting.
2. Check the tire pressures and adjust as
7. Adjust the toe setting.
necessary.
3. Make sure the vehicle is at curb weight and
that the spare wheel, jack and vehicle tools
are stowed in their designated positions.
Additional items should be removed from
the vehicle.
4. Bounce the vehicle to make sure that the
suspension is in its normal resting position.
5. Loosen the rear lower arm adjustment cam
nut.
TIE0003051
8. Tighten the rear lower arm adjustment cam

nut.
90 Nm
TIE0014255
6. NOTE: Do not fully tighten the rear lower arm

adjustment cam nut at this stage.
TIE39079
2007.50 Focus 3/2007 G163124en

204-01-1 Front Suspension 204-01-1
.
SECTION 204-01 Front Suspension

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 204-01-2

Front Suspension................................................................................................................ 204-01-3
Overview............................................................................................................................. 204-01-3

Front Suspension................................................................................................................ 204-01-4
REMOVAL AND INSTALLATION

Wheel Hub...................................................................................................... (14 371 0) 204-01-5
Lower Arm...................................................................................................... (14 706 0) 204-01-7
Front Stabilizer Bar............................................................................................................. 204-01-11
Lower Arm Ball Joint....................................................................................... (14 735 0) 204-01-20
Wheel Knuckle.................................................................................................................... 204-01-23
Strut and Spring Assembly................................................................................................. 204-01-29
DISASSEMBLY AND ASSEMBLY

Strut and Spring Assembly................................................................................................. 204-01-33
SPECIFICATIONS
Description Nm lb-ft lb-in
Top mount retaining bolts 32 24 -
Top mount brace to bulkhead retaining nuts 25 18 -
Thrust bearing retaining nut 50 37 -
Stabilizer bar link retaining nuts 48 35 -
Wheel knuckle to strut and spring assembly pinch 90 66 -
bolt
Lower arm ball joint heat shield retaining nut 9 - 80
Brake caliper anchor plate retaining bolts 115 85 -
Lower arm ball joint retaining nut 70 52 -
Tie-rod end retaining nut 48 35 -
Stabilizer bar to stabilizer bar link retaining nut 48 35 -
Stabilizer bar clamp retaining bolts 48 35 -
Lower arm front retaining bolt 175 129 -
Lower arm rear clamp retaining bolts 115 85 -
Lower arm ball joint to lower arm retaining bolts 70 52 -
Front axle crossmember front retaining bolts 115 85 -
Front axle crossmember rear retaining bolt 275 203 -
Front axle crossmember bracket retaining bolts 70 52 -
Wheel hub retaining bolt a) - -
Catalytic converter to rear muffler flange retaining 51 38 -
nuts - Vehicles with diesel engine
nuts - All except vehicles with diesel engine
Engine support insulator front retaining bolt 80 59 -
Wheel speed sensor retaining bolt 9 - 80
Steering column to steering gear pinion retaining 28 21 -
bolt
a) Refer to the procedure in this section.
2007.50 Focus 3/2007 G422317en

Front Suspension
Overview
E42462
NOTE: The Anti-lock Brake System (ABS) sensor

ring is incorporated into the wheel hub. Incorrect
installation of the wheel hub would result in an ABS
malfunction.
The front suspension features McPherson struts
and 'L' shaped lower arms which are attached to
the front axle crossmember by means of two
maintenance-free bushings.
The ball joint is attached to the lower arm by means
of three rivets. Bolt-on replacement ball joints are
available for service operations.
The correct installation position must be observed
when installing the strut and spring assembly turret
support bearings. To make sure that the strut and
spring assembly turret support bearings, springs
and piston rods are all aligned correctly, the spring
retainers and strut and spring assembly turret
support bearings have alignment marks.
2007.50 Focus 3/2007 G187539en

Front Suspension
REFER to Section 204-00 [Suspension System -
General Information].
2007.50 Focus 3/2007 G17395en

Wheel Hub(14 371 0)

Special Tool(s) 2. Remove the components in the order
indicated in the following illustration(s) and
Remover/Installer, Wheel
table(s).
Hub/Wheel Bearing
204-348
1
E42977
Protector, Axle Shaft

205-332
15108 E39195
Item Description
1. Remove the wheel knuckle. 1 Wheel hub
For additional information, refer to: Wheel See Removal Detail
Knuckle - 3-Door (204-01 Front Suspension, See Installation Detail
3. To install, reverse the removal procedure.
Removal Details
Item 1 Wheel hub
1. Using the special tools, remove the wheel
hub.
205-332
204-348
E44828
Installation Details
2007.50 Focus 3/2007 G307405en

Item 1 Wheel hub
1. Using the special tool, install the wheel hub.
204-348
204-348
204-348
TIE44829
2007.50 Focus 3/2007 G307405en

Lower Arm(14 706 0)

Special Tool(s) • Rotate the locking tangs counterclockwise.
Protector, Ball Joint Gaiter
204-349
E42949
General Equipment
Ball joint separator
1. Remove the wheel and tire. E40677
For additional information, refer to: Wheel

and Tire (204-04 Wheels and Tires, Removal 3. Remove the components in the order
and Installation). indicated in the following illustration(s) and
table(s).
2. Remove the engine undershield.
2007.50 Focus 3/2007 G410655en

1 2
E39200
5. Check the front toe setting and adjust as

Item Description
necessary.
1 Lower arm ball joint For additional information, refer to:
See Removal Detail Specifications - 3-Door (204-00 Suspension
See Installation Detail System - General Information,
2 Lower arm Specifications)
See Removal Detail / Front Toe Adjustment (204-00 Suspension
See Installation Detail System - General Information, General
Procedures).
Removal Details
2007.50 Focus 3/2007 G410655en

Item 1 Lower arm ball joint 3. Using a suitable ball joint separator, detach
the lower arm from the wheel knuckle.
1. Using the special tool to prevent the ball joint
from rotating, remove the lower arm ball joint
retaining nut.
• Discard the lower arm ball joint retaining nut.
TIE44353
Item 2 Lower arm

TIE39073 1. Remove the lower arm front retaining bolt.
2.
CAUTION: Make sure the special tool is
installed with the curved surface facing
upwards to prevent damage to the ball joint
seal.
Install the special tool.
TIE0036674
2. Remove the lower arm rear clamp retaining

bolts.
TIE44354
TIE0036676
2007.50 Focus 3/2007 G410655en

Item 2 Lower arm Tighten the lower arm rear clamp retaining
bolts.
1. NOTE: Do not fully tighten the lower arm rear
clamp retaining bolts at this stage.
Install the lower arm rear clamp retaining
bolts.
115 Nm
TIE0036677
4. Tighten the lower arm front retaining bolt.

TIE0036676
2. NOTE: Do not fully tighten the lower arm

front retaining bolt at this stage.
Install the lower arm front retaining bolt.
175 Nm
TIE0036675
Item 1 Lower arm ball joint

1.
WARNING: Install a new lower arm ball
joint retaining nut. Failure to follow this
TIE0036674 instruction may result in personal injury.
Using the special tool to prevent the ball joint
3. from rotating, install the lower arm ball joint
CAUTION: While tightening the rear clamp
retaining nut.
retaining bolts, make sure the lower arm
does not move.
NOTE: Make sure the lower arm rear clamp and
the crossmember are correctly aligned.
70 Nm
TIE39074
2007.50 Focus 3/2007 G410655en

Front Stabilizer Bar

Special Tool(s) Centralize the steering wheel and lock it in
position.
204-349
E42949
Alignment Pins, Subframe

205-316 (15-097A)
TIE38834
15097A
2. Detach the steering column from the steering
gear pinion.
Separator, Ball Joint
211-020 • Discard the bolt.
13006
General Equipment
Securing strap
Transmission jack
TIE0027063
All vehicles
3. Remove the front wheels and tires.
CAUTION: Make sure the strut and spring
assembly does not move in a forwards or
and Tire (204-04 Wheels and Tires, Removal
rearwards direction, to prevent damage to
and Installation).
the top mount center cup.
1. NOTE: Make sure the road wheels are in the
straight ahead position.
E40677
2007.50 Focus 3/2007 G410656en

5. Detach the exhaust flexible pipe from the
CAUTION: Over bending of the exhaust
rear muffler flange.
flexible pipe may cause damage resulting in
failure. • Discard the gasket and nuts.
Support the exhaust flexible pipe with a
suitable support wrap or a suitable splint.
48 Nm
E50598
TIE0002772
Vehicles with diesel engine
8.
CAUTION: Using suitable cable ties,
6. support the rear muffler and exhaust tailpipe
CAUTION: Take care when removing the
exhaust hanger insulators to prevent assembly to prevent damage to the exhaust
damage. hanger insulators.
Detach the exhaust flexible pipe from the Detach the exhaust flexible pipe from the
front axle crossmember exhaust hanger rear muffler flange.
insulators. • Discard the gasket and nuts.
51 Nm
TIE39009 TIE40628
All except vehicles with diesel engine 9. Remove the components in the order
7. table(s).
support the rear muffler and exhaust tailpipe
assembly to prevent damage to the exhaust
hanger insulators.
2007.50 Focus 3/2007 G410656en

2 48 Nm
48 Nm 1
E39001
Item Description
1 Tie-rod end retaining nut
See Removal Detail
See Installation Detail
2 Stabilizer bar link retaining nut
See Removal Detail
3 Lower arm ball joint retaining nut
See Removal Detail
2007.50 Focus 3/2007 G410656en

80 Nm 4
TIE45173
Item Description
4 Engine support insulator front retaining
bolt
5 Front axle crossmember
See Removal Detail
2007.50 Focus 3/2007 G410656en

48 Nm 6
48 Nm 6
E40394
11.
Item Description WARNING: Install a new steering column
to steering gear pinion bolt. Failure to
6 Stabilizer bar clamp retaining bolts follow this instruction may result in
7 Stabilizer bar clamps personal injury.
8 Stabilizer bar NOTE: Make sure the road wheels are in the
See Removal Detail straight ahead position.
2007.50 Focus 3/2007 G410656en

Attach the steering column to the steering 12. Check the front toe setting and adjust as
gear pinion. necessary.
Specifications - 3-Door (204-00
Specifications)
/ Front Toe Adjustment (204-00 Suspension
System - General Information, General
Procedures).
28 Nm
TIE0027064
Removal Details
Item 1 Tie-rod end retaining nut Using the special tool, detach the tie-rod end
from the wheel knuckle on both sides.
1.
CAUTION: Leave the tie-rod end retaining
nut in place to protect the ball joint stud.
NOTE: Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
211-020
Loosen the the tie-rod end retaining nut on
both sides.
1. Remove the cotter pin.
2. Loosen the retaining nut.
• Discard the cotter pin.
E52983
1 Item 2 Stabilizer bar link retaining nut

2 1. NOTE: Use a 5 mm Allen key to prevent the
ball joint stud from rotating.
Detach the stabilizer bar link from the
stabilizer bar on both sides.
Item 3 Lower arm ball joint retaining nut

E53155
stud from rotating, remove the lower arm ball
2. joint retaining nut on both sides.
CAUTION: Protect the ball joint seal using
a soft cloth to prevent damage.
2007.50 Focus 3/2007 G410656en

• Discard the lower arm ball joint retaining nut. 2.
WARNING: Make sure the front axle
crossmember is secured to the transmission
jack. Failure to follow this instruction may
result in personal injury.
Using a suitable securing strap, secure the
front axle crossmember, stabilizer bar and
lower arm assembly to the transmission jack.
3. Remove the front axle crossmember bracket
retaining bolts on both sides.
TIE39073
2.
CAUTION: Make sure that the special tool
is installed with the curved surface facing
seal.
TIE44500
4. Remove the front axle crossmember

retaining bolts (transmission jack shown
removed for clarity).
TIE44354
3. Using a suitable ball joint separator, detach

the lower arm from the wheel knuckle on
both sides.
TIE39071
5.
CAUTION: To prevent damage to the
power steering lines, only lower the
crossmember sufficiently to allow the
stabilizer bar to be removed.
Lower the front axle crossmember.
TIE44353
Item 5 Front axle crossmember

1. Using a transmission jack and a wooden
block, support the front axle crossmember,
stabilizer bar and lower arm assembly.
2007.50 Focus 3/2007 G410656en

Item 8 Stabilizer bar
1. Remove the stabilizer bar bushings.
TIE0046824
Item 8 Stabilizer bar 3. Raise the front axle crossmember engaging
the alignment pins into the front axle
1.
CAUTION: The stabilizer bar bushings crossmember alignment holes.
must be located correctly on the flats of the
stabilizer bar with no lubricant.
205-316
Install the stabilizer bar bushings. 2
1
TIE0000859
2.
CAUTION: Make sure the front axle
TIE0046825 crossmember does not move while
tightening the front axle crossmember
2. Position the stabilizer bar on the front axle retaining bolts.
crossmember. Install the front axle crossmember retaining
bolts (transmission jack removed for clarity).
1. 115 Nm
Using a transmission jack and the special
tool, position and align the front axle
crossmember.
1. Insert the alignment pins through the front
axle crossmember alignment holes. 275 Nm
2. Slide the locking plates into the groove of the TIE39072
special tool and tighten the alignment pin
sleeve.
2007.50 Focus 3/2007 G410656en

3. Install the front axle crossmember bracket NOTE: Use a 5 mm Allen key to prevent the ball
retaining bolts on both sides. joint stud from rotating.
Attach the tie-rod end to the wheel knuckle
on both sides.
1. Tighten the retaining nut.
2. Install the cotter pin.
70 Nm
TIE44501
1 48 Nm
4. Remove the special tool.
5. Remove the securing strap.
E53156
6. Lower and remove the transmission jack and
the wooden block.

1.
stud from rotating, install the lower arm ball
joint retaining nut on both sides.
70 Nm
TIE39074
Item 2 Stabilizer bar link retaining nut

1. NOTE: Use a 5 mm Allen key to prevent the
Attach the stabilizer bar link to the stabilizer
bar on both sides.
Item 1 Tie-rod end retaining nut

1. NOTE: Install a new tie-rod end retaining nut
cotter pin.
2007.50 Focus 3/2007 G410656en

Lower Arm Ball Joint(14 735 0)

Special Tool(s) CAUTION: Make sure the strut and spring
Protector, Ball Joint Gaiter assembly does not move in a forwards or
204-349 rearwards direction, to prevent damage to
1. Remove the wheel and tire.
E42949 and Tire (204-04 Wheels and Tires, Removal
and Installation).
General Equipment 2. Remove the components in the order
Ball joint separator indicated in the following illustration(s) and
table(s).
Electric hand drill
1
E53176
4. Check the front toe setting and adjust as
Item Description
necessary.
1 Lower arm ball joint For additional information, refer to:
See Removal Detail Specifications (204-00 Suspension System
See Installation Detail - General Information, Specifications)
3. To install, reverse the removal procedure. / Front Toe Adjustment (204-00 Suspension
Procedures).
Removal Details
Item 1 Lower arm ball joint
joint retaining nut.
2007.50 Focus 3/2007 G410657en

• Discard the lower arm ball joint retaining nut. 3. Using a suitable ball joint separator, detach
TIE39073
TIE44353
2.
is installed with the curved surface facing 4. Remove the lower arm ball joint.
upwards to prevent damage to the ball joint • Using a suitable electric hand drill remove
seal. the rivets.
TIE0036826
TIE44354
Item 1 Lower arm ball joint 2.
1. Using suitable M10 nuts and M10 x 30 mm joint retaining nut. Failure to follow this
bolts, install a new lower arm ball joint. instruction may result in personal injury.
70 Nm
TIE0036827
2007.50 Focus 3/2007 G410657en

stud from rotating, install the lower arm ball
70 Nm
TIE39074
2007.50 Focus 3/2007 G410657en

Wheel Knuckle
Special Tool(s) Special Tool(s)
Lever, Wheel Knuckle Separator, Ball Joint
204-159 (14-039) 211-020
13006
14039
Protector, Ball Joint Gaiter General Equipment

204-349 Ball joint separator
E42949
and Installation).
2. Remove the components in the order
table(s).
2007.50 Focus 3/2007 G410658en

1 9 8
10
3 9 Nm
9 Nm 6
2
4
E40389
1 Brake caliper and anchor plate assembly 6 Lower arm ball joint heat shield
See Removal Detail 7 Lower arm ball joint retaining nut
See Installation Detail See Removal Detail
2 Brake disc See Installation Detail
See Removal Detail 8 Wheel knuckle to strut and spring
3 Wheel speed sensor retaining bolt assembly pinch bolt
4 Wheel hub retaining bolt
9 Strut and spring assembly
5 Tie-rod end retaining nut See Removal Detail
See Removal Detail
See Installation Detail 10 Wheel knuckle
2007.50 Focus 3/2007 G410658en

Removal Details
Item 1 Brake caliper and anchor plate assembly 2. Loosen the retaining nut.
1. • Discard the cotter pin.
CAUTION: Suspend the brake caliper and
anchor plate assembly to prevent load being
placed on the brake hose.
Detach the brake caliper and anchor plate
1
assembly from the wheel knuckle.
2
E53155
2.
TIE0030230
Using the special tool, detach the tie-rod end
from the wheel knuckle.
Item 2 Brake disc

1. Remove the brake disc.
• Remove and discard the retaining washer (if 211-020
equipped).
E52983

E0032118

1.
Loosen the tie-rod end retaining nut on both
sides.
2007.50 Focus 3/2007 G410658en

• Discard the lower arm ball joint retaining nut. 4. CAUTIONS:
Support the halfshaft. The inner constant
velocity (CV) joint must not be bent more
than 23 degrees. The outer CV joint must not
be bent more than 45 degrees.
Do not apply excessive force to the strut

and spring assembly. Do not pull the strut
and spring assembly outwards by more than
28 mm.
NOTE: Make sure the halfshaft is still fully engaged
in the CV joint housing.
TIE39073
Detach the wheel hub from the halfshaft.
2. • Pull the strut and spring assembly outwards.
installed with the curved surface facing
upwards to prevent damage to the ball joint Item 9 Strut and spring assembly
seal. 1. Using the special tool, detach the wheel
Install the special tool. knuckle from the strut and spring assembly.
204-159
TIE0000944
TIE44354

TIE44353
2007.50 Focus 3/2007 G410658en

Item 8 Wheel knuckle to strut and spring Using the special tool to prevent the ball joint
assembly pinch bolt stud from rotating, install the lower arm ball
1.
WARNING: Install a new wheel knuckle
to strut and spring assembly pinch bolt.
CAUTION: The wheel knuckle to strut and
spring assembly pinch bolt must be 70 Nm
installed from the front of the vehicle.
Attach the wheel knuckle to the strut and
spring assembly.
TIE39074

1. NOTE: Install a new tie-rod end retaining nut
90 Nm cotter pin.
TIE0005688
on both sides.
1. CAUTIONS:
Support the halfshaft. The inner constant
velocity (CV) joint must not be bent more
2
28 mm.
1 48 Nm
Attach the wheel hub to the halfshaft.
• Pull the strut and spring assembly outwards.
E53156
2.
2007.50 Focus 3/2007 G410658en

Item 1 Brake caliper and anchor plate assembly
1. Attach the brake caliper and anchor plate
assembly to the wheel knuckle.
115 Nm
TIE0036772
2007.50 Focus 3/2007 G410658en

Strut and Spring Assembly

Special Tool(s) 4. Detach the strut and spring assembly top
mount brace from the bulkhead (left-hand
Lever, Wheel Knuckle
side shown).
204-159
25 Nm
14039

1. Remove the engine upper cover. TIE0036727
2. Remove the cowl panel grille.
For additional information, refer to: Cowl 5. Remove the strut and spring assembly top
Panel Grille (501-02 Front End Body Panels, mount brace (left-hand side shown).
Removal and Installation). • Loosely install the strut and spring assembly
3. Remove the bulkhead extension panel. top mount bolts.
1. Remove the retaining screws and washers.
2. Detach the panel from the retaining clips.
32 Nm
E42604
1
E50990 6. Remove the wheel and tire.
and Installation).
table(s).
2007.50 Focus 3/2007 G401518en

3
E40390
1 Stabilizer bar link to strut and spring 4 Strut and spring assembly top mount
assembly retaining nut retaining bolts
See Removal Detail See Removal Detail
See Installation Detail See Installation Detail
2 Brake hose 5 Strut and spring assembly
3 Wheel knuckle to strut and spring 8. To install, reverse the removal procedure.
assembly pinch bolt
See Removal Detail
Removal Details
Item 1 Stabilizer bar link to strut and spring
assembly retaining nut
joint from rotating.
2007.50 Focus 3/2007 G401518en

Item 3 Wheel knuckle to strut and spring Item 4 Strut and spring assembly top mount
assembly pinch bolt retaining bolts
1. Using the special tool, detach the strut and CAUTION: With the aid of another
spring assembly from the wheel knuckle. technician, support the strut and spring
assembly.
204-159
TIE0000944
Item 4 Strut and spring assembly top mount Attach the strut and spring assembly to the
retaining bolts wheel knuckle.
1.
CAUTION: With the aid of another
technician, support the strut and spring
assembly.
Install the strut and spring assembly top
mount bolts.
90 Nm
TIE0005688
32 Nm
Item 1 Stabilizer bar link to strut and spring
assembly retaining nut
E0036770
ball joint from rotating.
Item 3 Wheel knuckle to strut and spring

assembly pinch bolt
1.
WARNING: Install a new wheel knuckle
to strut and spring assembly pinch bolt.
Failure to follow this instruction may result
in personal injury.
CAUTION: The wheel knuckle to strut and
spring assembly pinch bolt must be
installed from the front of the wheel
knuckle.
2007.50 Focus 3/2007 G401518en

Install the stabilizer bar link to strut and
spring assembly retaining nut.
48 Nm
TIE0021919
2. Remove the strut and spring assembly top

mount bolts.
TIE44530
2007.50 Focus 3/2007 G401518en

Strut and Spring Assembly

Special Tool(s) WARNING: The spring is under extreme
Compressor, Coil Spring tension; care must be taken at all times.
204-167 (14-042) Failure to follow this instruction may result
in personal injury.
1. Disassemble the components in the order
table(s).
14042
Adapters for 204-167

204-167-01 (14-042-01)
1404201
1 50 Nm
E38791
1 Thrust bearing retaining nut 3 Thrust bearing and spring seat assembly
See Disassembly Detail See Assembly Detail
See Assembly Detail 4 Boot
2 Top mount
2007.50 Focus 3/2007 G296118en

Item Description 2. To assemble, reverse the disassembly

procedure.
5 Bump stop
6 Spring
See Assembly Detail
Disassembly Details
Item 1 Thrust bearing retaining nut Using the special tools, compress the spring.
1.
WARNING: The spring is under extreme
tension; care must be taken at all times. 204-167-01
in personal injury.
NOTE: Make a note of the position of the top
mount, the top mount bearing alignment marking,
the strut alignment marking and the spring seat cut
out, to aid assembly.
204-167
TIE0022852
2.
CAUTION: Use an Allen key to prevent
the piston rod from rotating.
Remove the thrust bearing retaining nut.
Assembly Details
Item 6 Spring
CAUTION: The ends of the spring must
locate correctly in the spring seats.
Item 3 Thrust bearing and spring seat assembly

CAUTION: Make sure the thrust bearing
and spring seat assembly is correctly
seated onto the boot before assembly.
Item 1 Thrust bearing retaining nut

CAUTION: Make sure the alignment
markings on the top mount and the top
mount bearing are aligned with the spring
seat cut out and the alignment marking on
the strut.
2007.50 Focus 3/2007 G296118en

204-02-1 Rear Suspension 204-02-1
.
SECTION 204-02 Rear Suspension

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 204-02-2

Rear Suspension................................................................................................................ 204-02-3
Vehicles with ball joint stabilizer bar link 3-door and 5-door............................................... 204-02-3
Vehicles with solid stabilizer bar link 3-door and 5-door .................................................... 204-02-6
Wagon................................................................................................................................ 204-02-7

Rear Suspension................................................................................................................ 204-02-9

Wheel Hub — Vehicles With: Rear Drum Brakes............................................................... 204-02-10
Wheel Hub — Vehicles With: Rear Disc Brakes................................................................. 204-02-12
Upper Arm...................................................................................................... (15 701 0) 204-02-14
Front Lower Arm............................................................................................. (15 690 0) 204-02-16
Rear Lower Arm — Vehicles With: Solid Stabilizer Bar Link.............................................. 204-02-18
Rear Lower Arm — Vehicles With: Ball Joint Stabilizer Bar Link........................................ 204-02-21
Stabilizer Bar — Vehicles With: Solid Stabilizer Bar Link................................................... 204-02-24
Stabilizer Bar — Vehicles With: Ball Joint Stabilizer Bar Link............................................ 204-02-27
Wheel Knuckle.................................................................................................................... 204-02-31
Spring............................................................................................................. (15 621 0) 204-02-38
SPECIFICATIONS
Stabilizer bar link to rear lower arm retaining nut – 15 11 -
Vehicles with solid stabilizer bar link
Stabilizer bar link to rear lower arm retaining nut – 48 35 -
Vehicles with ball joint stabilizer bar link
Stabilizer bar to stabilizer link retaining nut – 70 52 -
Rear axle crossmember retaining bolts 125 92 -
Upper arm retaining bolts 115 85 -
Front lower arm retaining bolts 115 85 -
Rear lower arm to wheel knuckle retaining bolt 115 85 -
Rear lower arm adjustment cam nut 90 66 -
Wheel hub retaining bolts 55 41 -
Wheel knuckle front retaining bolts 125 92 -
Shock absorber upper mount retaining bolt 25 18 -
Shock absorber lower mount retaining bolt 115 85 -
2007.50 Focus 3/2007 G163200en

Rear Suspension
Vehicles with ball joint stabilizer bar link 3-door and 5-door
10
2
1
11
4
6
12
3
7
8
9
E55087
1 Crossmember 5 Wheel hub
2 Stabilizer bar 6 Upper arm
3 Ball joint stabilizer bar link 7 Front lower arm
4 Wheel knuckle 8 Rear lower arm
2007.50 Focus 3/2007 G427101en

Item Description Item 2 : Stabilizer Bar

9 Bump stop The stabilizer bar is uniquely shaped with modified
10 Shock absorber locating holes to accomodate the ball joint stabilizer
bar link.
11 Spring
12 Rear lower arm adjustment cam nut
Item 3 : Ball Joint Stabilizer Bar Link
E55089
The ball joint stabilizer bar link has been introduced

to provide a quicker response to suspension
movement. This enables the stabilizer bar to
2007.50 Focus 3/2007 G427101en

respond more directly to wheelstation movement. Item 5: Wheel Hub
The ball joint stabilizer bar link is assembled
between the rear lower arm and stabilizer bar with The wheel hub assembly incorporates the wheel
retaining nuts. bearing, wheel speed sensor ring, wheel hub and
wheel spindle as one assembly.
Item 4: Wheel Knuckle

Item 8: Rear Lower Arm
The wheel knuckle provides a wider track width
and attachment surface for the unique wheel hub The rear lower arm has a unique shape to
assembly. incorporate the ball joint stabilizer bar link.
Item 10: Shock Absorber
The shock absorber includes a unique upper mount

damper to provide additional noise reduction.
2007.50 Focus 3/2007 G427101en

Vehicles with solid stabilizer bar link 3-door and 5-door
10
2
11 1
4 6
12
3
7
8
9
E55088
1 Crossmember 7 Front lower arm
2 Stabilizer bar 8 Rear lower arm
3 Solid stabilizer bar link 9 Bump stop
4 Wheel knuckle 10 Shock absorber
5 Wheel hub 11 Spring
6 Upper arm 12 Rear lower arm adjustment cam
2007.50 Focus 3/2007 G427101en

Item 4: Wheel Knuckle Item 10: Shock Absorber
The wheel knuckle provides a wider track width The shock absorber includes a unique upper mount
and attachment surface for the unique wheel hub damper to provide additional noise reduction.
assembly.
Wagon
Item 5: Wheel Hub
The wagon is only available with a solid stabilizer
The wheel hub assembly incorporates the wheel bar link.
bearing, wheel speed sensor ring, wheel hub and
9 1
7
4
6
2
11
5
8
10
E55086
2007.50 Focus 3/2007 G427101en

Item Description
1 Crossmember
2 Stabilizer bar
3 Solid stabilizer bar link
4 Wheel knuckle
5 Wheel hub
6 Upper arm
7 Front lower arm
8 Rear lower arm
9 Shock absorber
10 Spring
11 Rear lower arm adjustment cam
Item 4: Wheel Knuckle
The wheel knuckle provides a wider track width

and attachment surface for the unique wheel hub
assembly.
Item 5: Wheel Hub
The wheel hub assembly incorporates the wheel

bearing, wheel speed sensor ring, wheel hub and
Item 9: Shock Absorber
Nivomat shock absorbers are available as an

option to provide load leveling rear suspension.
2007.50 Focus 3/2007 G427101en

Rear Suspension
REFER to Section 204-00 [Suspension System -
2007.50 Focus 3/2007 G17411en

Wheel Hub — Vehicles With: Rear Drum Brakes

2. Remove the rear wheel speed sensor.
1. Remove the brake drum.
For additional information, refer to: Rear
For additional information, refer to: Brake
Wheel Speed Sensor (206-09 Anti-Lock
Drum (206-02 Drum Brake, Removal and
Control, Removal and Installation).
Installation).
table(s).
E50633
Item Description 4. To install, reverse the removal procedure.

1 Wheel hub
See Removal Detail
Removal Details
Item 1 Wheel hub
1.
CAUTION: Suspend the brake backing
plate, wheel cylinder and brake shoes
assembly to prevent load being placed on
the brake hose.
2007.50 Focus 3/2007 G388086en

Remove the wheel hub.
TIE0036853
Item 1 Wheel hub
1. Install the wheel hub.
55 Nm
55 Nm
E0036854
2007.50 Focus 3/2007 G388086en

Wheel Hub — Vehicles With: Rear Disc Brakes

206-09B [Anti-Lock Control - Traction
1. Remove the brake disc. For additional
Control] / 206-09C [Anti-Lock Control -
information, refer to Section 206-04 [Rear
Stability Assist].
Disc Brake].
2. Remove the rear wheel speed sensor. For
additional information, refer to
table(s).
Section 206-09A [Anti-Lock Control] /
TIE40717

1 Wheel hub
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G307406en

Item 1 Wheel hub
1. Remove the wheel hub.
TIE0036853
Item 1 Wheel hub
55 Nm
55 Nm
E0036854
2007.50 Focus 3/2007 G307406en

Upper Arm(15 701 0)

General Equipment 4. NOTE: The spacer must be positioned
exactly as shown.
Transmission jack
Install the spacer.
Removal 1. Remove the bump stop.
2. Install the spacer between the rear lower arm
1. Remove the spring. For additional and the rear axle crossmember making sure
information, refer to: (204-02 Rear that the spacer is in a vertical plane.
Suspension)
Spring - Vehicles Built Up To: 07/2004
(Removal and Installation), 2
2. Fabricate a 20 mm wide by 113 mm long 1
spacer.
TIE0014145
5. Detach the upper arm from the wheel

knuckle.
TIE0004698
3.
CAUTION: The suspension must be set
to the design height setting.
Using a transmission jack and a wooden
block, raise the suspension to the design
height setting.
E0025371
• Position the transmission jack and the
wooden block as shown. 6. NOTE: Make a note of the position of the
upper arm to aid installation.
TIE0024959
2007.50 Focus 3/2007 G287947en

Remove the upper arm. 2. Install the bump stop.
TIE0025372 TIE45129
4. Install the spring. For additional information,

Installation refer to: (204-02 Rear Suspension)
1. Install the upper arm to the rear axle Spring - Vehicles Built Up To: 07/2004
crossmember. (Removal and Installation),
Spring - Vehicles Built From: 07/2004
115 Nm
TIE0025373
2. Attach the upper arm to the wheel knuckle.
115 Nm
E0025374
3. Lower the suspension from the design height

setting.
1. Remove the spacer.
2007.50 Focus 3/2007 G287947en

Front Lower Arm(15 690 0)

General Equipment 1. Remove the bump stop.
Transmission jack 2. Install the spacer between the rear lower arm
and the rear axle crossmember making sure
that the spacer is in a vertical plane.
Removal
1. Remove the spring. For additional 2
information, refer to: (204-02 Rear
Suspension)
1
Spring (Removal and Installation).
2. Fabricate a 20 mm wide by 113 mm long
spacer.
TIE0014145
5.
CAUTION: The front lower arm is marked
FRONT. Make a note of the position of the
front lower arm to aid installation.
Remove the front lower arm.
TIE0004698
3.
height setting.
• Position the transmission jack and the TIE0024965
wooden block as shown.
Installation
1. Install the front lower arm.
115 Nm
TIE0024959
4. NOTE: The spacer must be positioned

exactly as shown.
TIE0024966
Install the spacer.
2007.50 Focus 3/2007 G287949en

setting.
2. Install the bump stop.
TIE45129
3. Install the spring. For additional information,

refer to: (204-02 Rear Suspension)
2007.50 Focus 3/2007 G287949en

Rear Lower Arm — Vehicles With: Solid Stabilizer Bar Link

Transmission jack
table(s).
1. Remove the spring. For additional
Suspension)
115 Nm 2 1
TIE40444
4. Check the toe setting and adjust as

Item Description
necessary. For additional information, refer
1 Rear lower arm adjustment cam nut to: (204-00 Suspension System - General
See Removal Detail Information)
See Installation Detail Specifications (Specifications),
2 Rear lower arm to wheel knuckle retaining Rear Toe Adjustment (General Procedures).
bolt 5. NOTE: Final tightening of the rear lower arm
adjustment cam nut should be carried out
when the vehicle weight is on the road
wheels.
2007.50 Focus 3/2007 G296126en

Tighten the rear lower arm adjustment cam
nut.
90 Nm
TIE39079
Removal Details
Item 1 Rear lower arm adjustment cam nut • Position the transmission jack and the
spacer.
TIE0024959
TIE0004698
exactly as shown.
2.
CAUTION: The suspension must be set Install the spacer.
1. Remove the bump stop.
Using a transmission jack and the wooden 2. Install the spacer between the rear lower arm
block, raise the suspension to the design and the rear axle crossmember making sure
height setting. that the spacer is in a vertical plane.
TIE0014145
2007.50 Focus 3/2007 G296126en

4. Using paint or typing correction fluid, mark 5. Remove the rear lower arm adjustment cam
the position of the rear lower arm adjustment nut.
cam to the rear axle crossmember.
TIE0024960
Item 1 Rear lower arm adjustment cam nut 2. Install the bump stop.
1
NOTE: Align the mark on the rear lower arm
adjustment cam to the mark on the rear axle
crossmember.
2
Install the rear lower arm adjustment cam
nut.
TIE45129
8 Nm
TIE0036771

setting.
2007.50 Focus 3/2007 G296126en

Rear Lower Arm — Vehicles With: Ball Joint Stabilizer Bar Link
Transmission jack
table(s).
1. Remove the spring. For additional
Suspension)
115 Nm 2 1
TIE40445

Item Description
1 Rear lower arm adjustment cam nut to: (204-00 Suspension System - General
See Removal Detail Information)
See Installation Detail Specifications (Specifications),
2 Rear lower arm to wheel knuckle retaining Rear Toe Adjustment (General Procedures).
bolt 5. NOTE: Final tightening of the rear lower arm
adjustment cam nut should be carried out
when the vehicle weight is on the road
wheels.
2007.50 Focus 3/2007 G296127en

nut.
90 Nm
TIE39079
Removal Details
Item 1 Rear lower arm adjustment cam nut • Position the transmission jack and the
spacer.
TIE0024959
TIE0004698
exactly as shown.
2.
CAUTION: The suspension must be set Install the spacer.
Using a transmission jack and a wooden 2. Install the spacer between the rear lower arm
block, raise the suspension to the design and the rear axle crossmember making sure
height setting. that the spacer is in a vertical plane.
TIE0014145
2007.50 Focus 3/2007 G296127en

4. Using paint or typing correction fluid, mark 5. Remove the rear lower arm adjustment cam
the position of the rear lower arm adjustment nut.
cam to the rear axle crossmember.
TIE0024960
Item 1 Rear lower arm adjustment cam nut 2. Install the bump stop.
1
NOTE: Align the mark on the rear lower arm
adjustment cam to the mark on the rear axle
crossmember.
2
Install the rear lower arm adjustment cam
nut.
TIE45129
8 Nm
TIE0036771

setting.
2007.50 Focus 3/2007 G296127en

Stabilizer Bar — Vehicles With: Solid Stabilizer Bar Link

General Equipment 2. Remove the spring on both sides. For
additional information, refer to: (204-02 Rear
Transmission jacks
Suspension)
Hydraulic press Spring (Removal and Installation),
1. Remove the rear wheels and tires. Spring (Removal and Installation),
and Tire (204-04 Wheels and Tires, Removal 3. Remove the components in the order
and Installation). indicated in the following illustration(s) and
table(s).
1 1
48 Nm 2
E54596

1 Stabilizer bar link
2 Stabilizer bar clamp retaining bolts
3 Stabilizer bar
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G427703en

Item 3 Stabilizer bar 2. Remove the stabilizer bar bushing on both
sides.
1. Remove the stabilizer bar clamp on both
sides.
TIE0031784
Item 3 Stabilizer bar • Position the transmission jack and the
wooden block as shown (left-hand side
1. Fabricate two 20 mm wide by 113 mm long
shown).
spacers.
TIE0024959
TIE0004698

2. exactly as shown.
CAUTION: Both sides of the suspension
must be set to the design height setting. Install the spacer on both sides.
Using 2 transmission jacks and wooden 1. Remove the bump stop.
blocks, raise the suspension to the design
height setting on both sides.
2007.50 Focus 3/2007 G427703en

2. Install the spacer between the rear lower arm 2. Using ahydraulic press, press the stabilizer
and the rear axle crossmember making sure bar clamp onto the stabilizer bar bushing.
that the spacer is in a vertical plane.
1 2
1
TIE0004694
TIE0014145
6. Position the stabilizer bar.

4.
CAUTION: The stabilizer bar bushing
must be located correctly on the stabilizer Item 1 Stabilizer bar link
bar, with no lubricant. 1. NOTE: Make sure that the stabilizer bar link
NOTE: Make sure that the stabilizer bar bushing retaining nuts are tightened before lowering
nipple is on the left-hand side. the suspension from the design height
setting.
Install the stabilizer bar bushing on both
sides. Lower the suspension from the design height
setting on both sides.
TIE0036747
5. Install the stabilizer bar clamp on both sides.

TIE45129
1. Apply water to the stabilizer bar clamp to
assist installation.
2007.50 Focus 3/2007 G427703en

Stabilizer Bar — Vehicles With: Ball Joint Stabilizer Bar Link

Hydraulic press
table(s).
1. Remove the rear wheels and tires.
and Installation).
1
2
1
3 4 3
E40436
1 Stabilizer bar link 3 Stabilizer bar clamp

See Removal Detail See Installation Detail
See Installation Detail 4 Stabilizer bar
2 Stabilizer bar clamp retaining bolts See Removal Detail
Removal Details
2007.50 Focus 3/2007 G296129en

Item 1 Stabilizer bar link 2. Remove the stabilizer bar clamp lower
retaining bolt on both sides.
1. Loosen the stabilizer bar link to stabilizer
bar retaining nut on both sides.
E49841
E49059
Item 4 Stabilizer bar
2. Detach the stabilizer bar link from rear lower 1. Remove the stabilizer bar bushings.
arm on both sides.
TIE0031784
E0036377
2. Remove the stabilizer bar link from the

Item 2 Stabilizer bar clamp retaining bolts stabilizer bar on both sides.
1. Remove the stabilizer bar clamp upper
retaining bolt on both sides.
• Remove the parking brake cable support
bracket.
E49060
E49819
2007.50 Focus 3/2007 G296129en

Item 4 Stabilizer bar Install the stabilizer bar bushings on both
sides.
1.
WARNING: Make sure the washer is
installed to the ball joint stabilizer bar link
stud. Failure to follow this instruction may
Check the washer is clamped on to the ball
joint stabilizer bar link stud.
TIE0036747
Item 3 Stabilizer bar clamp

1. Install the stabilizer bar clamps.
1. Apply water to the clamps to assist
E49999 installation.
2. Using a suitable hydraulic press, press the
2. Loosely install the stabilizer bar link to the clamp onto the bushing on both sides.
1 2
TIE0004694
E49060
Item 2 Stabilizer bar clamp retaining bolts
3. 1. NOTE: Before installing the stabilizer bar
CAUTION: The stabilizer bar bushings clamp retaining bolts, make sure the parking
must be located correctly on the stabilizer brake cable support bracket is correctly
bar, with no lubricant. located.
NOTE: Make sure the bushing nipple is on the Install the stabilizer bar clamp upper
left-hand side. retaining bolt on both sides.
2007.50 Focus 3/2007 G296129en

• Install the parking brake cable support 2. Tighten the stabilizer bar link to stabilizer
bracket. bar retaining nut on both sides.
48 Nm
70 Nm
E49839
E49061
2. Install the stabilizer bar clamp lower retaining

bolt on both sides.
48 Nm
E49840
Item 1 Stabilizer bar link

1. Attach the stabilizer bar link to the rear lower
arm on both sides.
48 Nm
E0036378
2007.50 Focus 3/2007 G296129en

Wheel Knuckle
General Equipment
All vehicles
Transmission jack
6. Detach the rear brake hose from the wheel
knuckle.
Removal
Vehicles with rear disc brakes
1. Remove the brake disc shield.
Disc Shield (206-04 Rear Disc Brake,
Vehicles with rear drum brakes

2. Remove the wheel hub.
TIE44587
Hub - Vehicles With: Rear Drum Brakes
(204-02 Rear Suspension, Removal and 7. Detach the parking brake cable from the
Installation). wheel knuckle.
3. Detach the parking brake cable guide from
the wheel knuckle.
TIE44588
TIE0000348 8. Detach the wheel speed sensor wiring

harness from the wheel knuckle.
4. Disconnect the parking brake cable.
TIE44589
TIE0000318
5. Pull the parking brake cable and parking

brake cable guide through the wheel knuckle.
2007.50 Focus 3/2007 G388087en

9. Remove the spring. For additional 2. Install the spacer between the rear lower arm
information, refer to: and the rear axle crossmember making sure
that the spacer is in the vertical plane.
Spring (204-02, Removal and Installation),
Spring (204-02 Rear Suspension, Removal
and Installation),
Spring - Convertible (204-02 Rear 2
spacer. 1
TIE0014145
13. Detach the front lower arm from the wheel

knuckle.
TIE0004698
11.
height setting.
• Position the transmission jack and the TIE0001978
14. Detach the upper arm from the wheel
knuckle.
TIE0024959

E0025371
exactly as shown.
Install the spacer.
2007.50 Focus 3/2007 G388087en

15. Mark the position of the rear lower arm • Lower and remove the transmission jack.
adjustment cam to the rear axle
crossmember.
TIE0001982
TIE0024960
Installation
16. Remove the rear lower arm. All vehicles
1. Using a transmission jack, support the wheel
knuckle.
2. NOTE: Do not fully tighten the wheel knuckle
retaining bolts at this stage.
Install the wheel knuckle.
TIE0025413
17. Remove the air deflector.
TIE0001982
3. NOTE: Do not fully tighten the upper arm to

wheel knuckle retaining bolt at this stage.
Attach the upper arm to the wheel knuckle.
TIE44528
18. Remove the wheel knuckle.
E0025371
2007.50 Focus 3/2007 G388087en

4. NOTE: Do not fully tighten the front lower • Position the transmission jack and the
arm to wheel knuckle retaining bolt at this wooden block as shown.
stage.
Attach the front lower arm to the wheel
knuckle.
TIE0024959

TIE0001978 exactly as shown.
Install the spacer.
5. Lower and remove the transmission jack. • Install the spacer between the rear lower arm
6. NOTE: Do not fully tighten the rear lower arm and the rear axle crossmember making sure
retaining bolt and the rear lower arm that the spacer is in the vertical plane.
Attach the rear lower arm to the wheel
knuckle and the rear axle crossmember.
TIE45679
9. Tighten the wheel knuckle retaining bolts.

TIE0025413
7. 125 Nm
height setting.
E56696
2007.50 Focus 3/2007 G388087en

10. Tighten the upper arm to wheel knuckle Install the rear lower arm.
retaining bolt.
8 Nm
115 Nm
TIE0036771
E0025374
14. Lower the suspension from the design

11. Tighten the front lower arm to wheel height setting.
knuckle retaining bolt.
115 Nm
TIE0028753
TIE45129
12. Tighten the rear lower arm to wheel knuckle
retaining bolt. 15. Install the air deflector.
115 Nm
E44956 TIE44528
13. NOTE: Do not fully tighten the rear lower 16. Install the spring. For additional
arm adjustment cam nut at this stage. information, refer to:
NOTE: Align the mark on the rear lower arm Spring (204-02, Removal and Installation),
adjustment cam to the mark on the rear axle Spring (204-02 Rear Suspension, Removal
crossmember. and Installation),
Spring - Convertible (204-02 Rear
2007.50 Focus 3/2007 G388087en

17. Attach the wheel speed sensor wiring 21. Connect the parking brake cable.
harness to the wheel knuckle.
TIE0000318
TIE44589
22. Attach the parking brake cable guide to the

18. Attach the parking brake cable to the wheel wheel knuckle.
knuckle.
TIE0000348
TIE44588

19. Attach the rear brake hose to the wheel
knuckle.
Hub - Vehicles With: Rear Drum Brakes
Installation).

24. Install the brake disc shield.
Disc Shield (206-04 Rear Disc Brake,
All vehicles
TIE44587
Vehicles with rear drum brakes to: (204-00 Suspension System - General
Information)
20. Push the parking brake cable and parking
brake cable guide through the wheel Specifications - 3-Door (Specifications),
knuckle. Specifications (Specifications),
Specifications (Specifications),
Rear Toe Adjustment (General Procedures).
2007.50 Focus 3/2007 G388087en

26. NOTE: Final tightening of the rear lower
arm adjustment cam nut must be carried
out when the vehicle weight is on the road
wheels.
nut.
90 Nm
TIE39079
2007.50 Focus 3/2007 G388087en

Spring(15 621 0)
Special Tool(s) Vehicles with ball joint stabilizer bar link
Compressor, Coil Spring 3. Detach the stabilizer bar link from the rear
204-167 (14-042) lower arm on both sides.
14042
Adapters for 204-167

204-215 (15-111)
204215 E0036377
General Equipment All vehicles

Trolley jack 4. Using a suitable trolley jack, support the
wheel knuckle.
Removal 5. Detach the shock absorber from the wheel
knuckle.
All vehicles
and Installation).

2. Detach the stabilizer bar link from the rear
lower arm on both sides.
TIE0022186
6.
WARNING: As the spring is under
extreme tension care must be taken at all
times. Failure to follow this instruction may
TIE0024919
2007.50 Focus 3/2007 G338716en

Using the special tools, compress the spring. Using the special tools, compress the spring.
204-215 204-215
204-167 204-167
TIE44571 TIE44571
7. Remove the trolley jack. 3.

8. extreme tension care must be taken at all
result in personal injury. CAUTION: Make sure the top seat
mounting is installed, and the spring ends
With the aid of another technician, pull the
butt correctly against the upper and lower
rear lower arm downwards to release the
spring seats.
spring from the spring seats and remove the
spring. Install the spring.
4. Remove the special tools.
Installation 5. Using a suitable trolley jack, position and
align the wheel knuckle with the shock
All vehicles absorber.
1. Using a suitable trolley jack, support the 6. NOTE: Do not fully tighten the shock
wheel knuckle. absorber to wheel knuckle retaining bolt at
2. this stage.
2007.50 Focus 3/2007 G338716en

Attach the shock absorber to the wheel All vehicles
knuckle.
10. Install the wheel and tire.
and Tire (204-04 Wheels and Tires,
11. Tighten the shock absorber to wheel
knuckle retaining bolt.
115 Nm
TIE0022186
7. Remove the trolley jack.

8. Attach the stabilizer bar link to the rear lower TIE0001955
arm on both sides.
48 Nm
E0036378

9. Attach the stabilizer bar link to the rear lower
arm on both sides.
15 Nm
TIE0024920
2007.50 Focus 3/2007 G338716en

204-04-1 Wheels and Tires 204-04-1
.
SECTION 204-04 Wheels and Tires

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 204-04-2

Wheels and Tires................................................................................................................ 204-04-3
Symptom Chart................................................................................................................... 204-04-4

Wheel and Tire................................................................................................................... 204-04-8
SPECIFICATIONS
Steel wheel nuts 90 66 -
Five spoke steel wheel nuts 130 96 -
Alloy wheel nuts 130 96 -
Wheel and Tire Assembly Runout Specifications

Description Alloy Wheel (mm) Steel Wheel (mm)
Maximum lateral runout 0.3 0.6
Maximum radial runout 0.3 0.5
2007.50 Focus 3/2007 G928381en

Wheels and Tires

Visual Inspection Chart
Mechanical
Wheel(s)
Tire(s)
Tire pressure(s) *
Wheel nuts
Wheel studs
* Vehicles equipped with a tire pressure monitoring system must be inspected for correct operation
using the diagnostic tool.
To maximize tire performance, inspect the tires for During the road test, drive the vehicle on a road
signs of incorrect inflation and uneven wear which that is smooth and free of undulations. If vibration
may indicate a need for balancing, rotation or is apparent, note and record the following:
suspension alignment. Tires should also be
– the speed at which the vibration occurs.
checked frequently for cuts, stone bruises,
abrasions, blisters and for objects that may have – what type of vibration occurs in each speed
become embedded in the tread. More frequent range.
inspections are recommended when rapid or – mechanical or audible
extreme temperature changes occur or when road – how the vibration is affected by changes in the
surfaces are rough or occasionally littered with following:
foreign material. – engine torque
As a further visible check of tire condition, tread – vehicle speed
wear indicators are molded into the bottom of the – engine speed
tread grooves. When these indicator bands become
visible, new tires must be installed. – type of vibration - sensitivity:
– torque sensitive
– vehicle speed sensitive
Tire Wear Diagnosis – engine speed sensitive
Uneven wear is usually caused by either excessive The following explanations help isolate the source
camber or excessive toe on tires. of the vibration.
Sometimes incorrect toe settings or worn struts will
cause severe `cupping' or `scalloped' tire wear on Torque Sensitive
non-driven wheels.
Severely incorrect toe settings will also cause other This means that the condition can be improved or
unusual wear patterns. made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or
applying engine torque.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure always begins Vehicle Speed Sensitive

with a road test. The road test and customer
interview (if available) will provide much of the This means that the vibration always occurs at the
information needed to find the source of a vibration. same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear
selected.
2007.50 Focus 3/2007 G25362en

Engine Speed Sensitive A thumping noise usually means that the tire is flat
or has soft spots making a noise as they slap the
This means that the vibration occurs at varying roadway. Tire whine can be distinguished from axle
vehicle speeds when a different transmission gear noise. Tire whine remains the same over a range
is selected. It can sometimes be isolated by of speeds.
increasing or decreasing engine speed with the
A complete road test procedure is described in
transmission in NEUTRAL or by stall testing with
Section 100-04.
the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related REFER to: Noise, Vibration and Harshness (NVH)
to the tires. (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
If the road test indicates that there is tire whine,
but no shake or vibration, the noise originates with
the contact between the tire and the road surface.
Symptom Chart

• Tire(s) show excess wear on • Tire(s) under-inflated. • ADJUST the tire pressure(s).
edge of tread
• Vehicle overloaded. • CORRECT as necessary.
REFER to: (204-00 Suspension
Front Toe Adjustment (General
Procedures).
• Tire(s) show excess wear in • Tire(s) over-inflated. • ADJUST the tire pressure(s).
center of tread
• Other excessive tire wear • Incorrect tire pressure(s). • ADJUST the tire pressure(s).
concerns
• Wheel and tire assemblies • ROTATE the wheel and tire
need rotating. assemblies.
Procedures).
• Vehicle overloaded. • CORRECT as necessary.
• Loose or leaking front strut and • TIGHTEN or INSTALL new
spring assembly. suspension components as
necessary.
REFER to: Shock Absorber
and Spring Assembly (204-01
Front Suspension, Removal
and Installation).
2007.50 Focus 3/2007 G25362en


• Wheel bearings worn. • INSTALL new wheel bearings
as necessary. REFER to:
Front Wheel Bearing (204-01
and Installation),
Rear Wheel Bearing (204-02
Rear Suspension, Removal
and Installation).
• Suspension components, • CHECK or INSTALL new
bushings and ball joints. suspension components as
necessary.
• Excessive lateral or radial • BALANCE the wheel and tire
runout of wheel or tire. assemblies. Using a suitable
dial indicator gauge and
holding fixture, CHECK lateral
and radial runout of the wheel
and tire assemblies. INSTALL
new wheel and tire assemblies
as necessary. REFER to: (204-
04 Wheels and Tires)
Wheel and Tire (Removal and
Installation).
• Wobble or shimmy affecting • Damaged wheel. • INSPECT the wheel rims for
wheel runout damage. BALANCE the wheel
and tire assemblies. Using a
suitable dial indicator gauge
and holding fixture, CHECK
lateral and radial runout of the
wheel and tire assemblies.
INSTALL new wheel and tire
assemblies as necessary.
REFER to: (204-04 Wheels and
Tires)
Installation).
• Front wheel bearing. • CHECK or INSTALL new wheel
bearings as necessary.
REFER to: Front Wheel
Bearing (204-01 Front
Installation).
• Excessive vehicle vibration, • Suspension components. • CHECK or INSTALL new
rough steering suspension components as
necessary.
• Vehicle vibrations from wheels • Incorrect tire pressure(s). • ADJUST the tire pressure(s).
and tires
2007.50 Focus 3/2007 G25362en


• Wheel or tire imbalance. • BALANCE the wheel and tire
assemblies.
• Uneven tire wear. • INSTALL a new tire(s) as
necessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
• Brake disc imbalance. • CHECK the brake disc for
foreign material.
• Water in tire(s). • REMOVE the water.
• Bent wheel. • INSTALL a new wheel and tire
assembly.
• Incorrectly seated tire bead. • SPIN the wheel on the vehicle.
EXAMINE the area where the
tire and the wheel meet. If that
section of the tire appears to
waver while being rotated, the
tire bead may not be correctly
seated on the wheel. REMOVE
the tire and CLEAN the bead
seat areas on both wheel and
tire.
• Excessive lateral or radial • BALANCE the wheel and tire
runout of wheel or tire. assemblies. Using a suitable
dial indicator gauge and
holding fixture, CHECK the
lateral and radial runout of the
wheel and tire assemblies.
INSTALL new wheel and tire
assemblies as necessary.
REFER to: (204-04 Wheels and
Tires)
Installation).
• Foreign material between • CLEAN mounting surfaces.
wheel mounting face and hub
mounting surface.
• Front wheel bearing. • CHECK or INSTALL new wheel
bearings as necessary.
REFER to: Front Wheel
Bearing (204-01 Front
Installation).
2007.50 Focus 3/2007 G25362en


• Rust streaks from the wheel • Wheel nuts. • REMOVE the wheel and tire
stud holes in the wheel assembly. Inspect the wheel
nuts and wheel and tire
assembly for damage.
INSTALL new wheel nuts and
wheel and tire assemblies as
necessary. REFER to: (204-04
Wheels and Tires)
Installation).
• Seized wheel nuts • Corrosion. • CAUTION: Do not permit
lubricant to get on cone sets of
stud holes or on cone angle of
wheel nuts. If corrosion is
slight, wire brush away. If
corrosion is excessive,
INSTALL new wheel studs and
nuts. REFER to: (204-04
Wheels and Tires)
Installation).
If the condition persists,
LUBRICATE the first three
threads of each wheel stud with
a graphite-based lubricant.
• Vehicle overloaded • CORRECT as necessary.
2007.50 Focus 3/2007 G25362en

Wheel and Tire

Removal
CAUTION: Do not use heat to loosen a

seized wheel nut. Heat may damage the
wheel and wheel hub.
1. Loosen the wheel nuts.
2. Raise and support the vehicle. For additional
information, refer to: (100-02 Jacking and
Lifting)
Installation
1.
WARNING: Remove any corrosion or dirt
from the mounting surfaces of the wheel,
wheel hub or brake disc. Corrosion or dirt
on the mounting surfaces may cause the
wheel nuts to loosen and the wheel to come
off while the vehicle is in motion. Failure to
follow this instruction may result in personal
injury.
Clean the wheel hub and mounting surfaces.
3. Lower the vehicle.
4. Tighten the wheel nuts in the sequence
shown.
1 4
90 Nm
3
2
5
E0021340
2007.50 Focus 3/2007 G37378en

205-04-1 Front Drive Halfshafts 205-04-1
.
SECTION 205-04 Front Drive Halfshafts

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 205-04-2

Front Drive Halfshafts......................................................................................................... 205-04-3

Front Drive Halfshafts......................................................................................................... 205-04-4

Front Halfshaft LH.......................................................................................... (14 320 0) 205-04-6
Front Halfshaft RH.......................................................................................... (14 321 0) 205-04-11
Intermediate Shaft.............................................................................................................. 205-04-15
Inner Constant Velocity (CV) Joint Boot......................................................... (14 336 0) 205-04-16
Outer Constant Velocity (CV) Joint Boot........................................................ (14 338 0) 205-04-19

Front Halfshaft LH.......................................................................................... (14 320 8) 205-04-21
Front Halfshaft RH.......................................................................................... (14 321 8) 205-04-24
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives Specificat
Specificat ions
ions
Silicone Grease ESE-M1C1
Constant Velocity Joint Grease ESP-M1C2 71-A
07-A
Capacity
Description Driveshaft Joint Grease Fill Capacity
Inner (Grams) Outer (Grams)
1.6L engine with manual transaxle 100 100
1.8L/2.0L engine with manual transaxle 170 100
2.0L Diesel engine with manual transaxle 170 140
Vehicles with automatic transaxle 170 100
Item Nm lb-ft lb-in
Lower arm ball joint retaining nut 70 52 -
Intermediate shaft center bearing cap retaining nuts 25 18 -
Wheel hub retaining bolt a) - -
Constant velocity joint boot clamps with special tool 21 15 -
204-169
2007.50 Focus 3/2007 G429052en

Front Drive Halfshafts

Overview
E42461
The front axle halfshafts both have the same length

as each other.
The vehicle uses improved constant velocity joints
which are designed for the larger bending radii
occurring in conjunction with the new transmission
and the increased travel of the suspension springs.
The constant velocity joints satisfy durability
requirements of 240,000 km.
A support mounting is located on the right-hand
drive halfshaft. A new bearing cap and new nuts
should be used when installing this support
mounting.
2007.50 Focus 3/2007 G288151en

Front Drive Halfshafts

Inspection and Verification 3. Inspect for inboard CV joint stub shaft pilot
bearing housing seal leakage at the front wheel
NOTE: New front wheel drive halfshafts should not driveshaft CV joint.
be installed unless disassembly and inspection 4. Make sure front axle wheel hub retainer is the
reveals unusual wear. correct prevailing torque type.
1. Inspect front wheel driveshaft joint boots for 5. The silicone front wheel driveshaft CV joint boot
evidence of cracks, tears or splits. will sweat during operation, causing a light film
of grease to show on the outside of the front
NOTE: While inspecting the front wheel driveshaft
wheel driveshaft CV joint boot. This condition
CV joint boots, watch for indentations (dimples) in
is normal.
the boot convolutions. If an indentation is observed,
it must be removed. NOTE: Halfshafts are not balanced and do not
contribute to rotational vibration.
2. Inspect the underbody for any indication of
grease splatter in the vicinity of the front wheel 6. If the concerns remain after the inspection,
driveshaft CV joint boots outboard and inboard determine the symptoms and go to the Symptom
locations, which is an indication of front wheel Chart. For additional Noise, Vibration and
driveshaft CV joint boot and/or front wheel Harshness (NVH). REFER to Section 100-04
driveshaft CV joint boot clamp damage. [Noise, Vibration and Harshness].
Symptom Chart
• Clicking, Popping or Grinding • Inadequate or contaminated • INSPECT, CLEAN and
Noises While Turning lube in outboard/inboard front LUBRICATE as necessary.
wheel driveshaft CV joint.
• Another component contacting • INSPECT and REPAIR as
driveshaft assembly. necessary.
• Wheel bearings, brakes, • INSPECT and REPAIR as
suspension or steering necessary. REFER to
components. Section 204-00 [Suspension
System - General Information]
/ 206-00 [Brake System -
General Information] / 211-00
[Steering System - General
Information].
• Vibration at Highway Speeds • Out of balance front wheels or • REPAIR or INSTALL new as
tires. necessary. REFER to
Section 204-04 [Wheels and
Tires].
• Out-of-round tires. • REPAIR or INSTALL new as
necessary. REFER to
Section 204-04 [Wheels and
Tires].
• Incorrectly seated outboard • REPAIR or INSTALL new as
front wheel driveshaft CV joint necessary.
in front wheel hub. REFER to Halfshaft Disas-
semblv and Assembly in this
section.
2007.50 Focus 3/2007 G17442en


• Shudder Vibration During • Excessively high CV joint • CHECK ride height, VERIFY
Acceleration. operating angles caused by correct spring rate and CHECK
incorrect ride height. items under Halfshaft Joint
Pullout. REPAIR or INSTALL
new as necessary.
• Excessively worn or damaged • INSPECT and INSTALL new
inboard front wheel driveshaft as necessary.
joint or outboard front wheel
driveshaft joint.
• Halfshaft Joint Pullout • Inboard driveshaft bearing • INSPECT and REPAIR or
retainer circlip missing or not INSTALL new as necessary.
correctly seated in differential
side gear.
• Engine/transaxle assembly • CHECK engine mounts for
mispositioned. damage or wear. REPAIR or
INSTALL new as necessary.
• Frame rail or strut tower out of • CHECK underbody dimen-
position or damaged. sions. REFER to REFER to
Section 501-00 [Body System
- General Information].
• Front suspension components • CHECK for worn bushings or
worn or damaged. bent components (front stabil-
izer bar, front suspension lower
arm). REPAIR or INSTALL new
as necessary.
2007.50 Focus 3/2007 G17442en

Front Halfshaft LH(14 320 0)

Special Tool(s) General Equipment
Remover, Halfshaft Tire lever
204-226 (16-092)
Materials
Name Specification
16092
Silicone Grease ESE-M1C171-A
Transmission Fluid WSD-M2C200-C
Adapter for 204-226

204-226-01 (16-092-01) Removal
All vehicles
1609201
Protector, Ball Joint Gaiter and Installation).
204-349 2. Remove the wheel hub retaining bolt.
• Discard the wheel hub retaining bolt.
E42949
Slide Hammer
205-047 (15-011)
15011
TIE0036822
Protector, Halfshaft Seal

205-775 3. NOTE: Use a suitable brass drift if necessary.
Push the halfshaft into the tripode housing
as far as the stop (approximately 20 mm).
E47098
Remover, Halfshaft
308-256 (16-089)
16089
General Equipment
2007.50 Focus 3/2007 G325344en

4. Using the special tool to prevent the ball joint • Remove the special tool.
stud from rotating, remove and discard the
lower arm ball joint retaining nut.
TIE44353
TIE39073 7. CAUTIONS:
The inner constant velocity (CV) joint
5. must not be bent more than 23 degrees. The
installed with the curved surface facing outer CV joint must not be bent more than
upwards to prevent damage to the ball joint 45 degrees.
seal.
Install the special tool. and spring assembly. Do not pull the strut
28 mm.
Make sure the strut and spring assembly
does not move in a forwards or rearwards
direction, to prevent damage to the top
mount center cup.
NOTE: Make sure the halfshaft is still fully engaged
in the tripode housing.
Detach the halfshaft from the wheel hub.
• Pull the strut and spring assembly outwards
TIE44354 approximately 28 mm.
6.
CAUTION: Make sure the strut and spring Vehicles with 5-speed manual transaxle (iB5)
assembly does not move in a forwards or 8. CAUTIONS:
The inner CV joint must not be bent more
Using a suitable ball joint separator, detach be bent more than 45 degrees.
Make sure the halfshaft seal is not
damaged.
NOTE: Plug the transaxle to prevent oil loss or dirt
ingress.
Using the special tool, remove the halfshaft.
• Discard the snap ring.
2007.50 Focus 3/2007 G325344en

• Allow the oil to drain into a suitable container. Using the special tools, remove the halfshaft.
• Allow the oil to drain into a suitable container.
204-226
308-256
205-047
ELE0001559
204-226-01
Vehicles with 4-speed automatic transaxle ELE0001548
9. CAUTIONS:
The inner CV joint must not be bent more Vehicles with automatic transaxle (CFT23)
than 23 degrees. The outer CV joint must not 11. CAUTIONS:
The inner CV joint must not be bent
Make sure that the halfshaft seal is not more than 23 degrees. The outer CV joint
damaged. must not be bent more than 45 degrees.
Plug the transaxle to prevent oil loss or Make sure that the halfshaft seal is not
dirt ingress. damaged.
Using the special tools, remove the halfshaft. Plug the transaxle to prevent dirt ingress.
• Discard the snap ring. Using a suitable tire lever, remove the
• Allow the oil to drain into a suitable container. halfshaft.
204-226
205-047
204-226-01
ELE0001548
TIE44964
Vehicles with 5-speed manual transaxle
(MTX75) or 6-speed manual transaxle (MMT6)
Installation
10. CAUTIONS:
The inner CV joint must not be bent Vehicles with automatic transaxle (CFT23)
more than 23 degrees. The outer CV joint 1. Coat the halfshaft seal with grease.
must not be bent more than 45 degrees.
Make sure that the halfshaft seal is not All vehicles

damaged. 2. CAUTIONS:
Plug the transaxle to prevent oil loss or
dirt ingress.
2007.50 Focus 3/2007 G325344en

Attach the lower arm ball joint to the wheel
knuckle.
be bent more than 45 degrees. 6.
Make sure that the halfshaft seal is not
damaged.
Make sure the snap ring is correctly
from rotating, install the lower arm ball joint
seated.
retaining nut.
NOTE: Install a new snap ring.
Attach the left-hand halfshaft to the
transaxle.
• Remove the special tool before fully installing 70 Nm
the halfshaft.
TIE39074
7.
CAUTION: Install a new wheel hub
205-775 retaining bolt.
C1601549 NOTE: Do not tighten the wheel hub retaining bolt
at this stage.
3. Push the halfshaft into the tripode housing Install the wheel hub retaining bolt.
4. CAUTIONS:

28 mm.
Make sure the strut and spring assembly TIE0036822
mount center cup. 8. Install the wheel and tire.
Attach the halfshaft to the wheel hub. For additional information, refer to: Wheel
• Pull the strut and spring assembly outwards and Installation).
approximately 28 mm.
9. Tighten the wheel hub retaining bolt (wheel
5. and tire shown removed for clarity).
assembly does not move in a forwards or • Tighten the wheel hub retaining bolt in two
rearwards direction, to prevent damage to stages.
the top mount center cup. • Stage 1: 35 Nm.
2007.50 Focus 3/2007 G325344en

• Stage 2: 90 degrees.
TIE0036822
Vehicles with 4-speed automatic transaxle

10. With the vehicle on a level surface, check
the transmission fluid level.
Transmission Fluid Drain and Refill
(307-01 Automatic
Transmission/Transaxle - Vehicles With:
4-Speed Automatic Transmission (4F27E),
Vehicles with manual transaxle

11. With the vehicle on a level surface, check
the transmission fluid level and top up with
clean transmission fluid until the fluid level
is 5 - 10 mm below the fluid filler plug.
2007.50 Focus 3/2007 G325344en

Front Halfshaft RH(14 321 0)

Special Tool(s) Push the halfshaft into the tripode housing
204-349 4. Remove the crashbox.
E42949
Protector, Halfshaft Seal

205-775
E47098 E47211
General Equipment 5. Using the special tool to prevent the ball joint
stud from rotating, remove and discard the
lower arm ball joint retaining nut.
Materials
Name Specification
Removal
and Tire (204-04 Wheels and Tires, Removal TIE39073
and Installation).
2. Remove the wheel hub retaining bolt. 6.
• Discard the wheel hub retaining bolt. installed with the curved surface facing
seal.
TIE0036822
3. NOTE: Use a suitable brass drift if necessary.

TIE44354
2007.50 Focus 3/2007 G420868en

7. • Remove the intermediate shaft center
bearing heat shield (if equipped).
Using a suitable ball joint separator, detach
• Remove the special tool.
ELE0000839
10. CAUTIONS:
The inner CV joint must not be bent
more than 23 degrees. The outer CV joint
must not be bent more than 45 degrees.
TIE44353
Make sure the halfshaft seal is not

8. CAUTIONS: damaged.
The inner constant velocity (CV) joint Plug the transaxle to prevent oil loss or
must not be bent more than 23 degrees. The dirt ingress.
outer CV joint must not be bent more than
Remove the halfshaft and intermediate shaft
45 degrees.
assembly.
Do not apply excessive force to the strut • Allow the oil to drain into a suitable container
and spring assembly. Do not pull the strut (all except vehicles with CFT23).
28 mm.
Make sure the strut and spring assembly
mount center cup.
NOTE: Make sure that the halfshaft is still fully
engaged in the tripode housing.
Detach the halfshaft from the wheel hub.
• Pull the strut and spring assembly outwards ELE0001690
9. Remove the intermediate shaft center
bearing cap. Installation
• Discard the bearing cap and retaining nuts. Vehicles with automatic transaxle (CFT23)
1. Coat the halfshaft seal with grease.
All vehicles
2. CAUTIONS:
2007.50 Focus 3/2007 G420868en

Make sure the halfshaft seal is not Do not apply excessive force to the strut
damaged. and spring assembly. Do not pull the strut
Attach the right-hand halfshaft and
28 mm.
intermediate shaft assembly to the transaxle.
• Remove the special tool before fully installing Make sure the strut and spring assembly
the halfshaft. does not move in a forwards or rearwards
mount center cup.
Attach the halfshaft to the wheel hub.
• Pull the strut and spring assembly outwards
205-775 approximately 28 mm.
6.
Attach the lower arm ball joint to the wheel
E0033342
knuckle.
3. NOTE: Install a new intermediate shaft center 7.

bearing cap and retaining nuts. joint retaining nut. Failure to follow this
NOTE: Make sure that the intermediate shaft instruction may result in personal injury.
center bearing is correctly positioned in the Using the special tool to prevent the ball joint
intermediate shaft center bearing retaining bracket. from rotating, install the lower arm ball joint
Install the intermediate shaft center bearing retaining nut.
cap.
• Position the center bearing cap.
• Position the intermediate shaft center bearing
heat shield (if equipped). 70 Nm
• Tighten the center bearing cap retaining nuts.
25 Nm
TIE39074
8.
CAUTION: Install a new wheel hub
retaining bolt.
ELE0001082 NOTE: Do not tighten the wheel hub retaining bolt
at this stage.
4. Push the halfshaft into the tripode housing

5. CAUTIONS:
2007.50 Focus 3/2007 G420868en

Install the wheel hub retaining bolt. • Stage 2: 90 degrees.
TIE0036822
TIE0036822
9. Install the crashbox. Vehicles with automatic transaxle

1. Tighten the bolt M10 x 16. 12. With the vehicle on a level surface, check
the transmission fluid level.
2. Tighten the bolts M10 x 25.
(307-01A Automatic
4-Speed Automatic Transaxle (4F27E),
General Procedures)
/ Transmission Fluid Drain and Refill
(307-01C, General Procedures).
40 Nm 2 Vehicles with manual transaxle

2 40 Nm
40 Nm 1 13. With the vehicle on a level surface, check
E49015 the transmission fluid level and top up with
clean transmission fluid until the fluid level
10. Install the wheel and tire. is 5 - 10 mm below the fluid filler plug.
11. Tighten the wheel hub retaining bolt (wheel
and tire shown removed for clarity).
• Tighten the wheel hub retaining bolt in two
stages.
• Stage 1: 35 Nm.
2007.50 Focus 3/2007 G420868en

Intermediate Shaft
Special Tool(s) Attach the intermediate shaft to the
right-hand halfshaft.
Clamping Tool, Boot
Retaining Clamp 2. Pack the tripode joint with grease.
204-169 (14-044) For additional information, refer to:
Specifications - 3-Door (205-04 Front Drive
Halfshafts, Specifications).
14044
1. Insert a small screwdriver under the boot
seat to allow the air to escape.
Materials 2. Slide the tripode joint in as far as the stop,
then pull it out 20 mm.
Name Specification • Remove the screwdriver.
Constant Velocity Joint ESP-M1C207-A
Grease 1
Removal
1. Remove the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH - 3-Door (205-04 Front Drive
Halfshafts, Removal and Installation).
2. ELE0022817
2
CAUTION: Use vise jaw protectors.
NOTE: Make sure the boot is not damaged.
3. NOTE: Install new constant velocity (CV) joint
Detach the intermediate shaft from the
boot retaining clamps.
right-hand halfshaft.
Locate the retaining clamp in the boot ring
• Remove and discard the constant velocity
groove and using the special tool, tighten
(CV) joint boot retaining clamps and slide
the CV joint boot retaining clamps.
back the boot.
• Detach the intermediate shaft from the
halfshaft.
21 Nm
• Remove the grease.
204-169
ELE0002485
4. Install the right-hand halfshaft.

W1402009
Installation Halfshafts, Removal and Installation).
1.
CAUTION: Use vise jaw protectors.
2007.50 Focus 3/2007 G325346en

Inner Constant Velocity (CV) Joint Boot(14 336 0)

Special Tool(s) Detach the inner constant velocity joint from
the front halfshaft.
Clamping Tool, Boot
Retaining Clamp • Hold the front halfshaft in a vice.
204-169 (14-044) 1. Cut and discard the boot clamps. Slide the
boot back.
2. Remove the tripode housing.
14044
• Remove the grease.
Remover, Bearing/Gear 2
205-310 (15-091)
TI15091
Remover, Bearing/Gear
1
205-311 (15-092) ELM1402018
3. Remove the snap ring.

15092
Installer, Extension Housing

Bushing/Oil Seal
308-046 (16-016)
16016
Materials
E0002041
Name Specification
Constant velocity joint ESP-M1C207-A 4. Using the special tools detach the tripode
high-temperature star.
grease
• Remove and discard the rubber boot.
Removal 205-310
1. Remove the halfshaft.
Halfshaft LH (205-04 Front Drive Halfshafts,
Removal and Installation)
/ Front Halfshaft RH - 3-Door (205-04 Front
Drive Halfshafts, Removal and Installation).
2.
CAUTION: Use vice with soft jaw
205-311
protectors. E0001661
2007.50 Focus 3/2007 G357292en

Installation • Drive the tripode star onto the front drive
halfshaft as far as it will go.
1. NOTE: Install a new clamping strap.
NOTE: Install a new rubber boot.
Place the clamping strap and inner CV joint
rubber boot in position on the front halfshaft.
308-046
ELE0002040
4. NOTE: Install a new snap ring.

Install the snap ring.
ELE0022107
2. Insert the clamping strap in the boot ring

groove and tighten with the special tool.
21 Nm
E0002041
5. Fill the constant velocity joint with grease.

204-169 For additional information, refer to:
ELE0002482 Specifications - 3-Door (205-04 Front Drive
3. 1. Insert a small screwdriver under the boot
CAUTION: Do not damage the universal
joint rollers. seat to allow the air to escape.
2. Push on the tripode housing to stop, then
NOTE: Chamfer points towards front halfshaft. pull it back 20 mm.
Attach the tripode star using the special tool. • Remove the screwdriver.
ELE0022817
2
2007.50 Focus 3/2007 G357292en

Insert the clamping strap in the boot ring
21 Nm
204-169
ELE0002483
7. Install the halfshaft.

/ Front Halfshaft RH - 3-Door (205-04 Front
Drive Halfshafts, Removal and Installation).
2007.50 Focus 3/2007 G357292en

Outer Constant Velocity (CV) Joint Boot(14 338 0)

Special Tool(s) Install the outer CV joint boot.
Clamping Tool, Boot • Pack the CV joint with grease.
Retaining Clamp For additional information, refer to:
204-169 (14-044) Specifications - 3-Door (205-04 Front Drive
• Press the rubber boot into the groove of the
14044
CV joint.
General Equipment
2. Position the rubber boot.
Expanding pliers, snap-ring
• Remove the screwdriver.
Materials
Name Specification
Constant velocity joint ESP-M1C207-A 1
high-temperature
grease
2
Removal
1. Remove the inner CV joint boot.
For additional information, refer to: Inner ELE0002481
Constant Velocity (CV) Joint Boot (205-04
Front Drive Halfshafts, Removal and 2. NOTE: Install a new clamping strap.
Installation).
Insert the inner clamping strap into the ring
2. groove of the rubber boot and tighten with
CAUTION: Use a vice with protective jaw
covers. the special tool.
Remove the outer CV joint boot.
21 Nm
• Cut and discard the boot clamps.
• Remove the grease packing.
204-169
E51617
ELE0019558
Installation
1. NOTE: Install a new rubber boot.
2007.50 Focus 3/2007 G20837en

Insert the outer clamping strap into the ring
groove of the rubber boot and tighten with
the special tool.
21 Nm
204-169
E51616
4. Install the inner CV joint boot.

For additional information, refer to: Inner
Constant Velocity (CV) Joint Boot (205-04
Front Drive Halfshafts, Removal and
Installation).
2007.50 Focus 3/2007 G20837en

Front Halfshaft LH(14 320 8)

Special Tool(s) • Remove the grease from inside the joint.
Gaiter clamp tightening tool
204-169 (14-044)
2
14044
Separating tool, Bearing/Gear

205-310 (15-091)
1
ELM1402018
TI15091 2. Detach the circlip.

205-311 (15-092)
15092

Bushing/Oil Seal
308-046 (16-016)
E0002041
16016 3. Using the special tools detach the tripode

star.
Materials
Name Specification 205-310
Constant velocity joint ESP-M1C207-A

high-temperature
grease
Disassembly
1.
covers. 205-311
E0001661
Detach the inner constant velocity joint from
the front halfshaft. 4. Detach the outer CV joint boot.
• Clamp the front halfshaft in a vice. • Separate and discard the clamping straps.
1. Separate and discard the clamping straps. • Remove and discard the rubber boot.
Slide the boot back.
2. Remove the tripode housing.
2007.50 Focus 3/2007 G20838en

• Remove the grease. 2. Insert the small and large clamping straps
in the boot ring grooves and tighten them
with the special tool.
21 Nm
ELE0019558 204-169
E51616
Assembly
1. NOTE: Install a new rubber boot. 3. NOTE: Install a new clamping strap.
Install the outer CV joint boot. NOTE: Install a new rubber boot.
• Pack the CV joint with grease. Place the clamping strap and inner CV joint
For additional information, refer to: rubber boot in position on the front halfshaft.
CV joint.
1 ELE0022107
4. Attach the inner CV joint boot.

2 • Insert the clamping strap in the boot ring
ELE0002481 21 Nm
204-169
ELE0002482
5.
joint rollers.
2007.50 Focus 3/2007 G20838en

NOTE: Chamfer points towards the front halfshaft. • Remove the screwdriver.
Install the tripode star.
• Using the special tool, push the tripode star 1
onto the front halfshaft to the stop.
ELM1402510
2
308-046 8. NOTE: Install a new clamping strap.

ELE0002040 Insert the clamping strap in the boot ring
Install the snap-ring. 21 Nm
204-169
ELE0002483
E0002041

2. Push on the CV joint to stop, then pull it back
20 mm.
2007.50 Focus 3/2007 G20838en

Front Halfshaft RH(14 321 8)

Special Tool(s) • Remove the grease.
Gaiter clamp tightening tool
204-169 (14-044)
14044
Separating tool, Bearing/Gear

205-310 (15-091)
W1402009
TI15091 2. Remove circlip.

205-311 (15-092)
15092

Bushing/Oil Seal
308-046 (16-016)
E0002041
16016 3. Using the special tools detach the tripode

star.
Materials
Name Specification 205-310
Constant velocity joint ESP-M1C207-A

high-temperature
grease
Disassembly
1.
covers. 205-311
E0001661
Detach the intermediate shaft from the front
halfshaft. 4. Detach the outer CV joint boot.
• Hold the front halfshaft in a vice. • Separate and discard the clamping straps.
• Separate and discard the clamping straps. • Remove and discard the rubber boot.
Slide the boot back.
• Remove the intermediate shaft.
2007.50 Focus 3/2007 G20840en

• Remove the grease. Insert the small and large clamping straps
in the boot ring grooves and tighten them
with the special tool.
21 Nm
ELE0002042 204-169
E51616
Assembly
1. NOTE: Install a new rubber boot. 3. NOTE: Install a new clamping strap.
Install the outer CV joint boot. NOTE: Install a new rubber boot.
• Pack the CV joint with grease. Place the clamping strap and inner CV joint
For additional information, refer to: rubber boot in position on the front halfshaft.
CV joint.
1 ELE0022107
4. Attach the inner CV joint boot.

2 • Insert the clamping strap in the boot ring
ELE0002481 21 Nm
2. NOTE: Install new clamping straps.
204-169
ELE0002482
5.
joint rollers.
2007.50 Focus 3/2007 G20840en

NOTE: Chamfer points towards the front halfshaft. • Remove the screwdriver.
Install the tripode star.
• Using the special tool, push the tripode star 1
onto the front halfshaft to the stop.
ELE0022817
2
308-046 8. Insert the clamping strap in the boot ring

ELE0002040
6. NOTE: Install a new snap ring. 21 Nm

Install the snap ring.
204-169
ELE0002485
E0002041

2. Push on the CV joint to stop, then pull it back
20 mm.
2007.50 Focus 3/2007 G20840en

206-00-1 Brake System - General Information 206-00-1
.
SECTION 206-00 Brake System - General Information

CONTENTS PAGE

Brake System..................................................................................................................... 206-00-2
Road Test........................................................................................................................... 206-00-2
Pinpoint Tests..................................................................................................................... 206-00-11
Component Tests................................................................................................................ 206-00-18
Brake System Check.......................................................................................................... 206-00-18
Brake Booster Functional Test............................................................................................ 206-00-18
GENERAL PROCEDURES
Brake System Bleeding.................................................................................. (12 141 0) 206-00-21
Brake System Pressure Bleeding................................................................... (12 141 0) 206-00-22
Brake System Leak Check................................................................................................. 206-00-23
Brake Disc Runout Check.............................................................................. (12 221 0) 206-00-24
Check................................................................................................................................. 206-00-24
Brake System
General Equipment The driver should have a thorough knowledge of
the brake system operation and accepted general
Pressure/vacuum gauge set
performance guidelines to make good comparisons
Worldwide diagnostic system (WDS) and detect performance concerns.
An experienced technician will always establish a
route that will be used for all brake diagnosis road
The brake system operates by transferring effort
tests. The road selected will be reasonably smooth
applied to the brake pedal by the driver to the
and level. Gravel or bumpy roads are not suitable
brakes at each wheel.
because the surface does not allow the tires to grip
The braking effort is distributed to each wheel, the road equally. Crowned roads should be avoided
using a hydraulic system. The system is assisted because of the large amount of weight shifted to
using a vacuum brake booster that reduces pedal the low set of wheels on this type of road. Once
effort and increases hydraulic pressure. the route is established and consistently used, the
The parking brake operates on the rear wheels road surface variable can be eliminated from the
and is applied using a hand operated control. test results.
Before a road test, get a complete description of
the customer concerns or suspected condition.
Inspection and Verification From the description, the technician will be able to
match possible causes with symptoms. Certain
NOTE: Before carrying out any diagnosis, make components will be identified as possible sources
sure that the brake system warning indicator is while others will be eliminated by the evidence.
functional. More importantly, the customer description can
1. Verify the customer concern. reveal unsafe conditions which should be checked
2. Visually inspect for obvious signs of mechanical or corrected before a road test. The description will
or electrical damage. also help form the basic approach to the road test
by narrowing the concern to specific components,
Visual Inspection Chart vehicle speed or conditions.
Mechanical Electrical Begin the road test with a general brake
• Tire pressure(s) • Electrical performance check. Using the description of the
connector(s) concern, test the brakes at different vehicle speeds
• Wheels and tires
using both light and heavy pedal pressure.
• Fluid leak(s) • Wiring harness(s)
Determine if the concern is in the front or rear
• Switch(es) braking system. First use the foot brake and then
the parking brake. If the condition (i.e. pull,
3. If an obvious cause for an observed or reported vibration, pulsation) occurs only on operation of
concern is found, correct the case (if possible) the parking brake, the concern is in the rear brake
before proceeding to the next step. system. If the condition occurs when the foot brake
4. If the cause if not visually evident, verify the is depressed, the concern is in the front brake
symptom and refer to the Symptom Chart. system.
Avoid locking the brakes and sliding the tires. This
condition will not indicate brake efficiency. A heavily
Road Test braked but turning wheel will stop the vehicle in a
shorter distance than locked wheels.
Carry out a road test to compare actual vehicle
braking performance with the performance If the concern becomes evident during this check,
standards expected by the driver. The ability of the make sure it fits the description given before the
test driver to make valid comparisons and detect road test. If the concern is not evident, attempt to
performance deficiencies will depend on duplicate the condition using the information from
experience. the description.
If a concern exists, use the Brake System Symptom
Chart in order to isolate it to a specific sub-system
and condition description. From this description, a
2007.50 Focus 3/2007 G288148en

list of possible sources can be used to further condition.
narrow the cause to a specific component or
Symptom Chart
• Brakes pull or drift • Worn or damaged brake shoes • INSTALL new brake shoes or
or brake pads and linings. brake pads. REFER to:
Brake Shoes (206-02 Drum
Brake, Removal and Installa-
tion),
Brake Pads - 2.5L Duratec-ST
(VI5) (206-03 Front Disc
tion),
Brake Pads (206-03 Front Disc
tion),
Brake Pads (206-04 Rear Disc
tion).
• Abnormal wear or distortion of • INSTALL a new front brake
front brake disc. disc. REFER to: (206-03 Front
Disc Brake)
Brake Disc (Removal and
Installation),
Brake Disc - 2.5L Duratec-ST
(VI5) (Removal and Installa-
tion).
• Incorrect rear brake adjust- • ADJUST the parking brake
ment. cable.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
• Incorrect wheel alignment • ADJUST the wheel alignment.
adjustment. REFER to: (204-00 Suspension
Procedures),
Rear Toe Adjustment (General
Procedures).
• Incorrect wheel bearing preload • ADJUST or INSTALL a new
adjustment. wheel bearing.
REFER to: Wheel Hub (204-01
and Installation).
2007.50 Focus 3/2007 G288148en


• Grease or fluid on the brake • INSTALL new brake shoes or
shoes or brake pads; glazed brake pads. REFER to:
linings. Brake Shoes (206-02 Drum
tion),
tion),
tion),
tion).
• Stuck or seized wheel cylinders • INSTALL a new wheel cylinder
or brake calipers. or brake caliper. REFER to:
Wheel Cylinder (206-02 Drum
tion),
Brake Caliper (206-03 Front
Disc Brake, Removal and
Installation),
Brake Caliper - 2.5L Duratec-
ST (VI5) (206-03 Front Disc
tion),
Brake Caliper (206-04 Rear
Installation).
• The red brake warning indicator • Low brake fluid level. • FILL the reservoir. CHECK the
is always on brake and clutch system for
leaks including brake fluid in
the brake booster.
• Leaking brake master cylinder • INSTALL a new brake master
primary piston cup. cylinder. REFER to: (206-06
Hydraulic Brake Actuation)
Brake Master Cylinder - LHD
Brake Master Cylinder - RHD
• Parking brake control not fully • FREE UP and ADJUST the
released. parking brake cable.
INSTALL new components as
necessary.
2007.50 Focus 3/2007 G288148en


• Malfunctioning anti-lock braking • REFER to: Anti-Lock Control
system (ABS). (206-09 Anti-Lock Control,
• Shorted indicator circuit. • REFER to: Instrument Cluster
(413-01 Instrument Cluster,
• Vibration when the brakes are • Grease or fluid on the brake • INSTALL new brake shoes or
applied shoes or brake pads; glazed brake pads. REFER to:
linings. Brake Shoes (206-02 Drum
tion),
tion),
tion),
tion).
• Worn or damaged brake shoes • INSTALL new brake shoes or
or brake pads. brake pads. REFER to:
tion),
tion),
tion),
tion).
• Loose caliper mounting bolt(s). • TIGHTEN the caliper mounting
bolt(s).
• Damaged brake drum contact • INSTALL a new brake drum.
surface. REFER to: Brake Drum (206-
02 Drum Brake, Removal and
Installation).
2007.50 Focus 3/2007 G288148en


• Excessive brake disc thickness • REFER to: Brake Disc Runout
variation or brake disc runout. Check (206-00 Brake System
- General Information,
• Wheels and tires. • CHECK the tires. BALANCE or
INSTALL new tires as neces-
sary.
REFER to: Wheels and Tires
• Loose or missing wheel hub • TIGHTEN or INSTALL new
bolts. wheel hub bolts as necessary.
• Worn or damaged brake drums • INSTALL new brake drums or
or brake discs. brake discs. REFER to:
Brake Drum (206-02 Drum
tion),
Brake Disc (206-03 Front Disc
tion),
Brake Disc - 2.5L Duratec-ST
tion),
Brake Disc (206-04 Rear Disc
tion).
• Pedal goes down fast • Low brake fluid level. • FILL the reservoir. CHECK the
brake and clutch system for
leaks including brake fluid in
the brake booster.
• Leak in the hydraulic system. • REPAIR the leak. CHECK the
entire hydraulic system. FILL
and BLEED the brake system.
REFER to: (206-00 Brake
Brake System Bleeding
Brake System Pressure
Bleeding (General Proced-
ures).
2007.50 Focus 3/2007 G288148en


• Air in the system. • CHECK for leaks. BLEED the
brake system. REFER to: (206-
Information)
ures).
• Brake disc “brake knock back” • CARRY OUT a brake disc
(Brake pads push the brake runout check.
caliper piston back into the REFER to: Brake Disc Runout
brake caliper. Caused by Check (206-00 Brake System
excessive brake disc lateral - General Information,
runout or loose wheel bear- General Procedures).
ings.)
• Worn brake shoes or brake • INSTALL new brake shoes or
pads. brake pads. REFER to:
tion),
tion),
tion),
tion).
• Worn brake master cylinder • GO to Pinpoint Test A.
piston cups or scored cylinder
bore.
• Pedal eases down slowly • Air in the system. • BLEED the brake system.
REFER to: (206-00 Brake
ures).
• Malfunctioning brake master • GO to Pinpoint Test B.
cylinder.
• Low engine vacuum
(stationary).
2007.50 Focus 3/2007 G288148en


• Pedal is low or feels spongy • Worn brake shoes or brake • INSTALL new brake shoes or
pads. brake pads. REFER to:
tion),
tion),
tion),
tion).
• Air in the system. • CHECK for leaks. BLEED the
brake system. REFER to: (206-
Information)
ures).
• Brake lockup during light brake • Glazed or worn brake shoes or • INSTALL new brake shoes or
pedal force brake pads. brake pads. REFER to:
tion),
tion),
tion),
tion).
• Brake booster. • GO to Pinpoint Test C.
• Low engine vacuum.
2007.50 Focus 3/2007 G288148en


• Excessive or erratic pedal • Worn brake shoes or brake • INSTALL new brake shoes or
travel pads. brake pads. REFER to:
tion),
tion),
tion),
tion).
• Wheel bearings • CARRY OUT a brake disc
runout check.
REFER to: Brake Disc Runout
Check (206-00 Brake System
• Brake drag • Incorrectly adjusted parking • ADJUST the parking brake
brake. cable.
• Brake booster. • REFER to brake booster oper-
ation check in this procedure.
• Seized wheel cylinder or brake • INSTALL a new wheel cylinder
caliper. or brake caliper. REFER to:
Wheel Cylinder (206-02 Drum
tion),
Installation),
tion),
Installation).
2007.50 Focus 3/2007 G288148en


• Seized brake caliper slide pins. • INSTALL a new brake caliper.
REFER to:
Installation),
tion),
Installation).
• Seized parking brake cables. • INSTALL new parking brake
cables. REFER to: (206-05
Parking Brake and Actuation)
Parking Brake Cable - Vehicles
With: Rear Drum Brakes
Parking Brake Cable - Vehicles
With: Rear Disc Brakes
• Excessive brake pedal effort • Worn or contaminated brake • INSTALL new brake shoes or
shoes or brake pads. brake pads. REFER to:
tion),
tion),
tion),
tion).
• Malfunctioning vacuum pump • INSTALL a new brake vacuum
(diesel). pump.
• Disconnected or damaged • CONNECT or INSTALL a new
brake booster vacuum pipe. brake booster vacuum pipe as
necessary.
• Brake booster. • GO to Pinpoint Test D.
2007.50 Focus 3/2007 G288148en


• Brake noise • Worn or damaged brake shoes • INSTALL new brake shoes or
or brake pads. brake pads. REFER to:
tion),
tion),
tion),
tion).
• Brake booster. • GO to Pinpoint Test E.
• Slow or incomplete brake pedal • Brake booster. • GO to Pinpoint Test F.
return • Seized brake pedal pivot.
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then
hold?
→ Yes
CHECK parking brake adjustment and
ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
If the condition still exists. BLEED the brake
system. REFER to: (206-00 Brake System -
General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures).
→ No
GO to A2.
2007.50 Focus 3/2007 G288148en


A2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system
leaks. Refer to Brake Master Cylinder
Component Test in this procedure.
• Are any leaks present?
→ Yes
REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
Procedures).
→ No
GO to A3.
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
→ Yes
INSTALL a new brake master cylinder.
REFER to: (206-06 Hydraulic Brake Actuation)
Brake Master Cylinder - LHD (Removal and
Installation),
Brake Master Cylinder - RHD (Removal and
Installation).
→ No
PINPOINT TEST B : PEDAL EASES DOWN SLOWLY

B1: CHECK THE BRAKE PEDAL OPERATION
1 Depress the brake pedal.
• Does the pedal ease down slowly?
→ Yes
GO to B2.
→ No
Refer to the Brake Master Cylinder
Component Test in this procedure.
2007.50 Focus 3/2007 G288148en


B2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks.
• Are any leaks present?
→ Yes
REPAIR as necessary. ADD fluid and BLEED
Procedures).
→ No
GO to B3.
B3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
→ Yes
INSTALL a new brake master cylinder.
REFER to: (206-06 Hydraulic Brake Actuation)
Installation),
Installation).
→ No
GO to B4.
B4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2 Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
→ Yes
INSTALL a new brake booster check valve.
→ No
GO to B5.
B5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
2007.50 Focus 3/2007 G288148en


2 Using a suitable vacuum gauge, check the
vacuum pressure.
• Is the vacuum pressure above 40.5 kPa (0.4
bar) with the brake booster non-operational?
→ Yes
→ No
INSTALL a new brake booster check valve
vacuum hose. TEST the system for normal
operation.
PINPOINT TEST C : BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE

C1: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment
and pedal travel.
• Is the push rod and pedal travel OK?
→ Yes
TEST the brake pedal application. GO to
Pinpoint Test D.
→ No
INSTALL a new brake booster. REFER to:
(206-07 Power Brake Actuation)
Brake Booster - LHD (Removal and Installation),
Brake Booster - RHD (Removal and Installation).
PINPOINT TEST D : EXCESSIVE BRAKE PEDAL EFFORT

D1: CHECK BRAKE APPLICATION
1 With the engine off, apply and release the brake
pedal five times to deplete all vacuum from the
brake booster. Apply the brake pedal, hold with
light pressure. Start the engine.
• Does the brake pedal hold?
→ Yes
GO to D2.
→ No
GO to D3.
2007.50 Focus 3/2007 G288148en


D2: CHECK THE BRAKE BOOSTER FOR LEAKS
1 Run the engine at approximately 1000 rpm,
release the accelerator pedal and turn the
engine off. Wait 90 seconds and apply the
brakes. Two or more brake applications should
be power assisted.
• Does the brake booster work?
→ Yes
→ No
GO to D4.
D3: CHECK THE BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin
and fully depress the brake pedal.
• Did the pedal move freely?
→ Yes
→ No
INSTALL new brake pedal bushings. TEST
D4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2 Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
→ Yes
INSTALL a new brake booster check valve.
REFER to: (206-07 Power Brake Actuation)
→ No
GO to D5.
D5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
2007.50 Focus 3/2007 G288148en


2 Using a suitable vacuum gauge, check the
vacuum pressure.
• Is the vacuum pressure above 40.5 kPa (0.4
bar) with the brake booster non-operational?
→ Yes
GO to D6.
→ No
INSTALL a new vacuum hose and fittings.
D6: CHECK THE BRAKE BOOSTER
1 Check the brake booster. REFER to the Brake
Booster Operation Check in this procedure.
• Is the brake booster OK?
→ Yes
→ No
PINPOINT TEST E : BRAKE NOISE

E1: CHECK FOR PEDAL NOISE
1 Run the engine at idle for 10 seconds or longer.
2 Apply the brake pedal and listen for noise.
3 Compare results with a known good system.
• Was a noise present?
→ Yes
GO to E2.
→ No
2007.50 Focus 3/2007 G288148en


E2: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment
and travel.
• Is the push rod and pedal travel OK?
→ Yes
BLEED the brake system. REFER to: (206-00
Brake System - General Information)
Procedures).
→ No
PINPOINT TEST F : SLOW OR INCOMPLETE BRAKE PEDAL RETURN

F1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at approximately 1200 rpm
whilst making several brake applications.
2 Pull the brake pedal upwards with approximately
44.5 N (10 lbs) force.
3 Release the brake pedal and measure the
distance to the floor panel and note the reading.
4 Make a hard brake application.
5 Release the brake pedal and measure the
distance to the floor panel and note the reading.
6 Compare the measurements.
• Did the brake pedal return to its original posi-
tion?
→ Yes
→ No
GO to F2.
2007.50 Focus 3/2007 G288148en


F2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal for free operation.
• Did the brake pedal operate freely?
→ Yes
→ No
INSTALL new brake pedal bushings. TEST
Component Tests 4. Apply the brake pedal until it stops moving

downward or an increased resistance to the
pedal travel occurs.
Hydraulic Leak Check 5. Hold the brake pedal in the applied position and
raise the engine speed to approximately 2000
NOTE: There is a common clutch and brake fluid rpm.
reservoir, therefore it is possible that a clutch leak
can lead to reduction in the reservoir level. NOTE: The additional movement of the brake pedal
is the result of the increased engine manifold
It is possible that all evidence of fluid leakage may vacuum which exerts more force on the brake
have washed off if the vehicle has been operated booster during engine rundown. This means that
in rain or snow, as brake fluid is water-soluble. additional stroke is available in the brake master
Refill the system, bleed then apply the brakes cylinder and the brake system is not bottoming out.
several times. Examine the system to verify that
the reservoir fluid level is actually dropping. Locate 6. Release the accelerator pedal and observe that
and repair the external leak. If the fluid level drops the brake pedal moves downward as the engine
and no external leak can be found, check for a returns to idle speed.
brake master cylinder bore end seal leak.
Brake Booster Functional Test
Brake System Check
Inspect all hoses and connections. All unused
vacuum connectors should be capped. Hoses and
Brake Pedal Reserve Check their connections should be correctly secured and
in good condition with no holes and no collapsed
Where a low brake pedal or the feel of a areas. Inspect the check valve on the brake booster
bottomed-out condition exists, check for brake for damage.
pedal reserve.
1. Operate the engine at idle with the transaxle in Brake Booster Operation Check
the NEUTRAL position.
2. Apply the brake pedal lightly three or four times. 1. Check the hydraulic brake system for leaks or
3. Allow 15 seconds for the vacuum to replenish low fluid.
the brake booster. 2. With the transaxle in the NEUTRAL position,
NOTE: This increased resistance may feel like stop the engine and apply the parking brake.
something has bottomed out. Apply the brake pedal several times to exhaust
all the vacuum in the system.
2007.50 Focus 3/2007 G288148en

3. With the engine turned off and the vacuum in Normal Conditions
the system exhausted, apply the brake pedal
and hold it down. Start the engine. If the vacuum The following conditions are considered normal
system is operating, the brake pedal will tend and are not indications that the brake master
to move downward under constant foot cylinder is in need of service.
pressure. If no motion is felt, the vacuum – Modern brake systems are not designed to
booster system is not functioning. produce as hard a pedal effort as in the past.
4. Remove the vacuum hose from the brake Complaints of light pedal efforts should be
booster. Manifold vacuum should be available compared to pedal efforts of another vehicle, of
at the brake booster end of the hose with the the same model and year.
engine at idle speed and the transaxle in the – During normal operation of the brake pedal, the
NEUTRAL position. Make sure that all unused fluid level in the reservoir will rise during brake
vacuum outlets are correctly capped, hose pedal application and fall during release. The
connectors are correctly secured and vacuum net fluid level (i.e., after brake pedal application
hoses are in good condition. When it is and release) will remain unchanged.
established that manifold vacuum is available
to the brake booster, connect the vacuum hose – A trace of brake fluid will exists on the brake
to the brake booster and repeat Step 3. If no booster shell below the master cylinder
downward movement of the brake pedal is felt, mounting flange. This results from the normal
install a new brake booster. REFER to: (206-07 lubricating action of the master cylinder bore
Power Brake Actuation) end seal.
– The fluid level will fall with brake shoe and lining
Brake Booster - LHD (Removal and Installation), wear.
5. Operate the the engine a minimum of 10
seconds at approximately 1200 rpm. Stop the Abnormal Conditions
engine and let the vehicle stand for 10 minutes.
Then, apply the brake pedal with approximately NOTE: Prior to performing any diagnosis, make
89 N (20 lb) force. The pedal feel (brake sure the brake system warning indicator is
application) should be the same as that noted functional.
with the engine operating. If the brake pedal
Changes in brake pedal feel or travel are indicators
feels hard (no power assist), install a new
that something could be wrong with the braking
vacuum check valve and then repeat the test.
system. The diagnostic procedure and techniques
If the brake pedal still feels hard, install a new
use brake pedal feel, warning indicator illumination
brake booster. REFER to: (206-07 Power Brake
and low brake fluid level as indicators in diagnosing
Actuation)
braking system concerns. The following conditions
Brake Booster - LHD (Removal and Installation), are considered abnormal and indicate that the
Brake Booster - RHD (Removal and Installation). brake master cylinder is in need of service.
If the brake pedal movement feels spongy, bleed
– The brake pedal goes down fast. This could be
caused by an external or internal leak.
– The brake pedal eases down slowly. This could
Brake System Bleeding (General Procedures), be caused by an external or internal leak.
– The brake pedal is low and or feels spongy. This
Procedures).
condition may be caused by no fluid in the brake
master cylinder reservoir, reservoir cap vent
Brake Master Cylinder holes clogged or air in the hydraulic system.
– The brake pedal effort is excessive. This may
Usually, the first and strongest indicator of anything be caused by a bind or obstruction in the pedal
wrong with the braking system is a feeling through or linkage, clogged fluid control valve or
the brake pedal. In diagnosing the condition of the insufficient booster vacuum.
brake master cylinder, check pedal feel as – The rear brakes lock up during light pedal force.
evidence of a brake concern. Check for the red This may be caused by incorrect tire pressures,
brake warning indicator illumination and the fluid grease or fluid on the brake shoes and linings,
level in the master cylinder reservoir.
2007.50 Focus 3/2007 G288148en

damaged brake shoes and linings, incorrectly
adjusted parking brake, or damaged or
contaminated brake pressure control valves.
– The brake pedal effort is erratic. This condition
could be caused by a brake booster malfunction,
extreme caliper piston knock back or incorrectly
installed brake shoes and linings.
– The red brake warning indicator is ON. This may
be caused by low fluid level, ignition wire routing
too close to the fluid level indicator assembly,
or float assembly damage.
Bypass Condition Test
1. Check the fluid in the brake master cylinder

reservoir. Fill the brake master cylinder reservoir
if low or empty.
2. Observe the fluid level in the brake master
cylinder reservoir. If after several brake
applications, the fluid level remains the same,
measure the wheel turning torque required to
rotate the wheels with the brakes applied as
follows:
Place the transaxle in the NEUTRAL position.
Raise and support the vehicle. REFER to: (100-02
Jacking and Lifting)
Apply the brakes with a minimum of 445 N (100
lb) and hold for approximately 15 seconds. With
the brakes still applied, exert a torque on the front
wheels of 10.1 Nm (75 lb ft). If either wheel rotates,
install a new brake master cylinder. REFER to:
(206-06 Hydraulic Brake Actuation)
Installation),
Installation).
Non-Pressure Leaks
Any empty brake master cylinder reservoir

condition may be caused by two types of
non-pressure external leaks.
Type 1: An external leak may occur at the brake
master cylinder reservoir cap because of incorrect
positioning of the gasket and cap. Reposition the
cap and gasket.
Type 2: An external leak may occur at the brake
master cylinder reservoir mounting seals. Service
such a leak by installing new seals.
2007.50 Focus 3/2007 G288148en

GENERAL PROCEDURES
Brake System Bleeding(12 141 0)

General Equipment 9.
CAUTION: Make sure that the bleed nipple
Worldwide Diagnostic System (WDS) cap is installed after bleeding the brake
line(s). This will prevent corrosion to the
bleed nipple. Failure to follow this instruction
Bleeding may result in the bleed nipple becoming
seized.
All Vehicles
Repeat the procedure for the remaining brake
WARNING: Brake fluid contains polyglycol lines.
ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after Vehicles with anti-lock brakes
handling. If brake fluid contacts the eyes,
flush the eyes for 15 minutes with cold 10. NOTE: This step is only necessary when
running water. Get medical attention if changing the brake fluid to remove the used
irritation persists. If taken internally, drink brake fluid from the hydraulic control unit
water and induce vomiting. Get medical (HCU).
attention immediately. Failure to follow Using WDS, bleed the brake system.
these instructions may result in personal
injury.
CAUTION: If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
NOTE: Make sure that the vehicle is standing on
a level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
1.
CAUTION: The brake fluid reservoir must
remain full with new, clean brake fluid at all
times during bleeding.
Install the bleed tube to the bleed nipple.
2. Immerse the end of the bleed tube in a bleed
jar containing a small quantity of approved
brake fluid.
3. Position the bleed jar base at least 300 mm
above the bleed nipple to maintain fluid
pressure and prevent air leaking past the
threads of the bleed nipple.
4. Loosen the bleed nipple by one-half turn.
5. Operate the brake pedal fully (pumping brake
fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position.
6. Fill the brake fluid reservoir to the MAX mark.
7. Continue operating the brake pedal until
air-free fluid is being pumped into the bleed
jar.
8. With the brake pedal fully depressed tighten
the bleed nipple.
2007.50 Focus 3/2007 G17458en

GENERAL PROCEDURES
Brake System Pressure Bleeding(12 141 0)

General Equipment
Vehicles with anti-lock brakes
Worldwide Diagnostic System (WDS)
4. NOTE: This step is only necessary when
Brake/clutch system pressure bleeder/filler changing the brake fluid to remove the used
brake fluid from the hydraulic control unit
(HCU).
Bleeding
Using WDS, bleed the brake system.
All vehicles
WARNING: Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after
flush the eyes for 15 minutes with cold
running water. Get medical attention if
irritation persists. If taken internally, drink
water and induce vomiting. Get medical
attention immediately. Failure to follow
injury.
NOTE: Make sure that the vehicle is standing on
a level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
1. Fill the brake fluid reservoir to the MAX mark.
2. CAUTIONS:
Make sure that the pressure within the
brake system does not exceed 1 bar.
Make sure that the pressure bleeding

equipment is filled with new brake fluid to
the correct specification.
Using the brake/clutch system pressure
bleeder/filler, pressure bleed the system in
accordance with the manufacturer's
instructions.
3.
CAUTION: Make sure that the bleed nipple
cap is installed after bleeding the brake
line(s). This will prevent corrosion to the
bleed nipple. Failure to follow this instruction
may result in the bleed nipple becoming
seized.
Fill the brake fluid reservoir to the MAX mark
as necessary.
2007.50 Focus 3/2007 G17459en

GENERAL PROCEDURES
Brake System Leak Check

Check
1. NOTE: Brake fluid is water soluble and it is
possible that all evidence of fluid leakage
has been washed off if the vehicle has been
operated in rain or snow.
Check the brake fluid level. Add brake fluid
as necessary.
2. Apply the brakes several times and make
sure the pedal feel is not spongy. If
necessary, bleed the brake system.
For additional information, refer to Brake
System Bleeding in this section.
3. Check the brake fluid level and verify that
the fluid level is actually dropping.
4. NOTE: If the brake fluid level drops and no
external leak is evident, check for a brake
master cylinder bore end seal leak.
Locate and correct the external leak.
2007.50 Focus 3/2007 G17460en

GENERAL PROCEDURES
Brake Disc Runout Check(12 221 0)

Special Tool(s) 2. Slowly rotate the wheel and tire and note the
readings.
Dial Indicator Gauge (Metric)
205-069 (15-046)
1 206-003
15046 205-069 1
Holding Fixture, Dial Indicator 1 205-070

2
Gauge
205-070 (15-022A)
TIE0036133
15022A
2. NOTE: Using paint or typing correction fluid,
mark the position of the wheel in relation to
Holding Fixture, Dial Indicator the wheel hub.
Gauge (Disc Brake) Remove the wheel and tire. For additional
206-003 (12-003) information, refer to Section 204-04 [Wheels
and Tires].
12003
3. Remove the brake pads. For additional
information, refer to Section 206-03 [Front
Disc Brake] / 206-04 [Rear Disc Brake].
General Equipment 4. Install the wheel nuts and tighten the wheel
Micrometer 0-125 mm nuts to 10 Nm, to hold the brake disc in
place.
Check 5. NOTE: The total dial indicator gauge reading
should not exceed 0.05 mm.
1. NOTE: The total dial indicator gauge reading
should not exceed 0.05 mm. Using the special tools, measure the brake
disc runout on the inner and outer faces of
Using the special tools, measure the brake the brake disc (outer face measurement
disc runout on the inner face of the brake shown).
disc (wheel and tire shown removed for
clarity). 1. Position the dial indicator gauge so that it
contacts the brake disc approximately 10 mm
1. Position the dial indicator gauge so that it from the outer edge.
contacts the brake disc approximately 10 mm
from the outer edge.
2007.50 Focus 3/2007 G289887en

GENERAL PROCEDURES
2. Slowly rotate the brake disc and note the 9. If the brake disc runout measurement without
readings. the wheel and tire fitted is outside the
specification, check the wheel hub face
runout.
1 206-003
10. NOTE: Using paint or typing correction
fluid, mark the position of the brake disc in
relation to the wheel hub.
Remove the brake disc. For additional
1 205-070 2 Disc Brake] / 206-04 [Rear Disc Brake].
1 205-069
11. NOTE: Make sure that the wheel hub face
is clean and free of rust and foreign
TIE0035481
material.
NOTE: Re-position the dial indicator gauge so that
6. NOTE: If any of the readings vary by more it contacts the wheel hub approximately 10 mm
than 0.015 mm or the brake disc thickness from the outer edge of the wheel hub.
is less than the specified minimum, a new
Check the wheel hub face runout.
brake disc must be installed and the brake
disc runout re-checked. • Slowly rotate the wheel hub and note the
readings.
Check the brake disc thickness variation.
• Using a suitable micrometer, measure the
brake disc thickness at eight positions, 45
degrees apart and approximately 15 mm from
the outer edge of the brake disc.
TIE0035482
12. If the wheel hub runout exceeds 0.03 mm,

install a new wheel hub. For additional
MPU1201004
Suspension] / 204-02 [Rear Suspension].
13. If the wheel hub face runout is within
7. If all the brake disc runout measurements
specification, install a new brake disc. For
and the thickness variation are within the
specifications, check the wheel balance.
Section 206-03 [Front Disc Brake] / 206-04
8. If just the brake disc runout measurement [Rear Disc Brake].
with the wheel and tire fitted exceeds the
specification, the wheel and tire must be
rotated through 90 degrees in relation to the
brake disc and the brake disc runout
re-checked.
• If the brake disc runout measurement still
exceeds the specification, repeat the wheel
and tire rotation and checking process until
the measurement is within specification.
2007.50 Focus 3/2007 G289887en

206-02-1 Drum Brake 206-02-1
.
SECTION 206-02 Drum Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-02-2

Drum Brake......................................................................................................................... 206-02-3

Brake Drum......................................................................................................................... 206-02-4
Brake Shoes....................................................................................................................... 206-02-5
Wheel Cylinder................................................................................................................... 206-02-7
Brake Backing Plate........................................................................................................... 206-02-9
206-02-2 Drum Brake 206-02-2
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Specification
Silicon grease ESA-M1C171-A
Super DOT 4 brake fluid ESD-M6C57-A
Drum Brake Dimensions

Description mm
New brake drum nominal diameter 228.3
Worn brake drum discard diameter* 230.2
Brake shoe width 38
Worn brake shoe lining discard thickness** 1
Brake shoe adjuster pre-set diameter 228
* When the discard thickness has been reached, install a new brake drum/brake shoes.
** When the discard thickness has been reached, install new brake shoes.
Brake hose to wheel cylinder union 18 13 -
Wheel cylinder retaining bolts 10 - 89
2007.50 Focus 3/2007 G307377en

206-02-3 Drum Brake 206-02-3
Drum Brake
REFER to Section 206-00 [Brake System -
2007.50 Focus 3/2007 G17465en

206-02-4 Drum Brake 206-02-4
Brake Drum
1. Release the parking brake.
2. Remove the wheel and tire. table(s).
and Installation).
E50225

1 Brake Drum
See Removal Detail
Removal Details
Item 1 Brake Drum
CAUTION: Do not use a screwdriver or any
other similar tool to remove the brake drum
from the wheel hub.
NOTE: Remove and discard the brake drum
retaining clip (if equipped).
2007.50 Focus 3/2007 G401523en

206-02-5 Drum Brake 206-02-5
Brake Shoes
Materials 1. Remove the brake drum.
Name Specification For additional information, refer to: Brake

Drum (206-02 Drum Brake, Removal and
Silicone Grease ESE-M1C171-A Installation).
table(s).
2
4
E50226
1 Brake shoe hold down springs 3 Brake shoe adjuster
2 Brake shoe release springs 4 Brake shoes

Removal Details
Item 2 Brake shoe release springs NOTE: Hold the wheel cylinder pistons in place
with a rubber band.
1.
CAUTION: Do not damage the wheel
cylinder boots.
2007.50 Focus 3/2007 G401524en

206-02-6 Drum Brake 206-02-6
Detach the brake shoes from the wheel Remove the brake shoe return springs.
cylinder (wheel hub shown removed for
clarity). Item 4 Brake shoes
1. Disconnect the parking brake cable from the
brake shoe.
TIE0000321
2. NOTE: Fully release the brake shoe adjuster. TIE0031434
NOTE: Discard the upper return spring.
Item 4 Brake shoes
1. Clean the backing plate and apply grease to
the brake shoe contact points.
Item 2 Brake shoe release springs

NOTE: Install a new brake shoe upper return
spring.
1. Adjust the brake shoes to obtain a brake
shoe diameter of 228 mm.
2007.50 Focus 3/2007 G401524en

206-02-7 Drum Brake 206-02-7
Wheel Cylinder
General Equipment 1. Remove the brake shoes.
Brake hose clamp For additional information, refer to: Brake
Shoes (206-02 Drum Brake, Removal and
CAUTION: If brake fluid is spilt on the Installation).
immediately washed down with cold water. 2. Remove the components in the order
table(s).
18 Nm 1
2 10 Nm
E50227

1 Brake hose to wheel cylinder union 4. Bleed the brake system.
See Removal Detail For additional information, refer to: Brake
2 Wheel cylinder retaining bolts System Bleeding (206-00 Brake System -
General Information, General Procedures)
3 Wheel cylinder / Brake System Pressure Bleeding (206-00
See Removal Detail Brake System - General Information,
Removal Details
Item 1 Brake hose to wheel cylinder union 1. Using a suitable brake hose clamp, clamp
the brake hose.
1. Loosen the brake hose to wheel cylinder
union.
2007.50 Focus 3/2007 G401525en

206-02-8 Drum Brake 206-02-8
2. Loosen the union.
E50644
Item 3 Wheel cylinder

1.
CAUTION: Cap the brake hose to prevent
fluid loss or dirt ingress.
Disconnect the brake hose from the wheel
cylinder.
2007.50 Focus 3/2007 G401525en

206-02-9 Drum Brake 206-02-9
Brake Backing Plate

1. Remove the wheel cylinder. 3. Disconnect the wheel speed sensor electrical
For additional information, refer to: Wheel connector.
Cylinder (206-02 Drum Brake, Removal and
Installation).
2. Detach the parking brake cable from the
brake backing plate (wheel hub shown
1. Depress the retaining clip.
2. Detach the cable.
TIE41380
2 4. Remove the components in the order

table(s).
1
TIE0032745
2 55 Nm 1
E50228
2007.50 Focus 3/2007 G401526en

206-02-10 Drum Brake 206-02-10

1 Wheel hub retaining bolts 3 Brake backing plate
2 Wheel hub
Item 3 Brake backing plate
CAUTION: Make sure that the mating faces
are clean and free from rust and foreign
material.
2007.50 Focus 3/2007 G401526en

206-03-1 Front Disc Brake 206-03-1
.
SECTION 206-03 Front Disc Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-03-2
Front Brake Disc Specification........................................................................................ 206-03-2

Front Disc Brake................................................................................................................. 206-03-3

Brake Pads......................................................................................................................... 206-03-4
Brake Caliper...................................................................................................................... 206-03-7
Brake Disc.......................................................................................................................... 206-03-9

Brake Caliper...................................................................................................................... 206-03-10
SPECIFICATIONS
Specification
Front Brake Disc Specification

mm
Brake disc diameter – vehicles with 2.0L engine, 1.6L diesel or 2.0L diesel 300
Brake disc diameter – vehicles with 1.6L or 1.8L engine 278
New brake disc nominal thickness 25
Worn brake disc discard thickness * 23
Maximum brake disc thickness variation 0.025
Worn brake pad discard thickness** 1.5
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
Brake caliper retaining bolts 28 21 -
Brake hose to brake caliper union 18 13 -
2007.50 Focus 3/2007 G163345en

Front Disc Brake

2007.50 Focus 3/2007 G17475en

Brake Pads
Special Tool(s) CAUTION: If brake fluid is spilt on the
Retractor, Brake Caliper paintwork, the affected area must be
Piston immediately washed down with cold water.
206-005 (12-014) 1. Remove the wheel and tire. For additional
information, refer to Section 204-04 [Wheels
and Tires].
12014 2. Remove the components in the order
table(s).
Materials
Name Specification
2007.50 Focus 3/2007 G296169en

3 28 Nm
TIE39368
1 Brake caliper retaining clip 4 Outer brake pad

2 Brake caliper retaining bolt covers
5 Inner brake pad
3 Brake caliper retaining bolts See Removal Detail
4. Depress the brake pedal, check the fluid level
in the brake fluid reservoir and top up if
necessary with brake fluid.
2007.50 Focus 3/2007 G296169en

Removal Details
Item 3 Brake caliper retaining bolts Remove the inner brake pad.
CAUTION: Suspend the brake caliper to
prevent load being placed on the brake
hose.
Item 5 Inner brake pad

1. NOTE: The inner brake pad is secured to the
brake caliper piston by a spring clip.
TIE0033033
1.
CAUTION: When the brake caliper piston
is retracted into the piston housing, brake
fluid will be displaced into the brake fluid
reservoir.
NOTE: Make sure the brake pad contact points
are clean and free from contamination.
Using the special tool, retract the brake
caliper piston.
206-005
TIE0002183
Item 4 Outer brake pad

NOTE: Remove the adhesive foil from the rear of
the brake pad.
2007.50 Focus 3/2007 G296169en

Brake Caliper
General Equipment CAUTION: If brake fluid is spilt on the
Brake hose clamp paintwork, the affected area must be
Materials 1. Remove the wheel and tire. For additional
Name Specification information, refer to Section 204-04 [Wheels
and Tires].
table(s).
4 28 Nm
18 Nm 2 7
TIE39369
1 Brake caliper retaining clip 6 Inner brake pad

See Removal Detail
2 Brake hose to brake caliper union See Installation Detail
See Removal Detail
7 Brake caliper
3 Brake caliper retaining bolt covers See Removal Detail
4 Brake caliper retaining bolts 3. To install, reverse the removal procedure.
5 Outer brake pad 4. Bleed the brake system. For additional
See Installation Detail information, refer to Section 206-00 [Brake
System - General Information].
2007.50 Focus 3/2007 G296170en

Removal Details
Item 2 Brake hose to brake caliper union Remove the inner brake pad.
1. Loosen the brake hose to brake caliper
union.
1. Using a suitable brake hose clamp, clamp
the brake hose.
TIE0033033
1
2 Item 7 Brake caliper

1.
TIE0001768 fluid loss or dirt ingress.
Disconnect the brake hose from the caliper.
Item 6 Inner brake pad • Rotate the caliper counterclockwise.
1. NOTE: The inner brake pad is secured to the
brake caliper piston by a spring clip.
TIW1201078

NOTE: Remove the adhesive foil from the rear of
the brake pad.
2007.50 Focus 3/2007 G296170en

Brake Disc
1. Remove the wheel and tire. For additional
table(s).
and Tires].
115 Nm 1
TIE40341

1 Brake caliper anchor plate retaining bolts NOTE: Make sure the wheel hub face is clean and
free of rust and foreign material.
2 Brake caliper and anchor plate
See Removal Detail 4. If a new brake disc has been installed, install
new brake pads.
3 Brake disc
See Removal Detail For additional information, refer to Brake
Pads in this section.
Removal Details
Item 2 Brake caliper and anchor plate
Item 3 Brake disc
CAUTION: Suspend the brake caliper and
anchor plate to prevent load being placed NOTE: Remove and discard the retaining washer
on the brake hose. (if equipped).
1. Detach the brake caliper and anchor plate

2007.50 Focus 3/2007 G296171en

206-03-10 Front Disc Brake 206-03-10
Brake Caliper
Materials 1. Disassemble the components in the order
Name Specification table(s).
Super DOT 4 Brake ESD-M6C57-A
Fluid
2 3
TIE40333

procedure.
1 Brake caliper dust seal
2 Brake caliper piston
See Disassembly Detail
3 Brake caliper piston seal
See Assembly Detail
Disassembly Details
Item 2 Brake caliper piston 2.
WARNING: Use only as much
1. Place a suitable block of wood between the compressed air as is necessary to remove
body of the brake caliper and the brake the brake caliper piston. Excessive pressure
caliper piston. may force the piston out of the caliper bore
with sufficient force to cause personal injury.
2007.50 Focus 3/2007 G296172en

206-03-11 Front Disc Brake 206-03-11
Never attempt to catch the piston as it comes Apply compressed air through the brake
out of the bore. Failure to follow these hose union housing to remove the brake
instructions may result in personal injury. caliper piston.
CAUTION: Do not use a screwdriver or any
other similar tool to pry the brake caliper Item 3 Brake caliper piston seal
piston out of the brake caliper bore. CAUTION: Do not use a screwdriver or any
other similar tool to pry the brake caliper
seal out of the brake caliper bore.
Assembly Details
Item 3 Brake caliper piston seal
WARNING: Install a new brake caliper if
rust, pitting or scores are evident in the
brake caliper bore or on the brake caliper
piston.
NOTE: Lubricate the piston, piston bore and piston
seal with super DOT 4 brake fluid prior to
installation.
2007.50 Focus 3/2007 G296172en

206-04-1 Rear Disc Brake 206-04-1
.
SECTION 206-04 Rear Disc Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-04-2
Rear Disc Brake Specification........................................................................................ 206-04-2

Rear Disc Brake.................................................................................................................. 206-04-3

Brake Caliper...................................................................................................................... 206-04-4
Brake Pads......................................................................................................................... 206-04-8
Brake Disc.......................................................................................................................... 206-04-11
Brake Disc Shield............................................................................................................... 206-04-13
206-04-2 Rear Disc Brake 206-04-2
SPECIFICATIONS
Specification
Rear Disc Brake Specification

Description mm
Brake disc diameter – vehicles with 1.6L diesel, 1.8L diesel or 2.0L engine 280
Brake disc diameter – vehicles with 1.6L or 1.8L engine 260
New brake disc nominal thickness 11
Worn brake disc discard thickness * 9
Maximum brake disc thickness variation 0.025
Worn brake pad discard thickness ** 1.5
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
Brake caliper retaining bolts 35 26 -
Brake hose to brake caliper union 18 13 -
2007.50 Focus 3/2007 G307379en

206-04-3 Rear Disc Brake 206-04-3
Rear Disc Brake

2007.50 Focus 3/2007 G17486en

206-04-4 Rear Disc Brake 206-04-4
Brake Caliper
Special Tool(s) 3. Loosen the brake hose to brake caliper
union.
Retractor, Rear Brake Caliper
Piston 1. Using a brake hose clamp, clamp the brake
206-085 (12-025) hose.
206085
1
General Equipment
Brake hose clamp
Materials 2
Name Specification
TIE0003430
immediately washed down with cold water. 4. Remove the components in the order
1. Release the parking brake. table(s).
and Installation).
2007.50 Focus 3/2007 G296177en

206-04-5 Rear Disc Brake 206-04-5
2 35 Nm 4
7
6
5
E39460
1 Parking brake cable 6 Inner brake pad

2 Brake caliper retaining clip 7 Brake caliper

See Removal Detail
3 Brake caliper retaining bolt covers
4 Brake caliper retaining bolts
See Removal Detail 6. Bleed the brake system. For additional
information, refer to: (206-00 Brake System
5 Outer brake pad - General Information)
Brake System Bleeding (General
Procedures),
Procedures).
Removal Details
2007.50 Focus 3/2007 G296177en

206-04-6 Rear Disc Brake 206-04-6
Item 1 Parking brake cable Item 7 Brake caliper
1. Detach the parking brake cable from the 1.
brake caliper lever.
NOTE: The brake hose union has a right-handed
thread.
Disconnect the brake hose from the brake
caliper.
• Rotate the brake caliper clockwise when
viewed as shown.
14 Nm
TIE0032908
Item 4 Brake caliper retaining bolts

CAUTION: Suspend the brake caliper to
hose.
TIE0034723
Item 6 Inner brake pad 2.
CAUTION: Do not apply grease or
1. lubricant to the brake pad contact points or
CAUTION: Support the brake caliper
the brake caliper piston.
during brake caliper piston retraction.
NOTE: The inner brake pad is equipped with an
NOTE: To retract the brake caliper piston, apply
anti-rattle spring.
pressure to the brake caliper piston while rotating
the brake caliper piston clockwise. NOTE: Make sure that the brake pad contact points
Using the special tool, retract the brake
caliper piston. Install the inner brake pad.
206-085
E58942
TIE0033150
2007.50 Focus 3/2007 G296177en

206-04-7 Rear Disc Brake 206-04-7
NOTE: Make sure that the brake pad contact points
2007.50 Focus 3/2007 G296177en

206-04-8 Rear Disc Brake 206-04-8
Brake Pads
Special Tool(s)
All vehicles
Retractor, Rear Brake Caliper
Piston 1. Remove the wheel and tire.
206-085 (12-025) For additional information, refer to: Wheel
and Installation).
206085
Vehicles with manual parking brake
Materials
Name Specification Vehicles with electronic parking brake (EPB)
Super DOT 4 brake fluid ESD-M6C57-A 3. Release the EPB.
1. Remove the ignition key.
paintwork, the affected area must be 2. Activate the EPB switch (vehicles equipped
immediately washed down with cold water. for cold climate only).
NOTE: Make sure that the brake pad contact points NOTE: High forces may be required to release
are clean and free of foreign material. the cable.
3. Pull the emergency EPB release cable.
table(s).
2 35 Nm 4
6
5
E39459
2007.50 Focus 3/2007 G296178en

206-04-9 Rear Disc Brake 206-04-9
1 Parking brake cable All vehicles

See Removal Detail
6. Fully depress and release the brake pedal.
2 Brake caliper retaining clip
7. Check the fluid level in the brake fluid
3 Brake caliper retaining bolt covers reservoir and top up if necessary with brake
fluid.
4 Brake caliper retaining bolts
See Removal Detail
Vehicles with electronic parking brake (EPB)
5 Outer brake pad
8. Activate the EPB switch.
6 Inner brake pad
Removal Details
Item 1 Parking brake cable
Item 4 Brake caliper retaining bolts
1. Detach the parking brake cable from the
brake caliper lever. CAUTION: Suspend the brake caliper to
hose.
TIE0032908
Item 6 Inner brake pad Using the special tool, retract the brake
caliper piston.
1. CAUTIONS:
When the brake caliper pistons are
retracted into the piston housing, brake fluid
will be displaced into the brake fluid 206-085
reservoir.
Support the brake caliper during brake

caliper piston retraction.
NOTE: To retract the brake caliper piston, apply
pressure to the brake caliper piston while rotating
the brake caliper piston clockwise.
TIE0033150
2007.50 Focus 3/2007 G296178en

206-04-10 Rear Disc Brake 206-04-10
2.
CAUTION: Do not apply grease or
lubricant to the brake pad contact points or
the brake caliper piston.
NOTE: The inner brake pad is equipped with an
anti-rattle spring.
Install the inner brake pad.
E58942
2007.50 Focus 3/2007 G296178en

206-04-11 Rear Disc Brake 206-04-11
Brake Disc
1. Remove the brake pads.
For additional information, refer to: Brake table(s).
Pads (206-04 Rear Disc Brake, Removal
and Installation).
70 Nm 1
E39462

1 Brake caliper anchor plate retaining bolts NOTE: Make sure the wheel hub face is clean and
free of rust and foreign material.
2 Brake caliper and anchor plate
3 Brake disc
See Removal Detail
Removal Details
Item 3 Brake disc
NOTE: Remove and discard the retaining clip (if
equipped).
2007.50 Focus 3/2007 G296179en

206-04-12 Rear Disc Brake 206-04-12
Item 3 Brake disc
1. If a new brake disc has been installed, install
new brake pads.
Pads (206-04 Rear Disc Brake, Removal
and Installation).
2007.50 Focus 3/2007 G296179en

206-04-13 Rear Disc Brake 206-04-13
Brake Disc Shield

1. Remove the brake disc. 3. Remove the components in the order
For additional information, refer to Brake indicated in the following illustration(s) and
Disc - in this section. table(s).
2. Disconnect the wheel speed sensor electrical
connector.
TIE41380
2 70 Nm 1
70 Nm 1
TIE40342

1 Wheel hub retaining bolts
2 Wheel hub
3 Brake disc shield
2007.50 Focus 3/2007 G296180en

206-05-1 Parking Brake and Actuation 206-05-1
.
SECTION 206-05 Parking Brake and Actuation

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-05-2

Parking Brake..................................................................................................................... 206-05-3
Conventional parking brake................................................................................................ 206-05-3
Electronic parking brake..................................................................................................... 206-05-3

Parking Brake..................................................................................................................... 206-05-6
Symptom Chart................................................................................................................... 206-05-6
Pinpoint Tests..................................................................................................................... 206-05-6
GENERAL PROCEDURES
Parking Brake Cable Adjustment................................................................... (12 662 0) 206-05-10

Parking Brake Control......................................................................................................... 206-05-12
Parking Brake Cable — Vehicles With: Rear Drum Brakes................................................ 206-05-14
Parking Brake Cable — Vehicles With: Rear Disc Brakes................................................. 206-05-19
SPECIFICATIONS
Parking brake control retaining bolts 35 26 -
Exhaust flexible pipe to exhaust muffler and tailpipe 51 38 -
nuts
Electronic parking brake release actuator retaining 23 17 -
bolts
Electronic parking brake module support bracket 23 17 -
retaining nut
Electronic parking brake module support bracket 9 - 80
retaining bolts
Electronic parking brake module retaining nuts 5 - 44
2007.50 Focus 3/2007 G307380en

Parking Brake
Conventional parking brake The layout and operation of the mechanical parking
brake are similar to the current Focus.
A conventional parking brake is used.
Electronic parking brake
E45459
Item Description • Clutch pedal switch

• Electronic parking brake actuator
1 Electronic parking brake actuator
• Brake pedal switch
2 Handbrake cable
3 Emergency release
Pushbutton for operation of the electronic
The electronic parking brake actuator can only be parking brake
replaced as a complete unit.
The pushbutton for operation of the electronic
An electronic parking brake is available as an parking brake is located in the centre console. To
option for the vehicle. In comparison to a release the electronic parking brake press the
conventional handbrake, the electronic parking pushbutton, to engage it pull the button.
brake offers the following advantages:
• Ease of operation, as the electronic parking
brake is always applied firmly, regardless of the
strength of the driver.
• Safety, as the vehicle can be slowed down with
the electronic parking brake if the hydraulics of
the brake system fail while driving. The system
is automatically coordinated with the ABS
system to prevent the braked wheels from
locking up.
The system comprises the following components:
• Pushbutton for operation of the electronic
parking brake
• Emergency release mechanism
2007.50 Focus 3/2007 G187551en

Neutral position Emergency release
E45461 E45465
When the pushbutton is in the neutral position, the If the electronic parking brake has been released
following pins are connected to each other: by means of the emergency release mechanism
• 1 and 6 then it is necessary to release the electronic
parking brake via the pushbutton after the service
• 4 and 2
repairs have been carried out.
• 5 and 3
It is also possible to release the electronic parking
For safety reasons six change-over contacts which brake manually if required. There is a rubber mat
switch the three circuits are integrated in the underneath the storage compartment in the centre
pushbutton. The system will still function if one of console which needs to be removed in order to
the circuits fails. An error message then appears access and operate the emergency release
on the display of the instrument cluster. mechanism. The electronic parking brake is then
released by firmly pulling the T-shaped handle
upwards until a loud noise is heard.
Engaged position
• The electronic parking brake reinitialises itself
When the pushbutton is in the engaged position, during its first electrical operation after an
the following pins are connected to each other: emergency release.
• 1 and 4
• 2 and 5 Electronic parking brake actuator
• 3 and 6
3 4
Released position 2
5
When the pushbutton is in the released position,
the following pins are connected to each other:
• 1 and 5
• 4 and 3
• 2 and 6 1
8 6 1
9 7
E45460
Item Description
1 Handbrake cable
2 Connections
3 DC motor
4 Electronic parking brake control module
2007.50 Focus 3/2007 G187551en

Item Description Engaging the parking brake

5 Emergency release cable When the electronic parking brake is engaged, a
6 Splined shaft distinction is made between static and dynamic
braking. If the foot brake fails the vehicle can be
7 Transmission braked dynamically by means of the electronic
parking brake.
8 Hollow shaft
9 Force sensor
Dynamic braking
The electronic parking brake actuator is positioned
underneath the spare wheel well. The following At speeds above 4 km/h the vehicle is gradually
components are integrated in the parking brake braked if the pushbutton is lifted up. If one of the
actuator: braked wheels locks up then the force under which
• Electronic parking brake control module the parking brake cables are applied is reduced.
• DC motor The vehicle continues to brake while the button is
pulled up.
• Transmission
• Force sensor
• Hollow shaft Static braking
• Splined shaft
At speeds below 4 km/h or if the vehicle is
• Handbrake cable stationary the pushbutton is lifted up briefly to
• Emergency release cable engage the electronic parking brake.
If the ignition key is removed within 10 minutes of
Mechanical layout turning the ignition off, then the electronic parking
brake is automatically engaged. The electronic
The motor/gearing unit is a floating fit in the parking brake control module switches to "sleep"
electronic parking brake actuator. mode 10 minutes after the ignition is switched off.
It is then no longer possible to engage the
A hollow shaft is driven via the gearing. A splined electronic parking brake.
shaft engages in turn in the hollow shaft. The
hollow shaft is connected to a force sensor via a The automatic engagement of the electronic
link which can be released mechanically parking brake is configured separately for each
(emergency release). The parking brake cables different country at the factory. The automatic
are hooked into the force sensor and the splined engagement of the electronic parking brake is
shaft. disabled in countries where the handbrake cables
are prone to freezing up. The automatic
After renewing the rear brake pads, always press engagement of the electronic parking brake is
the brake pedal several times before operating the enabled in all other countries. The automatic
electronic parking brake. engagement of the electronic parking brake can
be activated or deactivated with WDS according
to the customer's wishes.
Operation
When the electronic parking brake is operated the Releasing the parking brake
DC motor is actuated using a map stored in the
electronic parking brake control module. The values In order to release the parking brake, it is
stored in the map are used as reference values. necessary for the ignition to be switched on, the
The voltage signal supplied from the force sensor pushbutton to be pressed and the brake pedal or
is compared to the reference values. If the value clutch pedal to be depressed.
matches the reference value then the DC motor is
no longer actuated. In order to prevent automatic engagement of the
electronic parking brake when the ignition key is
removed from the switch, press and hold the button
while switching off the ignition and removing the
key.
2007.50 Focus 3/2007 G187551en

Parking Brake
Inspection and Verification Visual Inspection Chart
1. Verify the customer concern by operating the Mechanical Electrical
parking brake system. – Parking brake control – Parking brake
2. Visually inspect for obvious signs of mechanical warning circuit.
REFER to: Parking
Brake Control REFER to: Instru-
(206-05, Removal ment Cluster (413-
and Installation). 01, Diagnosis and
– Cable and conduit Testing).
REFER to: Parking
Brake Cable (206-
05, Removal and
Installation).

concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the concern is not visually evident, verify the
Symptom Chart
Symptom Chart
• The parking brake will not apply • Parking brake control. • GO to Pinpoint Test A.
• Cable and conduit.
• The parking brake will not • Parking brake control. • GO to Pinpoint Test B.
release • Cable and conduit.
Pinpoint Tests
PINPOINT TEST A : THE PARKING BRAKE WILL NOT APPLY
A1: CHECK FOR MISADJUSTED REAR PARKING BRAKE CABLE
1 Operate the parking brake control several times
to adjust the cable.
• Does the parking brake now engage correctly?
→ Yes
Vehicle OK
→ No
GO to A2.
2007.50 Focus 3/2007 G17495en


A2: CHECK FOR WORN BRAKE SHOES OR PADS
1 Inspect the brake shoes or pads for excessive
wear.
REFER to: Specifications (206-00, Specifica-
tions)
/ Brake Shoes (206-02 Drum Brake, Removal
and Installation)
/ Brake Pads (206-04, Removal and Installation).
• Are the brake shoe linings or brake pads OK?
→ Yes
GO to A3.
→ No
INSTALL new brake shoes or pads.
REFER to: Brake Shoes (206-02 Drum Brake,
/ Brake Pads (206-04, Removal and Installa-
tion).
A3: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables and conduits
for damage, rust or fraying.
• Are the parking brake cables and conduits OK?
→ Yes
CHECK for other causes such as loose
parking brake control or conventional brake
system components.
→ No
REPAIR or INSTALL cables and conduit as
necessary. TEST the system for normal
operation.
2007.50 Focus 3/2007 G17495en

PINPOINT TEST B : THE PARKING BRAKE WILL NOT RELEASE
B1: CHECK PARKING BRAKE CONTROL
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
REFER to: Lifting (100-02, Description and
Operation).
– With the aid of another technician, release the
parking brake and check the operation of the
brake cables and levers.
• Did the parking brake release?
→ Yes
CHECK the other causes such as conven-
tional brake system components. REPAIR or
→ No
GO to B2.
B2: CHECK PARKING BRAKE CABLES
1 Loosen the parking brake cable tension.
– Rotate the rear wheels by hand.
• Did the rear wheels turn freely?
→ Yes
INSTALL a new parking brake control.
REFER to: Parking Brake Control (206-05,
→ No
GO to B3.
B3: CHECK FRONT PARKING BRAKE CABLE
1 Disconnect the parking brake front cable and
conduit from the rear brake cable and conduit
at the equalizer.
– Rotate the rear wheels by hand.
• Did the rear wheels turn freely?
→ Yes
INSTALL a new front parking brake cable and
conduit.
REFER to: Parking Brake Cable (206-05,
→ No
GO to B4.
2007.50 Focus 3/2007 G17495en


B4: CHECK REAR PARKING BRAKE CABLES
1 Disconnect the parking brake at the rear brakes,
one at a time.
– Rotate the wheel affected by the disconnected
parking brake.
• Did the wheel turn freely?
→ Yes
INSTALL a new parking brake control lever
on the rear drum brakes or caliper assembly
on rear disc brakes.
REFER to: Brake Shoes (206-02 Drum Brake,
/ Brake Caliper (206-04, Removal and Install-
ation).
→ No
REFER to: Brake System (206-00, Diagnosis
and Testing).
2007.50 Focus 3/2007 G17495en

GENERAL PROCEDURES
Parking Brake Cable Adjustment(12 662 0)

All vehicles • Stage 1: Tighten the parking brake cable
adjustment nut to 2 Nm.
1. Remove the parking brake control boot.
• Stage 2: Raise the parking brake control
twelve notches.
• Stage 3: Fully release the parking brake
control.
• Stage 4: Loosen the parking brake cable
adjustment nut to the end of the thread.

6. Raise and support the vehicle.
For additional information, refer to: Jacking
(100-02 Jacking and Lifting, Description
TIE0036498
and Operation)
/ Lifting (100-02 Jacking and Lifting,
2. Release the parking brake. Description and Operation).
3. Loosen the parking brake cable adjustment 7. NOTE: Make sure the parking brake control
nut to the end of the parking brake cable is fully released.
thread. Adjust the parking brake cable in five stages.
• Remove the parking brake cable adjustment • Stage 1: Insert a 0.7 mm feeler gauge
nut lock nut. between the parking brake lever and the
brake caliper abutment on both sides.
• Stage 2: With the aid of another technician,
tighten the parking brake cable adjustment
nut until movement is observed on one of
parking brake levers.
• Stage 3: Remove the feeler gauges.
• Stage 4: Rotate the rear wheels and tires
and check for brake drag. If brake drag is
felt, loosen the parking brake cable
adjustment nut to the end of the parking
E53607 brake cable thread, clean the parking brake
cables and repeat the parking brake cable
adjustment procedure.
4. Make sure the parking brake cable is • Stage 5: Install the parking brake cable
correctly located. adjustment nut lock nut.
5.
CAUTION: The torque applied to the
adjustment nut must not exceed 10 Nm.
Failure to follow this instruction will cause
damage to the parking brake cable thread.
NOTE: Make sure the parking brake control is fully
released.
NOTE: Before carrying out the adjustment to a new 0.7 mm
or relocated parking brake cable, settle the parking
brake system.
Settle the parking brake system in four E53720
stages.
2007.50 Focus 3/2007 G401817en

GENERAL PROCEDURES
Vehicles with rear drum brakes 12. Install the rear wheels and tires.
8. Remove the rear wheels and tires. For additional information, refer to: Wheel
and Installation). 13. Check the parking brake cable adjustment
in two stages.
9. Remove the brake drum.
• Stage 1: Raise and release the parking brake
• Remove and discard the retaining washer (if
control and check that it returns to the fully
equipped).
released position. If the parking brake control
does not fully release, repeat the parking
brake cable adjustment procedure.
• Stage 2: Rotate the rear wheels and tires
and check for brake drag. If brake drag is
felt, loosen the parking brake cable
adjustment nut two full turns and repeat the
parking brake cable adjustment procedure.
All vehicles
14. Install the parking brake control boot.
TIE0005463
10. NOTE: Make sure the parking brake control

is fully released.
Adjust the parking brake cable in four stages.
• Stage 1: Insert a 2.0 mm feeler gauge
between the parking brake lever end stop
and the rear brake shoe on both sides.
• Stage 2: With the aid of another technician,
tighten the parking brake cable adjustment
nut until movement is observed on one of
parking brake levers.
• Stage 3: Remove the feeler gauges.
• Stage 4: Install the parking brake cable
adjustment nut lock nut.
2 mm
E53721
11. Install the brake drum.
2007.50 Focus 3/2007 G401817en

Parking Brake Control

3. Disconnect the parking brake control switch
1. Remove the floor console. For additional
electrical connector.
information, refer to Section 501-12
[Instrument Panel and Console].
TIE0000337

table(s).
1
35 Nm 2
2 35 Nm
TIE40385
2007.50 Focus 3/2007 G296185en

1 Parking brake cable adjustment nut 6. Adjust the parking brake cable.
For additional information, refer to Parking
2 Parking brake control retaining bolts
Brake Cable Adjustment in this section.
3 Parking brake control
See Removal Detail
Removal Details
Item 3 Parking brake control Position the parking brake cable retaining
tab away from the parking brake cable.
1. NOTE: Make a note of the position of the
parking brake cable retaining tab, to aid
installation.
NOTE: The parking brake cable retaining tab must
be positioned away from the parking brake cable,
to aid removal.
TIE44517
Item 3 Parking brake control Reposition the parking brake cable retaining
tab.
1.
CAUTION: When repositioning the
parking brake cable retaining tab, make sure
that the parking brake cable retaining tab
does not clamp the parking brake cable.
NOTE: Make sure that the parking brake cable is
correctly located in the parking brake control.
TIE44517
2007.50 Focus 3/2007 G296185en

Parking Brake Cable — Vehicles With: Rear Drum Brakes

Materials 4. Raise and support the vehicle.
Name Specification For additional information, refer to: Lifting
Lubricant ESE-M99B144-B
and Operation).
1. Remove the parking brake control boot. 5. Remove the air deflector on both sides.
TIE0036498
TIE44528
2. Release the parking brake. 6. Remove the components in the order

3. Loosen the parking brake cable adjustment indicated in the following illustration(s) and
nut to the end of the thread. table(s).
TIE0032663
2007.50 Focus 3/2007 G401818en

1 2
TIE40387
1 Exhaust muffler and tailpipe assembly 3 Exhaust system heat shield center section
See Removal Detail 4 Exhaust system heat shield front section
2 Exhaust hanger insulators
See Removal Detail
2007.50 Focus 3/2007 G401818en

9 6
8
7
5
9
E51913
5 Parking brake cable end connectors 8 Parking brake cable floor panel clips
6 Parking brake cable support hangers
See Removal Detail 9 Parking brake cables
7 Parking brake equalizer 8. Adjust the parking brake cable.
See Removal Detail
For additional information, refer to: Parking
Brake Cable Adjustment (206-05 Parking
Brake and Actuation, General Procedures).
2007.50 Focus 3/2007 G401818en

Removal Details
Item 1 Exhaust muffler and tailpipe assembly
Item 5 Parking brake cable end connectors
1.
CAUTION: Over bending of the exhaust 1. Detach the parking brake cable guide from
flexible pipe may cause damage resulting in the tie bar on both sides.
failure.
suitable support wrap or suitable splint.
TIE0000348
2. NOTE: The left-hand parking brake cable has

TIE0014991 a black sleeve and the right-hand parking
brake cable has a white sleeve. Note the
2. Detach the exhaust muffler and tailpipe color of the sleeves to aid installation.
assembly from the exhaust flexible pipe. Disconnect the parking brake cables.
• Discard the gasket and nuts.
51 Nm
TIE0000318
TIE40628
3. Pull the parking brake cable and guide

Item 2 Exhaust hanger insulators through the tie bar on both sides.
NOTE: Support the exhaust muffler and tailpipe
assembly. Item 6 Parking brake cable support hangers
1. NOTE: There are marks on the cable outer
to indicate the clip positions. Note the
position of the clips on the outer cable to aid
installation.
2007.50 Focus 3/2007 G401818en

Detach the parking brake cable from the Detach the parking brake cables from the
parking brake cable support hanger. bracket.
E51914 E52378
Item 7 Parking brake equalizer Item 8 Parking brake cable floor panel clips
1. Detach the parking brake cables from the 1. Detach the parking brake cables from the
parking brake equalizer. floor panel on both sides.
• Turn the cable through 90 degrees. • Release the cables from the clips.
TIE0000346 TIE0031402

a black sleeve and the right-hand parking
color of the sleeves to aid installation.
Item 8 Parking brake cable floor panel clips
Item 2 Exhaust hanger insulators
NOTE: Check the parking brake cable floor panel
clips for damage and fatigue. Install new parking NOTE: Check the exhaust hanger insulators for
brake cable floor panel clips as required. damage and fatigue. Install new exhaust hanger
insulators as required, using a suitable lubricant.
Item 6 Parking brake cable support hangers
NOTE: Check the parking brake cable support
hangers for damage and fatigue. Install new NOTE: Install a new exhaust flexible pipe gasket
parking brake cable support hangers as required. and nuts.
2007.50 Focus 3/2007 G401818en

Parking Brake Cable — Vehicles With: Rear Disc Brakes

3. Remove the air deflector on both sides.
Materials
Name Specification
Lubricant ESE-M99B144-B
information, refer to Section 100-02 [Jacking
and Lifting].
TIE44528

table(s).
1 2
TIE40387
2007.50 Focus 3/2007 G296186en


1 Exhaust muffler and tailpipe assembly See Removal Detail
3 Exhaust system heat shield center section
2 Exhaust hanger insulators
4 Exhaust system heat shield front section
7
10
9
8
5
10
TIE40388
5 Brake caliper parking brake levers 7 Parking brake cable support brackets
See Removal Detail 8 Parking brake equalizer
6 Parking brake cable support clips
2007.50 Focus 3/2007 G296186en

9 Parking brake cable floor panel clips 6. Adjust the parking brake cable.
For additional information, refer to Parking
10 Parking brake cables
Brake Cable Adjustment - in this section.
Removal Details
Item 5 Brake caliper parking brake levers
1.
CAUTION: Over bending of the exhaust 1. NOTE: The left-hand parking brake cable has
flexible pipe may cause damage resulting in a black sleeve and the right-hand parking
failure. brake cable has a white sleeve. Note the
Support the exhaust flexible pipe with a colour of the sleeves to aid installation.
suitable support wrap or suitable splint. Detach the parking brake cable from the
brake caliper parking brake lever on both
sides.
TIE0014991
TIE0032908
2. Detach the exhaust muffler and tailpipe
assembly from the exhaust flexible pipe.
• Discard the gasket and nuts. Item 8 Parking brake equalizer
a black sleeve and the right-hand parking
51 Nm
colour of the sleeves to aid installation.
Detach the parking brake cables from the
parking brake equalizer.
1. Detach the parking brake cables from the
bracket.
TIE40628

NOTE: Support the exhaust muffler and tailpipe
assembly.
2007.50 Focus 3/2007 G296186en

2. Detach the parking brake cables from the
equalizer. 1
2
TIE44529
NOTE: Install a new exhaust flexible pipe gasket
and nuts.

NOTE: Check the exhaust hanger insulators for
damage and fatigue. Install new exhaust hanger
insulators as required, using a suitable lubricant.
2007.50 Focus 3/2007 G296186en

206-06-1 Hydraulic Brake Actuation 206-06-1
.
SECTION 206-06 Hydraulic Brake Actuation

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-06-2

Hydraulic Brake Actuation.................................................................................................. 206-06-3

Brake Pedal and Bracket — LHD....................................................................................... 206-06-4
Brake Master Cylinder — LHD........................................................................................... 206-06-8
Brake Fluid Reservoir......................................................................................................... 206-06-11
SPECIFICATIONS
Specification
Brake fluid - Super DOT4 ESD-M6C57-A
Brake master cylinder retaining nuts 25 18 -
Brake tube to brake master cylinder unions 15 11 -
Brake pedal bracket retaining bolts 23 17 -
Strut and spring assembly top mount brace retaining 32 24 -
bolts
nuts
2007.50 Focus 3/2007 G307382en

Hydraulic Brake Actuation

2007.50 Focus 3/2007 G17506en

Brake Pedal and Bracket — LHD

table(s).
1. Remove the accelerator pedal.
Accelerator Pedal (310-02 Acceleration
Control, Removal and Installation).
1
E50883
Item Description
1 Instrument panel lower outer trim panel
See Removal Detail
2007.50 Focus 3/2007 G401819en

23 Nm 5
23 Nm 6
23 Nm 4
E50884
2 Brake pedal switches 5 Brake pedal and bracket retaining nut

See Removal Detail 6 Brake booster retaining nuts
7 Brake pedal and bracket
3 Brake booster actuating rod pin
See Removal Detail 3. To install, reverse the removal procedure.
4 Brake pedal and bracket retaining bolt
Removal Details
2007.50 Focus 3/2007 G401819en

Item 1 Instrument panel lower outer trim panel When removing the brake pedal switches,
1. Detach the diagnostic link connector (DLC) the BPP switch is rotated counterclockwise
from the instrument panel lower trim panel. and the stoplamp switch is rotated
clockwise. Failure to follow this instruction
may result in damage to the switches.
Remove the brake pedal switches.
1. BPP switch (colored blue and white).
2. Stoplamp switch (colored black).
TIE44539
1
Item 2 Brake pedal switches 2
1. Disconnect the electrical connectors.

1. Brake pedal position (BPP) switch. TIE42126
2. Stoplamp switch.
Item 3 Brake booster actuating rod pin
1 1. Detach the brake booster actuating rod from
the brake pedal.
1. Using a suitable cable tie, secure the locking
tangs in the depressed position.
2. Remove the brake booster actuating rod pin.
1
2
TIE42125
2. CAUTIONS:
Make sure that the brake pedal is kept in
the rest position and is not depressed or 2
moved during the removal of the brake pedal
switches. Failure to follow this instruction
TIE0038397
Item 2 Brake pedal switches switches. Failure to follow this instruction
may result in damage to the switches and
1. CAUTIONS:
engine system failures.
the rest position and is not depressed or When installing the brake pedal switches,
moved during installation of the brake pedal the BPP switch is rotated clockwise and the
stoplamp switch is rotated counterclockwise.
2007.50 Focus 3/2007 G401819en

Failure to follow this instruction will result
in the switch plunger binding inside the
switches.
Make sure the brake pedal switches are
correctly installed.
NOTE: To prevent damage to the engine
management system, the BPP switch must be
installed before the stoplamp switch.
NOTE: The BPP switch and the stoplamp switch
are automatically adjusted during installation.
Install the brake pedal switches.
2
E42127
2. Connect the electrical connectors.

1. BPP switch.
2. Stoplamp switch.
2
TIE42125
3. NOTE: When the brake pedal switches are

synchronized, the stoplamp switch status is
changed before the BPP switch status.
Depress the brake pedal and check for
correct synchronization of the brake pedal
switches using WDS.
• If the synchronization is incorrect, remove
the brake pedal switches and repeat the
brake pedal switches installation.
2007.50 Focus 3/2007 G401819en

Brake Master Cylinder — LHD

4. Tighten the bleed nipple.
Materials
Name Specification
2 4
Brake Fluid - Super ESD-M6C57-A 3
DOT4
immediately washed down with cold water. 1
1.
CAUTION: The brake fluid reservoir
extension cap must not become
contaminated. E0007637
Remove the brake fluid reservoir extension

cap. 3. Install the brake fluid reservoir extension
cap.
4. Remove the battery tray.
For additional information, refer to: Battery
Tray - 2.0L Duratec-HE (MI4)/1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma)/1.8L Duratec-HE (MI4) (414-01
Battery, Mounting and Cables, Removal
and Installation)
/ Battery Tray - 1.6L Duratorq-TDCi (DV)
Diesel/1.8L Duratorq-TDCi (Lynx)
Diesel/2.0L Duratorq-TDCi (DW) Diesel
E40614 (414-01 Battery, Mounting and Cables,
2. NOTE: It will be necessary to carry out this 5. Detach the brake fluid reservoir extension
step on both sides in order to completely from the bulkhead extension panel.
drain the brake reservoir.
Drain the brake fluid reservoir.
1. Connect one end of a suitable piece of clear
plastic pipe to the bleed nipple and place the
other end into a suitable container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all the brake
fluid is drained from the brake fluid reservoir.
TIE40615

table(s).
2007.50 Focus 3/2007 G401821en

4 15 Nm
6 2
25 Nm 5
TIE40738
1 Brake fluid reservoir extension 5 Brake master cylinder retaining nuts

See Removal Detail 6 Brake master cylinder
2 Clutch master cylinder supply line See Installation Detail
See Removal Detail
3 Low brake fluid warning indicator switch 8. Bleed the brake system.
electrical connector
4 Brake tubes System Bleeding (206-00 Brake System -
See Removal Detail General Information, General Procedures)
/ Brake System Pressure Bleeding (206-00
Brake System - General Information,
Removal Details
Item 1 Brake fluid reservoir extension
Item 2 Clutch master cylinder supply line
CAUTION: Cap the brake fluid reservoir
connections to prevent fluid loss or dirt 1.
CAUTION: Cap the clutch master cylinder
ingress. supply line to prevent fluid loss or dirt
ingress.
Disconnect the clutch master cylinder supply
line from the brake fluid main reservoir.
2007.50 Focus 3/2007 G401821en

Item 4 Brake tubes fluid loss or dirt ingress.
1. Disconnect the brake tubes from the brake
CAUTION: Cap the brake tubes to prevent
master cylinder.
Item 6 Brake master cylinder
CAUTION: Make sure the brake master
cylinder vacuum seal is correctly
positioned before installation.
2007.50 Focus 3/2007 G401821en

Brake Fluid Reservoir

Materials
Name Specification 4. Tighten the bleed nipple.
Brake Fluid - Super ESD-M6C57-A
DOT4 2 4
3
1.
CAUTION: The brake fluid reservoir
extension cap must not become 1
contaminated.
Remove the brake fluid reservoir extension
cap. E0007637
3. Install the brake fluid reservoir extension

cap.
4. Remove the brake fluid reservoir extension.
• Disconnect the feed hose coupling from the
master cylinder.
E40614
2. NOTE: It will be necessary to carry out this

step on both sides in order to completely
drain the brake fluid reservoir.
Drain the brake fluid reservoir. E48998

other end into a suitable container. 5. Remove the components in the order
2. Loosen the bleed nipple. indicated in the following illustration(s) and
table(s).
2007.50 Focus 3/2007 G401823en

TIE40737

1 Clutch master cylinder supply line 7. Bleed the brake system.
See Removal Detail For additional information, refer to: Brake
2 Low brake fluid warning indicator switch System Bleeding (206-00 Brake System -
electrical connector General Information, General Procedures)
/ Brake System Pressure Bleeding (206-00
3 Brake fluid main reservoir retaining pin Brake System - General Information,
4 Brake fluid main reservoir General Procedures).
See Removal Detail
Removal Details
Item 1 Clutch master cylinder supply line
1.
CAUTION: Cap the clutch master cylinder
supply line to prevent fluid loss or dirt
ingress.
Disconnect the clutch master cylinder supply
line from the brake fluid main reservoir.
Item 4 Brake fluid main reservoir

CAUTION: Cap the brake fluid reservoir
hose connections to prevent fluid loss or
dirt ingress.
2007.50 Focus 3/2007 G401823en

206-07-1 Power Brake Actuation 206-07-1
.
SECTION 206-07 Power Brake Actuation

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-07-2

Power Brake System.......................................................................................................... 206-07-3

Brake Booster — LHD........................................................................................................ 206-07-4
SPECIFICATIONS
Specification
Brake fluid - Super DOT4 ESD-M6C57-A
Brake master cylinder to brake booster retaining 25 18 -
nuts
Brake booster retaining nuts 23 17 -
Brake tubes to hydraulic control unit (HCU) unions 18 13 -
Brake vacuum pump retaining bolts - Vehicles with 18 13 -
1.6L diesel engine
Brake vacuum pump retaining bolts - Vehicles with 22 16 -
2.0L diesel engine
Brake vacuum pump retaining nut - Vehicles with 22 16 -
2.0L diesel engine
bolts
nuts
Exhaust gas recirculation (EGR) valve tube support 10 7 -
bracket retaining bolt
Fuel filter line bracket retaining nut 10 7 -
Fuel filter shield retaining bolts 6 - 53
Refrigerant line connectors 9 - 80
2007.50 Focus 3/2007 G307384en

Power Brake System

2007.50 Focus 3/2007 G17519en

Brake Booster — LHD

General Equipment
3. Disconnect the brake vacuum pipe from the
Worldwide Diagnostic System (WDS) the brake booster.
1. Remove the brake master cylinder.
Master Cylinder - LHD (206-06 Hydraulic
Brake Actuation, Removal and Installation).
2. Remove the brake master cylinder to
hydraulic control unit (HCU) brake tubes.
TIE0038392

table(s).
18 Nm
TIE44945
1
E50883
2007.50 Focus 3/2007 G401824en


1 Instrument panel lower outer trim panel See Removal Detail
23 Nm 4
E51569
2 Brake pedal switches 4 Brake booster retaining nuts

See Removal Detail 5 Brake booster
3 Brake booster actuating rod pin See Installation Detail
See Removal Detail
2007.50 Focus 3/2007 G401824en

6. Bleed the brake system. For additional Procedures),
information, refer to: (206-00 Brake System Brake System Pressure Bleeding (General
- General Information) Procedures).
Brake System Bleeding (General
Removal Details
Item 1 Instrument panel lower outer trim panel When removing the brake pedal switches,
1. Detach the diagnostic link connector (DLC) the BPP switch is rotated counterclockwise
from the instrument panel lower trim panel. and the stoplamp switch is rotated
clockwise. Failure to follow this instruction
Remove the brake pedal switches.
TIE44539
1
Item 2 Brake pedal switches 2

1. Brake pedal position (BPP) switch. TIE42126
2. Stoplamp switch.
1 1. Detach the brake booster actuating rod from
the brake pedal.
1. Using a suitable cable tie, secure the locking
tangs in the depressed position.
2. Remove and discard the brake booster
actuating rod pin.
2 1
TIE42125
2. CAUTIONS:
the rest position and is not depressed or
moved during the removal of the brake pedal 2
switches. Failure to follow this instruction
TIE0038397
2007.50 Focus 3/2007 G401824en

Item 5 Brake booster NOTE: Remove and discard the brake booster
gasket.
CAUTION: Make sure that any tubes are
clear from the front of the brake booster.
Item 5 Brake booster 2. Stoplamp switch (colored black).
CAUTION: Make sure that the brake
booster gasket is correctly positioned on
the brake booster before installation. 1
NOTE: Install a new brake booster gasket.

NOTE: Install a new brake booster actuating rod
pin.
2
Item 2 Brake pedal switches
E42127
1. CAUTIONS:
Make sure that the brake pedal is kept in 2. Connect the electrical connectors.
the rest position and is not depressed or
moved during installation of the brake pedal 1. BPP switch.
switches. Failure to follow this instruction 2. Stoplamp switch.
may result in damage to the switches and
engine system failures.
1
When installing the brake pedal switches,
the BPP switch is rotated clockwise and the
stoplamp switch is rotated counterclockwise.
Failure to follow this instruction will result
in the switch plunger binding inside the
switches.
Make sure the brake pedal switches are
correctly installed. 2
TIE42125
NOTE: To prevent damage to the engine
management system, the BPP switch must be
installed before the stoplamp switch. 3. NOTE: When the brake pedal switches are
synchronized, the stoplamp switch status is
NOTE: The BPP switch and the stoplamp switch changed before the BPP switch status.
are automatically adjusted during installation.
Depress the brake pedal and check for
Install the brake pedal switches. correct synchronization of the brake pedal
1. BPP switch (colored blue and white). switches using WDS.
• If the synchronization is incorrect, remove
the brake pedal switches and repeat the
brake pedal switches installation.
2007.50 Focus 3/2007 G401824en

206-09A-1 Anti-Lock Control 206-09A-1
.
SECTION 206-09A Anti-Lock Control

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-09A-2

Anti-Lock Control................................................................................................................ 206-09A-3
Inspection and Verification.................................................................................................. 206-09A-3

Hydraulic Control Unit (HCU)............................................................................................. 206-09A-4
Rear Wheel Speed Sensor................................................................................................. 206-09A-9
Anti-Lock Brake System (ABS) Module.............................................................................. 206-09A-11
SPECIFICATIONS
Specificat
ions
Super DOT 4 brake fluid ESD-
M6C57-A
Hydraulic control unit (HCU) and anti-lock brake 9 - 80
system (ABS) module assembly to support bracket
retaining bolts
HCU and ABS module assembly support bracket 9 - 80
retaining bolt
ABS module to HCU retaining bolts 2 - 18
Brake tube to HCU unions 18 13 -
Brake tube in-line connector unions 18 13 -
Wheel speed sensor retaining bolts 5 - 44
bolts
nuts
Windshield wiper arms retaining nuts 15 11 -
2007.50 Focus 3/2007 G307385en

Anti-Lock Control
Refer to Wiring Diagrams Section 206-09A, for
schematic and connector information.
General Equipment
Worldwide diagnostic system (WDS)

2. Visually inspect for obvious signs of mechanical
Mechanical Electrical
• Wheel speed • Fuse(s)
sensor(s) • Electrical
• Wheel speed sensor connector(s)
ring(s) • Wiring harness(s).

4. If the cause is not visually evident, connect the
diagnostic tool to the data link connector and
select the vehicle to be tested from the
diagnostic tool menu.
2007.50 Focus 3/2007 G325340en

Hydraulic Control Unit (HCU)

Materials 3. Install the brake fluid reservoir cap.
Name Specification 4. Remove the battery tray.
Brake Fluid - Super ESD-M6C57-A For additional information, refer to: Battery
DOT4 Tray - 2.0L Duratec-HE (MI4)/1.4L
CAUTION: If brake fluid is spilt on the (Sigma)/1.8L Duratec-HE (MI4) (414-01
paintwork, the affected area must be Battery, Mounting and Cables, Removal
immediately washed down with cold water. and Installation)
1. / Battery Tray - 1.6L Duratorq-TDCi (DV)
CAUTION: The brake fluid reservoir cap Diesel/1.8L Duratorq-TDCi (Lynx)
must not become contaminated. Diesel/2.0L Duratorq-TDCi (DW) Diesel
Remove the brake fluid reservoir cap. (414-01 Battery, Mounting and Cables,
5.
CAUTION: Cap the anti-lock brake system
(ABS) module electrical connector and
socket to prevent dirt and fluid ingress.
Disconnect the ABS module electrical
connector.
1. Depress the locking tangs.
2. Release the retainer.
E40614
1 1

step on both sides in order to completely 2
other end into a suitable container. E0038475
3. Depress the brake pedal until all the brake 6. Remove the components in the order
fluid is drained from the brake fluid reservoir. indicated in the following illustration(s) and
4. Tighten the bleed nipple. table(s).
2 4
3
E0007637
2007.50 Focus 3/2007 G401826en

18 Nm 1
18 Nm 2
18 Nm 3
9 Nm 4
TIE40585
1 Hydraulic control unit (HCU) to brake 3 HCU to rear brake tubes

master cylinder brake tubes See Removal Detail
See Installation Detail 4 HCU and ABS module assembly support
2 HCU to front brake tubes bracket retaining bolt
See Removal Detail 5 HCU and ABS module assembly
2007.50 Focus 3/2007 G401826en

2 Nm 7
9 Nm 6
E40588

6 HCU and ABS module assembly to 8. Bleed the brake system.
support bracket retaining bolts For additional information, refer to: Brake
7 ABS module to HCU retaining bolts System Bleeding (206-00 Brake System -
8 HCU / Brake System Pressure Bleeding (206-00
See Installation Detail General Procedures).
Removal Details
2007.50 Focus 3/2007 G401826en

Item 1 Hydraulic control unit (HCU) to brake Remove the HCU to right-hand front caliper
master cylinder brake tubes brake tube.
1. CAUTIONS:
Cap the brake tubes to prevent fluid loss
or dirt ingress.
Plug the HCU ports to prevent fluid loss

or dirt ingress. 18 Nm
NOTE: Make a note of the position of the brake
tubes, to aid installation.
Disconnect the brake tubes from the HCU.
• Detach the tubes from the securing clips. E50800
2. Remove the HCU to master cylinder brake
tubes. Item 3 HCU to rear brake tubes
1. CAUTIONS:
or dirt ingress.

15 Nm or dirt ingress.
TIE0038767 • Detach the tubes from the securing clips.
2.
Item 2 HCU to front brake tubes fluid loss or dirt ingress.
1. CAUTIONS: Remove the HCU to rear brake tubes.
or dirt ingress.

or dirt ingress.
18 Nm
2.
E50801
Item 8 HCU
WARNING: Do not touch the HCU or ABS
module contact points as this may affect
the brake system operation. Failure to
follow this instruction may result in
personal injury.
2007.50 Focus 3/2007 G401826en

CAUTION: Plug the ABS module ports to prevent dirt ingress.
Item 8 HCU
Item 1 Hydraulic control unit (HCU) to brake
WARNINGS: master cylinder brake tubes
Do not install a damaged HCU. Failure to CAUTION: Do not remove the brake tube
follow this instruction may result in blanking caps or HCU port blanking plugs
personal injury. until the brake tubes are ready to be
installed.
Make sure that the HCU is correctly located
on the ABS module. Failure to follow this
CAUTIONS:
Do not drop or knock the HCU. Failure to
follow this instruction will cause damage
to the hydraulic components.
Do not remove the ABS module port
blanking plugs until the HCU is ready to
be installed.
Item 5 HCU and ABS module assembly

WARNING: Do not install a damaged HCU
and ABS module assembly. Failure to
personal injury.
CAUTION: Do not drop or knock the HCU
to the electronic and hydraulic
components.
Item 3 HCU to rear brake tubes

CAUTION: Do not remove the brake tube
blanking caps or HCU port blanking plugs
until the brake tubes are ready to be
installed.
Item 2 HCU to front brake tubes

installed.
2007.50 Focus 3/2007 G401826en

Rear Wheel Speed Sensor

Clean the wheel speed sensor, wheel speed
sensor electrical connector and the area
around the wheel speed sensor.
and Tires].
2.
CAUTION: Make sure that the wheel indicated in the following illustration(s) and
speed sensor, wheel speed sensor electrical table(s).
connector and the area around the wheel
speed sensor are free from contamination
and moisture.
4 1
3 5 Nm 2
TIE40587
1 Wheel speed sensor electrical connector 3 Wheel speed sensor

2 Wheel speed sensor retaining bolt 4 Wheel speed sensor O-ring

See Removal Detail
Removal Details
Item 1 Wheel speed sensor electrical connector
1. Disconnect the wheel speed sensor electrical
connector.
2007.50 Focus 3/2007 G296210en

Item 4 Wheel speed sensor O-ring 3.
CAUTION: Plug the wheel speed sensor
1. Using a suitable lint-free cloth, clean the housing to prevent dirt ingress.
wheel speed sensor O-ring sealing groove. Plug the wheel speed sensor housing.
2. Using a suitable lint-free cloth, clean the
wheel speed sensor retaining bolt housing.
Item 4 Wheel speed sensor O-ring Position the wheel speed sensor.
1. CAUTIONS:
Make sure that the wheel speed sensor
housing is free from contamination and
moisture.
Make sure that the wheel speed sensor

O-ring is correctly seated.
Do not install the wheel speed sensor
O-ring onto the wheel speed sensor.
Install the wheel speed sensor O-ring.
TIE42907
2. NOTE: A resistance should only be detected

during the final 2 mm of installation of the
wheel speed sensor.
Install the wheel speed sensor.
TIE42906
Item 3 Wheel speed sensor

CAUTIONS:
Make sure that the wheel speed sensor is
correctly seated. TIE42908
Do not rotate the wheel speed sensor

during installation.
1.
CAUTION: Make sure that the wheel
speed sensor is correctly aligned with the
wheel speed sensor housing.
2007.50 Focus 3/2007 G296210en

Anti-Lock Brake System (ABS) Module

Materials 3. Install the brake fluid reservoir cap.
Name Specification 4. Remove the battery tray.
Brake Fluid - Super ESD-M6C57-A For additional information, refer to: Battery
DOT4 Tray - 2.0L Duratec-HE (MI4)/1.4L
CAUTION: If brake fluid is spilt on the (Sigma)/1.8L Duratec-HE (MI4) (414-01
paintwork, the affected area must be Battery, Mounting and Cables, Removal
immediately washed down with cold water. and Installation)
5.
(ABS) module electrical connector and
socket to prevent dirt and fluid ingress.
Disconnect the ABS module electrical
connector.
1. Depress the locking tangs.
E40614
1 1

step on both sides in order to completely 2
other end into a suitable container. E0038475
3. Depress the brake pedal until all the brake 6. Remove the components in the order
fluid is drained from the brake fluid reservoir. indicated in the following illustration(s) and
4. Tighten the bleed nipple. table(s).
2 4
3
E0007637
2007.50 Focus 3/2007 G401827en

18 Nm 1
18 Nm 2
18 Nm 3
9 Nm 4
TIE40585

2007.50 Focus 3/2007 G401827en

2 Nm 7
9 Nm 6
E40586

7 ABS module to HCU retaining bolts System Bleeding (206-00 Brake System -
8 ABS module / Brake System Pressure Bleeding (206-00
See Installation Detail General Procedures).
Removal Details
2007.50 Focus 3/2007 G401827en

1. CAUTIONS:
or dirt ingress.

1. CAUTIONS:
or dirt ingress.

2.
or dirt ingress.

or dirt ingress.
18 Nm
2.
E50801
Item 8 ABS module

module contact points as this may affect
the brake system operation. Failure to
personal injury.
2007.50 Focus 3/2007 G401827en

CAUTION: Plug the ABS module ports to prevent dirt ingress.
Item 8 ABS module
Do not install a damaged ABS module. CAUTION: Do not remove the brake tube
Failure to follow this instruction may result blanking caps or HCU port blanking plugs
in personal injury. until the brake tubes are ready to be
installed.
Make sure that the ABS module is correctly
located on the HCU. Failure to follow this
CAUTIONS:
Do not drop or knock the ABS module.
damage to the electronic components.
blanking plugs until the ABS module is
ready to be installed.

personal injury.
components.

installed.

installed.
2007.50 Focus 3/2007 G401827en

206-09B-1 Anti-Lock Control - Traction Control 206-09B-1
.
SECTION 206-09B Anti-Lock Control - Traction Control

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-09B-2

Anti-Lock Control - Traction Control................................................................................... 206-09B-3

Hydraulic Control Unit (HCU)............................................................................................. 206-09B-4
Rear Wheel Speed Sensor............................................................................. (12 785 0) 206-09B-9
Anti-Lock Brake System (ABS) Module.............................................................................. 206-09B-10
SPECIFICATIONS
Specificat
ions
M6C57-A
Hydraulic control unit (HCU) and anti-lock brake 9 - 80
system (ABS) module assembly to support bracket
retaining bolts
HCU and ABS module assembly support bracket 9 - 80
retaining bolt
ABS module to HCU retaining bolts 5.5 - 49
2007.50 Focus 3/2007 G307386en

Anti-Lock Control - Traction Control

REFER to Section 206-09A [Anti-Lock Control] /
206-09B [Anti-Lock Control - Traction Control] /
206-09C [Anti-Lock Control - Stability Assist].
2007.50 Focus 3/2007 G17539en


and Installation)
1. Diesel/1.8L Duratorq-TDCi (Lynx)
CAUTION: The brake fluid reservoir cap
(414-01 Battery, Mounting and Cables,
Remove the brake fluid reservoir cap. Removal and Installation)
2. NOTE: It will be necessary to carry out this / Battery Tray - 1.6L (Z6) (414-01 Battery,
step on both sides in order to completely Mounting and Cables, Removal and
drain the brake fluid reservoir. Installation).
Drain the brake fluid reservoir. 5.
1. Connect one end of a suitable piece of clear (ABS) module electrical connector and
plastic pipe to the bleed nipple and place the socket to prevent dirt and fluid ingress.
other end into a suitable container. Disconnect the anti-lock brake system (ABS)
2. Loosen the bleed nipple. module electrical connector.
3. Depress the brake pedal until all the brake 1. Depress the locking tangs.
2 4 1 1
3
E0038475
E0007637

3. Install the brake fluid reservoir cap. indicated in the following illustration(s) and
4. Remove the battery tray. table(s).
2007.50 Focus 3/2007 G384572en

18 Nm 1
18 Nm 2
18 Nm 3
9 Nm 4
TIE40585

2007.50 Focus 3/2007 G384572en

7 5.5 Nm
9 Nm 6
E44131

7 ABS module to HCU retaining bolts System Pressure Bleeding (206-00 Brake
8 HCU Procedures)
See Removal Detail / Brake System Pressure Bleeding (206-00
See Installation Detail Brake System - General Information,
2007.50 Focus 3/2007 G384572en

Removal Details
1. CAUTIONS:
or dirt ingress.

1. CAUTIONS:
or dirt ingress.

2.
or dirt ingress.

or dirt ingress.
18 Nm
2.
E50801
2007.50 Focus 3/2007 G384572en

Item 8 HCU this instruction may result in personal
injury.
module contact points as this may affect CAUTION: Plug the ABS module ports to
the electronic program. Failure to follow prevent fluid loss or dirt ingress.
Item 8 HCU
installed.
on the ABS module. Failure to follow this
CAUTIONS:
blanking plugs until the HCU is ready to
be installed.

personal injury.
components.

installed.

installed.
2007.50 Focus 3/2007 G384572en

Rear Wheel Speed Sensor(12 785 0)

Removal
1. For additional information, refer to
Stability Assist].
2007.50 Focus 3/2007 G17542en

Anti-Lock Brake System (ABS) Module

and Installation)
1. Diesel/1.8L Duratorq-TDCi (Lynx)
CAUTION: The brake fluid reservoir cap
Remove the brake fluid reservoir cap. Removal and Installation)
2. NOTE: It will be necessary to carry out this / Battery Tray - 1.6L (Z6) (414-01 Battery,
step on both sides in order to completely Mounting and Cables, Removal and
drain the brake fluid reservoir. Installation).
Drain the brake fluid reservoir. 5.
1. Connect one end of a suitable piece of clear (ABS) module electrical connector and
plastic pipe to the bleed nipple and place the socket to prevent dirt and fluid ingress.
other end into a suitable container. Disconnect the anti-lock brake system (ABS)
2. Loosen the bleed nipple. module electrical connector.
3. Depress the brake pedal until all the brake 1. Depress the locking tangs.
2 4 1 1
3
E0038475
E0007637

3. Install the brake fluid reservoir cap. indicated in the following illustration(s) and
4. Remove the battery tray. table(s).
2007.50 Focus 3/2007 G384577en

18 Nm 1
18 Nm 2
18 Nm 3
9 Nm 4
TIE40585

2007.50 Focus 3/2007 G384577en

7 5.5 Nm
9 Nm 6
E44131

7 ABS module to HCU retaining bolts System Pressure Bleeding (206-00 Brake
8 ABS module Procedures)
See Removal Detail / Brake System Pressure Bleeding (206-00
See Installation Detail Brake System - General Information,
2007.50 Focus 3/2007 G384577en

Removal Details
1. CAUTIONS:
or dirt ingress.

1. CAUTIONS:
or dirt ingress.

2.
or dirt ingress.

or dirt ingress.
18 Nm
2.
E50801
2007.50 Focus 3/2007 G384577en

Item 8 ABS module this instruction may result in personal
injury.
module contact points as this may affect CAUTION: Plug the ABS module ports to
the electronic program. Failure to follow prevent fluid loss or dirt ingress.
Item 8 ABS module
Do not install a damaged ABS module. CAUTION: Do not remove the brake tube
Failure to follow this instruction may result blanking caps or HCU port blanking plugs
in personal injury. until the brake tubes are ready to be
installed.
Make sure that the ABS module is correctly
located on the HCU. Failure to follow this
CAUTIONS:
Do not remove the HCU port blanking
plugs until the ABS module is ready to be
installed.

personal injury.
components.

installed.

installed.
2007.50 Focus 3/2007 G384577en

206-09C-1 Anti-Lock Control - Stability Assist 206-09C-1
.
SECTION 206-09C Anti-Lock Control - Stability Assist

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 206-09C-2

Anti-Lock Control - Stability Assist...................................................................................... 206-09C-3
Anti-lock Brake System (ABS) and Emergency Brake Assist (EBA).................................. 206-09C-3
ABS module.................................................................................................................... 206-09C-3

Anti-Lock Control - Stability Assist...................................................................................... 206-09C-5

Hydraulic Control Unit (HCU)............................................................................................. 206-09C-6
Stability Assist Module........................................................................................................ 206-09C-11
Rear Wheel Speed Sensor............................................................................. (12 785 0) 206-09C-16
Steering Wheel Rotation Sensor........................................................................................ 206-09C-17
Yaw Rate Sensor and Accelerometer................................................................................. 206-09C-22
SPECIFICATIONS
Specificat
ions
M6C57-A
Hydraulic control unit (HCU) and stability assist 9 - 80
module assembly to support bracket retaining bolts
HCU and stability assist module assembly support 9 - 80
bracket retaining bolt
Stability assist module to HCU retaining bolts 5.5 - 49
Yaw rate sensor bracket retaining bolts 9 - 80
Yaw rate sensor retaining nuts 4 - 35
Wheel speed sensor retaining bolts 5 - 44
Steering wheel retaining bolt 48 35 -
bolts
nuts
Windshield wiper arms retaining nuts 15 11 -
2007.50 Focus 3/2007 G307387en

Anti-Lock Control - Stability Assist
Anti-lock Brake System (ABS) and Emergency Brake Assist (EBA)
ABS module
E40965
The ABS module is attached to the bulkhead on

the left-hand side for all vehicle markets.
Modules pre-filled with brake fluid are available for
service operations.
Diagnosis is done using WDS.
2007.50 Focus 3/2007 G181238en

Communication with other control units is done on Active sensors are used to determine the rotational
the high-speed CAN bus. The exception to this are speeds of the wheels at the hub. After the ignition
the yaw rate and lateral acceleration sensor is switched on, the ABS module supplies the
modules which communicate with the electronic sensors with power. The sensors work in
stability programme module via a special CAN bus. accordance with the Hall effect principle and
generate a square wave output signal. The signal
acts in proportion to the rotational speed of the
Combined yaw rate sensor and lateral sensor ring.
acceleration sensor The ABS sensor rings are built into the seals in the
front wheel bearings.
The wheel sensors are joined to the main wiring
harness using a separate connecting cable.
1
Rear wheel sensors
E40966
Item Description
1 Combined yaw rate sensor and lateral
acceleration sensor
The combined yaw rate sensor and lateral
E42468
acceleration sensor is similar to that on vehicles
with the electronic stability programme. The sensor The ABS Anti-lock Brake System sensor rings are
is attached to the floor crossmember. Its operating built into the hubs of the rear axle.
principle is the same.
When installing a replacement bearing, ensure that
The combined yaw rate sensor and lateral the new part is aligned correctly.
acceleration sensor has its own CAN bus. As a
result, the signals can be transmitted to the The sensors are joined to the main wiring harness
electronic stability programme module in a specific using a separate connecting cable.
way. The ABS module evaluates the signals from all
four sensors to calculate road speed based on all
wheel rotational speeds. The road speed is
Front wheel sensors transmitted on the CAN bus. The powertrain control
module (PCM) uses this signal and the
programmed tyre size to calculate road speed.
The calculated vehicle speed is forwarded on the
CAN bus and is requested by other control units
that need this input information.
E42467
2007.50 Focus 3/2007 G181238en

Anti-Lock Control - Stability Assist

REFER to Section 206-09A [Anti-Lock Control] /
206-09B [Anti-Lock Control - Traction Control] /
206-09C [Anti-Lock Control - Stability Assist].
2007.50 Focus 3/2007 G37415en


General Equipment 4. Install the brake fluid reservoir cap.
Worldwide diagnostic system (WDS) 5. Remove the battery tray.
CAUTION: If brake fluid is spilt on the For additional information, refer to: Battery
paintwork, the affected area must be Tray - 2.0L Duratec-HE (MI4)/1.4L
immediately washed down with cold water. Duratec-16V (Sigma)/1.6L Duratec-16V
1. Obtain and record the stability assist Battery, Mounting and Cables, Removal
program code using WDS. and Installation)
step on both sides in order to completely 6.
CAUTION: Cap the stability assist module
drain the brake fluid reservoir. electrical connector and socket to prevent
Drain the brake fluid reservoir. dirt and fluid ingress.
1. Connect one end of a suitable piece of clear Disconnect the stability assist module
plastic pipe to the bleed nipple and place the electrical connector.
other end into a suitable container. 1. Depress the locking tangs.
2. Loosen the bleed nipple. 2. Release the retainer.
1 1
2 4
3 2
1
E0038475

E0007637
table(s).
2007.50 Focus 3/2007 G401828en

18 Nm 1
18 Nm 2
18 Nm 3
9 Nm 4
TIE40585

See Installation Detail 4 HCU and stability assist module assembly
2 HCU to front brake tubes support bracket retaining bolt
See Removal Detail 5 HCU and stability assist module assembly
2007.50 Focus 3/2007 G401828en

7 5.5 Nm
9 Nm 6
E44131
9. Bleed the brake system.

Item Description
6 HCU and stability assist module assembly System Bleeding (206-00 Brake System -
to support bracket retaining bolts General Information, General Procedures)
7 Stability assist module to HCU retaining / Brake System Pressure Bleeding (206-00
bolts Brake System - General Information,
8 HCU
See Removal Detail 10.
WARNING: The stability assist program
See Installation Detail must be re-configured. Failure to follow this
Configure the stability assist program using
WDS.
2007.50 Focus 3/2007 G401828en

Removal Details
1. CAUTIONS:
or dirt ingress.

1. CAUTIONS:
or dirt ingress.

2.
or dirt ingress.

or dirt ingress.
18 Nm
2.
E50801
2007.50 Focus 3/2007 G401828en

Item 8 HCU Failure to follow this instruction may result
in personal injury.
WARNING: Do not touch the HCU or
stability assist module contact points as CAUTION: Plug the stability assist module
this may affect the electronic program. ports to prevent fluid loss or dirt ingress.
Item 8 HCU
installed.
on the stability assist module. Failure to
personal injury.
CAUTIONS:
Do not remove the stability assist module
port blanking plugs until the HCU is ready
to be installed.
Item 5 HCU and stability assist module

assembly
and stability assist module assembly.
in personal injury.
damage to the electronic and hydraulic
components.

installed.

installed.
2007.50 Focus 3/2007 G401828en

Stability Assist Module

General Equipment 4. Install the brake fluid reservoir cap.
Worldwide diagnostic system (WDS) 5. Remove the battery tray.
CAUTION: If brake fluid is spilt on the For additional information, refer to: Battery
paintwork, the affected area must be Tray - 2.0L Duratec-HE (MI4)/1.4L
immediately washed down with cold water. Duratec-16V (Sigma)/1.6L Duratec-16V
1. Obtain and record the stability assist Battery, Mounting and Cables, Removal
program code using WDS. and Installation)
step on both sides in order to completely 6.
CAUTION: Cap the stability assist module
drain the brake fluid reservoir. electrical connector and socket to prevent
Drain the brake fluid reservoir. dirt and fluid ingress.
1. Connect one end of a suitable piece of clear Disconnect the stability assist module
plastic pipe to the bleed nipple and place the electrical connector.
other end into a suitable container. 1. Depress the locking tangs.
2. Loosen the bleed nipple. 2. Release the retainer.
1 1
2 4
3 2
1
E0038475

E0007637
table(s).
2007.50 Focus 3/2007 G401829en

18 Nm 1
18 Nm 2
18 Nm 3
9 Nm 4
TIE40585

See Installation Detail 4 HCU and stability assist module assembly
2 HCU to front brake tubes support bracket retaining bolt
See Removal Detail 5 HCU and stability assist module assembly
2007.50 Focus 3/2007 G401829en

8
7 5.5 Nm
9 Nm 6
E44095
9. Bleed the brake system.

Item Description
6 HCU and stability assist module assembly System Bleeding (206-00 Brake System -
to support bracket retaining bolts General Information, General Procedures)
7 Stability assist module to HCU retaining / Brake System Pressure Bleeding (206-00
bolts Brake System - General Information,
8 Stability assist module
See Removal Detail 10.
WARNING: The stability assist program
See Installation Detail must be re-configured. Failure to follow this
Configure the stability assist program using
WDS.
2007.50 Focus 3/2007 G401829en

Removal Details
1. CAUTIONS:
or dirt ingress.

1. CAUTIONS:
or dirt ingress.

2.
or dirt ingress.

or dirt ingress.
18 Nm
2.
E50801
2007.50 Focus 3/2007 G401829en

Item 8 Stability assist module Failure to follow this instruction may result
in personal injury.
WARNING: Do not touch the HCU or
stability assist module contact points as CAUTION: Plug the stability assist module
this may affect the electronic program. ports to prevent fluid loss or dirt ingress.
Item 8 Stability assist module
Do not install a damaged stability assist CAUTION: Do not remove the brake tube
module. Failure to follow this instruction blanking caps or HCU port blanking plugs
may result in personal injury. until the brake tubes are ready to be
installed.
Make sure that the stability assist module
is correctly located on the HCU. Failure to
personal injury.
CAUTIONS:
Do not drop or knock the stability assist
module. Failure to follow this instruction
will cause damage to the electronic
components.
Do not remove the HCU port blanking
plugs until the stability assist module is
ready to be installed.
Item 5 HCU and stability assist module

assembly
in personal injury.
damage to the electronic and hydraulic
components.

installed.

installed.
2007.50 Focus 3/2007 G401829en

Rear Wheel Speed Sensor(12 785 0)

Removal
1. For additional information, refer to
Stability Assist].
2007.50 Focus 3/2007 G22967en

Steering Wheel Rotation Sensor

General Equipment 2. Remove the driver air bag module.
Worldwide diagnostic system (WDS) For additional information, refer to: Driver
Air Bag Module (501-20 Supplemental
WARNINGS: Restraint System, Removal and
Installation).
To avoid accidental deployment, the air
bag control module backup power supply 3. NOTE: Make sure the road wheels are in the
must be depleted. Wait at least one minute straight ahead position.
after disconnecting the battery ground Centralize the steering and lock it in position.
cable(s) before commencing any repair or
adjustment to the supplemental restraint
system (SRS), or any component(s)
adjacent to the SRS sensors. Failure to
follow these instructions may result in
personal injury.
To minimize the possibility of premature
deployment, do not use radio key code
savers when working on the supplemental
restraint system. Failure to follow this
Never probe the electrical connectors of TIE38836
air bag modules or any other supplemental
restraint system component. Failure to 4. Remove the components in the order
follow this instruction may result in indicated in the following illustration(s) and
personal injury. table(s).
1. Disconnect the battery ground cable.
Disconnect and Connect (414-01 Battery,
Mounting and Cables, General Procedures).
2007.50 Focus 3/2007 G325406en

3 48 Nm
7
6
TIE40324
1 Audio control switch (if equipped) 6 Clockspring electrical connector

See Removal Detail 7 Clockspring and steering wheel rotation
2 Steering column lower shroud sensor assembly
3 Steering wheel retaining bolt
4 Steering wheel All vehicles
See Removal Detail
5 Steering wheel rotation sensor electrical
connector
2007.50 Focus 3/2007 G325406en

6.
WARNING: The electronic stability
Vehicles with global closing
program must be re-configured. Failure to 7. Initialize the door window motors.
follow this instruction may result in personal For additional information, refer to: Door
injury. Window Motor Initialization (501-11 Glass,
Configure the electronic stability program Frames and Mechanisms, General
using WDS. Procedures).
Removal Details
Item 1 Audio control switch (if equipped)
Item 4 Steering wheel
1. Detach the audio control switch from the
steering column lower shroud. 1.
CAUTION: Make sure the clockspring
• Using a thin bladed screwdriver, release the rotor is not allowed to rotate.
locking tang. Using a suitable piece of tape, secure the
clockspring rotor to the clockspring outer
case.
TIE40358
TIE40357
2. Remove the audio control switch.
• Disconnect the electrical connector.
2. Disconnect the steering wheel switches
electrical connector (if equipped).
3.
CAUTION: Care must be taken not to
damage the clockspring pins.
Remove the steering wheel.
• Feed the driver air bag module wiring
harnesses through the steering wheel.
TIE40359
Item 2 Steering column lower shroud

1. Release the steering column locking lever
to aid the removal of the steering column
shroud.
E41065
2007.50 Focus 3/2007 G325406en

Item 7 Clockspring and steering wheel rotation • Release the locking tangs.
sensor assembly
1.
CAUTION: Make sure the clockspring to
steering wheel rotation sensor retaining clips
do not get damaged.
Remove the steering wheel rotation sensor.
TIE40360
Item 7 Clockspring and steering wheel rotation Install the clockspring and steering wheel
sensor assembly rotation sensor assembly.
1. CAUTIONS: 3. WARNINGS:
Do not remove the tape securing the If there is a break between installing the
clockspring at this stage. clockspring and steering wheel rotation
sensor assembly and installing the steering
Make sure the clockspring to steering wheel, or the vehicle is left unattended by
wheel rotation sensor retaining clips do not the technician, the centralizing procedure
get damaged. MUST be carried out. Failure to follow this
Install the steering wheel rotation sensor.
1. Align the steering wheel rotation sensor Incorrect centralization may result in
locating tangs to the clockspring. premature component failure. If in doubt
2. Make sure the retaining clips lock into when centralizing the clockspring, repeat the
position on the steering wheel rotation procedure. Failure to follow this instruction
sensor. may result in personal injury.
CAUTIONS:
1
Do not turn the clockspring and steering
2 wheel rotation sensor assembly in a
clockwise direction more than three turns.
Make sure the road wheels are in the
2 straight ahead position.
1 When carrying out the clockspring
centralizing procedure, the first turns must
be in the counterclockwise direction.
TIE40361 Centralize the clockspring.
1. Turn the clockspring and steering wheel
2. rotation sensor assembly in a
CAUTION: Make sure the road wheels are
in the straight ahead position. counterclockwise direction until a resistance
is felt.
NOTE: Make sure the turn signal lamp switch is in
the off position.
rotation sensor assembly in a clockwise
direction, until the arrow marked on the rotor
2007.50 Focus 3/2007 G325406en

of the clockspring aligns with the raised 'V' 1. Remove the tape securing the clockspring.
section on the outer cover of the clockspring
at the 195 degrees position.
rotation sensor assembly in a clockwise
direction three turns.
1 3
TIE40326
2
TIE40325
4. NOTE: When the clockspring is centralized,

the U-shaped part of the flat flexible cable
will be visible.
Check to see if the U-shaped part of the flat
flexible cable is visible.
• Secure the clockspring rotor to the
clockspring outer.
E40362

1.
CAUTION: Make sure the road wheels are
in the straight ahead position.
Install the steering wheel.
2007.50 Focus 3/2007 G325406en

Yaw Rate Sensor and Accelerometer

NOTE: The yaw rate sensor and accelerometer
cannot be separated. 5. Disconnect the yaw rate sensor and
accelerometer electrical connector and
1. Remove the right-hand front seat. position it to one side.
Seat (501-10 Seating, Removal and
Installation).
2. Remove the front scuff plate trim panel.
Scuff Plate Trim Panel (501-05 Interior Trim
and Ornamentation, Removal and
Installation).
3. Remove the B-pillar trim panel.
For additional information, refer to: B-Pillar
TIE40458
Trim Panel - 3-Door (501-05 Interior Trim
Installation). 6. Remove the components in the order
4. Locally detach the carpet from the floor panel indicated in the following illustration(s) and
and crossmember. table(s).
TIE0007802
2007.50 Focus 3/2007 G296219en

3 9 Nm
4 Nm 1
TIE40459
1 Yaw rate sensor and accelerometer 3 Yaw rate sensor and accelerometer
assembly bracket bolts assembly nuts
2 Yaw rate sensor and accelerometer 4 Yaw rate sensor and accelerometer
assembly bracket assembly
Item 4 Yaw rate sensor and accelerometer
assembly
WARNING: Make sure the yaw rate sensor
and accelerometer assembly is correctly
positioned. Failure to follow this
2007.50 Focus 3/2007 G296219en

211-00-1 Steering System - General Information 211-00-1
.
SECTION 211-00 Steering System - General

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 211-00-2
Steering Wheel Alignment.............................................................................................. 211-00-2
Specifications...................................................................................................................... 211-00-3
Steering Wheel Alignment.............................................................................................. 211-00-3

Steering System — 1.6L (Z6)............................................................................................. 211-00-4
Symptom Chart................................................................................................................... 211-00-4
Components Tests.............................................................................................................. 211-00-11
Steering System................................................................................................................. 211-00-14
Symptom Chart................................................................................................................... 211-00-14
Components Tests.............................................................................................................. 211-00-32
Steering Gear Checks After a Collision.............................................................................. 211-00-36
GENERAL PROCEDURES
Power Steering System Flushing — Vehicles With: Electro-Hydraulic Power
Steering (EHPS)........................................................................................... (13 001 0) 211-00-38
Power Steering System Bleeding — 1.6L (Z6)............................................... (13 416 1) 211-00-40
Power Steering System Bleeding — Vehicles With: Electro-Hydraulic Power
Steering (EHPS)........................................................................................... (13 416 1) 211-00-42
Power Steering System Filling — 1.6L (Z6)................................................... (13 002 0) 211-00-43
Power Steering System Filling — Vehicles With: Electro-Hydraulic Power
Steering (EHPS)........................................................................................... (13 002 0) 211-00-44
SPECIFICATIONS
Specifications
Grease SA-M1C9107-A
Hydraulic Fluid WSA-M2C195-A
Hydraulic Fluid WSS-M2C204-A2
Steering Wheel Alignment

Description Degrees
Maximum allowable steering wheel misalignment +/- 3.00
Turning Effort
Description Nm lb-in
Turning effort 8 71
2007.50 Focus 3/2007 G163364en

SPECIFICATIONS
Specifications
Hydraulic Fluid - vehicles with electrical hydraulic power steering WSA-M2C195-A
Power Steering Fluid - vehicles with hydraulic power steering 5M51-3F823-AA
Grease SA-M1C9107-A
Steering Wheel Alignment

Description Degrees
Maximum allowable steering wheel misalignment +/- 3.00
Turning Effort
Description Nm lb-in
Turning effort 8 71
2007.50 Focus 3/2007 G424518en

Steering System — 1.6L (Z6)

Special Tool(s) Visual Inspection Chart
Alignment Pins, Subframe Mechanical Electrical
205-316 (15-097A)
• Tire pressure(s) • Power steering pres-
• Accessory drive belt sure (PSP) switch
• Tie-rod ends
15097 • Tie-rod(s)
• Steering gear
housing
Simulator, Driver and
Passenger Air Bags and Side • Front strut and
Air Curtains spring assemblies
501-073 (40-016) • Front suspension
lower arm ball joints
501073 • Front suspension
lower arm bushings
• Pinch bolt on
steering column
Inspection and Verification shaft flexible coup-
ling
1. Verify the customer concern. • Wheels and tires
2. Visually inspect for obvious signs of mechanical • Power steering line
or electrical damage. fluid leaks
• Steering gear
bellows

4. If the cause is not visually evident, verify the
Symptom Chart
Symptom Chart
• Drift left or right • Vehicle attitude incorrect (front • CHECK for abnormal loading,
or rear is high or low). coil spring sag or non-standard
springs.
2007.50 Focus 3/2007 G424520en


• Incorrect wheel alignment. • CHECK the wheel alignment
and adjust if necessary.
REFER to: Specifications (204-
00 Suspension System -
General Information,
Specifications)
/ Front Toe Adjustment (204-00
Suspension System -
General Information, General
Procedures)
/ Rear Toe Adjustment (204-00
Suspension System -
Procedures).
• Incorrect front axle cross- • Using the special tool, CHECK
member alignment. the front axle crossmember
alignment.
• Damaged or worn front wheel • CHECK and INSTALL new
bearings. front wheel hubs as necessary.
and Installation).
Testing).
• Steering linkage. • CARRY OUT the steering
linkage component test.
REFER to Steering Linkage
Component Test.
• Steering gear. • CARRY OUT the steering
Component Test.
• Wheels and tires. • CHECK the wheels and tires.
REFER to: Wheels and Tires
• Steering wheel off center • Vehicle attitude incorrect (front • CHECK for abnormal loading,
springs.
2007.50 Focus 3/2007 G424520en


• Incorrect wheel alignment. • CHECK the wheel alignment.
Specifications)
Suspension System -
Procedures).
• Front suspension lower arm • REFER to: Suspension System
ball joint. (204-00 Suspension System
Component Test.
Component Test.
• Vibration • Incorrect wheel alignment. • CHECK the wheel alignment
and adjust if necessary.
Specifications)
Suspension System -
Procedures).
BALANCE or INSTALL new
wheels and tires as necessary.
bearings. front wheel hubs as necessary.
and Installation).
2007.50 Focus 3/2007 G424520en


• Front strut and spring assem- • CHECK and INSTALL new
blies. suspension components as
necessary.
REFER to: Suspension System
(204-00 Suspension System
necessary.
Component Test.
• Steering effort is high/low • Loose or worn accessory drive • CHECK the accessory drive
belt. belt.
REFER to: Accessory Drive
Belt - 1.6L (Z6) (303-05
Accessory Drive, Removal
and Installation).
• Power steering lines restriction. • CHECK the power steering
lines for damage, kinks or
restrictions. INSTALL new
REFER to: (211-02 Power
Steering)
Power Steering Pump to
Steering Gear Pressure Line
- 1.6L (Z6) (Removal and
Installation),
Steering Gear to Power
Steering Fluid Reservoir
Return Line - 1.6L (Z6)
• Power steering fluid aeration. • BLEED the power steering
system.
System Bleeding - 1.6L (Z6)
(211-00 Steering System -
Procedures).
2007.50 Focus 3/2007 G424520en


• Steering column. • CHECK if the floor covering is
obstructing the steering gear
pinion.
• CHECK the installation of the
floor seal.
• CARRY OUT the steering
column universal joint
component test. REFER to
Steering Column Universal
Joint Component Test.
Component Test.
Component Test.
• Worn power steering pump. • INSTALL a new power steering
pump.
Pump - 1.6L (Z6) (211-02
Power Steering, Removal
and Installation).
• Excessive noise • Power steering fluid aeration. • BLEED the power steering
system.
System Bleeding - 1.6L (Z6)
(211-00 Steering System -
Procedures).
• Power steering lines. • CHECK the power steering line
clamps are secure. REFER to:
(211-02 Power Steering)
- 1.6L (Z6) (Removal and
Installation),
Return Line - 1.6L (Z6)
• CHECK the steering gear
transfer lines for clearance from
the steering gear.
2007.50 Focus 3/2007 G424520en


• Steering gear bushings worn • CHECK and INSTALL new
or perished. components as necessary.
REFER to: Steering Gear - 3-
Door (211-02 Power
Steering, Removal and
Installation).
• Loose steering gear retaining • CHECK and INSTALL new
bolts. steering gear retaining bolts as
necessary.
Door (211-02 Power
Steering, Specifications).
• Worn power steering pump. • INSTALL a new power steering
pump.
Pump - 1.6L (Z6) (211-02
and Installation).
• Worn tie-rod. • CARRY OUT the Tie-Rod
component test. REFER to Tie-
Rod Component Test.
• Steering does not vary with • Worn tie-rod ends. • INSTALL new components as
increased wheel rotation necessary.
REFER to: Tie-Rod End - 1.6L
(Z6) (211-03 Steering
Linkage, Removal and
Installation).
• Worn front suspension bush- • CHECK and INSTALL new
ings. components as necessary.
• Worn front suspension lower • CARRY OUT the suspension
arm ball joints. ball joint inspection component
test.
REFER to: Steering Gear - 3-
Door (211-02 Power
Steering, Removal and
Installation).
2007.50 Focus 3/2007 G424520en


bolts. steering gear retaining bolts as
necessary.
Door (211-02 Power
• Loose steering column • CHECK and INSTALL new
retaining bolts. steering column retaining bolts
as necessary.
04 Steering Column,
Specifications).
• Loose steering column to • CHECK and INSTALL a new
steering gear pinion retaining steering column to steering
bolt. gear pinion retaining bolt as
necessary.
Door (211-02 Power
• Excessive steering gear back- • CARRY OUT the steering
lash. linkage component test.
Component Test.
• Engine stalls when parking with • PSP switch or circuit. • GO to Pinpoint Test A.
engine speed at idle
PINPOINT TEST A : ENGINE STALLS WHEN PARKING WITH ENGINE SPEED AT IDLE
NOTE: Use a digital multimeter for all electrical measurements.
A1: CHECK THE VOLTAGE TO THE PSP SWITCH

1 Disconnect PSP Switch C170.
3 Measure the voltage between the PSP switch
C170, circuit 7-CE6 (YE), harness side and
ground.
• Is the voltage greater than 10 volts?
→ Yes
INSTALL a new PSP switch.
→ No
GO to A2.
E53243
2007.50 Focus 3/2007 G424520en


A2: CHECK THE PSP SWITCH CIRCUIT FOR OPEN CIRCUIT OR HIGH RESISTANCE
1 Ignition switch in position 0.
2 Disconnect Powertrain Control Module (PCM)
C680.
3 Measure the resistance between the PCM C680
pin AC, circuit 7-CE6 (YE), harness side and
the PSP switch C170, circuit 7-CE6 (YE),
harness side.
• Is the resistances less than 5 ohms?
→ Yes
INSTALL a new PCM.
REFER to: Programmable Module Installation
(418-01 Module Configuration, General
E53244 Procedures).
→ No
REPAIR circuit 7-CE6 (YE).
Components Tests
Tie-Rod
Steering Linkage
CAUTION: The steering gear boots must
1. Grasp the steering wheel firmly and move it up be handled carefully to avoid damage. Use
and down and to the left and right without new steering gear boot clamps when
turning the steering wheel, to check for steering installing the steering gear boots.
column bearing wear, steering column universal NOTE: Noises such as knocks, which may appear
joint free play, steering wheel or steering column to originate from the steering linkage, may also be
looseness. The steering column cannot be generated by front suspension components.
repaired. Install a new steering column.
REFER to: Steering Column (211-04 Steering
Column, Removal and Installation). REFER to: Jacking (100-02 Jacking and Lifting,
Description and Operation)
2. With the road wheels in the straight ahead / Lifting (100-02 Jacking and Lifting, Description
position, gently turn the steering wheel to the and Operation).
left and the right to check free play in the
steering linkage.
3. There should be no excessive free play at the
steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test.
CHECK steering column universal joint, REFER
to Steering Column Universal Joint Component
Test. If there is no free play in the tie-rod and
the steering column, install a new steering gear.
REFER to: Steering Gear - 3-Door (211-02
Power Steering, Removal and Installation). TIE0005728
2007.50 Focus 3/2007 G424520en

2. Firmly grasp the road wheel and apply a rocking With the aid of another technician holding the
motion to check for any free play in the wheel steering against the left-hand steering lock stop,
bearing or suspension components. firmly grasp the left-hand road wheel and apply
a rocking motion to check for any free play in
the tie-rod.
TIE0005727
3. NOTE: To isolate the steering gear design E56375

clearance, check the right-hand tie-rod with
the steering held against the right-hand 8. Detach the steering gear boot from the steering
steering lock stop. gear body and check for free play at the tie-rod
inner ball joint.
With the aid of another technician holding the
steering against the right-hand steering lock 9. If there is free play at the tie-rod inner ball joint,
stop, firmly grasp the right-hand road wheel and install a new tie-rod.
apply a rocking motion to check for any free play REFER to: Tie-Rod - 1.6L (Z6) (211-03 Steering
in the tie-rod. Linkage, Removal and Installation).
10. If there is free play at the tie-rod end, install a
new tie-rod end.
REFER to: Tie-Rod End - 1.6L (Z6) (211-03
Steering Linkage, Removal and Installation).
Turning Effort Test
NOTE: Before carrying out this test, make sure

that the suspension components are serviceable.
TIE0005729 NOTE: Before carrying out this test, make sure
that the steering column is serviceable.
4. Detach the steering gear boot from the steering
gear body and check for free play at the tie-rod
that the front toe adjustment and tire pressures are
inner ball joint.
correct.
5. If there is free play at the tie-rod inner ball joint,
install a new tie-rod. 1. Park the vehicle on a dry, even surface and
apply the parking brake.
REFER to: Tie-Rod - 1.6L (Z6) (211-03 Steering
2. Remove the driver air bag module.
Linkage, Removal and Installation).
6. If there is free play at the tie-rod end, install a REFER to: Driver Air Bag Module (501-20B
new tie-rod end. Supplemental Restraint System, Removal and
Installation).
REFER to: Tie-Rod End - 1.6L (Z6) (211-03
3. Connect the air bag simulators to the
Steering Linkage, Removal and Installation).
sub-harnesses in place of the driver air bag
7. NOTE: To isolate the steering gear design module at the top of the steering column.
clearance, check the left-hand tie-rod with
the steering held against the left-hand
steering lock stop.
2007.50 Focus 3/2007 G424520en

4. Start the engine and turn the steering wheel 2. Articulate the free yoke in a figure of eight
from lock to lock several times until the power movement.
steering fluid has reached normal operating • If the movement is not smooth or resistance
temperature. is felt, renew the steering column.
5. Using a suitable torque wrench and socket, REFER to: Steering Column (211-04 Steering
check the steering wheel turning effort. Column, Removal and Installation).
6. If the steering wheel turning effort is greater than 3. Hold both of the steering column shaft universal
the specification, install a new steering gear. joint yokes and then twist them clockwise and
REFER to: Specifications (211-00 Steering counterclockwise.
System - General Information, Specifications) • If any movement is felt, install a new steering
/ Steering Gear - 3-Door (211-02 Power column.
Steering, Removal and Installation).
Column, Removal and Installation).
Steering Column Shaft Universal Joint
28 Nm
TIE0029884
1.
WARNING: Install a new steering column
shaft to steering gear pinion retaining bolt.
in personal injury.
Detach the steering column shaft from the
steering gear pinion.
• Discard the steering column shaft to steering
gear pinion retaining bolt.
2
TIE45919
2. Check for smooth movement of the steering

column shaft universal joint.
1. Hold the steering column shaft universal joint
yoke.
2007.50 Focus 3/2007 G424520en

Steering System
Alignment Pins, Subframe Mechanical Electrical
205-316 (15-097A)
• Tire pressure(s) • Battery
• Loose tie-rod end(s) • Battery cables
• Loose strut and • Steering angle
15097 spring assemblies or sensor electrical
ball joints connector
• Loose pinch bolts on • Power steering pump
Simulator, Driver and steering column control module elec-
Passenger Air Bags and Side shaft flexible coup- trical connectors
Air Curtains ling • Power steering pump
501-073 (40-016)
• Wheels and tires control module
• Power steering line ground cable
501073
fluid leaks • Power steering pump
• Steering gear control module
General Equipment bellows ground cable
retaining screw
• Steering angle
sensor warning
Inspection and Verification indicator
• Fuse(s)
2. Visually inspect for obvious signs of mechanical 3. If an obvious cause for an observed or reported
or electrical damage. concern is found, correct the cause (if possible)
Symptom Chart
Symptom Chart
• Drift left or right • Vehicle attitude incorrect (front • CHECK for abnormal loading,
springs.
and ADJUST if necessary.
Procedures).
• Incorrect front axle cross- • Using the special tool, CHECK
member alignment. the front axle crossmember
alignment.
2007.50 Focus 3/2007 G163366en


• Worn front wheel bearings. • CHECK and INSTALL new
wheel hubs as necessary.
and Installation).
Testing).
• Steering linkage. • CARRY OUT the Steering
Linkage Component Test.
Component Test in this
procedure.
• Steering gear. • CARRY OUT the Steering
procedure.
• Wheels and tires. • REFER to: Wheels and Tires
• Steering wheel off center • Vehicle attitude incorrect (front • CHECK for abnormal loading,
springs.
Procedures).
• Suspension lower arm ball • CARRY OUT the Ball Joint
joint. Inspection Component Test.
procedure.
2007.50 Focus 3/2007 G163366en


procedure.
• Vibration • Incorrect wheel alignment. • CHECK the wheel alignment
Procedures).
BALANCE or INSTALL new
wheels and tires as necessary.
bearings. wheel hubs as necessary.
and Installation).
• Front strut and spring assem- • CHECK and INSTALL new
blies. suspension components as
necessary.
necessary.
procedure.
2007.50 Focus 3/2007 G163366en


• Steering effort is high/low • Power steering hose restriction. • CHECK the power steering
hoses for damage, kinks or
restrictions. INSTALL new
REFER to: (211-02 Power
Steering)
- 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4)/1.6L
Duratorq-TDCi (DV)
(DW) Diesel (Removal and
Installation),
Return Line - 2.0L Duratec-
HE (MI4)/1.8L Duratec-HE
(MI4)/1.6L Duratorq-TDCi
(DV) Diesel/2.0L Duratorq-
TDCi (DW) Diesel (Removal
and Installation).
• Power steering fluid. • CHECK the power steering
fluid level.
• Power steering pump. • REFER to WDS.
• Steering column. • CHECK if the floor covering is
obstructing the steering gear
pinion.
• CHECK the installation of the
floor seal.
• CARRY OUT the Steering
Column Universal Joint
Component Test. REFER to
Steering Column Universal
Joint Component Test.
procedure.
procedure.
2007.50 Focus 3/2007 G163366en


• Excessive noise • Power steering operation noise. • CARRY OUT the Power
Steering Operation Noise
Check.
REFER to: Noise, Vibration and
Harshness (NVH) (100-04,
• Aeration of the power steering • BLEED the power steering
fluid. system.
System Bleeding - Vehicles
With: Electro-Hydraulic Power
Steering (EHPS) (211-00
Steering System - General
Information, General Proced-
ures).
• Power steering lines. • CHECK that the power steering
line clamps are secure. REFER
to: (211-02 Power Steering)
Duratorq-TDCi (DV)
(DW) Diesel (Removal and
Installation),
Return Line - 2.0L Duratec-
(MI4)/1.6L Duratorq-TDCi
TDCi (DW) Diesel (Removal
and Installation).
• CHECK the steering gear
transfer lines for clearance from
the steering gear.
REFER to: Steering Gear (211-
02 Power Steering, Removal
and Installation).
2007.50 Focus 3/2007 G163366en


bolts. bolts as necessary.
and Installation).
• Power steering pump rubber • CHECK and INSTALL new
mountings. power steering pump rubber
mountings as necessary.
• Power steering pump. • INSTALL a new power steering
pump.
Pump - 2.0L Duratec-HE
(MI4)/1.8L Duratec-HE
(MI4)/2.5L Duratec-ST
(VI5)/1.6L Duratorq-TDCi
TDCi (DW) Diesel (211-02
and Installation).
• Tie-rod. • CARRY OUT the Tie-Rod
Component Test. REFER to
Tie-Rod Component Test.
• Steering does not vary with • Worn tie-rod ends. • INSTALL new components as
increased wheel rotation necessary.
REFER to: Tie Rod End (211-
03 Steering Linkage,
• Worn front suspension bush- • CHECK and INSTALL new
ings. components as necessary.
• Worn suspension ball joints. • CARRY OUT the Ball Joint
Inspection Component Test.
and Installation).
2007.50 Focus 3/2007 G163366en


bolts. bolts as necessary.
02 Power Steering, Specifica-
tions).
• Loose steering column • CHECK and INSTALL new
retaining bolts. bolts as necessary.
04 Steering Column,
Specifications).
• Loose steering column to • CHECK and INSTALL a new
steering gear pinion retaining bolt as necessary.
bolt. REFER to: Steering Gear (211-
and Installation).
• Excessive steering gear back- • CARRY OUT the Steering
lash. Linkage Component Test.
procedure.
• Steering assist does not vary • Powertrain control module • REFER to WDS.
with vehicle speed (PCM).
• Electro-hydraulic power • REFER to WDS.
steering (EHPS) control
module.
NOTE: The warning light is illumin- • Ignition circuit. • GO to Pinpoint Test A.
ated when the ignition is switched • Electro-hydraulic power
ON for approximately three steering (EHPS) control module
seconds then extinguishes. ground circuit.
• Steering system warning light
stays on
• CAN circuit. • REFER to WDS.
2007.50 Focus 3/2007 G163366en


• DTC B1238: Over temperature • Electro-hydraulic power • CLEAR the DTCs. Drive the
fault steering (EHPS) control vehicle 30km (20 miles) or until
module. the vehicle reaches normal
operating temperature. REFER
to WDS. If the DTC is present,
INSTALL a new power steering
pump.
and Installation).
REPEAT the self-test, CLEAR
the DTCs.
• DTC B1317: Battery voltage • Charging system. • CHECK the charging system.
high REFER to: Charging System
(414-00 Charging System -
Repeat the self-test, CLEAR
the DTCs.
• DTC B1318: Battery voltage • Battery. • GO to Pinpoint Test B.
low • Charging system.
• Circuit(s).
• DTC B1342: Electro-hydraulic • EHPS control module. • GO to Pinpoint Test C.
power steering (EHPS) control
module is faulty
• DTC B2477: Module configura- • Electro-hydraulic power • CONFIGURE the EHPS control
tion failure steering (EHPS) control module.
module. REFER to: Module Configura-
tion (418-01 Module Configur-
ation, General Procedures).
the DTCs.
2007.50 Focus 3/2007 G163366en


• DTC C1099: Electronic power • Electro- hydraulic power • CLEAR the DTCs. Drive the
steering motor malfunction steering (EHPS) control vehicle 30km (20 miles) or until
module. the vehicle reaches normal
operating temperature. REFER
to WDS. If the DTC is present,
INSTALL a new power steering
pump.
and Installation).
the DTCs.
• DTC C1955: Steering angle • Circuit(s). • GO to Pinpoint Test D.
sensor circuit open
• DTC C1956: Steering angle • Circuit(s). • GO to Pinpoint Test E.
sensor circuit failure
• DTC P1796: CAN controller • Circuit(s). • GO to Pinpoint Test F.
circuit (Bus off)
• DTC U1900: CAN communica- • Powertrain control module • Check the electronic engine
tion bus fault (PCM). controls. REFER to: (303-14
Electronic Engine Controls)
Electronic Engine Controls -
2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4) (Descrip-
tion and Operation),
1.6L Duratorq-TDCi (DV)
Diesel (Description and
Operation),
1.8L Duratorq-TDCi (Lynx)
Operation),
2.0L Duratorq-TDCi (DW)
Operation).
the DTCs.
• Circuit(s). • CHECK the CAN bus,
REFER to: Communications
Network (418-00 Module
Communications Network,
2007.50 Focus 3/2007 G163366en


• DTC U2011: Module trans- • Electro-hydraulic power • INSTALL a new power steering
mitted invalid data steering (EHPS) control pump.
module. REFER to: Power Steering
and Installation).
the DTCs.
PINPOINT TEST B : STEERING SYSTEM WARNING LIGHT STAYS ON

A1: CHECK THE ELECTRO-HYDRAULIC POWER STEERING (EHPS) CONTROL MODULE GROUND
CIRCUIT
1 Disconnect EHPS Control Module C793.
2 Measure the resistance between the EHPS
control module C793 pin 2, circuit 31-CE7 (BK),
harness side and ground.
• Is the resistance less than 5 ohms?
→ Yes
GO to A2.
→ No
REPAIR circuit 31-CE7 (BK). TEST the
system for normal operation.
TIE45521
A2: CHECK FOR IGNITION VOLTAGE TO THE EHPS CONTROL MODULE

2007.50 Focus 3/2007 G163366en


4 With the engine at 2000 rpm, measure the
voltage between the EHPS control module C794
pin 1, circuit 15-CE7 (GN/BU), harness side and
ground.
→ Yes
CHECK the CAN bus,
REFER to: Communications Network (418-00
TIE45522 Module Communications Network, Diagnosis
and Testing).
→ No
GO to A3.
A3: CHECK FOR CONTINUITY BETWEEN THE BATTERY JUNCTION BOX (BJB) AND THE EHPS
CONTROL MODULE
1 Disconnect Fuse 22 (10A).
2 Measure the resistance between the BJB fuse
22 (10A), harness side and the EHPS control
module C794 pin 1, circuit 15-CE7 (GN/BU),
→ Yes
REPAIR circuit 15-DC22 (GN/BU). TEST the
→ No
REPAIR circuit 15-CE7 (GN/BU). TEST the
PINPOINT TEST C : DTC B1318: BATTERY VOLTAGE LOW

B1: CHECK THE BATTERY VOLTAGE

2007.50 Focus 3/2007 G163366en


3 Check the battery voltage with the ignition in the
ON position.
• Is the battery voltage greater than 10 volts?
→ Yes
GO to B2.
→ No
CHECK the battery and charging system.
REFER to: Charging System (414-00 Char-
ging System - General Information,
REPEAT the self-test, CLEAR the DTCs.
B2: CHECK FOR VOLTAGE TO THE ELECTRO-HYDRAULIC POWER STEERING (EHPS) CONTROL
MODULE
3 Measure the voltage between the EHPS control
module C793 pin 1, circuit 30-CE7 (RD),
→ Yes
GO to B3.
→ No
REPAIR circuit 30-CE7 (RD). TEST the
TIE45523
B3: CHECK FOR CONTINUITY BETWEEN THE BATTERY JUNCTION BOX (BJB) AND THE EHPS
CONTROL MODULE
1 Disconnect Fuse 2 (80A).
2007.50 Focus 3/2007 G163366en


2 Measure the resistance between the BJB fuse
2 (80A), harness side and the EHPS control
→ Yes
INSTALL a new power steering pump.
REFER to: Power Steering Pump - 2.0L
Duratec-HE (MI4)/1.8L Duratec-HE
(MI4)/2.5L Duratec-ST (VI5)/1.6L Duratorq-
TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW)
Diesel (211-02 Power Steering, Removal
and Installation).
→ No
PINPOINT TEST D : DTC B1342: ELECTRO-HYDRAULIC POWER STEERING (EHPS) CONTROL

MODULE IS FAULTY
C1: CHECK THE EHPS CONTROL MODULE GROUND CIRCUIT

2 Short the digital multimeter probes together and
make a note of the resistance.
3 Measure and make a note of the resistance
between the EHPS control module C793 pin 2,
circuit 31-CE7 (BK), harness side and ground.
TIE45521
2007.50 Focus 3/2007 G163366en


4 Calculate the real resistance value. Subtract
step 2 resistance value from step 3 resistance
value.
• Is the resistance less than 0.1 ohms?
→ Yes
GO to C2.
→ No
REPAIR circuit 31-CE7 (BK). TEST the
C2: CHECK FOR VOLTAGE TO THE EHPS CONTROL MODULE
2 Measure the voltage between the EHPS control
→ Yes
GO to C3.
→ No
TIE45523
C3: CHECK FOR IGNITION VOLTAGE TO THE EHPS CONTROL MODULE

2007.50 Focus 3/2007 G163366en


4 With the engine at 2000 rpm, measure the
voltage between the EHPS control module C794
pin 1, circuit 15-CE7 (GN/BU), harness side and
ground.
→ Yes
CLEAR the DTCs. REPEAT the self-test. If
DTC B1342 remains, INSTALL a new power
TIE45522
steering pump.
and Installation).
→ No
REPAIR circuit 15-CE7 (GN/BU). TEST the
PINPOINT TEST E : DTC C1955: STEERING ANGLE SENSOR CIRCUIT OPEN

D1: CHECK THE STEERING ANGLE SENSOR CIRCUIT FOR A SHORT TO BATTERY OR IGNITION
1 Disconnect Electro-Hydraulic Power Steering
(EHPS) Control Module C792.
2 Disconnect Steering Angle Sensor C795.
3 Measure the voltage between the steering angle
sensor C795 pin 1, circuit 8-CE10 (WH/VT),
• Is any voltage present?
→ Yes
REPAIR circuit 8-CE10 (WH/VT). TEST the
→ No
GO to D2.
TIE45524
2007.50 Focus 3/2007 G163366en


D2: CHECK THE STEERING ANGLE SENSOR CIRCUIT FOR A SHORT TO GROUND
1 Measure the resistance between the steering
angle sensor C795 pin 1, circuit 8-CE10
(WH/VT), harness side and ground.
• Is the resistance greater than 10,000 ohms?
→ Yes
GO to D3.
→ No
TIE45525
D3: CHECK FOR CONTINUITY BETWEEN THE STEERING ANGLE SENSOR AND THE EHPS
CONTROL MODULE
(WH/VT), harness side and the EHPS control
module C792 pin 3, circuit 8-CE10 (WH/VT),
harness side.
→ Yes
INSTALL a new steering angle sensor.
REFER to: Steering Angle Sensor (211-02
TIE45526
Power Steering, Removal and Installation).
→ No
PINPOINT TEST F : DTC C1956: STEERING ANGLE SENSOR CIRCUIT FAILURE

E1: CHECK THE STEERING ANGLE SENSOR CIRCUIT FOR A SHORT TO GROUND
2 Disconnect Electro-Hydraulic Power Steering
(EHPS) Control Module C792.
2007.50 Focus 3/2007 G163366en


(YE/VT), harness side and ground.
→ Yes
GO to E2.
→ No
REPAIR circuit 7-CE10 (YE/VT). TEST the
TIE45527
E2: CHECK FOR CONTINUITY BETWEEN THE STEERING ANGLE SENSOR AND THE EHPS
CONTROL MODULE
(YE/VT), harness side and the EHPS control
module C792 pin 1, circuit 7-CE10 (YE/VT),
harness side.
→ Yes
GO to E3.
TIE45528 → No
REPAIR circuit 7-CE10 (YE/VT). TEST the
E3: CHECK THE STEERING ANGLE SENSOR CIRCUIT FOR A SHORT TO IGNITION
2 Measure the voltage between the steering angle
sensor C795 pin 2, circuit 9-CE10 (BN/WH),
→ Yes
REPAIR circuit 9-CE10 (BN/WH). TEST the
→ No
GO to E4.
TIE45529
CONTROL MODULE
2007.50 Focus 3/2007 G163366en


(BN/WH), harness side and the EHPS control
module C792 pin 2, circuit 9-CE10 (BN/WH),
harness side.
→ Yes
GO to E5.
TIE45530 → No
REPAIR circuit 9-CE10 (BN/WH). TEST the
CONTROL MODULE
2 Clear the DTCs.
5 REFER to WDS.
• Is DTC C1956 present?
→ Yes
INSTALL a new power steering pump.
and Installation).
→ No
INSTALL a new steering angle sensor.
REFER to: Steering Angle Sensor (211-02
Power Steering, Removal and Installation).
2007.50 Focus 3/2007 G163366en

PINPOINT TEST G : DTC P1796: CAN CONTROLLER CIRCUIT (BUS OFF)
F1: CHECK THE CAN BUS CIRCUIT

• Is WDS able to communicate with the instru-
ment cluster?
→ Yes
REPAIR circuit 4-EC7W (GY/RD) or circuit 5-
EC7W (BU/RD). TEST the system for normal
operation.
→ No
CHECK the CAN bus,
REFER to: Communications Network (418-00
Module Communications Network, Diagnosis
and Testing).
Components Tests procedure. If there is no free play in the tie-rod

and the steering column, install a new steering
gear.
Steering Linkage REFER to: Steering Gear (211-02 Power
Steering, Removal and Installation).
1. Grasp the steering wheel firmly and move it up
and down and to the left and right without
turning the steering wheel to check the steering
Tie-Rod
column bearing for wear, steering column shaft
for wear, steering wheel for looseness and CAUTION: Steering gear boots must be
steering column for looseness. If the steering handled carefully to avoid damage. Use
column bearing or the steering column shaft is new steering boot clamps when installing
worn install a new steering column. the steering gear boots.
REFER to: Steering Column (211-04 Steering NOTE: Noises such as knocks, which may appear
Column, Removal and Installation). to originate from the steering linkage, may also be
If the steering wheel or the steering column is generated by front suspension components.
loose, tighten the steering wheel or the steering
column retaining bolts. REFER to: Noise, Vibration and Harshness (NVH)
REFER to: Specifications (211-04 Steering (100-04 Noise, Vibration and Harshness,
Column, Specifications). Diagnosis and Testing).
2. With the road wheels in the straight ahead 1. Raise and support the vehicle. REFER to:
position, gently turn the steering wheel to the (100-02 Jacking and Lifting)
left and the right to check for free play in the
steering linkage.
3. There should be no excessive free play at the
steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
Universal Joint Component Test in this
2007.50 Focus 3/2007 G163366en

TIE0005728 TIE0005729
2. Firmly grasp the road wheel and apply a rocking 5. Detach the steering gear boot from the steering
motion checking for any free play in the wheel gear body and check for free play at the tie-rod
bearing or suspension components. inner ball joint.
3. 6. If there is free play at the tie-rod inner ball joint,
CAUTION: To prevent damage to the install a new tie-rod.
steering linkage, turn the steering wheel to
move the steering linkage to the right-hand REFER to: Tie Rod (211-03 Steering Linkage,
steering lock stop. Removal and Installation).
7. Check the tie-rod end for free play. Install a new
Turn the steering wheel to position the steering
tie-rod end if necessary.
linkage against the right-hand steering lock stop.
REFER to: Tie Rod End (211-03 Steering
8.
steering linkage, turn the steering wheel to
move the steering linkage to the left-hand
steering lock stop.
Turn the steering wheel to position the steering
linkage against the left-hand steering lock stop.
TIE0005727
4. NOTE: To isolate the steering gear design

clearance, check the right-hand steering
linkage with the steering held against the
right-hand steering lock stop.
steering linkage against the right-hand steering
lock stop, firmly grasp the road wheel and apply
a rocking motion checking for any free play in TIE0005727
the steering linkage.
9. NOTE: To isolate the steering gear design
clearance, check the left-hand steering
linkage with the steering held against the
left-hand steering lock stop.
steering against the left-hand steering lock stop,
firmly grasp the road wheel and apply a rocking
motion checking for any free play in the steering
linkage.
2007.50 Focus 3/2007 G163366en

6. If the steering wheel turning effort is greater than
the specification, install a new steering gear.
REFER to:
Specifications (211-00 Steering System -
General Information, Specifications),
Steering Gear (211-02 Power Steering, Removal
and Installation).
Steering Column Universal Joint

E56375 1.
10. Detach the steering gear boot from the steering to steering gear pinion retaining bolt. Failure
gear body and check for free play at the tie-rod to follow this instruction may result in
inner ball joint. personal injury.
11. If there is free play at the tie-rod inner ball joint, Detach the steering column from the steering
install a new tie-rod. gear pinion.
REFER to: Tie Rod (211-03 Steering Linkage, • Discard the steering column to steering gear
Removal and Installation). pinion retaining bolt.
12. Check the tie-rod end for free play. Install a new
tie-rod end if necessary. 1
Turning Effort Test 2

that the suspension components are serviceable.
NOTE: Before carrying out this test, make sure 2
TIE45919
that the steering column is serviceable.
2. Check for smooth movement of the steering
column universal joint.
that the toe adjustment and tire pressures are
correct. 1. Hold the steering column universal joint yoke.
2. Articulate the free yoke in a figure of eight
1. Park the vehicle on a dry, even surface and movement.
apply the parking brake.
• If the movement is not smooth or resistance
2. Remove the driver air bag module. REFER to: is felt, install a new steering column.
(501-20 Supplemental Restraint System)
Driver Air Bag Module - Vehicles Built Up To: Column, Diagnosis and Testing).
06/2004 (Removal and Installation),
Driver Air Bag Module - Vehicles Built From:
06/2004 (Removal and Installation).
3. Connect the air bag simulators to the
sub-harnesses in place of the driver air bag
module at the top of the steering column.
4. Start the engine and turn the steering wheel
from lock to lock several times until the power
steering fluid has reached normal operating
temperature.
5. Using a suitable torque wrench and socket,
check the steering wheel turning effort. TIE45918
2007.50 Focus 3/2007 G163366en

3. Hold both of the steering column universal joint
yokes and twist them clockwise and
counterclockwise.
• If movement is felt, install a new steering
column.
Column, Diagnosis and Testing).
2007.50 Focus 3/2007 G163366en

Steering Gear Checks After a Collision

General Equipment TIE-RODS
Feeler gauge 1. Using a straight edge and feeler gauge, check
the tie-rods to see if they are straight. If the
Straight edge distance between the tie-rod and straight edge
is greater than 0.5 mm, install a new steering
Items to be observed when checking the steering gear.
system
REFER to: Steering Gear - Vehicles Built From:
The following list of steering gear conditions and 12/2003 (211-02, Removal and Installation).
the methods of testing should be taken into account 2. Check the tightening torque of the tie-rod end
when carrying out checks to the steering system: to wheel knuckle nut.
• If the steering gear has no faults after REFER to: Tie Rod End (211-03 Steering
completing the following checks, do not install Linkage, Removal and Installation).
a new steering gear.
3. Check the tightening torque of the tie-rod end
• Surface corrosion and marks on the tie-rod are locking nut.
acceptable.
• When checking for turning effort torque peaks
in the steering gear, turn the steering wheel from
steering lock stop to steering lock stop in CHECK FOR TURNING EFFORT TORQUE
approximately 15 seconds. PEAKS IN THE STEERING GEAR
• A steady increase of turning effort torque from 1. Lower and support the vehicle making sure that
steering center to steering lock stop is the road wheels are just clear of the floor.
acceptable. 2. With the ignition switch in position I, slowly turn
• When checking for power steering fluid leaks, the steering wheel from steering lock stop to
turn the steering wheel to the steering lock stop steering lock stop. If a turning effort torque peak
in approximately 10 seconds. or judder is felt while turning the steering wheel,
• Noises from the power steering, for example detach the tie-rods from the wheel knuckles.
the power steering pump relief valve, are 3. Slowly turn the steering wheel from steering
acceptable. lock stop to steering lock stop. If a turning effort
torque peak or judder is felt while turning the
STEERING GEAR HOUSING
steering wheel, install a new steering gear.
REFER to: Lifting (100-02, Description and 12/2003 (211-02, Removal and Installation).
Operation).
CHECK FOR POWER STEERING FLUID LEAKS
2. Visually inspect the steering gear housing for
cracks and damage. If the steering gear housing 1. Lower the vehicle.
is cracked or damaged, install a new steering 2. Run the engine at a fast idle and slowly turn the
gear. steering wheel to the left-hand steering lock
stop. Hold the steering wheel in this position for
5 seconds with a turning effort torque of 15 Nm
12/2003 (211-02, Removal and Installation).
at the steering wheel rim.
3. Turn the steering wheel away from the left-hand
steering lock stop for 30 seconds.
4. Run the engine at a fast idle and slowly turn the
steering wheel to the right-hand steering lock
stop. Hold the steering wheel in this position for
5 seconds with a turning effort torque of 15 Nm
at the steering wheel rim.
2007.50 Focus 3/2007 G538091en

5. Turn the steering wheel away from the
right-hand steering lock stop.
6. Check for power steering fluid leaks at the
steering gear housing and the power steering
line connections to the steering gear. If there is
a power steering fluid leak at the steering gear,
install a new steering gear.
12/2003 (211-02, Removal and Installation).
2007.50 Focus 3/2007 G538091en

GENERAL PROCEDURES
Power Steering System Flushing — Vehicles With:

Electro-Hydraulic Power Steering (EHPS)(13 001 0)
Vehicles with 1.8L, 2.0L or diesel engine • Allow the fluid to drain into a suitable
container.
1. Remove the headlight assembly.
Headlamp Assembly (417-01 Exterior
Lighting, Removal and Installation).
All vehicles
Lifting)
Lifting (Description and Operation). TIE0036038
3. Remove the engine undershield (if equipped).
6. Place the end of the steering gear return line
into a suitable container.
7. Lower the vehicle until the wheels are clear
of the floor to allow the steering wheel to be
rotated from lock to lock.
8. NOTE: When filling the power steering fluid
reservoir, make sure the fluid is clean and
not agitated prior to use. The fluid should be
poured slowly into the reservoir to minimize
the possibility of aeration. The fluid level
should be checked with the fluid cold.
E40677
Fill the power steering reservoir to the MAX
4. Remove the radiator splash shield. mark with the appropriate fluid.
General Information, Specifications).
9.
CAUTION: When flushing the power
steering system, make sure that the power
steering fluid in the reservoir does not fall
below the MIN mark.
NOTE: When filling the power steering fluid
reservoir, make sure the fluid is clean and not
agitated prior to use. The fluid should be poured
TIE39201 slowly into the reservoir to minimize the possibility
of aeration. The fluid level should be checked with
the fluid cold.
5. NOTE: Using a suitable blanking cap, cap
the power steering fluid reservoir. Start the engine and slowly turn the steering
wheel from lock to lock.
Disconnect the steering gear return line from
the power steering fluid reservoir.
2007.50 Focus 3/2007 G163374en

GENERAL PROCEDURES
• With the aid of another technician, add the 13. Install the engine undershield.
appropriate fluid until the system is free of
contaminated fluid.
10. Raise and support the vehicle. For
additional information, refer to: (100-02
11. Remove the blanking cap from the power E40677
steering fluid reservoir and connect the
power steering gear return line. 14. Lower the vehicle.
15. Fill the reservoir to the MAX mark with the
appropriate fluid as necessary.
Vehicles with 1.8L, 2.0L or diesel engine

16. Install the headlight assembly.
TIE0036038
12. Install the radiator splash shield.
TIE39201
2007.50 Focus 3/2007 G163374en

GENERAL PROCEDURES
Power Steering System Bleeding — 1.6L (Z6)(13 416 1)

Special Tool(s) 5. Check the fluid level. Fill the power steering
fluid reservoir to the MAX mark with the
Adaptor, Power Steering
appropriate fluid. For additional information,
Bleeding
refer to: (211-00 Steering System - General
211-189 (13-016)
Information)
13016 Specifications (Specifications).
6. NOTE: When bleeding the power steering
system the vacuum will decrease. Maintain
Hand Vacuum a sufficient vacuum of 38cm-Hg, using the
Pump/Pressure Pump special tools. If the vacuum decreases by
416-D001 (23-036A) more than 5cm-Hg in 5 minutes, the system
should be checked for leaks.
23036A
Using the special tools, bleed the power
steering system.
• Start the engine and slowly turn the steering
wheel from lock to lock once; then turn the
Bleeding steering wheel to the right, just off the stop.
1. NOTE: When filling the power steering fluid • Switch OFF the engine and using the special
reservoir, make sure the fluid is clean and tools apply a vacuum of 38cm-Hg. Maintain
not agitated prior to use. The fluid should be the vacuum until the air is evacuated from
poured slowly into the reservoir to minimize the system (minimum of five minutes).
the possibility of aeration. The fluid level • Release the vacuum at the special tools.
should be checked with the fluid cold. • Repeat the power steering bleeding
procedure, turning the steering wheel to the
Fill the power steering reservoir to the MAX left, just off the stop.
mark with the appropriate fluid. For
Steering System - General Information)
Specifications (Specifications).
2. Raise the vehicle until the road wheels are
clear of the floor. Support the vehicle.
and Operation). 211-189 416-D001
3. NOTE: Make sure that the fluid in the TIE0001863

reservoir does not fall below the MIN mark,
as air could enter the system. 7. Remove the special tools. Fill the power
Start the engine and slowly turn the steering steering reservoir to the MAX mark with the
wheel from lock to lock. appropriate fluid if necessary. For additional
information, refer to: (211-00 Steering System
4. Switch OFF the engine and examine the hose - General Information)
connections, steering gear boots, valve body
and pump for external leaks. Specifications (Specifications),
8. Start the engine, turn the steering wheel from
lock to lock. If excessive noise is apparent,
repeat the power steering bleeding
procedure.
2007.50 Focus 3/2007 G418583en

GENERAL PROCEDURES
10. If the noise level is still unacceptable, leave
the vehicle standing overnight then repeat
the power steering system bleeding
procedure.
2007.50 Focus 3/2007 G418583en

GENERAL PROCEDURES
Power Steering System Bleeding — Vehicles With:

Electro-Hydraulic Power Steering (EHPS)(13 416 1)
Vehicles with 1.8L, 2.0L or diesel engine 7. Start the engine, turn the steering wheel from
lock to lock. If excessive noise is apparent,
1. Remove the headlamp assembly.
refer to the steering system diagnostic and
For additional information, refer to: testing.
For additional information, refer to: Steering
System (211-00 Steering System - General
Information, Diagnosis and Testing).
All vehicles
8. If the noise level is still unacceptable, leave
2. NOTE: When filling the power steering fluid the vehicle standing overnight then start the
reservoir, make sure the fluid is clean and engine and slowly turn the steering wheel
not agitated prior to use. The fluid should be from lock to lock until the air is expelled.
the possibility of aeration. The fluid level 9. If the noise level is still unacceptable, install
should be checked with the fluid cold. a new power steering pump.
Fill the power steering reservoir to the MAX For additional information, refer to: Power
mark with the appropriate fluid. Steering Pump - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4)/2.5L Duratec-ST (VI5)/1.6L
For additional information, refer to: Duratorq-TDCi (DV) Diesel/2.0L
Specifications (211-00 Steering System - Duratorq-TDCi (DW) Diesel (211-02 Power
General Information, Specifications). Steering, Removal and Installation).
3. Raise the vehicle until the road wheels are 10. Lower the vehicle.
clear of the floor. Support the vehicle. For
Jacking and Lifting) Vehicles with 1.8L, 2.0L or diesel engine
Jacking (Description and Operation), 11. Install the headlamp assembly.
Lifting (Description and Operation). For additional information, refer to:
4. NOTE: Make sure the fluid in the reservoir
does not fall below the MIN mark, as air could
enter the system.
Start the engine and slowly turn the steering
wheel from lock to lock until the air is
expelled.
• With the aid of another technician, add the
appropriate fluid until the system is free of
contaminated fluid.
5. Switch OFF the engine and examine the hose
connections, steering gear boots, valve body
and pump for external leaks.
6. Check the fluid level. Fill the power steering
2007.50 Focus 3/2007 G163375en

GENERAL PROCEDURES
Power Steering System Filling — 1.6L (Z6)(13 002 0)

Special Tool(s) • If the vacuum decreases by more than
5cm-Hg in 5 minutes, the system should be
Adaptor, Power Steering
checked for leaks.
Bleeding
211-189 (13-016) 4. Remove the special tools. Fill the reservoir
to the MAX mark with the appropriate fluid
as necessary. For additional information,
13016 refer to: (211-00 Steering System - General
Information)
Hand Vacuum Specifications (Specifications).
Pump/Pressure Pump
416-D001 (23-036A)
23036A
Refill
1. NOTE: When filling the power steering fluid
the possibility of aeration. The fluid level
Fill the power steering fluid reservoir to the
MAX mark with the appropriate fluid. For
2. Using the special tools, apply a vacuum of
62cm-Hg - 75cm-Hg for 30 seconds.
211-189 416-D001
TIE0001863
3. Observe the vacuum gauge reading.
2007.50 Focus 3/2007 G418584en

GENERAL PROCEDURES
Power Steering System Filling — Vehicles With: Electro-Hydraulic

Power Steering (EHPS)(13 002 0)
Vehicles with 1.8L, 2.0L or diesel engine 7. Start the engine and turn the steering wheel
from lock to lock. If excessive noise is
1. Remove the headlamp assembly.
apparent, bleed the system.
For additional information, refer to: Power
Steering System Bleeding - Vehicles With:
Electro-Hydraulic Power Steering (EHPS)
(211-00 Steering System - General
All vehicles Information, General Procedures).
2. NOTE: When filling the power steering fluid 8. Switch OFF the engine.
poured slowly into the reservoir to minimize Vehicles with 1.8L, 2.0L or diesel engine
the possibility of aeration. The fluid level 9. Install the headlamp assembly.
Fill the power steering reservoir to the MAX Headlamp Assembly (417-01 Exterior
mark with the appropriate fluid. Lighting, Removal and Installation).
Specifications - 3-Door (211-00 Steering
Specifications).
3. NOTE: Make sure the fluid in the reservoir
does not fall below the MIN mark, as air could
enter the system.
Start the engine and fill the power steering
Specifications).
4. Slowly turn the steering wheel from lock to
lock five times.
5. Switch OFF the engine.
6. Fill the power steering fluid reservoir to the
MAX mark with the appropriate fluid as
necessary.
Specifications).
2007.50 Focus 3/2007 G163377en

211-02-1 Power Steering 211-02-1
.
SECTION 211-02 Power Steering

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 211-02-2

Power Steering................................................................................................................... 211-02-3
Electro-hydraulic power steering........................................................................................ 211-02-3
Brushless direct current motor............................................................................................ 211-02-5
Power steering pump.......................................................................................................... 211-02-6

Power Steering................................................................................................................... 211-02-7

Power Steering Pump — 1.6L (Z6)................................................................ (13 434 0) 211-02-8
Power Steering Pump — Vehicles With: Electro-Hydraulic Power Steering
(EHPS).......................................................................................................... (13 434 0) 211-02-11
Power Steering Pump to Steering Gear Pressure Line — Vehicles With:
Electro-Hydraulic Power Steering (EHPS)................................................... (13 440 0) 211-02-14
Power Steering Pump to Steering Gear Pressure Line — 1.6L (Z6).............. (13 440 0) 211-02-18
Power Steering Pressure Line and Return Line Assembly — Vehicles With:
Electro-Hydraulic Power Steering (EHPS)................................................... (13 433 0) 211-02-21
Steering Gear..................................................................................................................... 211-02-23
Steering Gear — 1.6L (Z6)................................................................................................. 211-02-32
Steering Angle Sensor........................................................................................................ 211-02-42
Steering Gear to Power Steering Fluid Reservoir Return Line — Vehicles
With: Electro-Hydraulic Power Steering (EHPS).......................................... (13 439 0) 211-02-43
Steering Gear to Power Steering Fluid Reservoir Return Line — 1.6L (Z6)... (13 439 0) 211-02-47
SPECIFICATIONS
Item Nm lb-ft lb-in
Steering column shaft to steering gear pinion 28 21 -
retaining bolt
Steering angle sensor retaining screws 6 - 53
Power steering lines to steering gear valve body 18 13 -
retaining screw
Power steering line to steering gear union - Vehicles 35 26 -
with 1.6L (Z6) engine
Steering gear mounting bolts 90 66 -
Power steering line bracket to vehicle body retaining 23 17 -
bolt
Power steering line bracket to steering gear 14 10 -
retaining bolt - Vehicles with 1.6L (Z6) engine
Power steering line to power steering pump union 33 24 -
- Vehicles with 1.6L (Z6) engine
Power steering pump retaining bolts - Vehicles with 35 26 -
1.6L (Z6) engine
Power steering line to power steering pump union 30 22 -
Power steering pump retaining bolts 23 17 -
Steering gear heat shield retaining bolts 7 - 62
Steering gear heat shield retaining bolts - Vehicles 9 - 80
with 1.6L (Z6) engine
nuts - Vehicles with diesel engine
nuts - All except vehicles with diesel engine
Engine support insulator front retaining bolt 80 59 -
Front axle crossmember rear retaining bolts 275 203 -
2007.50 Focus 4/2007 G418586en

Power Steering
Electro-hydraulic power steering
C
B
E40956
Item Description
Steering gear
A Pump speed (in rev/min)
B Steer angle rate (in degrees/second)
C Road speed (in km/h)
2
1
The electrohydraulic power steering system uses 3
an electrically-driven hydraulic pump and a 4
conventional rack and pinion steering system. This
ensures precise steering operation and steering
assistance with minimum energy consumption.
Under continuous monitoring of the turning speed
5
of the steering wheel with the aid of the integrated
steering angle sensor, and under evaluation of the E42459
vehicle speed input signal, the control module uses
a map to adjust the rate of the pump. Item Description
1 Input shaft
2 Steering angle sensor
3 Valve body
2007.50 Focus 4/2007 G183842en

Item Description NOTE: The steering angle rotor is incorporated

into the valve body of the steering gear and cannot
4 Cylinder be re-used.
5 Oil line Installed above the steering valve, the steering
angle sensor forms an integral part of the rack and
Conventional rack and pinion steering pinion steering system.
Integrated steering angle sensor The steering angle sensor is a inductive sensor.
Heat shield and cable grommet are part of the The steering angle sensor monitors the speed with
steering gear which the steering wheel is being turned. This
information is sent to the control module.
Integrated steering angle sensor
2
E42458
Item Description
1 Steering angle sensor
2 Sensor wheel
2007.50 Focus 4/2007 G183842en

Brushless direct current motor
1
2
3
4
5
10
E42460
Commutation in the motor is done electronically.

Item Description
As a result, there are no brushes to wear away.
1 Connector The entire system is designed for maintenance-free
operation.
2 Control unit
In more than 85% of all driving situations, the
3 Seal power steering pump operates at standby speed
4 Bearing and consumes less than 4A. However, pump speed
can quickly increase to full rotational speed if
5 Shaft emergency steering manoeuvres require it.
6 Cover The system has a continuously variable pump
rotational speed.
7 Rotor with magnets
8 Stator
9 Distributor
10 Bearing
In the electrohydraulic power steering system, a
brushless 12 volt direct current motor drives the
hydraulic pump. Higher pumping rates are only
provided when they are required for steering
manoeuvres. This avoids unnecessary energy
consumption in the majority of phases in a drive
cycle.
2007.50 Focus 4/2007 G183842en

Power steering pump
E42465
NOTE: The power steering pump must be filled

and vented as specified.
The power steering pump comprises an electric
motor, the hydraulic pump and the reservoir for the
power steering fluid.
Using a brushless motor increases reliability and
prolongs service life.
The hydraulic pump is a gear pump; a resonance
chamber incorporated into the pump body reduces
noise emissions.
A pressure limiting valve built into the pump
housing limits the hydraulic fluid pressure to a
maximum of approx. 120 bar.
There is no service interval specified for the power
steering fluid.
2007.50 Focus 4/2007 G183842en

Power Steering
REFER to: Steering System (211-00
Steering System - General Information, Diagnosis
and Testing).
2007.50 Focus 4/2007 G37425en

Power Steering Pump — 1.6L (Z6)(13 434 0)

Special Tool(s)
2. Remove the accessory drive belt.
Remover/Installer, Cooling
Hose Clamp For additional information, refer to:
303-397 (24-003) Accessory Drive Belt - 1.6L (Z6) (303-05
Accessory Drive, Removal and Installation).
24003
table(s).
1. Remove the engine upper cover.
TIE39686
2007.50 Focus 4/2007 G418591en

3 33 Nm
2
23 Nm 4
E52693
1 Power steering pressure (PSP) switch 4 Power steering pump upper retaining bolt
electrical connector 5 Power steering pump
2 Power steering fluid supply hose See Removal Detail
See Removal Detail
3 Power steering pump to steering gear
pressure line
See Removal Detail
2007.50 Focus 4/2007 G418591en

211-02-10 Power Steering 211-02-10
5. Fill and bleed the power steering system. General Procedures)
For additional information, refer to: Power / Power Steering System Bleeding - 1.6L (Z6)
Steering System Filling - 1.6L (Z6) (211-00 (211-00 Steering System - General
Steering System - General Information, Information, General Procedures).
Removal Details
Item 2 Power steering fluid supply hose Discard the power steering pump pressure
1. CAUTIONS: line union washers.
Cap the power steering fluid supply hose
to prevent fluid loss or dirt ingress.
Cap the power steering pump connection

Using the special tool, disconnect the power
steering fluid supply hose from the power
steering pump.
• Allow the fluid to drain into a suitable
container.
E52519
303-397
Item 5 Power steering pump
1. Remove the power steering pump.
1. Loosen and detach the lower retaining bolt
from the engine block.
2. Rotate and remove the power steering pump.
E52694
Item 3 Power steering pump to steering gear

pressure line 2
1. CAUTIONS:
Cap the power steering pump to steering
gear pressure line to prevent fluid loss or 23 Nm 1
dirt ingress. E52695

pressure line
NOTE: Install new washers to the power steering
pump pressure line union.
2007.50 Focus 4/2007 G418591en

211-02-11 Power Steering 211-02-11
Power Steering Pump — Vehicles With: Electro-Hydraulic Power

Steering (EHPS)(13 434 0)
Special Tool(s) All vehicles
Remover/Installer, Hose 3. Remove the right-hand headlamp assembly.
Clamp For additional information, refer to:
303-397 Headlamp Assembly (417-01 Exterior
24003 4. Disconnect the power steering pump
electrical connectors.
General Equipment
Removal
All vehicles
1. Obtain and record the power steering system
program code using WDS.
TIE0036331
Vehicles with 2.5L engine
2.
CAUTION: Cap the power steering fluid 5. Remove the right-hand front wheel and tire.
reservoir extension outlet port and the power
steering pump supply hose to prevent fluid For additional information, refer to: Wheel
loss or dirt ingress. and Tire (204-04 Wheels and Tires, Removal
and Installation).
Remove the power steering fluid reservoir
extension. 6. Remove the engine undershield.
1. Detach the power steering fluid reservoir • Rotate the locking tangs counterclockwise.
extension from the radiator grille opening
panel reinforcement.
2. Using the special tool, detach the power
steering pump supply hose from the power
steering fluid reservoir extension.
container.
E40677
E63775
2007.50 Focus 4/2007 G163382en

211-02-12 Power Steering 211-02-12
7. Remove the radiator splash shield. 10.
CAUTION: Cap the power steering fluid
return line to prevent fluid loss or dirt
ingress.
Disconnect the power steering fluid return
line from the power steering pump.
container.
TIE39201
8. Remove the right-hand front fender splash

shield.
TIE0036038
11. Remove the power steering pump.
E40674
9.
CAUTION: Cap the power steering pump
outlet union to prevent fluid loss or dirt
22 Nm
ingress.
Disconnect the power steering pressure line TIE0036335
from the power steering pump.

• Allow the fluid to drain into a suitable Installation
container.
2. Fill and bleed the power steering system. For
Power Steering System Filling - Vehicles
With: Electro-Hydraulic Power Steering
(EHPS) (General Procedures),
Power Steering System Bleeding - Vehicles
30 Nm With: Electro-Hydraulic Power Steering
(EHPS) (General Procedures).
TIE0036336 3.
WARNING: The power steering system
must be re-configured. Failure to follow this
2007.50 Focus 4/2007 G163382en

211-02-13 Power Steering 211-02-13
Configure the EHPS control module.
For additional information, refer to: Module
Configuration (418-01 Module
Configuration, General Procedures).
2007.50 Focus 4/2007 G163382en

211-02-14 Power Steering 211-02-14
Power Steering Pump to Steering Gear Pressure Line — Vehicles

With: Electro-Hydraulic Power Steering (EHPS)(13 440 0)
1. Raise and support the vehicle. 4. Remove the right-hand front fender splash
For additional information, refer to: Jacking shield.
/ Lifting.
• Rotate the locking tangs counterclockwise.
E40674

E40677
table(s).
3. Remove the radiator splash shield.
TIE39201
2007.50 Focus 4/2007 G296227en

211-02-15 Power Steering 211-02-15
23 Nm 3
4
30 Nm 1
2
TIE39075
1 Power steering pump union 3 Power steering fluid lines support bracket
See Removal Detail to vehicle body
See Removal Detail
2 Power steering pump to steering gear See Installation Detail
pressure line retaining bolt
See Removal Detail 4 Power steering fluid lines support bracket
See Installation Detail to steering gear
See Removal Detail
7. Fill and bleed the power steering system.
Steering System Filling
/ Power Steering System Bleeding.
Removal Details
Item 1 Power steering pump union
1.
outlet union to prevent fluid loss or dirt
ingress.
Disconnect the power steering pressure line
from the power steering pump.
2007.50 Focus 4/2007 G296227en

211-02-16 Power Steering 211-02-16
• Allow the fluid to drain into a suitable Detach the power steering fluid lines bracket
container. from the vehicle body.
30 Nm
TIE0036336 TIE45914
Item 2 Power steering pump to steering gear 2. Detach the power steering line to steering
pressure line retaining bolt gear pressure line from the support bracket.
1. Disconnect the power steering lines from the 1. Release the retaining clip.
steering gear valve body. 2. Open the support bracket.
1. Remove the retaining bolt.
2. Rotate the clamp plate.
container.
2
1 1
TIE45915
2
Item 4 Power steering fluid lines support

bracket to steering gear
TIE0036745
1. Detach the power steering fluid lines support
bracket from the steering gear.
bracket to vehicle body
1. NOTE: Note the position of the power
steering fluid lines support bracket to aid
installation.
TIE45916
2. Remove the power steering line to steering

gear pressure line.
2007.50 Focus 4/2007 G296227en

211-02-17 Power Steering 211-02-17
1. Release the retaining clip.
2. Open the support bracket.
TIE45917
CAUTION: Make sure the power steering
fluid lines are a minimum of 15 mm from
the auxiliary drive belts.

pressure line retaining bolt
1. Connect the power steering lines to the
steering gear valve body.
2. Install the retaining bolt.
18 Nm 2
1
TIE0036746
2007.50 Focus 4/2007 G296227en

211-02-18 Power Steering 211-02-18
Power Steering Pump to Steering Gear Pressure Line — 1.6L

(Z6)(13 440 0)
and Operation)
Description and Operation).
E40677

table(s).
33 Nm 2
4 14 Nm
35 Nm 3
E52516
2007.50 Focus 4/2007 G418596en

211-02-19 Power Steering 211-02-19
1 Power steering pressure and return line 5. Fill and bleed the power steering system.
support clamps For additional information, refer to: Power
Steering System Filling - 1.6L (Z6) (211-00
2 Power steering pump pressure line union
Steering System - General Information,
See Removal Detail
General Procedures)
/ Power Steering System Bleeding - 1.6L (Z6)
3 Steering gear valve body pressure line (211-00 Steering System - General
union Information, General Procedures).
See Removal Detail
pressure line bracket
See Removal Detail
Removal Details
Item 2 Power steering pump pressure line union Discard the steering gear pressure line union
washers.
1.
outlet to prevent fluid loss or dirt ingress.
container.
NOTE: Note the position of the power steering
pump to steering gear pressure line to aid
installation.
Discard the steering gear pressure line union
washers.
container.
E52519
E52519
Item 3 Steering gear valve body pressure line

union
1.
CAUTION: Cap the steering gear inlet to
prevent fluid loss or dirt ingress.
NOTE: Note the position of the power steering
pump to steering gear pressure line to aid
installation.
2007.50 Focus 4/2007 G418596en

211-02-20 Power Steering 211-02-20
pressure line bracket
1. Detach the power steering pump to steering
gear pressure line bracket from the steering
gear.
E52521
Item 3 Steering gear valve body pressure line
union
1. Install new steering gear pressure line union
washers.
E52519
Item 2 Power steering pump pressure line union

1. Install new power steering pump pressure
line union washers.
E52519
2007.50 Focus 4/2007 G418596en

211-02-21 Power Steering 211-02-21
Power Steering Pressure Line and Return Line Assembly —

Vehicles With: Electro-Hydraulic Power Steering
(EHPS)(13 433 0)
4. CAUTION: Make sure that all openings
Removal are sealed.
Torque: 30 Nm
All vehicles
NOTE: Removal steps in this procedure may
contain installation details.
1. Remove the right-hand front wheel and tire.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2.
E66236

are sealed.
E40677
3.
TIE0036038
6. Torque: 7 Nm
x2
E40674
E66237
2007.50 Focus 4/2007 G551971en

211-02-22 Power Steering 211-02-22
7. Torque: 23 Nm Right-hand drive vehicles
10. Torque: 4 Nm
x2
E66238
E66241
8. Torque: 7 Nm
All vehicles
are sealed.
Torque: 18 Nm
x3
E66239 1
2
Left-hand drive vehicles
9. Torque: 4 Nm
TIE0036745
Installation
2. Fill the power steering system.
Refer to: Power Steering System Filling -
Vehicles With: Electro-Hydraulic Power
Steering (EHPS) (211-00 Steering System -
E66240 General Information, General Procedures).
3. Bleed the power steering system.
Refer to: Power Steering System Bleeding -
Vehicles With: Electro-Hydraulic Power
Steering (EHPS) (211-00 Steering System -
General Information, General Procedures).
2007.50 Focus 4/2007 G551971en

211-02-23 Power Steering 211-02-23
Steering Gear
Special Tool(s) Centralize the steering and lock it in position.
204-349
E42949

205-316 (15-097A)
TIE38834
15097A 2. Detach the steering column shaft from the

Separator, Ball Joint • Discard the retaining bolt.
211-020 (13-006)
13006
General Equipment
Securing strap
TIE0027063
Transmission jack
3. Remove both front wheels and tires.

All vehicles
and Installation).
the top mount center cup. 4. Remove the engine undershield (if equipped).
1. NOTE: Make sure the road wheels are in the • Rotate the locking tangs counterclockwise.
E40677
2007.50 Focus 4/2007 G418592en

211-02-24 Power Steering 211-02-24
48 Nm
E50598
TIE0002772
8.
51 Nm
TIE39009 TIE40628
7. table(s).
hanger insulators.
2007.50 Focus 4/2007 G418592en

211-02-25 Power Steering 211-02-25
2 48 Nm
48 Nm 1
E39001
Item Description
See Removal Detail
See Removal Detail
See Removal Detail
2007.50 Focus 4/2007 G418592en

211-02-26 Power Steering 211-02-26
80 Nm 4
TIE45173
Item Description
bolt
See Removal Detail
2007.50 Focus 4/2007 G418592en

211-02-27 Power Steering 211-02-27
7 Nm 7
10
90 Nm
9
E41741
NOTE: Install new gaskets and nuts.

Item Description
6 Steering gear exhaust heat shield
retaining bolts For additional information, refer to: Power
Steering System Filling (211-00 Steering
7 Steering gear exhaust heat shield System - General Information, General
8 Bulkhead floor seal Procedures)
/ Power Steering System Bleeding (211-00
9 Steering gear retaining bolts Steering System - General Information,
10 Steering gear General Procedures).
10. To install, reverse the removal procedure. necessary.
WARNING: Install a new steering column For additional information, refer to:
shaft to steering gear pinion bolt. Failure Specifications (204-00 Suspension
to follow this instruction may result in System - General Information,
personal injury. Specifications)
CAUTION: Never use jointing compound / Specifications (204-00 Suspension System
forward of the diesel particulate filter (if - General Information, Specifications)
equipped). / Specifications (204-00 Suspension System
- General Information, Specifications)
NOTE: Make sure the road wheels are in the / Front Toe Adjustment (204-00 Suspension
straight ahead position. System - General Information, General
NOTE: Coat the catalytic converter studs with Procedures).
anti-seize grease.
Removal Details
2007.50 Focus 4/2007 G418592en

211-02-28 Power Steering 211-02-28
Item 1 Tie-rod end retaining nut • Discard the lower arm ball joint retaining nut.
1.
sides.
TIE39073
2.
seal.
TIE0026775
2.
• Discard the tie-rod end retaining nut.
TIE44354
211-020

both sides.
E52983

TIE44353
rotating, remove the lower arm ball joint
retaining nut on both sides.
2007.50 Focus 4/2007 G418592en

211-02-29 Power Steering 211-02-29
Item 5 Front axle crossmember 5. Remove the front axle crossmember bracket
1. Detach the pressure and return lines from
the steering gear.
TIE44500
TIE0036370
retaining bolts (transmission jack removed
2. NOTE: Cap the power steering lines to
for clarity).
NOTE: Cap the steering gear inlet and outlet to
Disconnect the pressure and return lines
from the steering gear valve body.
container.
TIE39071
7. Remove the front axle crossmember.
1
2
TIE0036745
3. Using a transmission jack and a wooden

TIE0000144
4.
crossmember is secured to the transmission 8. Remove the stabilizer bar.
2007.50 Focus 4/2007 G418592en

211-02-30 Power Steering 211-02-30
• Remove the stabilizer bar clamp retaining
bolts on both sides.
TIE0036595
Item 5 Front axle crossmember 3. Raise the front axle crossmember engaging
the alignment pins into the chassis aligning
1. Install the stabilizer bar.
holes.
• Install the stabilizer bar clamp retaining bolts
on both sides.
205-316
2
1
48 Nm
TIE0000859
TIE0036596
3.
crossmember does not move while
2.
WARNING: Make sure the front axle tightening the front axle crossmember
crossmember is secured to the transmission retaining bolts.
Install the front axle crossmember retaining
Using the transmission jack and the special
tool, position and align the front axle 115 Nm
crossmember.
axle crossmember alignment holes.
2. Slide the locking plates into the groove of the
sleeve.
275 Nm
TIE39072
2007.50 Focus 4/2007 G418592en

211-02-31 Power Steering 211-02-31
4. Install the front axle crossmember bracket 9. Attach the pressure and return lines to the
retaining bolts on both sides. steering gear.
70 Nm 23 Nm
TIE44501 TIE0036773
5. Remove the special tool. Item 3 Lower arm ball joint retaining nut
6. Remove the securing strap. 1.
7. Lower and remove the transmission jack and joint retaining nut. Failure to follow this
the wooden block. instruction may result in personal injury.
8. NOTE: Check the pressure and return lines Using the special tool to prevent the ball joint
to steering gear valve body O-ring seals for from rotating, install the lower arm ball joint
damage or fatigue. Install new O-ring seals retaining nut on both sides.
if necessary.
Connect the pressure and return lines to the
1. Rotate the clamp plate. 70 Nm
18 Nm 2 TIE39074

1 1. NOTE: Use a 5 mm Allen key to prevent the
TIE0036746
bar on both sides.

on both sides.
2007.50 Focus 4/2007 G418592en

211-02-32 Power Steering 211-02-32
Steering Gear — 1.6L (Z6)

Special Tool(s) Centralize the steering and lock it in position.
204-349
E42949

205-316 (15-097A)
TIE38834
15097A 2. Detach the steering column shaft from the

Separator, Ball Joint • Discard the retaining bolt.
211-020 (13-006)
13006
General Equipment
Securing strap
TIE0027063
Transmission jack
3. Remove both front wheels and tires.

All vehicles
and Installation).
the top mount center cup. 4. Remove the engine undershield (if equipped).
1. NOTE: Make sure the road wheels are in the • Rotate the locking tangs counterclockwise.
E40677
2007.50 Focus 4/2007 G418593en

211-02-33 Power Steering 211-02-33
48 Nm
E50598
TIE0002772
8.
51 Nm
TIE39009 TIE40628
7. table(s).
hanger insulators.
2007.50 Focus 4/2007 G418593en

211-02-34 Power Steering 211-02-34
2 48 Nm
48 Nm 1
E39001
Item Description
See Removal Detail
See Removal Detail
See Removal Detail
2007.50 Focus 4/2007 G418593en

211-02-35 Power Steering 211-02-35
80 Nm 4
TIE45173
Item Description
bolt
See Removal Detail
2007.50 Focus 4/2007 G418593en

211-02-36 Power Steering 211-02-36
90 Nm
E52852

Item Description
6 Steering gear exhaust heat shield Steering System Filling - 1.6L (Z6) (211-00
7 Bulkhead floor seal Steering System - General Information,
General Procedures)
8 Steering gear retaining bolts / Power Steering System Bleeding - 1.6L
9 Steering gear (Z6) (211-00 Steering System - General
Information, General Procedures).
10. To install, reverse the removal procedure. 12. Check the toe setting and adjust as
WARNING: Install a new steering column necessary.
to steering gear pinion bolt. Failure to For additional information, refer to:
follow this instruction may result in Specifications (204-00 Suspension
personal injury. System - General Information,
CAUTION: Never use jointing compound Specifications)
forward of the diesel particulate filter (if / Specifications (204-00 Suspension System
equipped). - General Information, Specifications)
/ Specifications (204-00 Suspension System
NOTE: Make sure the road wheels are in the
- General Information, Specifications)
/ Front Toe Adjustment (204-00 Suspension
NOTE: Coat the catalytic converter studs with System - General Information, General
anti-seize grease. Procedures).
NOTE: Install new gaskets and nuts.
Removal Details
2007.50 Focus 4/2007 G418593en

211-02-37 Power Steering 211-02-37
Item 1 Tie-rod end retaining nut • Discard the lower arm ball joint retaining nut.
1.
sides.
TIE39073
2.
seal.
TIE0026775
2.
TIE44354
211-020

both sides.
E52983

TIE44353
rotating, remove the lower arm ball joint
2007.50 Focus 4/2007 G418593en

211-02-38 Power Steering 211-02-38
Item 5 Front axle crossmember Disconnect the power steering pump to
steering gear pressure line from the steering
1. Detach the steering gear to power steering
gear.
fluid reservoir return line from the steering
gear.
E52520
E52853
4. Discard the steering gear pressure line union
washers.
2. Detach the power steering pump to steering
gear pressure line from the steering gear.
E52519
E52521
5. CAUTIONS:
3. CAUTIONS: Cap the power steering line to prevent
Cap the power steering line to prevent
fluid loss or dirt ingress. Cap the power steering gear outlet to
Cap the power steering gear inlet to
prevent fluid loss or dirt ingress. Using the special tool, detach the steering
gear to power steering fluid reservoir return
line from the steering gear.
303-397
E52854
2007.50 Focus 4/2007 G418593en

211-02-39 Power Steering 211-02-39
6. Using a transmission jack and a wooden 10. Remove the front axle crossmember.
7.
8. Remove the front axle crossmember bracket
retaining bolts on both sides. TIE0000144
11. Remove the stabilizer bar.

• Remove the stabilizer bar clamp retaining
bolts on both sides.
TIE44500

for clarity). TIE0036595
TIE39071
1. Install the stabilizer bar.
2007.50 Focus 4/2007 G418593en

211-02-40 Power Steering 211-02-40
• Install the stabilizer bar clamp retaining bolts Install the front axle crossmember retaining
on both sides. bolts (transmission jack removed for clarity).
115 Nm
48 Nm
275 Nm
TIE0036596
TIE39072
2. 4. Install the front axle crossmember bracket

crossmember is secured to the transmission retaining bolts on both sides.
Using the transmission jack and the special
crossmember.
1. Insert the alignment pins through the front 70 Nm
sleeve.
3. Raise the front axle crossmember engaging
TIE44501
the alignment pins into the chassis aligning
holes.
205-316 6. Remove the securing strap.
2
1 7. Lower and remove the transmission jack and
the wooden block.
8. Using the special tool, attach the steering
gear to power steering fluid reservoir return
line to the steering gear.
3
TIE0000859
303-397
3.
retaining bolts.
E52854
2007.50 Focus 4/2007 G418593en

211-02-41 Power Steering 211-02-41
9. Install new steering gear pressure line union 12. Attach the steering gear to power steering
washers. fluid reservoir return line to the steering
gear.
14 Nm
E52519
E52856
10. Connect the power steering pump to

steering gear pressure line to the steering Item 3 Lower arm ball joint retaining nut
gear valve body.
1.
from rotating, install the lower arm ball joint
35 Nm
70 Nm
E52522
11. Attach the power steering pump to steering

gear pressure line to the steering gear.
TIE39074
14 Nm Item 2 Stabilizer bar link retaining nut

bar on both sides.
E52855 Item 1 Tie-rod end retaining nut

on both sides.
2007.50 Focus 4/2007 G418593en

211-02-42 Power Steering 211-02-42
Steering Angle Sensor

Centralize the steering and lock it in position. 1
2 6 Nm
TIE38833
Item Description
1 Steering angle sensor electrical connector
TIE38834
2 Steering angle sensor retaining screws
2. Raise and support the vehicle. 3 Steering angle sensor
For additional information, refer to: Jacking 5. To install, reverse the removal procedure.
(100-02, Description and Operation)
/ Lifting (100-02, Description and Operation).
E40677

table(s).
2007.50 Focus 4/2007 G296229en

211-02-43 Power Steering 211-02-43
Steering Gear to Power Steering Fluid Reservoir Return Line —

Vehicles With: Electro-Hydraulic Power Steering
(EHPS)(13 439 0)
1. Raise and support the vehicle. 4. Remove the right-hand front fender splash
For additional information, refer to: Jacking shield.
/ Lifting.
E40674

E40677
table(s).
TIE39201
2007.50 Focus 4/2007 G296230en

211-02-44 Power Steering 211-02-44
1 4
23 Nm 3
2
TIE39076
1 Steering gear to power steering fluid 3 Power steering fluid lines support bracket
reservoir return line to vehicle body
2 Steering gear to power steering fluid
reservoir return line retaining bolt 4 Power steering fluid lines support bracket
See Removal Detail to steering gear
Steering System Filling
/ Power Steering System Bleeding.
Removal Details
Item 1 Steering gear to power steering fluid
reservoir return line
1.
return line to prevent fluid loss or dirt
ingress.
Disconnect the power steering fluid return
line from the power steering pump.
2007.50 Focus 4/2007 G296230en

211-02-45 Power Steering 211-02-45
• Allow the fluid to drain into a suitable Detach the power steering fluid lines bracket
container. from the vehicle body.
TIE0036038 TIE45914
Item 2 Steering gear to power steering fluid 2. Detach the power steering fluid return line
reservoir return line retaining bolt from the support bracket.
1. Disconnect the power steering lines from the 1. Release the retaining clip.
steering gear valve body. 2. Open the support bracket.
container.
2
1 1
TIE45915
2

bracket to steering gear
TIE0036745
1. Detach the power steering fluid lines support
bracket from the steering gear.
1. NOTE: Note the position of the power
steering fluid lines support bracket to aid
installation.
TIE45916
2. Remove the power steering fluid return line.

1. Release the retaining clip.
2007.50 Focus 4/2007 G296230en

211-02-46 Power Steering 211-02-46
2. Open the support bracket.
TIE45917
CAUTION: Make sure the power steering
fluid lines are a minimum of 15 mm from
the auxiliary drive belts.

reservoir return line retaining bolt
1. Connect the power steering lines to the
18 Nm 2
1
TIE0036746
2007.50 Focus 4/2007 G296230en

211-02-47 Power Steering 211-02-47
Steering Gear to Power Steering Fluid Reservoir Return Line —

1.6L (Z6)(13 439 0)
and Operation)
TIE39201

shield.
E40677
E40674

table(s).
2007.50 Focus 4/2007 G418594en

211-02-48 Power Steering 211-02-48
2 14 Nm
23 Nm 2
2
2
E52676

1 Steering gear to power steering fluid 7. Fill and bleed the power steering system.
reservoir return line retaining clips For additional information, refer to: Power
See Removal Detail Steering System Filling - 1.6L (Z6) (211-00
2 Steering gear to power steering fluid Steering System - General Information,
reservoir return line retaining clamps and General Procedures)
bolts / Power Steering System Bleeding - 1.6L (Z6)
See Removal Detail (211-00 Steering System - General
Removal Details
reservoir return line retaining clips
1.
reservoir outlet union to prevent fluid loss
or dirt ingress.
NOTE: Note the position of the steering gear to
power steering fluid reservoir return line to aid
installation.
2007.50 Focus 4/2007 G418594en

211-02-49 Power Steering 211-02-49
Using the special tool, disconnect the Item 2 Steering gear to power steering fluid
steering gear to power steering fluid reservoir return line retaining clamps and bolts
reservoir return line from the power steering
fluid reservoir. 1. Detach the steering gear to power steering
fluid reservoir return line from the vehicle
body.
303-397
E52677
E52679
2.
CAUTION: Cap the steering gear outlet
union to prevent fluid loss or dirt ingress. 2. Remove the steering gear to power steering
NOTE: Note the position of the steering line to aid fluid reservoir return line.
installation. • Detach the retaining clip from the vehicle
Using the special tool, disconnect the body.
steering gear to power steering fluid
reservoir return line from the steering gear.
303-397
E52766
E52678
2007.50 Focus 4/2007 G418594en

211-03-1 Steering Linkage 211-03-1
.
SECTION 211-03 Steering Linkage

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 211-03-2

Steering Linkage................................................................................................................. 211-03-3

Tie Rod End.................................................................................................... (13 273 0) 211-03-4
Tie Rod End — 1.6L (Z6)............................................................................... (13 273 0) 211-03-6
Steering Gear Boot......................................................................................... (13 134 0) 211-03-8
Tie Rod........................................................................................................... (13 263 0) 211-03-10
Tie Rod — 1.6L (Z6)....................................................................................... (13 263 0) 211-03-13
SPECIFICATIONS
Tie-rod to steering gear 90 66 -
Tie-rod end locknut 62 46 -
2007.50 Focus 3/2007 G307389en

Steering Linkage
REFER to Section 211-00 [Steering System -
2007.50 Focus 3/2007 G17594en

Tie Rod End(13 273 0)

Special Tool(s) 2. Remove and discard the tie-rod end retaining
nut.
211-020 (13-006)
211-020 1
13006
Removal
TIE0026773
and Tires].
2. 4. NOTE: Make a note of the number of turns
CAUTION: Leave the tie-rod end retaining used to remove the tie-rod end.
Remove the tie-rod end.
Loosen the tie-rod end locknut and the
tie-rod end retaining nut.
1. Loosen the locknut.
TIE0026774
Installation
1
1. NOTE: Install the tie-rod end using the same
number of turns used to remove it.
TIE0026771
Install the tie-rod end.
3.
1. Release the tie-rod end.
TIE0026774
2007.50 Focus 3/2007 G307390en

2.
WARNING: Install a new tie-rod end
retaining nut. Failure to follow this
Attach the tie-rod end to the wheel knuckle.
2. Tighten the locknut.
47 Nm 1
62 Nm 2
E0036247
3. Install the wheel and tire. For additional

and Tires].
to Section 204-00 [Suspension System -
2007.50 Focus 3/2007 G307390en

Tie Rod End — 1.6L (Z6)(13 273 0)

Special Tool(s) Using the special tool, detach the tie-rod end
211-020 (13-006)
211-020
13006
Removal
E52983
and Installation). 4. NOTE: Make a note of the number of turns
used to remove the tie-rod end.
2.
Remove the tie-rod end.
• Discard the cotter pin.
TIE0026774
2 Installation
3
Install the tie-rod end.
1
E52510
3.
TIE0026774
2007.50 Focus 3/2007 G418599en

2.
NOTE: Install a new tie-rod end retaining nut cotter
pin.
3. Tighten the locknut.
2
1 47 Nm
3 62 Nm
E52511

and Installation).
necessary.
Toe Adjustment (204-00 Suspension
Procedures).
2007.50 Focus 3/2007 G418599en

Steering Gear Boot(13 134 0)

General Equipment Install the steering gear boot.
Pincers
Materials
Name Specification
Grease ESB-M1C119-B
Removal
1. Remove the tie-rod end.
For additional information, refer to Tie-Rod TIE0028478
End in this section.
2. Remove the tie-rod end locknut. 2. Using a suitable pair of pincers, install a new
steering gear boot inner clamp.
TIE0028060
TIE0028477
3. NOTE: Make sure the tie-rod is clean before

removing the steering gear boot. 3. NOTE: Make sure the steering gear boot
Remove the steering gear boot. outer clamp is located over the recess in the
tie-rod.
• Discard the clamps.
Using a suitable pair of pincers, install a new
steering gear boot outer clamp.
TIE0028061
TIE0028476
Installation
1. NOTE: Lubricate the steering gear boot.
2007.50 Focus 3/2007 G105651en

4. Install the tie-rod end locknut.
TIE0028060
5. Install the tie-rod end.

For additional information, refer to Tie-Rod
End in this section.
2007.50 Focus 3/2007 G105651en

Tie Rod(13 263 0)

Special Tool(s) 2. Loosen the retaining nut.
Clamping Tool, Boot
Retaining Clamp
204-169 2
14044
Separator, Ball Joint 1

211-020
TIE0026771
13006 3.
Socket, Steering Gear Using the special tool, detach the tie-rod end
Tie-Rod from the wheel knuckle.
211-245 (13-025) 1. Release the tie-rod end.
2. Remove and discard the tie-rod end retaining
13025
nut.
General Equipment
Pipe wrench 211-020 1
Pincers
2
Materials
Name Specification
TIE0026773
Removal
4. NOTE: Make a note of the number of turns
1. Remove the wheel and tire. used to remove the tie-rod end.
For additional information, refer to: Wheel Remove the tie-rod end.
and Installation).
2.
TIE0026774
2007.50 Focus 3/2007 G307391en

5. Remove the steering gear boot. 2. NOTE: Lubricate the steering gear boot
sealing area on the steering gear housing
• Disconnect the steering gear vent hose.
and tie-rod with grease.
• Remove and discard the steering gear
clamps. NOTE: Make sure that the alignment pin on the
steering gear housing fits into the recess of the
steering gear boot.
Install a new steering gear boot and a new
inner clamp.
E62014
6. Rotate the steering wheel to gain access to

the tie-rod retaining nut.
7. E62026
CAUTION: Do not clamp the steering rack
on exposed hydraulic sealing surfaces.
3. Using the special tool, tighten the steering
Using a pipe wrench remove the tie-rod. gear boot inner clamp.
• Connect the steering gear vent hose.
E62015
E62017
Installation
4. NOTE: Make sure that the steering gear boot
1. Using the special tool, install the tie-rod. outer clamp is located over the recess in the
tie-rod.
NOTE: Following installation, no radial movement
of the steering gear boot is permissible.
95 Nm
211-245
E62016
2007.50 Focus 3/2007 G307391en

Using a suitable pair of pincers, install a new 2. Tighten the locknut.
steering gear boot outer clamp (steering gear
shown removed for clarity).
47 Nm 1
62 Nm 2
E0036247
TIE0029338 7. Install the wheel and tire.

5. NOTE: Install the tie-rod end using the same and Tire (204-04 Wheels and Tires, Removal
number of turns used to remove it. and Installation).
NOTE: Do not fully tighten the tie-rod end locknut 8. Check the toe setting and adjust as
at this stage. necessary. For additional information, refer
Install the tie-rod end locknut and the tie-rod to: (204-00 Suspension System - General
end. Information)
Front Toe Adjustment (General Procedures).
TIE0026774
6.
2007.50 Focus 3/2007 G307391en

Tie Rod — 1.6L (Z6)(13 263 0)

General Equipment • Discard the steering gear boot.
Vise jaw protectors
Pincers
Materials
Name Specification
Grease ESB-M1C119-B
Removal
1. Remove the steering gear. E52806

Gear - 3-Door (211-02 Power Steering, 5. Rotate the steering gear pinion to expose
Removal and Installation). the steering gear rack.
2. NOTE: Make a note of the number of turns
used to remove the tie-rod end.
Remove the tie-rod end and the tie-rod end
locknut.
E52807
6. CAUTIONS:
Do not clamp the steering gear rack on
E52998
exposed hydraulic sealing surfaces.
Make sure vise jaw protectors are used.

3. Remove the steering gear boot clamps.
To counter the extensive torque forces
• Discard the steering gear boot clamps. required to remove the tie-rod, clamp the
steering gear rack teeth in a suitable vise.
Do not clamp the steering gear body.
E52805
4. Remove the steering gear boot.
2007.50 Focus 3/2007 G418600en

Secure the steering gear rack in a vise and Using a suitable pair of pincers, install the
remove the tie-rod. steering gear boot inner clamp.
E52808 E52811
Installation 4. NOTE: Install a new steering gear boot

clamp.
1. Install the tie-rod. NOTE: Make sure the steering gear boot outer
clamp is located over the recess in the tie-rod.
Using a suitable pair of pincers, install the
90 Nm steering gear boot outer clamp.
E52809
2. NOTE: Lubricate the steering gear boot.

NOTE: Install a new steering gear boot. E52812
Install the steering gear boot.

Install the tie-rod end locknut and the tie-rod
end.
62 Nm
E52810
3. NOTE: Install a new steering gear boot

clamp.
E52999
2007.50 Focus 3/2007 G418600en

6. Install the steering gear.
Gear - 3-Door (211-02 Power Steering,
2007.50 Focus 3/2007 G418600en

211-04-1 Steering Column 211-04-1
.
SECTION 211-04 Steering Column

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 211-04-2

Steering Column................................................................................................................. 211-04-3

Steering Wheel............................................................................................... (13 524 0) 211-04-4
Steering Column................................................................................................................. 211-04-7

Steering Column................................................................................................................. 211-04-10
SPECIFICATIONS
Item Nm lb-ft lb-in
Steering wheel retaining bolt 48 35 -
Driver air bag module ground spring retaining screw - 3 27
Steering column shaft to steering gear pinion 28 21 -
retaining bolt
Steering column retaining bolts 25 18 -
2007.50 Focus 3/2007 G164691en

Steering Column
REFER to Section 211-00 [Steering System -
2007.50 Focus 3/2007 G17604en

Steering Wheel(13 524 0)

Removal 4. Disconnect the steering wheel electrical
connector (vehicles with speed control
All vehicles shown).
For additional information, refer to: Driver
Restraint System, Removal and
Installation).
2. NOTE: Make sure that the road wheels are
in the straight ahead position.
Centralize the steering and lock it in position.
E52100
5. Remove the steering wheel retaining bolt.
TIE38836
3.
CAUTION: Make sure that the clockspring
rotor is not allowed to rotate. Secure in the
central position with a piece of suitable tape. E61144
Secure the clockspring rotor to the
clockspring outer. 6.
Remove the steering wheel.
• Feed the driver air bag wiring harness
through the steering wheel.
TIE40357
E41065
2007.50 Focus 3/2007 G415564en

Vehicles built up to 01/2005 Install the driver air bag module ground
spring.
7.
CAUTION: If installing a new steering
wheel with the original driver air bag module,
the driver air bag module ground spring must
be removed. 3 Nm
Remove the driver air bag module ground
spring.
E61773
All vehicles
3. NOTE: When the clockspring is centralized,
part of the flat flexible cable will be visible
and is U-shaped.
E61145
Look for the U-shaped part of the flat flexible
cable to confirm the clockspring is
Installation centralized.
Vehicles built up to 01/2005

1.
CAUTION: If installing the original driver
air bag module to a new steering wheel, the
driver air bag module ground cable must be
removed from the new steering wheel.
Remove the driver air bag module ground
cable.
E40362
4.
Install the steering wheel.
E61146
2.
CAUTION: If installing the original driver
air bag module to a new steering wheel, the
driver air bag module ground spring must
be installed to the new steering wheel.
2007.50 Focus 3/2007 G415564en

• Feed the driver air bag wiring harness 7. Remove the securing tape from the
through the steering wheel. clockspring.
E41065
TIE40357
5. Install the steering wheel retaining bolt. 8. Install the driver air bag module.
For additional information, refer to: Driver
48 Nm Air Bag Module (501-20 Supplemental
Installation).
TIE38835
6. Connect the steering wheel electrical

connector (vehicles with speed control
shown).
E52100
2007.50 Focus 3/2007 G415564en

Steering Column
For additional information, refer to: Driver table(s).
Installation).
2 3
25 Nm 7
5
1
4
6 28 Nm
E50620
1 Instrument panel lower outer trim panel 5 Steering column wiring harness
2 Audio control switch (if equipped) 6 Steering column shaft to steering gear
See Removal Detail pinion retaining bolt
3 Steering column upper shroud
See Removal Detail 7 Steering column retaining bolts
4 Steering column lower shroud
Removal Details
2007.50 Focus 3/2007 G401832en

Item 1 Instrument panel lower outer trim panel Detach the steering column upper shroud
from the steering column lower shroud
1. Detach the diagnostic link connector (DLC)
(steering wheel shown removed for clarity).
from the instrument panel lower trim panel.
• Using a thin bladed screwdriver, release the
retaining clips (one each side)
TIE44539
TIE38840
Item 2 Audio control switch (if equipped)
1. Using a thin bladed screwdriver, release the 2. NOTE: Make sure the road wheels are in the
locking tang. straight ahead position.
TIE40358
TIE38836
2. Disconnect the electrical connector.
1. Release the steering column locking lever
to aid the removal of the steering column
lower shroud.
TIE40359
Item 3 Steering column upper shroud

1. NOTE: Turn the steering wheel to gain
access to the steering column upper shroud
retaining clips.
2007.50 Focus 3/2007 G401832en

Item 5 Steering column wiring harness
1. Detach the wiring harness from the steering
column.
TIE45920
Item 7 Steering column retaining bolts
WARNING: Install new steering column
retaining bolts. Failure to follow this
Item 6 Steering column shaft to steering gear

pinion retaining bolt
shaft to steering gear pinion retaining bolt.
in personal injury.

1. Feed the audio control switch wiring harness
through the steering column lower shroud.
2007.50 Focus 3/2007 G401832en

Steering Column
table(s).
1 48 Nm
3
3 Nm
3 Nm
TIE38841
1 Steering wheel retaining bolt 4 Ignition switch
2 Steering wheel 5 Passive anti-theft system (PATS)

See Disassembly Detail transceiver
See Assembly Detail 6 Ignition lock cylinder
3 Multifunction switch / clockspring carrier See Disassembly Detail
2007.50 Focus 3/2007 G296236en

2. To assemble, reverse the disassembly procedure.
Disassembly Details
Item 2 Steering wheel 2. Using a pair of grippers, remove the left-hand
screw.
1.
CAUTION: Make sure the clockspring is
not allowed to rotate. Secure in the central
position with a piece of suitable tape.
Secure the clockspring rotor to the
clockspring outer.
E71088
3. Detach the the ignition switch body from the

steering column.
TIE40357

• Carefully feed the driver air bag module
wiring harness through the steering wheel.
Item 6 Ignition lock cylinder

1. Using a punch, remove the right-hand screw.
E71090
4. Turn the ignition key to position I.

5. Using a suitable tool, release the locking
tang.
E71089
E71091
2007.50 Focus 3/2007 G296236en

Assembly Details
1. Connect the electrical connectors.
• Carefully feed the driver air bag module
wiring harness through the steering wheel.
2. Remove the tape securing the clockspring.
TIE40357
2007.50 Focus 3/2007 G296236en

211-05-1 Steering Column Switches 211-05-1
.
SECTION 211-05 Steering Column Switches

CONTENTS PAGE

Ignition Switch..................................................................................................................... 211-05-2
Ignition Switch
2. Turn the ignition key to position 1.
table(s).
1 2
4 3
E39004
Item Description
All vehicles
1 Remote audio control switch (if equipped)
See Removal Detail
2 Steering column upper shroud Vehicles with global closing
See Removal Detail
5. Initialize the door window motors.
3 Steering column lower shroud For additional information, refer to: Door
See Removal Detail Window Motor Initialization (501-11 Glass,
4 Ignition switch electrical connector Frames and Mechanisms, General
Procedures).
5 Ignition switch
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G307409en

Item 1 Remote audio control switch (if Item 2 Steering column upper shroud
equipped) 1. NOTE: Turn the steering wheel to access the
1. Using a thin bladed screwdriver, release the steering column upper shroud retaining
locking tang. clips.
Detach the steering column upper shroud
from the steering column lower shroud
(steering wheel shown removed for clarity).
retaining clips (one each side).
TIE38838
2. Disconnect the audio control electrical

connector.
TIE38840

1. To aid the removal of the steering column
lower shroud, release the steering column
locking lever.
Item 5 Ignition switch

CAUTION: Do not turn the ignition switch
TIE38839 lock cylinder from position 1 when the
ignition switch has been removed.
Item 5 Ignition switch
1.
CAUTION: Do not turn the ignition switch
lock cylinder from position 1 when the
ignition switch has been removed.
Check and turn the ignition switch to
position 1.
2007.50 Focus 3/2007 G307409en

303-00-1 Engine System - General Information 303-00-1
.
SECTION 303-00 Engine System - General Information

CONTENTS PAGE

Engine................................................................................................................................. 303-00-3
Engine/transmission combinations .................................................................................... 303-00-3
1.6L Duratorq TDCi (DV6) engine ..................................................................................... 303-00-4
General .............................................................................................................................. 303-00-5
1.8L Duratec HE (MI4) engine ........................................................................................... 303-00-7
General .............................................................................................................................. 303-00-8

Engine................................................................................................................................. 303-00-10
Engine - Oil Leaks.............................................................................................................. 303-00-33
Ultraviolet (UV) Testing....................................................................................................... 303-00-33
Measure the compression pressure................................................................................... 303-00-34
Measure the compression pressure (Engine - 1.6L Duratec-16V, Engine - 1.6L Duratec-16V
Ti-VCT)............................................................................................................................. 303-00-34
Measure the compression pressure (Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE
(MI4))................................................................................................................................ 303-00-36
Measure the compression pressure (Engine - 2.5L Duratec-ST (VI5)).............................. 303-00-39
Measure the compression pressure (Engine - 1.6L Duratorq-TDCi (DV) Diesel).............. 303-00-41
Measure the compression pressure (Engine - 1.8L Duratorq-TDCI (Kent) Diesel)............ 303-00-44
Measure the compression pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel)............. 303-00-46
Measure the oil pressure (21 113 0)................................................................................... 303-00-49
Measure the oil pressure (Engine - 1.6L Duratec-16V, Engine - 1.6L Duratec-16V Ti-VCT). 303-00-49
Measure the oil pressure (Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4))......... 303-00-51
Measure the oil pressure (Engine - 2.5L Duratec-ST (VI5))............................................... 303-00-52
Measure the oil pressure (Engine - 1.6L Duratorq-TDCi (DV) Diesel)............................... 303-00-54
Measure the oil pressure (Engine - 1.8L Duratorq-TDCI (Kent) Diesel)............................. 303-00-55
Measure the oil pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel).............................. 303-00-56
Valve train analysis - static (engine off).............................................................................. 303-00-57
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter.................................................................................. 303-00-59
Camshaft Bearing Journal Clearance................................................................................. 303-00-60
Camshaft End Play............................................................................................................. 303-00-61
Camshaft Surface Inspection............................................................................................. 303-00-62
Camshaft Lobe Lift.............................................................................................................. 303-00-63
Crankshaft Main Bearing Journal Diameter........................................................................ 303-00-64
Crankshaft End Play........................................................................................................... 303-00-65
Cylinder Bore Taper............................................................................................................ 303-00-66
Piston Inspection................................................................................................................ 303-00-67
Piston Pin to Bore Diameter............................................................................................... 303-00-68
Piston Diameter.................................................................................................................. 303-00-69
Piston Ring End Gap.......................................................................................................... 303-00-70
Piston Ring-to-Groove Clearance....................................................................................... 303-00-71
.
Piston Pin Diameter............................................................................................................ 303-00-72
Connecting Rod Large End Bore........................................................................................ 303-00-73
Valve Stem Diameter.......................................................................................................... 303-00-74
Flywheel Inspection............................................................................................................ 303-00-75
Cylinder Head Distortion..................................................................................................... 303-00-76
Cylinder Block Distortion..................................................................................................... 303-00-77
Exhaust Manifold Cleaning and Inspection........................................................................ 303-00-78
Bearing Inspection.............................................................................................................. 303-00-79
Engine
Engine/transmission combinations
1 2 3
5 4
E42971
2007.50 Focus 3/2007 G187579en


1 1.6L Duratorq TDCi (DV6) engine 4 MMT6
2 1.8L Duratec HE (MI4) engine 5 MTX-75
3 2.0L Duratorq TDCi (DW10) engine
1.6L Duratorq TDCi (DV6) engine
E41992
2007.50 Focus 3/2007 G187579en

General Intake camshaft driven via a timing belt
Valves actuated by roller cam followers with
The 1.6L Duratorq TDCi (DV6) engine is a hydraulic clearance adjustment
comprehensively revised version of the familiar
1.4L Duratorq TDCi (DV4) engine used in the Turbocharger with variable turbine geometry and
Fiesta 2002.25. intercooler
The cylinder head has been completely Power output via a dual mass flywheel
re-designed. The exhaust camshaft is driven via a
short timing chain with timing chain tensioner.
Engine management
The intake air duct and air filter housing have also
been modified. The crank drive has been adapted Direct fuel injection using the common rail method
to the higher engine torque.
Solenoid valve controlled injector valve
A Bosch common rail fuel injection system is used.
Fully electronic regulation of fuel metering
In addition, engine management components have
been modified or added.
Engine emission control
Technical data and specifications Exhaust Gas Recirculation (EGR)
Cross-mounted 4-cylinder turbodiesel engine with Oxidation catalytic converter.
two overhead camshafts and 16 valves. European emissions level III
Light metal cylinder block with cylinder liners made
of cast iron.
Diagnostics
Cross flow cylinder head made of aluminium with
two overhead camshafts and four valves per Diagnosis by means of WDS via the Data Link
cylinder. Connector (DLC)
2007.50 Focus 3/2007 G187579en

Torque and power output
300 90
1 2
80
250
70
200
60
150 50
40
100
30
50
20
0 10
500 1000 1500 2000 2500 3000 3500 4000 4500
E41991
At an engine speed as low as 1750 rev/min there

Item Description
is already a torque of 240 Nm available.
1 Torque curve The engine delivers a maximum power of 81 kW
2 Power curve (110 PS) at 4000 rev/min.
The torque delivery curve has been particularly

well harmonised as a result of optimised fuel
induction and combustion.
2007.50 Focus 3/2007 G187579en

1.8L Duratec HE (MI4) engine
E43046
2007.50 Focus 3/2007 G187579en

General Electronic throttle valve
Intake manifold switching system with swirl valves
Design details of the familiar 1.8L Duratec HE
(M14) engine from the Mondeo have been revised. Ignition system with direct ignition coils
It is now equipped with an intake manifold Accessory drive system with one conventional and
switchover system with swirl valves and an ignition one elastic multi-groove belt
system with direct ignition coils.
In addition, an electric throttle valve is also used. Engine management
The Air Conditioning (A/C) compressor is located
underneath the engine, and the alternator is Visteon Powertrain Control Module (PCM) System
attached to the cylinder block underneath the intake 7
manifold (in front of the engine when looking Knock control with two knock sensors
towards the front of the vehicle).
The accessory drive system has been revised and
now has an additional elastic multi-groove belt Engine emission control
which drives the A/C compressor and does not
have a separate belt tensioner. European emissions level IV
European on-board diagnosis to monitor the
components relevant to exhaust emissions
Technical data and specifications
Stepper motor controlled EGR system
Cross-mounted 4-cylinder inline engine with two
overhead camshafts and 16 valves.
Diagnostics
Chain driven camshafts
Aluminium cylinder block with lower crankcase Diagnosis with WDS via the DLC
Mechanically operated bucket tappets to operate
the valves
2007.50 Focus 3/2007 G187579en

Torque and power output
170 1 90
160 80
150 70
140 60
130 50
120 40
110 30
100 20
90 10
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
E42710
Item Description
1 Torque curve
2 Power curve
By using an intake manifold switchover system
with swirl valves, it has been possible to increase
torque across the entire engine speed range, and
at the same time reduce fuel consumption.
The maximum torque of 172 Nm is achieved at an
engine speed of 4000 rev/min.
The engine delivers a maximum power of 88 kW
(120 PS) at 6000 rev/min.
2007.50 Focus 3/2007 G187579en

Engine
Socket, Spark Plug Worldwide Diagnostic System (WDS)
303-499
Materials
Name Specification
ES21202 Adhesive - Loctite 243 WSK-M2G349-A7

1. Verify the customer concern by operating the
system
Compression Test Adapter 2. Visually inspect for obvious signs of mechanical
303-1049A or electrical damage.
E62013
Compression Test Adapter Visual Inspection Chart
303-1052
– Coolant leaks – Fuse(s)
– Oil leaks – Loose or corroded
E47332 – Fuel system leaks connector(s)
– Visibly damaged or – Control module
Compression Test Adapter worn parts – Damaged or worn
303-1056 – Loose or missing switch(es)
nuts or bolts
E42936
Symptom Chart
• Loss of oil • Oil leaks on components that • CHECK for evidence of oil
are either coated in oil them- leaks on components. Use an
selves or on components local ultraviolet (UV) leak tester if an
to them. oil leak is not evident. INSTALL
new gaskets or components as
required.
• Internal or external leak at the • CHECK the coolant expansion
oil cooler. tank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
• Leak at the crankshaft seal. • INSTALL a new crankshaft
seal.
2007.50 Focus 3/2007 G296460en


• Leaks from oil carrying • CHECK for cracks in oil-
components or basic engine. carrying components of the
basic engine by means of a UV
leak test. INSTALL new
components or seals as
necessary.
• Oil consumption • Use of the wrong type of • DETERMINE the last type of
engine oil. engine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
2007.50 Focus 3/2007 G296460en


• Faulty positive crankcase vent- • CHECK if the PCV system is
ilation (PCV) system. operating correctly and repair
- Hoses or ventilation or as necessary. Engine - 1.4L
breather valves are blocked. Duratec-16V (Sigma)/1.6L
This causes excessive Duratec-16V (Sigma) -
pressure in the crankcase REFER to: Engine Emission
which causes more oil to Control (303-08 Engine
enter the combustion Emission Control - 1.4L
chamber. Duratec-16V (Sigma)/1.6L
- PCV oil separator is faulty Duratec-16V (Sigma)/1.6L
and engine oil can enter the Duratec-16V Ti-VCT (Sigma),
combustion chamber Diagnosis and Testing).
through the intake manifold. Engine - 1.8L Duratec-HE
(MI4)/2.0L Duratec-HE (MI4) -
REFER to: Engine Emission
Control (303-08 Engine
Emission Control - 2.0L
Duratec-HE (MI4), Diagnosis
and Testing).
Engine - 2.5L Duratec-ST (VI5)
-
Duratec-ST (VI5), Diagnosis
and Testing).
Engine - 1.6L Duratorq-TDCi
(DV) Diesel -
Duratorq-TDCi (DV) Diesel,
(DW) Diesel -
Duratorq-TDCi (DW) Diesel,
(Kent) Diesel -
Duratorq-TDCi (Lynx) Diesel,
2007.50 Focus 3/2007 G296460en


• Turbocharger seals. • INSTALL a new turbocharger.
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec-ST (VI5),
/ Turbocharger - 1.6L Duratorq-
TDCi (DV) Diesel (90 PS)
(303-04 Fuel Charging and
Controls - Turbocharger,
TDCi (DV) Diesel (110 PS)
(303-04 Fuel Charging and
Controls - Turbocharger,
TDCi (DV) Diesel (110 PS),
VIN Plate Emission Level
Code: K (303-04 Fuel Char-
ging and Controls -
Turbocharger, Removal and
Installation)
TDCi (Lynx) Diesel (303-04
Fuel Charging and Controls
- Turbocharger, Removal and
Installation)
- Turbocharger, Removal and
Installation).
2007.50 Focus 3/2007 G296460en


• Damaged gaskets or mating • CHECK the gaskets and
surfaces. mating surfaces for damage.
- Cylinder head gasket is Remove the cylinder head.
damaged or mating face are CHECK the mating faces, cylinder
warped. head gasket and the evenness of
- Valve stem seals are worn the cylinder head and engine
and engine oil can enter the block mating faces.
combustion chamber INSTALL new valve seals. Engine
between the valve stem and - 1.4L Duratec-16V (Sigma)/1.6L
the valve stem guide. Duratec-16V (Sigma) -
REFER to: Valve Seals (303-01A
Engine - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V
(Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT
REFER to: Valve Seals (303-01
Engine - 1.6L Duratec-16V Ti-
VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE
(MI4)/1.8L Duratec-HE (MI4), In-
vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Valve Stem Seals
(303-01 Engine - 2.5L Duratec-
ST (VI5), Removal and Installa-
tion).
Engine - 1.6L Duratorq-TDCi (DV)
Diesel -
(DV) Diesel, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW)
Diesel -
(Lynx) Diesel, In-vehicle Repair).
(Kent) Diesel -
(DW) Diesel, In-vehicle Repair).
• Piston ring or cylinder liner • INSTALL new components as
wear. necessary.
2007.50 Focus 3/2007 G296460en


• Damaged cylinder liners or • CHECK the running surfaces
excessive clearance of engine and clearances of the individual
components. engine components. INSTALL
- Pistons. new components as necessary.
- Piston rings (clearance in INSTALL a new cylinder block
groove and end gap). if necessary.
- Cylinder liners. • Check the pistons and piston
rings. REFER to: (303-00
Engine System - General
Information)
Piston Inspection (General
Procedures),
Piston Pin to Bore Diameter
Piston Diameter (General
Procedures),
Piston Ring End Gap (General
Procedures),
Piston Ring-to-Groove Clear-
ance (General Procedures),
Piston Pin Diameter (General
Procedures).
2007.50 Focus 3/2007 G296460en


• Coolant consumption • Cooling system components. • Check the cooling system
components. Engine - 1.4L
Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma) -
REFER to: Engine Cooling
(303-03 Engine Cooling -
1.4L Duratec-16V
(Sigma), Diagnosis and
Testing).
VCT -
1.6L Duratec-16V Ti-VCT
(Sigma), Diagnosis and
Testing).
and Testing).
-
(DV) Diesel -
Diesel, Diagnosis and
Testing).
(DW) Diesel -
Testing).
(Kent) Diesel -
Testing).
• Oil cooler. • INSTALL a new oil cooler.
2007.50 Focus 3/2007 G296460en


• Damaged gaskets or warped • CHECK the cylinder head
mating faces. gasket for damage. CHECK the
cylinder head for distortion.
• Cracks or fractures in engine • DETERMINE the damaged
components surrounded by engine component(s) and
coolant, such as cylinder liners install new component(s) as
and cylinder head combustion necessary.
chamber.
• Engine will not crank • Battery or cables. • CHECK the battery, bracket
and cables.
REFER to: Battery (414-01
Battery, Mounting and
Cables, Diagnosis and
Testing).
• Starter motor or cables. • CHECK the starting system.
REFER to: Starting System
(303-06 Starting System,
• Engine cranks but will not start • Fuel tank is empty. • CHECK the fuel level.
• Water in fuel (only diesel • Drain the water from the fuel
engine). system.
• Fuel filter blocked. • INSTALL a new fuel filter.
REFER to: (310-01 Fuel Tank
and Lines)
Fuel Filter - 2.0L Duratec-HE
Fuel Filter - 1.6L Duratorq-TDCi
(DV) Diesel (Removal and
Installation),
(DW) Diesel, Vehicles With:
Water-in-Fuel Sensor
(DW) Diesel, Vehicles
Without: Water-in-Fuel
Sensor (Removal and Install-
ation),
(Lynx) Diesel, Vehicles
ation).
2007.50 Focus 3/2007 G296460en


• Engine intake air system. • CHECK the intake air system.
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering, Diagnosis and
Testing).
• Glow plug faulty (only diesel • CHECK the glow plugs.
engine). INSTALL new glow plugs as
necessary.
REFER to: Glow Plug System
(303-07 Glow Plug System -
(DW) Diesel, Diagnosis and
Testing).
• Engine management system. • CHECK the engine manage-
ment system.
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
and Testing).
• Ignition system (only petrol • CHECK the ignition system.
engines). Engine - 1.4L Duratec-16V
(Sigma) -
REFER to: Engine Ignition
(303-07 Engine Ignition - 1.4L
Duratec-16V Ti-VCT (Sigma),
and Testing).
-
and Testing).
2007.50 Focus 3/2007 G296460en


• Incorrect valve timing. • CHECK and adjust the valve
timing. Engine - 1.4L Duratec-
16V (Sigma)/1.6L Duratec-16V
(Sigma) -
REFER to: Timing Belt -
Vehicles Built Up To: 04/2005
(303-01A Engine - 1.4L
Duratec-16V (Sigma), In-
vehicle Repair).
VCT -
(303-01 Engine - 1.6L
In-vehicle Repair).
REFER to: Timing Chain (303-
01 Engine - 2.0L Duratec-HE
(MI4)/1.8L Duratec-HE (MI4),
In-vehicle Repair).
-
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec-ST
(VI5), Removal and Installa-
tion).
(DV) Diesel -
(DV) Diesel, In-vehicle
Repair).
(Kent) Diesel -
(Lynx) Diesel, In-vehicle
Repair).
(DW) Diesel -
(DW) Diesel, In-vehicle
Repair).
2007.50 Focus 3/2007 G296460en


• Broken or damaged timing • CHECK the timing belt/timing
belt/timing chain or chain and sprockets/pulleys.
pulley/sprocket. INSTALL new components as
necessary. Engine - 1.4L
(303-01A Engine - 1.4L
vehicle Repair).
VCT -
(303-01 Engine - 1.6L
In-vehicle Repair).
In-vehicle Repair).
-
tion).
(DV) Diesel -
Repair).
(Kent) Diesel -
Repair).
(DW) Diesel -
Repair).
2007.50 Focus 3/2007 G296460en


• Very poor power output or fuel • Fuel system.
consumption too high or engine
running rough.
2007.50 Focus 3/2007 G296460en


• CHECK the fuel system.
(Sigma) -
REFER to: Fuel Charging and
Controls (303-04 Fuel Char-
ging and Controls - 1.6L
VCT -
and Testing).
-
and Testing).
(DV) Diesel -
Duratorq-TDCi (DV) Diesel,
(DW) Diesel -
Duratorq-TDCi (DW) Diesel,
(Kent) Diesel -
Controls - 1.8L Duratorq-
- 1.8L Duratorq-TDCi (Lynx)
2007.50 Focus 3/2007 G296460en


Testing).
• Engine intake air system. • CHECK the intake air system.
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering, Diagnosis and
Testing).
• Exhaust system blocked. • CHECK the exhaust system.
REFER to: Exhaust System
(309-00 Exhaust System,
• Engine management system. • CHECK the engine manage-
ment system.
and Testing).
• Fault in ignition system (only • CHECK the ignition system.
petrol engines). Engine - 1.4L Duratec-16V
(Sigma) -
and Testing).
-
and Testing).
2007.50 Focus 3/2007 G296460en


• Turbocharger. • CHECK the turbocharger.
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
TDCi (DV) Diesel (303-04
- Turbocharger, Diagnosis
and Testing)
and Testing)
and Testing).
2007.50 Focus 3/2007 G296460en


• Incorrect valve timing. Timing • CHECK and adjust valve
belt/timing sprocket or timing. INSTALL new compon-
pulley/sprocket damaged. ents as necessary. Engine -
1.4L Duratec-16V (Sigma)/1.6L
(303-01A Engine - 1.4L
vehicle Repair).
VCT -
(303-01 Engine - 1.6L
In-vehicle Repair).
In-vehicle Repair).
-
tion).
(DV) Diesel -
Repair).
(Kent) Diesel -
Repair).
(DW) Diesel -
Repair).
2007.50 Focus 3/2007 G296460en


• Ignition timing incorrect (only • CHECK the electronic engine
petrol engines). controls.
and Testing).
2007.50 Focus 3/2007 G296460en


• Noisy running • Engine auxiliary components • CHECK engine auxiliary
loose or damaged. components for damage or
looseness. CHECK and adjust
valve timing. INSTALL new
(Sigma) -
(303-01A Engine - 1.4L
vehicle Repair).
VCT -
(303-01 Engine - 1.6L
In-vehicle Repair).
In-vehicle Repair).
-
tion).
(DV) Diesel -
Repair).
(Kent) Diesel -
Repair).
(DW) Diesel -
Repair).
2007.50 Focus 3/2007 G296460en


• Noisy running, misfiring, back- • Incorrect fuel • DETERMINE which type of fuel
firing or knocking was last put in the tank (note
the country specific fuel
specifications).
• Water in fuel or fuel contamin- • CHECK the fuel system for
ated. water or other contamination.
2007.50 Focus 3/2007 G296460en


• Valve timing incorrect, timing • CHECK and adjust valve
belt/chain or pulley/sprocket timing. INSTALL new compon-
damaged. ents as necessary. Engine -
(303-01A Engine - 1.4L
vehicle Repair).
VCT -
(303-01 Engine - 1.6L
In-vehicle Repair).
In-vehicle Repair).
-
tion).
(DV) Diesel -
Repair).
(Kent) Diesel -
Repair).
(DW) Diesel -
Repair).
2007.50 Focus 3/2007 G296460en


• Noisy running or valve train • Valve clearance too large due • INSTALL new hydraulic lash
noise to faulty valve tappets or worn adjusters or adjust the valve
valve train components. clearance. Engine - 1.4L
REFER to: Valve Clearance
Adjustment (303-01A Engine
- 1.4L Duratec-16V
(Sigma), General Proced-
ures).
VCT -
Adjustment (303-01 Engine -
(Sigma), General Proced-
ures).
Duratec-HE (MI4), General
Procedures).
-
(DV) Diesel -
REFER to: Camshaft (303-01
Repair).
(DW) Diesel -
REFER to: Camshafts (303-01
Repair).
(Kent) Diesel -
REFER to: Camshafts (303-01
Repair).
2007.50 Focus 3/2007 G296460en


• Timing belt or timing chain • INSTALL a new timing belt or
damaged. timing chain. Engine - 1.4L
(303-01A Engine - 1.4L
vehicle Repair).
VCT -
(303-01 Engine - 1.6L
In-vehicle Repair).
In-vehicle Repair).
-
tion).
(DV) Diesel -
Repair).
(Kent) Diesel -
Repair).
(DW) Diesel -
Repair).
2007.50 Focus 3/2007 G296460en


• Timing belt or timing chain • CHECK the timing belt tension.
incorrectly tensioned. INSTALL a new timing belt or
timing chain as necessary.
(Sigma) -
(303-01A Engine - 1.4L
vehicle Repair).
VCT -
(303-01 Engine - 1.6L
In-vehicle Repair).
In-vehicle Repair).
-
tion).
(DV) Diesel -
Repair).
(Kent) Diesel -
Repair).
(DW) Diesel -
Repair).
2007.50 Focus 3/2007 G296460en


• Noisy running or engine noise • Engine components • CHECK the engine compon-
- Pistons. ents for wear or damage. Make
- Piston rings. sure all components are within
- Connecting rod big end, specification. INSTALL new
main bearing or thrust components as necessary.
bearing journals. Engine - 1.4L Duratec-16V
- Connecting rods bent or (Sigma)/1.6L Duratec-16V
damaged. (Sigma) -
01A Engine - 1.4L Duratec-
16V (Sigma)/1.6L Duratec-
16V (Sigma), Specifications).
VCT -
01 Engine - 1.6L Duratec-16V
Ti-VCT (Sigma), Specifica-
tions).
Specifications).
(DV) Diesel -
01A, Specifications).
(Kent) Diesel -
01 Engine - 1.8L Duratorq-
TDCi (Lynx) Diesel, Specific-
ations).
(DW) Diesel -
01 Engine - 2.0L Duratorq-
TDCi (DW) Diesel, Specifica-
tions).
Engine - Oil Leaks 2. Pour the UV-test fluid in accordance with the
quantity specified by the manufacturer through
NOTE: Before installing new gaskets or oil seals, the oil filler neck into the engine and install the
make sure that the fault is clearly established. oil filler cap.
If the oil leak cannot be identified clearly by a visual WARNING: Vehicles with manual transaxle,
inspection, carry out an ultraviolet (UV) test: shift the transaxle into Neutral. Failure to
personal injury.
Ultraviolet (UV) Testing
3. Start the engine and let it run for about five
minutes.
1. Clean the engine and transmission with a
suitable cleaning fluid. 4. Switch off the engine.
2007.50 Focus 3/2007 G296460en

NOTE: If no leak can be found, road test the Measure the compression pressure
vehicle under various loads and check the engine (Engine - 1.6L Duratec-16V, Engine -
for leaks again. 1.6L Duratec-16V Ti-VCT)
5. Check the engine for oil leaks using a suitable
UV lamp.
6. Rectify any leaks found and check the engine
for oil leaks.
Measure the compression pressure

NOTE: The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are
disconnected. This error message must be deleted
from the fault memory using worldwide diagnostic
system (WDS) after completing the compression
test.
NOTE: Valve clearance must be set correctly
before performing a compression test. Make sure
the engine is at the normal operating temperature.
NOTE: The varying design of compression
checking devices and fluctuating starter motor
speeds normally only allows for a comparison to
be made of the compression pressures in all
cylinders.
TIE44608
1. Remove the central junction box (CJB) cover.
TIE44609
2. Open the CJB and remove the fuel pump relay.

NOTE: The engine will start, run for a few seconds
and then stop.
3. Start the engine.
2007.50 Focus 3/2007 G296460en

TIE0028440 TIE44802
4. Disconnect the electronic ignition (EI) coil NOTE: Operate the starter motor with wide open
connector. throttle until the pointer on the measuring device
stops rising.
7. Carry out the measurement in accordance with
the instructions supplied with the measuring
device on every cylinder using a suitable
compression pressure recorder with a suitable
adapter.
15 Nm
TIE0030038
NOTE: Twist the spark plug connectors slightly

before disconnecting them. Pull on the connector
and not on the cable.
5. Remove the spark plug connectors.
TIE44801
8. Install the spark plugs.
TIE44800
6. Remove the spark plugs.

TIE0030038
9. Install the spark plug connectors.
2007.50 Focus 3/2007 G296460en

13. Using worldwide diagnostic system (WDS), clear
the fault codes from the powertrain control
module (PCM).

(Engine - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4))
TIE0028440
10. Connect the EI coil connector.
TIE44609
11. Install the fuel pump relay and close the CJB.
TIE44608
TIE44609

NOTE: The engine will start, run for a few seconds
and then stop.
TIE44608 3. Start the engine.
12. Install the CJB cover.
2007.50 Focus 3/2007 G296460en

REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
TIE39718
8. Remove the ignition coil-on-plug.
TIE44766
5. Remove the oil filler pipe. 303-499

• Release the securing clip and rotate the oil
filler pipe counterclockwise.
ELE0017343
9. Using the special tool, remove the spark plugs.
TIE39686
6. Remove the engine cover.
ELE0017344
NOTE: Operate the starter motor with wide open

throttle until the pointer on the measuring device
stops rising.
TIE39717 the instructions supplied with the measuring
7. Disconnect the ignition coil-on-plug electrical device on every cylinder using a suitable
connectors. compression pressure recorder with a suitable
adapter.
2007.50 Focus 3/2007 G296460en

14. Install the engine cover.
303-499
12 Nm
12 Nm
TIE0017349
TIE44767
11. Using the special tool, install the spark plugs.
15. Install the oil filler pipe.
• Rotate the oil filler pipe approximately 90
degrees clockwise until the securing clip
snaps into position.
16. Install the cowl panel grille.
TIE39719
12. Install the ignition coil-on-plug.
TIE44609
17. Install the fuel pump relay and close the CJB.
TIE39717
13. Connect the ignition coil-on-plug electrical

connectors.
TIE44765
2007.50 Focus 3/2007 G296460en

(Engine - 2.5L Duratec-ST (VI5))
TIE44608

19. Reset the PCM fault memory. TIE44608
TIE44609

3. NOTE: The engine will start, run for a few
seconds and then stop.
Start the engine.
REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec-ST (VI5), Removal and
Installation).
2007.50 Focus 3/2007 G296460en

5. Connect the battery ground cable. 9. Install the ignition coil-on-plug.
REFER to: Battery Disconnect and Connect REFER to: Ignition Coil-On-Plug (303-07 Engine
(414-01 Battery, Mounting and Cables, Ignition - 2.5L Duratec-ST (VI5), Removal and
General Procedures). Installation).
x5
E68679 TIE44609
6. Remove the spark plugs. 10. Install the fuel pump relay and close the CJB.
E68434
NOTE: Operate the starter motor with wide open

throttle until the pointer on the measuring device
stops rising.
the instructions supplied with the measuring
device on every cylinder using a suitable
compression pressure recorder with a suitable
adapter.
28 Nm
TIE44608
E68680
2007.50 Focus 3/2007 G296460en

(Engine - 1.6L Duratorq-TDCi (DV)
Diesel)
WARNINGS:
Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any fuel related components.
Highly flammable mixtures are always
present and can ignite. Failure to follow
VFE0035752
injury.
Do not carry out any repairs to the fuel 4. Remove the radiator undershield.
injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature has either reached
ambient temperature or is below 30°C,
whichever is the greater. Failure to follow
injury.
1. Using datalogger in worldwide diagnostic system
(WDS), check that the fuel pressure has
dropped to zero and that the fuel temperature
has either reached ambient temperature or is
below 30°C, whichever is the greater. TIE44583
2. Raise and support the vehicle. REFER to:
(100-02 Jacking and Lifting) 5. Remove the glow plug relay.
Lifting (Description and Operation). 7. Remove the cowl panel grille.
VFE0035742
3. Remove the engine undershield. TIE39694
2007.50 Focus 3/2007 G296460en

TIE39707 TIE39711
9. 12. Remove the glow plugs.

CAUTION: Do not disconnect the fuel
injection pump electrical connectors and
crank the engine. 303-1052
Disconnect the fuel injector electrical

connectors.
E39708
13. Install the special tool and a suitable

compression tester into the glow plug bore.
NOTE: Crank the engine with the starter motor
TIE39697 until the pointer on the compression tester stops
rising.
10. Detach the exhaust gas recirculation (EGR)
cooler (if equipped) and position it to one side. 14. Carry out the measurement on all cylinders,
following the measuring equipment
manufacturer's instructions.
15. Detach the compression tester and the special
tool.
8 Nm
TIE39709
11. Remove the glow plug power supply.
TIE39712
16. Install the glow plugs.
2007.50 Focus 3/2007 G296460en

20. Install the engine upper cover.
21. Install the cowl panel grille.
2 Nm REFER to: Cowl Panel Grille (501-02 Front End
(100-02 Jacking and Lifting)
TIE39710
17. Install the glow plug power supply.
10 Nm
TIE44583
23. Install the glow plug relay.
TIE44743
18. Attach the EGR cooler (if equipped).
VFE0035752
24. Install the radiator undershield.
TIE39707
19. Connect the fuel injector electrical connectors.
VFE0035742
25. Install the engine undershield.

27. Reset the PCM fault memory.
TIE39694
2007.50 Focus 3/2007 G296460en

Measure the compression pressure 3. NOTE: The engine upper cover is held in
(Engine - 1.8L Duratorq-TDCI (Kent) place by 4 ball clips. The ball clips are not
Diesel) vertical, but are angled backwards by
approximately 20 degrees.
WARNINGS: Location of the engine upper cover retaining
Do not smoke or carry lighted tobacco or clips.
Highly flammable mixtures are always
present and can ignite. Failure to follow 4 3
injury.
Do not carry out any repairs to the fuel 1
2
whichever is the greater. Failure to follow E58512
injury. 4. CAUTIONS:
1. Using datalogger in worldwide diagnostic system Care must be taken when releasing the
(WDS), check that the fuel pressure has 4th retaining clip and manoeuvering the
dropped to zero and that the fuel temperature engine upper cover past the manifold
has either reached ambient temperature or is absolute pressure (MAP) sensor. Failure to
below 30°C, whichever is the greater. follow this instruction may result in damage
to the MAP sensor.
Contact of the engine upper cover with

the cowl panel may cause damage
(scratches) on the engine upper cover. If the
ambient temperature is below 0°C, detach
the engine upper cover with extreme caution.
Failure to follow this instruction may cause
the engine upper cover to be damaged.
NOTE: Only remove and install the engine upper
cover in the sequence shown.
ELE0022088
Remove the engine upper cover.
2. Open the central junction box (CJB) and remove
the glow plug relay.
E61241
5. Disconnect the fuel injector electrical

E58511 connectors.
• Detach the wiring harness clips from the
cylinder head.
2007.50 Focus 3/2007 G296460en

15 Nm
E0023112 E0023115
6. Remove the glow plug power supply. 11. Install the glow plugs.
3 Nm
E0023114 E0023113
7. Remove the glow plugs. 12. Install the glow power supply.
303-1049A
E62193 E61241
8. Install the special tool and a suitable 13. Connect the fuel injector electrical connectors.
compression tester into the glow plug bore. • Attach the wiring harness clips to the cylinder
NOTE: Crank the engine with the starter motor head.
until the pointer on the compression tester stops 14. Apply soap solution to the ball clip mountings
rising. in the engine upper cover.
9. Carry out the measurement on all cylinders, • Soap solution (maximum concentration of
following the measuring equipment soap in water 1:200).
tool.
2007.50 Focus 3/2007 G296460en

injury.
Do not carry out any repairs to the fuel
whichever is the greater. Failure to follow
injury.
E58511
1. Using datalogger in world wide diagnostic
15. system (WDS), check that the fuel pressure has
CAUTION: Contact of the engine upper dropped to zero and that the fuel temperature
cover with the cowl panel may cause has either reached ambient temperature or is
damage (scratches) on the engine upper below 30°C, whichever is the greater.
cover. Failure to follow this instruction may
cause the engine upper cover to be
damaged.
Put the engine cover into installation position
and clip it in place by pressing at the places
shown.
• Make sure that the engine upper cover is
fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas
shown.
VFE0035742
ELE0022088
16. Install the glow plug relay and close the CJB.
17. Reset the PCM fault memory.

(Engine - 2.0L Duratorq-TDCi (DW)
Diesel)
VFE0035752
WARNINGS:
4. Remove the radiator undershield.
Highly flammable vapors are always
2007.50 Focus 3/2007 G296460en

the engine upper cover with extreme caution.
Remove the engine upper cover.
• Detach the engine upper cover ball clips in
the sequence shown.
TIE44583
5. Remove the glow plug relay.

TIE39594
10.
CAUTION: Do not disconnect the fuel
injection pump electrical connectors and
crank the engine.
Disconnect the fuel injector electrical
connectors.
11. Remove the exhaust gas recirculation (EGR)
cooler.
E50527
REFER to: Exhaust Gas Recirculation (EGR)
8. NOTE: The engine upper cover is held in Cooler (303-08D Engine Emission Control -
place by 3 ball clips. The ball clips are not 2.0L Duratorq-TDCi (DW) Diesel, Removal
vertical, but are angled backwards by and Installation).
approximately 20 degrees. 12. Remove the EGR valve.
Location of the engine upper cover ball clips. REFER to: Exhaust Gas Recirculation (EGR)
Valve (303-08D Engine Emission Control -
2.0L Duratorq-TDCi (DW) Diesel, Removal
and Installation).
1
3
4
E50472
9.
CAUTION: Contact of the engine upper
cover with the cowl panel may cause damage TIE39687
13. Remove the glow plug power supply.
2007.50 Focus 3/2007 G296460en

3 Nm 3 Nm
TIE39592 TIE39688
14. Remove the glow plugs. 19. Install the glow plug power supply.
20. Install the EGR valve.
303-1056
Valve (303-08D Engine Emission Control -
and Installation).
21. Install the EGR cooler.
Cooler (303-08D Engine Emission Control -
and Installation).
E39706
15. Install the special tool and a suitable

compression tester into the glow plug bore.
NOTE: Crank the engine with the starter motor
until the pointer on the compression tester stops
rising.
16. Carry out the measurement on all cylinders,
following the measuring equipment
TIE39594
tool.
22. Connect the fuel injector electrical connectors.
23. Apply soap solution to the ball clip mountings
in the engine upper cover.
5 Nm 5 Nm
• Soap solution (maximum concentration of
soap in water 1:200).
TIE39593
18. Install the glow plugs.
2007.50 Focus 3/2007 G296460en

E50473 VFE0035752
24. 28. Install the radiator undershield.

cover with the cowl panel may cause
damage (scratches) on the engine upper
cover. Failure to follow this instruction may
damaged.
Put the engine cover into installation position
shown.
fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas VFE0035742
shown.
25. Install the cowl panel grille. 29. Install the engine undershield.
Body Panels, Removal and Installation). 31. Reset the PCM fault memory.
(100-02 Jacking and Lifting) Measure the oil pressure (21 113 0)
Lifting (Description and Operation). The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
Measure the oil pressure (Engine - 1.6L

Duratec-16V, Engine - 1.6L Duratec-16V
Ti-VCT)
NOTE: The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity, extent
of oil filter contamination).
NOTE: Measure the oil pressure at the specified
TIE44583
engine speed.
27. Install the glow plug relay. 1. Raise and support the vehicle. REFER to:
2007.50 Focus 3/2007 G296460en

TIE45205 TIE44803
2. Disconnect the oil pressure switch electrical 6. NOTE: Measure the oil pressure at an oil
connector. temperature of 80°C.
NOTE: Oil pressure at 2000 rpm: 2.5 bar.
Measure the oil pressure.
TIE45206
3. Remove the oil pressure switch.
TIE0030036
8. Detach the oil pressure gauge and connector

from the oil pressure switch bore.
9. Coat the oil pressure switch with adhesive.
TIE0030036
15 Nm
4. Attach the oil pressure gauge with the oil
pressure gauge connector to the oil pressure
switch bore, and position it to allow reading from
above.
TIE45207
10. Install the oil pressure switch.
2007.50 Focus 3/2007 G296460en

TIE45205 ELE0021872
11. Connect the oil pressure switch electrical 4. Remove the oil pressure switch.
connector.

Duratec-HE (MI4)/2.0L Duratec-HE (MI4))
ELE0017346

above.
TIE40578
ELE0017347
7. NOTE: Measure the oil pressure at the

specified engine speed. Measure the oil
pressure at an oil temperature of 100° C.
NOTE: Oil pressure at 1500 rpm: 1.3 - 2.7 bar.
ELE0017345
3. Disconnect the oil pressure switch electrical
connector.
2007.50 Focus 3/2007 G296460en

TIE40578

ELE0017346
9. Detach the oil pressure gauge and connector Duratec-ST (VI5))
10. Coat the oil pressure switch with adhesive. 1. Raise and support the vehicle. REFER to:
15 Nm Lifting (Description and Operation).
ELE0017350

E65955
ELE0017345
12. Connect the oil pressure switch electrical

connector to the oil pressure switch.
E68443

connector.
2007.50 Focus 3/2007 G296460en

E68435
E68436
9. Detach the oil pressure gauge and connector

E68436

above.
E68435
E68436
7. NOTE: Measure the oil pressure at an oil

temperature of 100°C.
NOTE: Measure the oil pressure at idle speed and E68443
at 4000 rpm. 12. Connect the oil pressure switch electrical
NOTE: Minimum oil pressure at idle speed: 1.0 connector to the oil pressure switch.
bar.
NOTE: Minimum oil pressure at 4000 rpm: 3.5 bar.
NOTE: Maximum oil pressure: 4.8 bar.
2007.50 Focus 3/2007 G296460en

E65955 TIE39716
13. Install the engine undershield. 3. Attach the oil pressure gauge with the oil
14. Lower the vehicle. pressure gauge connector.
Measure the oil pressure (Engine - 1.6L specified engine speed. Measure the oil
Duratorq-TDCi (DV) Diesel) pressure at an oil temperature of 125° C.
NOTE: Measure the oil pressure at idle speed and
at 2000 rpm.
NOTE: Oil pressure at idle speed: 1.0 - 2.0 bar.
Check the oil pressure.
TIE39713

connector.
TIE39716
5. Detach the oil pressure gauge and the oil

pressure gauge connector.
TIE39714
TIE39715
2007.50 Focus 3/2007 G296460en

Care must be taken when releasing the

4th retaining clip and manoeuvering the
engine upper cover past the manifold
absolute pressure (MAP) sensor. Failure to
follow this instruction may result in damage
to the MAP sensor.
Contact of the engine upper cover with

the cowl panel may cause damage
TIE39713 the engine upper cover with extreme caution.
connector.
Duratorq-TDCI (Kent) Diesel) Remove the engine upper cover.
E0023117
E58511
1. NOTE: The engine upper cover is held in connector (components shown removed for
place by 4 ball clips. The ball clips are not clarity).
vertical, but are angled backwards by
approximately 20 degrees.
Location of the engine upper cover retaining
clips.
4 3
1
2 E0023118
4. Remove the oil pressure switch (components

E58512
2. CAUTIONS: pressure at an oil temperature of 80° C.
NOTE: Measure the oil pressure at idle speed and
at 2000 rpm.
2007.50 Focus 3/2007 G296460en

NOTE: Oil pressure at idle speed: 0.75 bar. 12.
NOTE: Oil pressure at 2000 rpm: 1.5 bar. cover with the cowl panel may cause
Attach the oil pressure gauge with the oil damage (scratches) on the engine upper
pressure gauge connector. cover. Failure to follow this instruction may
6. Check the oil pressure. damaged.
pressure gauge connector. Put the engine cover into installation position
8. Coat the oil pressure switch with adhesive. shown.
20 Nm fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas
shown.

Duratorq-TDCi (DW) Diesel)
E0023119
E0023117
TIE40578
2. Remove the engine under shield.

connector.
11. Apply soap solution to the ball clip mountings
in the engine upper cover.
• Soap solution (maximum concentration of
soap in water 1:200).
TIE39595

connector.
E58511
2007.50 Focus 3/2007 G296460en

35 Nm
TIE39596
4.
CAUTION: I
Remove the oil pressure switch. TIE39704
TIE39705
5. Attach the oil pressure gauge with the oil TIE39595

6. NOTE: Measure the oil pressure at the connector.
pressure at an oil temperature of 80° C.
NOTE: Measure the oil pressure at 2000 rpm and
at 4000 rpm.
Check the oil pressure.
VFE0035742
11. Install the engine under shield.

Valve train analysis - static (engine off)

Remove the valve cover.
TIE39705
2007.50 Focus 3/2007 G296460en

Check all valve train components for damage and
wear. Ensure that only original components are
installed and that all bolts and nuts have been
tightened to the correct tightening torque.
2007.50 Focus 3/2007 G296460en

GENERAL PROCEDURES
Camshaft Bearing Journal Diameter

1. Determine the diameter of the camshaft
journals.
• Using a micrometer measure the diameter
at 90 degrees intervals to determine if the
journals are out-of-round.
• Measure at two different points on the journal
to determine if there is any tapering.
• If the measurements are out of the specified
range, install a new camshaft.
V2102093
2007.50 Focus 3/2007 G17620en

GENERAL PROCEDURES
Camshaft Bearing Journal Clearance

• The value that is read off is the bearing
1. NOTE: Make sure that the following stages
clearance.
are followed exactly. The tappets or followers
must be removed to carry out this
measurement.
NOTE: Make sure that the camshaft is to
specification.
NOTE: The bearing caps and journals should be
free from engine oil and dirt.
Position on a width of plastigage on the
bearing cap.
• Insert the camshaft, without lubrication, into
the cylinder head. ELE0000597
• Position a plastigage strip, which should be
equal to the width of the bearing cap, on the
bearing journal.
ELE0000649
2. Following the tightening specification, install

the camshaft bearing caps. Refer to the
corresponding Section 303-01.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps, refer to
the corresponding Section 303-01.
4. Using the Plastigage, read off the
measurement.
• Compare the width of plastigage with the
plastigage scale.
2007.50 Focus 3/2007 G17621en

GENERAL PROCEDURES
Camshaft End Play

1. NOTE: Make sure that the camshaft is to
specification.
Using a Dial Indicator Gauge, measure the
end play.
• Slide the camshaft in both directions. Read
and note the maximum and minimum values
on the Dial Indicator Gauge.
• End play = maximum value minus minimum
value
• If the measurement is out of specification,
install new components.
V2102091
2007.50 Focus 3/2007 G17622en

GENERAL PROCEDURES
Camshaft Surface Inspection

1. Inspect the camshaft lobes for pitting or
damage in the active area. Minor pitting is
acceptable outside the active area.
45
GA3936A
2007.50 Focus 3/2007 G17623en

GENERAL PROCEDURES
Camshaft Lobe Lift

1. Determine the cam lift.
• Using a micrometer measure the cam in two
directions.
• The difference between the two
measurements is the cam lift.
V2102096
2007.50 Focus 3/2007 G17624en

GENERAL PROCEDURES
Crankshaft Main Bearing Journal Diameter

General Equipment
Micrometer
1. Measure the diameter of the main bearing
journals and the big-end bearing journals.
• Repeat the measurement with the
micrometer offset by 90°, in order to
determine any eccentricity which may be
present.
• Measure the journal at two different positions
to determine any conicity which may be
present.
1 AA2535C
2007.50 Focus 3/2007 G21023en

GENERAL PROCEDURES
Crankshaft End Play

General Equipment
Dial indicator
Dial indicator fixture
1. Determine the end float
• Place on the dial indicator and bracket .
• Determine the end float by raising the
crankshaft with the aid of a screwdriver.
• If necessary, correct the end float by using
new thrust half washers.
ELM2101729
2007.50 Focus 3/2007 G17627en

GENERAL PROCEDURES
Cylinder Bore Taper

1. NOTE: The main bearing caps or lower
crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
• Carry out the measurements in different
directions and at different heights to
determine if there is any out-of-roundness or
tapering.
• If the measurement is out of the specified
range, install a new block or hone out the
cylinder block (if aplicable/allowed).
mm
A
B
C
ELE0008659
2007.50 Focus 3/2007 G17628en

GENERAL PROCEDURES
Piston Inspection
1.
CAUTION: Do not use any aggressive
cleaning fluid or a wire brush to clean the
piston.
Carry out a visual inspection.
• Clean the piston skirt, pin bush, ring grooves
and crown and check for wear or cracks.
• If there are signs of wear on the piston skirt,
check whether the connecting rod is twisted
or bent.
V2102130
2007.50 Focus 3/2007 G17629en

GENERAL PROCEDURES
Piston Pin to Bore Diameter

1. NOTE: The piston and piston pin form a
matched pair. Do not mix up the
components.
Measure the diameter of the piston pin bore.
• Measure the diameter in two directions.
• If the values are not to specification, install
both a new piston and a new piston pin.
V2102132
2007.50 Focus 3/2007 G17630en

GENERAL PROCEDURES
Piston Diameter
General Equipment
Micrometer
1. NOTE: Mark the piston to make sure the
piston is installed correctly.
Using a Micrometer measure the piston
diameter.
IAV2102103
2007.50 Focus 3/2007 G17631en

GENERAL PROCEDURES
Piston Ring End Gap

1.
CAUTION: Do not mix up the piston rings.
Install the piston rings in the same position
and location.
Take the piston ring and use a piston without
rings to push the piston ring about 30 mm
into the cylinder bore.
V2102136
2. Using the Feeler Gauge, measure the piston

ring gap.
V2102104
2007.50 Focus 3/2007 G17632en

GENERAL PROCEDURES
Piston Ring-to-Groove Clearance

General Equipment
Feeler Gauge
1. NOTE: The piston ring must protrude from
the piston groove. To determine the piston
ring clearance, insert the Feeler Gauge right
to the back of the groove, behind the wear
ridge.
Using the Feeler Gauge , measure the piston
ring clearance.
ELM2103771
2007.50 Focus 3/2007 G17633en

GENERAL PROCEDURES
Piston Pin Diameter

1. NOTE: The piston and piston pin are a
matched pair. Do not mix up the
components.
Measure the piston pin diameter.
• Measure the diameter in two directions.
• If the values are not to specification, install
a new piston and a new piston pin.
V2102137
2007.50 Focus 3/2007 G17634en

GENERAL PROCEDURES
Connecting Rod Large End Bore

1. Measure the bearing bore in two directions.
The difference is the connecting rod bore
out-of-round. Verify the out-of-round and the
bearing bore is within specification.
GA3934A
2007.50 Focus 3/2007 G17635en

GENERAL PROCEDURES
Valve Stem Diameter

1. Using a micrometer measure the diameter
of the valve stems.
• If the measurements are not to specification,
install a new valve.
V2102139
2007.50 Focus 3/2007 G17636en

GENERAL PROCEDURES
Flywheel Inspection
1. Inspection details for the dual mass flywheel
are contained in the Diagnosis and Testing
procedure.For additional information, refer
to: (308-00 Manual Transmission/Transaxle
and Clutch - General Information)
Manual Transmission and Clutch - Vehicles
With: MT-75 (Diagnosis and Testing),
Manual Transaxle and Clutch - Vehicles With:
VXT-75 (Diagnosis and Testing),
Manual Transmission and Clutch - Vehicles
With: MT82 (Diagnosis and Testing).
2007.50 Focus 3/2007 G272661en

GENERAL PROCEDURES
Cylinder Head Distortion

General Equipment
Feeler gauge
Straight edge
1. Using a straight edge and feeler gauge,
measure the cylinder head distortion.
• Measure the mating face distortion.
• Refer to Specifications in the appropriate
engine section.
V2102122
2007.50 Focus 3/2007 G17638en

GENERAL PROCEDURES
Cylinder Block Distortion

1. Using a Straight Edge and a Feeler Gauge,
measure the cylinder block/cylinder head
distortion.
• Measure the mating face distortion.
• If the value is not to specification rework the
mating face (if allowed).
ELE0009440
2007.50 Focus 3/2007 G17639en

GENERAL PROCEDURES
Exhaust Manifold Cleaning and Inspection

1. Inspect the cylinder head joining flanges of
the exhaust manifold for evidence of exhaust
gas leaks.
2. Inspect the exhaust manifold for cracks,
damaged gasket surfaces, or other damage
that would make it unfit for further use.
2007.50 Focus 3/2007 G17640en

GENERAL PROCEDURES
Bearing Inspection
1. Inspect bearings for the following defects.
1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or bearing
not seated.
1 2
3 4 5
6 7
GA3940A
2007.50 Focus 3/2007 G17641en

Engine — 2.0L Duratec-HE (MI4)/1.8L
303-01A-1 Duratec-HE (MI4) 303-01A-1
.
SECTION 303-01A Engine — 2.0L Duratec-HE

CONTENTS PAGE
SPECIFICATIONS
Engine Data 1.8L............................................................................................................ 303-01A-3
Engine Data 2.0L............................................................................................................ 303-01A-3
Engine Oil....................................................................................................................... 303-01A-4
Oil system....................................................................................................................... 303-01A-4
Engine Oil Capacity 1.8/2.0L Engine.............................................................................. 303-01A-4
Valve Dimensions, 1.8/2.0L Engine................................................................................ 303-01A-4
Camshaft Dimensions, 1.8L Engine............................................................................... 303-01A-4
Camshaft Dimensions, 2.0L Engine............................................................................... 303-01A-5
Crankshaft 1.8/2.0L Engine............................................................................................ 303-01A-5
Cylinder Block, 1.8L/ 2.0L Engine................................................................................... 303-01A-5

Engine................................................................................................................................. 303-01A-8
1.8L Duratec HE (MI4) engine............................................................................................ 303-01A-8

Engine................................................................................................................................. 303-01A-11
GENERAL PROCEDURES
Valve Clearance Adjustment............................................................................................... 303-01A-12
IN-VEHICLE REPAIR
Intake Manifold............................................................................................... (21 183 0) 303-01A-16
Crankshaft Pulley........................................................................................... (21 572 0) 303-01A-20
Crankshaft Front Seal..................................................................................... (21 467 0) 303-01A-29
Engine Front Cover........................................................................................ (21 148 0) 303-01A-30
Valve Seals..................................................................................................... (21 238 0) 303-01A-35
Valves............................................................................................................. (21 215 4) 303-01A-37
Camshafts...................................................................................................... (21 284 0) 303-01A-39
Timing Chain................................................................................................... (21 314 0) 303-01A-48
Cylinder Head................................................................................................. (21 163 0) 303-01A-50
Oil Pan............................................................................................................ (21 154 0) 303-01A-64
Oil Pump......................................................................................................... (21 714 0) 303-01A-73
Crankshaft Rear Seal..................................................................................... (21 468 4) 303-01A-76
REMOVAL
Engine — Vehicles With: Manual Transaxle................................................... (21 134 0) 303-01A-82
Engine — Vehicles With: 4-Speed Automatic Transmission (4F27E)............ (21 134 0) 303-01A-91
303-01A-2 Duratec-HE (MI4) 303-01A-2
.
DISASSEMBLY
Engine............................................................................................................ (21 134 8) 303-01A-100
ASSEMBLY
Engine............................................................................................................ (21 134 8) 303-01A-108
INSTALLATION
Engine — Vehicles With: Manual Transaxle................................................... (21 134 0) 303-01A-121
Engine — Vehicles With: Automatic Transaxle.............................................. (21 134 0) 303-01A-130
303-01A-3 Duratec-HE (MI4) 303-01A-3
SPECIFICATIONS
Engine Data 1.8L
Description
Engine code QQDA QQDB
Firing order 1-3-4-2 1-3-4-2
Emission level Stage III Stage IV
Bore 83 mm 83 mm
Stroke 83.1 mm 83.1 mm
Cubic capacity 1798 cm³ 1798 cm³
Compression ratio 10.8 : 1 10.8 : 1
Power output at 6000 rpm 92 kW (125 PS) 92 kW (125 PS)
Maximum torque at 4000 rpm 165 Nm 165 Nm
Maximum engine speed (intermit- 6850 rpm 6850 rpm
tent)
Maximum engine speed (continous) 6500 rpm 6500 rpm
Idle speed 700±50 rpm 700±50 rpm
Number of main bearings 5 5
Camshaft drive Chain Chain
Maximum oil consumption 0.5 l/1000 Km 0.5 l/1000 Km
Engine Data 2.0L

Description
Engine code AODB
Firing order 1-3-4-2
Emission level Stage III
Bore 87.5 mm
Stroke 83.1 mm
Cubic capacity 1998 cm³
Compression ratio 10.8 : 1
Power output at 6000 rpm 107 kW (146 PS)
Maximum torque at 4500 rpm 185 Nm
Maximum engine speed (intermittent) 6850 rpm
Maximum engine speed (continous) 6500 rpm
Idle speed 700 ± 50 rpm
Number of main bearings 5
Camshaft drive Chain
Maximum oil consumption 0.5 l/1000 Km
2007.50 Focus 3/2007 G401887en

303-01A-4 Duratec-HE (MI4) 303-01A-4
SPECIFICATIONS
Engine Oil
Viscosity /ambient temperature Type Specification
Recommended engine oil
SAE 5W-30 /below -20°C to over Ford Formula E WSS-M2C913-B
+40°C
Alternative engine oils
SAE 10W-40 /-20°C to over +40°C Ford Formula XR+ ACEA A3/B3
SAE 5W-40 /below -20°C to over Ford Formula S ACEA A3/B3
+40°C

Item Specification
Sealant, oil pan contact surface to crankshaft rear seal retainer, oil pan to WSE-M4G323-A4
cylinder block, oil pan to front cover, engine front cover to cylinder block/oil
pan
Sealant, oil pressure switch and engine front cover blanking plug WSK-M2G349-A7
Anti-seize grease ESE-M1244-A
Silicone grease ESE-M1C171-AA
Oil system
Description bar
Pressure relief valve opening pressure 5
Engine Oil Capacity 1.8/2.0L Engine

Description Liters
Initial fill, including oil filter 4.6
Service fill including filter 4.3
Service fill excluding filter 3.9
Valve Dimensions, 1.8/2.0L Engine

Description mm
Valve clearance (engine cold), intake 0.220 - 0.280
Valve clearance (engine cold), exhaust 0.270 - 0.330
Valve stem diameter, intake 5.470 - 5.485
Valve stem diameter, exhaust 5.465 - 5.480
Camshaft Dimensions, 1.8L Engine

Description mm
Camshaft journal diameter 24.97 ± 0.01
Camshaft journal clearance 0.035 - 0.080
Camshaft end play 0.090 - 0.240
Camshaft lobe lift, intake, 120 PS engine 7.4
2007.50 Focus 3/2007 G401887en

303-01A-5 Duratec-HE (MI4) 303-01A-5
SPECIFICATIONS
Description mm
Camshaft lobe lift, intake, 125 PS engine 8.5
Camshaft lobe lift, exhaust 7.7
Camshaft Dimensions, 2.0L Engine

Description mm
Camshaft journal diameter 24.97 ± 0.01
Camshaft journal clearance 0.035 - 0.080
Camshaft lobe lift, intake 8.8
Camshaft lobe lift, exhaust 7.7
Crankshaft 1.8/2.0L Engine

Description mm
Crankshaft end play 0.335 ± 0.115
Cylinder Block, 1.8L/ 2.0L Engine

Description mm
Cylinder block distortion (maximum) 0.1
Cylinder head bolts a) - -
Cylinder block lower blanking plug 20 15 -
Timing chain guide retaining bolts 10 - 89
Timing chain tensioner retaining bolts 10 - 89
Camshaft bearing caps retaining bolts a) - -
Camshaft sprocket retaining bolts 72 53 -
Camshaft position (CMP) sensor retaining bolt 6 - 53
Engine front cover retaining bolts a) - -
Engine front cover upper blanking plug 10 - 89
Engine front cover lower blanking plug 12 9 -
Crankshaft pulley retaining bolts a) - -
Crankshaft rear seal carrier retaining bolts 10 - 89
Crankshaft position (CKP) sensor retaining bolts 7 - 62
Coolant plug to cylinder block 55 41 -
Coolant plugs (4) to cylinder head 75 55 -
Coolant pump retaining bolts 10 - 89
Coolant pump pulley retaining bolts 25 18 -
2007.50 Focus 3/2007 G401887en

303-01A-6 Duratec-HE (MI4) 303-01A-6
SPECIFICATIONS

Coolant outlet connector retaining bolts 10 - 89
Exhaust manifold retaining bracket retaining bolts 15 11 -
Exhaust manifold heat shield retaining bolts 10 - 89
Exhaust manifold to cylinder head retaining nuts 48 35 -
Exhaust manifold to exhaust manifold retaining 20 15 -
bracket
Exhaust manifold studs to cylinder head 17 13 -
Exhaust gas recirculation (EGR) tube to cylinder 55 41 -
head
Valve cover retaining bolts 10 - 89
Oil pressure switch 15 11 -
Oil pan retaining bolts 25 18 -
Oil filter adaptor retaining bolts 25 18 -
Oil level indicator tube retaining bolts 10 - 89
Oil drain plug 28 21 -
Oil pump retaining bolts a) - -
Oil pump sprocket retaining bolt 25 18 -
Oil pump screen and pickup tube retaining bolts 10 - 89
Oil pump chain guide retaining bolts 10 - 89
Oil pump chain tensioner retaining bolt 10 - 89
Flywheel retaining bolts a) - -
Positive crankcase ventilation housing retaining 10 - 89
bolts
Knock sensor (KS) retaining bolt 20 15 -
Thermostat housing retaining bolts 10 - 89
Accessory drive belt tensioner retaining bolt 18 13 -
Intake manifold retaining bolts 18 13 -
Transaxle retaining bolts 44 32 -
Halfshaft center bearing carrier retaining bolts 48 35 -
Intermediate shaft bearing cap retaining nuts 25 18 -
Starter motor retaining bolts 35 26 -
Ignition coil-on-plug retaining bolts 10 - 89
Spark plugs 12 9 -
Generator retaining bolts 48 35 -
Electrical connector retaining bracket retaining bolts 6 - 59
2007.50 Focus 3/2007 G401887en

303-01A-7 Duratec-HE (MI4) 303-01A-7
SPECIFICATIONS

Battery positive cable electrical connector retaining 12 9 -
nut
Ground cable retaining bolt to cylinder head 15 11 -
Air conditioning (A/C) compressor retaining bolts 24 18 -
Engine rear mount center retaining bolt 148 109 -
Engine front mount studs to front cover 10 - 89
Engine front mount retaining bolts 90 66 -
Engine front mount retaining nuts 80 59 -
Engine support insulator retaining bolts 80 59 -
Engine lifting eye retaining bolt 45 33 -
2007.50 Focus 3/2007 G401887en

303-01A-8 Duratec-HE (MI4) 303-01A-8
Engine
Cylinder block
Valve cover
1
E43001
Item Description
1 Alternator mounting point
The cylinder block has additional bolt mounting
points for attaching the alternator.
The alternator is bolted onto the left-hand side of
3 the engine (viewed from the rear of the vehicle)
The cylinder block also has attachment points for
the bolts of the knock sensors.
E42996
Item Description
1 Oil filler neck
2 Attachment points for bolting on the direct
ignition coils
3 Camshaft Position (CMP) sensor
Due to space restrictions the oil filler neck has been
extended, and it is attached to the valve cover via
a bayonet fixing.
Additional attachment points are provided to secure
the bolts for the direct ignition coils.
The bolt attachment point for the CMP sensor has
been rotated by 90°.
2007.50 Focus 3/2007 G187583en

303-01A-9 Duratec-HE (MI4) 303-01A-9
Positive crankcase ventilation Item Description
1 Positive Crankcase Ventilation (PCV)
Due to the increased space requirements of the
1 intake manifold it was necessary to modify the oil
separator and the shape and installation location
of the PCV hose.
E43111
2007.50 Focus 3/2007 G187583en

303-01A-10 Duratec-HE (MI4) 303-01A-10
Oil pan
E42993
Item Description
1 Protective cover
The oil pan has been modified in accordance with
the space requirements of the Air Conditioning
(A/C) compressor.
A protective metal hood is installed underneath the
A/C compressor to provide protection against
damage.
The protective hood is bolted to the A/C
compressor.
The thickness of the walls of the oil pan has been
increased, and additional reinforcement ribs have
now also been introduced.
2007.50 Focus 3/2007 G187583en

303-01A-11 Duratec-HE (MI4) 303-01A-11
Engine
REFER to Section 303-00 [Engine System -
2007.50 Focus 3/2007 G17645en

303-01A-12 Duratec-HE (MI4) 303-01A-12
GENERAL PROCEDURES
Valve Clearance Adjustment

Special Tool(s) 3. Disconnect the camshaft position (CMP)
sensor electrical connector.
Socket, Spark Plug
303-499
ES21202
General Equipment
Feeler gauges
Materials
TIE0036617
Name Specification
Silicone Sealant WSE-M4G323-A4 4. Disconnect the positive crankcase ventilation
(PCV) hose from the valve cover.
All vehicles
TIE0036618
TIE39686 5. Remove the ignition coil-on-plug.

TIE0036619
2007.50 Focus 3/2007 G388112en

303-01A-13 Duratec-HE (MI4) 303-01A-13
GENERAL PROCEDURES
6. Using the special tool, remove the spark Using a suitable set of feeler gauges,
plugs. measure the valve clearances.
303-499
ELE0017343 E0031829
7. Remove the engine cover retaining brackets. 11. NOTE: Only rotate the crankshaft in the
normal direction of rotation.
Rotate the crankshaft until each piston is at
TDC and measure the valve clearances.
12. NOTE: Only carry out the following steps
when the valve clearance(s) require
adjustment.
Specifications - 3-Door (303-01 Engine -
2.0L Duratec-HE (MI4)/1.8L Duratec-HE
(MI4), Specifications).
TIE0038256 Remove the camshafts.
8. Remove the valve cover. Camshafts (303-01 Engine - 2.0L
Duratec-HE (MI4)/1.8L Duratec-HE (MI4),
In-vehicle Repair).
13. NOTE: The number on the valve tappet is
the valve tappet thickness, however only
the decimal places are marked (for example
.650 = 3.650).
Determine the valve tappet thickness
required:
1. Remove the valve tappet and read the
thickness from the underside.
TIE0036622 2. Calculate the valve tappet thickness required
(thickness of currently installed valve tappet,
9. NOTE: Only rotate the crankshaft in the + the measured valve clearance, - the
normal direction of rotation. required valve clearance).
Rotate the crankshaft until piston No. 1 is at For additional information, refer to:
top dead center (TDC). Specifications - 3-Door (303-01 Engine -
10. NOTE: Note down each cylinder number (MI4), Specifications).
and the valve clearances measured. 3. Install the correct valve tappet.
14. NOTE: Do not install the valve cover at this
stage.
2007.50 Focus 3/2007 G388112en

303-01A-14 Duratec-HE (MI4) 303-01A-14
GENERAL PROCEDURES
Install the camshafts. 19. Install the engine cover retaining brackets.
Camshafts (303-01 Engine - 2.0L
In-vehicle Repair).
15. NOTE: Only rotate the crankshaft in the
16. Repeat this procedure as necessary until
all valve clearances are within the specified
tolerance. TIE0038256
17. Apply a small bead of sealant to the areas

as shown. 20. Using the special tool, install the spark
plugs.
303-499
12 Nm
12 Nm
ELE0021634
TIE0017349
18. NOTE: Install a new valve cover gasket if

necessary. 21. Install the ignition coil-on-plug.
Install the valve cover.
• Tighten the bolts in the sequence shown. 10 Nm 10 Nm
11 6 3 7 12
10
2 10 Nm1 1 13
9 5
TIE0036620
14
4 8
TIE0036679
2007.50 Focus 3/2007 G388112en

303-01A-15 Duratec-HE (MI4) 303-01A-15
GENERAL PROCEDURES
22. Connect the positive crankcase ventilation Vehicles with global closing
(PCV) hose to the valve cover.
For additional information, refer to: Door
Window Motor Initialization (501-11 Glass,
Frames and Mechanisms, General
Procedures).
TIE0036618
23. Connect the camshaft position (CMP)

TIE0036617
24. Connect the battery ground cable.

Mounting and Cables, General
Procedures).
TIE44765
2007.50 Focus 3/2007 G388112en

303-01A-16 Duratec-HE (MI4) 303-01A-16
IN-VEHICLE REPAIR
Intake Manifold(21 183 0)

Removal 5. Remove the oil level indicator tube lower
retaining bolt.
10 Nm
TIE0036815
TIE39686
6. Remove the intake manifold lower retaining

2. Disconnect the battery. bolt.
18 Nm
3. Remove the air cleaner outlet pipe.
TIE0036813
7. Detach the wiring harness from the intake

manifold.
TIE0036810

For additional information, refer to: Lifting
and Operation).
TIE0038268

9. Disconnect the knock sensor (KS) electrical
connector for cylinder 3 and 4 from the
intake manifold (if equipped).
2007.50 Focus 3/2007 G388113en

303-01A-17 Duratec-HE (MI4) 303-01A-17
IN-VEHICLE REPAIR
• Detach the knock sensor (KS) electrical • Remove the retaining nuts in the sequence
connector for cylinder 3 and 4 from the intake shown.
manifold.
10 Nm
3 1
2 4
VUE0022337
TIE0038271
13. Detach the hood latch from the radiator

10. Disconnect the manifold absolute pressure grille opening panel reinforcement.
(MAP) sensor electrical connector.
10 Nm
TIE0038218
TIE45284
14. Disconnect the brake booster vacuum line

11. Disconnect the knock sensor (KS) electrical from the intake manifold.
connector.
• Detach the KS electrical connector from the
intake manifold.
TIE0036580
TIE0038213
12. Detach the throttle body from the intake

manifold.
2007.50 Focus 3/2007 G388113en

303-01A-18 Duratec-HE (MI4) 303-01A-18
IN-VEHICLE REPAIR
15. Detach the engine wiring harness from the 18. Disconnect the vacuum hose from the
intake manifold. intake manifold.
E0036819 TIE0038216
16. Remove the oil level indicator and oil level 19. Remove the intake manifold retaining bolts
indicator tube. (engine shown removed for clarity).
• Detach the intake manifold from the cylinder
head.
18 Nm
10 Nm
TIE0036817
ELE0021910
17. Disconnect the vacuum hose from the
intake manifold.
20. Disconnect the positive crankshaft
ventilation (PCV) hose from the intake
manifold.
TIE0036818
ELE0017407
21. Remove the intake manifold.
2007.50 Focus 3/2007 G388113en

303-01A-19 Duratec-HE (MI4) 303-01A-19
IN-VEHICLE REPAIR
Installation
All vehicles
1. NOTE: Install a new intake manifold gasket
if necessary.
To install, reverse the removal procedure.

2. Initialize the window regulator motor.
Procedures).
2007.50 Focus 3/2007 G388113en

303-01A-20 Duratec-HE (MI4) 303-01A-20
IN-VEHICLE REPAIR
Crankshaft Pulley(21 572 0)

Special Tool(s)
Universal Flange Holding Removal
Wrench
205-072
15030A
Adapter for 205-072

205-072-02
20507202
TIE39686
Alignment Plate, Camshaft 2. Disconnect the battery ground cable.

303-376
21162B
3. Disconnect the camshaft position sensor
(CMP sensor) connector.
Socket, Spark Plug

303-499
ES21202
Timing Peg, Crankshaft TDC

303-507
TIE0036617
PZ21210
General Equipment
Bolt, M6 x 18 mm
Materials
Name Specification
Silicon sealer WSE-M4G323-A4
2007.50 Focus 3/2007 G388114en

303-01A-21 Duratec-HE (MI4) 303-01A-21
IN-VEHICLE REPAIR
4. Detach the positive crankcase ventilation 7. Remove the engine cover bracket.
(PCV) hose from the cylinder head cover.
TIE0038256
TIE0036618
8. Remove the cylinder head cover.

5. Remove the ignition coils.
• Lay the ignition coils to one side.
TIE0036622
TIE0036619
9. Remove the drive belt.
6. Remove the spark plugs with the special tool. Accessory Drive Belt - 2.0L Duratec-HE
(MI4)/1.8L Duratec-HE (MI4) (303-05
303-499 10. Detach the right-hand front wheel.

ELE0017343
2007.50 Focus 3/2007 G388114en

303-01A-22 Duratec-HE (MI4) 303-01A-22
IN-VEHICLE REPAIR
11. Detach the right-hand wheel arch cover 14. Remove the crankshaft front oil seal.
(shown with wheel arch cover removed for For additional information, refer to:
clarity). Crankshaft Front Seal (303-01 Engine -
(MI4), In-vehicle Repair).
15. Remove the front friction washer (engine
• Discard the friction washer.
E40674
12. NOTE: Only turn the crankshaft in the

Turn the crankshaft until piston no. 1 is
approx. 45 degrees before TDC. TIE0025399
Installation
All vehicles
1. NOTE: Install a new front friction washer.
Install the front friction washer (engine
45
TIE0025437
13. NOTE: Do not discard the crankshaft pulley

bolt.
Counterhold the crankshaft pulley using the
special tools and remove the pulley.
TIE0025399
2. Install the crankshaft front oil seal.

205-072 Crankshaft Front Seal (303-01 Engine - 2.0L
In-vehicle Repair).
205-072-02
ELE0017417
4. NOTE: Only turn the camshafts in the normal
direction of rotation.
2007.50 Focus 3/2007 G388114en

303-01A-23 Duratec-HE (MI4) 303-01A-23
IN-VEHICLE REPAIR
Carefully turn the camshafts using a spanner Turn the engine at the crankshaft pulley bolt
until the cams, cylinder no. 4, are positioned until the crankshaft contacts the special tool.
at the valve overlap.
5. Attach the special tool.
TIE0025436
E0014880 9. Remove the crankshaft pulley bolt.

• Discard the bolt.
6. Raise the vehicle.
10.
CAUTION: Tighten M6 x 18 mm bolt
hand-tight only.
Lifting (100-02 Jacking and Lifting,
Description and Operation). Install the crankshaft pulley and fasten to
the timing cover with an M6 x 18 mm bolt.
7. Remove the cylinder block lower blanking
plug and attach the special tool.
303-507
TIE0038196
ELE0017416
11. NOTE: Install a new crankshaft pulley bolt.
8. NOTE: Only turn the crankshaft in the Counterhold the crankshaft pulley using the
normal direction of rotation. special tools and tighten the crankshaft
pulley bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.
2007.50 Focus 3/2007 G388114en

303-01A-24 Duratec-HE (MI4) 303-01A-24
IN-VEHICLE REPAIR
• Stage 2: 90 degrees. 16. Remove the special tool.
303-507
205-072
205-072-02
ELE0017417
ELE0017416
12. Remove bolt, M6 x 18 mm. 17. NOTE: Only turn the crankshaft in the
Turn the crankshaft one and three quarters
of a turn until piston no. 1 is approx. 45
degrees before TDC.
ELE0018258

14. Remove the special tool. 45
TIE0025437
303-507
E0014880

ELE0017416
Description and Operation). 19. NOTE: Only turn the crankshaft in the
Turn the crankshaft until no. 1 piston is at
TDC.
2007.50 Focus 3/2007 G388114en

303-01A-25 Duratec-HE (MI4) 303-01A-25
IN-VEHICLE REPAIR
20. 24. Raise the vehicle.
CAUTION: Tighten M6 x 18 mm bolt
hand-tight only. For additional information, refer to:
NOTE: If the M6 x 18 mm bolt cannot be installed,
correct the valve timing.
Check the position of the crankshaft pulley
25. Remove the M6 x 18 mm bolt.
with an M6 x 18 mm bolt.
ELE0018258
ELE0018258

22. NOTE: If the special tool cannot be
attached, correct the valve timing.
Check the position of the camshafts using
the special tool.
303-507
ELE0017416
27. Screw in the cylinder block lower blanking

plug.
20 Nm
ELE0021301
28. NOTE: When installing a new timing cover,

the crankshaft position sensor (CKP
sensor) must be aligned using the tool
supplied.
2007.50 Focus 3/2007 G388114en

303-01A-26 Duratec-HE (MI4) 303-01A-26
IN-VEHICLE REPAIR
Align the CKP sensor (engine shown 31. Attach the right-hand front wheel.
removed for clarity). For additional information, refer to: Wheel
1. Loosen the CKP sensor bolts. and Tire (204-04 Wheels and Tires,
2. Insert the supplied tool so that it engages Removal and Installation).
with the teeth of the crankshaft pulley. 32. Install the drive belt.
Accessory Drive, Removal and
1 Installation).
33. Apply sealer thinly onto the indicated areas.
2
TIE0017984
29. Install the CKP sensor (engine shown

1. Install the CKP sensor bolts.
2. Remove the tool.
ELE0021634
34. NOTE: If necessary, install a new cylinder

head cover gasket.
7 Nm 1 Install the cylinder head cover.

• Tighten the bolts in the sequence shown.
2 11 6 3 7 12
TIE0017985
10
2 10 Nm1 1 13
30. Attach the right-hand wheel arch cover
(shown with wheel arch cover removed for 9 5
clarity).
14
4 8
TIE0036679
E40674
2007.50 Focus 3/2007 G388114en

303-01A-27 Duratec-HE (MI4) 303-01A-27
IN-VEHICLE REPAIR
35. Install the engine cover bracket. 38. Attach the positive crankcase ventilation
(PCV) hose to the cylinder head cover.
TIE0038256
TIE0036618
36. Install the spark plugs using the special

tool. 39. Connect the camshaft position (CMP)
sensor connector.
303-499
12 Nm
12 Nm
TIE0017349
TIE0036617
37. Install the ignition coils.

10 Nm 10 Nm Disconnect and Connect (414-01 Battery,
Procedures).
TIE0036620
TIE44765
2007.50 Focus 3/2007 G388114en

303-01A-28 Duratec-HE (MI4) 303-01A-28
IN-VEHICLE REPAIR
42. Initialize the window winder motors.
Procedures).
2007.50 Focus 3/2007 G388114en

303-01A-29 Duratec-HE (MI4) 303-01A-29
IN-VEHICLE REPAIR
Crankshaft Front Seal(21 467 0)

Special Tool(s) Using the special tool and the crankshaft
pulley retaining bolt, install the crankshaft
Remover, Crankshaft Seal
front seal (engine shown removed for clarity).
303-293 (21-143)
303-509
21143
Remover, Vibration Damper

Hub
303-509 (21-213)
E0022184
IA21213
2. Remove the crankshaft pulley retaining bolt

and the special tool.
Removal
• Discard the crankshaft pulley retaining bolt.
1. Remove the crankshaft pulley. 3. Install the crankshaft pulley.
For additional information, refer to: For additional information, refer to:
Crankshaft Pulley (303-01 Engine - 2.0L Crankshaft Pulley (303-01 Engine - 2.0L
Duratec-HE (MI4)/1.8L Duratec-HE (MI4), Duratec-HE (MI4)/1.8L Duratec-HE (MI4),
In-vehicle Repair). In-vehicle Repair).
2. Using the special tool, remove the crankshaft
front seal.
• Discard the seal.
303-293
ELE0021636
Installation
1. NOTE: Install a new crankshaft front seal.
2007.50 Focus 3/2007 G323906en

303-01A-30 Duratec-HE (MI4) 303-01A-30
IN-VEHICLE REPAIR
Engine Front Cover(21 148 0)

General Equipment 5. Remove the engine front cover lower
retaining bolts.
Vehicle jack
Materials
Name Specification
Silicone Sealant WSE-M4G323-A4
Removal
1. Remove the crankshaft pulley.
For additional information, refer to
Crankshaft Pulley in this section. ELE0017418

information, refer to Section 100-02 [Jacking 6. Disconnect the crankshaft position (CKP)
and Lifting]. sensor electrical connector.
3. Detach the air conditioning compressor (A/C
compressor) cover.
ELE0015349
TIE0036588 7. Lower the vehicle.

8. Remove the drive belt tensioner.
4. Detach the A/C compressor and secure it to
one side.
TIE0036732
TIE0036590
2007.50 Focus 3/2007 G388115en

303-01A-31 Duratec-HE (MI4) 303-01A-31
IN-VEHICLE REPAIR
9. Detach the coolant expansion tank and lay • Discard the nuts.
it to one side.
TIE0038250
TIE0036743
14. Remove the engine front mount studs.

10. Remove the coolant pump pulley.
TIE0038251
TIE0036734
15. Remove the engine front mount.
11. Support the engine with a vehicle jack. 16. Remove the engine front cover upper bolts.
12. Detach the A/C compressor line bracket • Remove the engine front cover.
from the engine front mount.
ELE0021630
TIE0036666
Installation
13. Remove the engine front mount nuts/bolts.
1. Clean the engine front cover mating faces.
2. NOTE: Install the engine front cover within
10 minutes of applying the silicon sealer.
2007.50 Focus 3/2007 G388115en

303-01A-32 Duratec-HE (MI4) 303-01A-32
IN-VEHICLE REPAIR
Apply sealer to the engine front cover (bead • Tighten bolts 20 through 22 to 48 Nm.
diameter: 3 mm).
22
19
18 20
12
21 8
11
7
4
1 5
3
9
6
2
10 13
14
15
16
17
E0014848
ELE0014850
4. Install the engine front mount.

3. Install the engine front cover (engine shown 5. Install the engine front mount studs.
• Tighten the bolts in the indicated sequence.
• Tighten bolts 1 through 8 to 10 Nm.
• Tighten the bolt 9 to 48 Nm.
• Tighten bolts 10 through 19 to 10 Nm.
12 Nm
TIE0038252
6. NOTE: Install new engine front mount nuts.
2007.50 Focus 3/2007 G388115en

303-01A-33 Duratec-HE (MI4) 303-01A-33
IN-VEHICLE REPAIR
Install the engine front mount nuts/bolts. 10. Attach the A/C compressor.
80 Nm
15 Nm
24 Nm
90 Nm
E0038253 TIE0036589
7. Attach the A/C line bracket to the engine 11. Connect the electrical connector for the
front mount. crankshaft position sensor (CKP sensor).
TIE0036667 ELE0015349
8. Raise and support the vehicle. For additional 12. Lower the vehicle.
13. Install the coolant pump pulley.
and Lifting].
9. Attach the air conditioning compressor (A/C
compressor) cover.
24 Nm 25 Nm
TIE0036735
TIE0036591
2007.50 Focus 3/2007 G388115en

303-01A-34 Duratec-HE (MI4) 303-01A-34
IN-VEHICLE REPAIR
14. Install the coolant expansion tank.
TIE0036744
15. Install the drive belt tensioner.
18 Nm
TIE0036733
16. Install the crankshaft pulley.

Crankshaft Pulley in this section.
2007.50 Focus 3/2007 G388115en

303-01A-35 Duratec-HE (MI4) 303-01A-35
IN-VEHICLE REPAIR
Valve Seals(21 238 0)

Special Tool(s) 2. Using the special tool, apply 7 to 10 bar of
compressed air into the cylinder.
Compressor, Valve Spring
303-361A (21-155A)
21155
303-363
Adapter for 303-361A
303-361-02 (21-155-02A)
ELE0022185
2115502A
3. Remove the valve tappets.
Installer, Valve Stem Collets 4. Using the special tools, remove the valve
303-362 (21-156) springs.
• Compress the valve spring.
• Remove the valve collets.
• Release the valve spring.
21156
• Remove the valve spring retainer and the
valve spring.
Adapter, Air Supply (Cylinder
Head) 303-361A
303-363 (21-157)
21157
303-363
Pliers, Valve Stem Seal 303-362

303-508 (21-165)
303-361-02
TIE0021635
21165 5. Using the special tools, remove the valve

seals.
Removal
1. Remove the camshafts.
Camshafts - in this section.
2007.50 Focus 3/2007 G323907en

303-01A-36 Duratec-HE (MI4) 303-01A-36
IN-VEHICLE REPAIR
• Discard the seals. • Release the valve spring.
303-361-02 303-361A
303-363 303-363
303-361A
303-362
303-508
303-361-02
TIE0018259 TIE0021635
Installation 3. Remove the special tools.

4. Install the valve tappets.
1. NOTE: Install new valve seals.
5. Install the camshafts.
NOTE: Cover the valve collet groove on the valve
stem with a protective sleeve. For additional information, refer to
Camshafts - in this section.
Using the special tools, install the valve
seals.
• Remove the protective sleeve.
303-361-02
303-363
303-361A
303-508
TIE0018259
2. Using the special tools, install the valve

springs.
• Install the valve spring retainer and the valve
springs.
• Install the valve collets.
2007.50 Focus 3/2007 G323907en

303-01A-37 Duratec-HE (MI4) 303-01A-37
IN-VEHICLE REPAIR
Valves(21 215 4)
Special Tool(s) • Remove the valve spring retainer and the
valve spring.
Compressor, Valve Spring
303-361A (21-155A)
303-361A
21155
303-362
303-361-02 (21-155-02A)
303-361-02
TIE0021829
2115502A 3. Using the special tool, remove the valve

seals.
Installer, Valve Stem Collets • Discard the seals.
303-362 (21-156)
303-508
21156
Pliers, Valve Stem Seal

303-508 (21-165)
21165
ELE0021637
4. Remove the valves.
Removal Installation
1. Remove the cylinder head. 1. Install the valves.
For additional information, refer to Cylinder 2. NOTE: Install new valve seals.
Head - in this section.
NOTE: Cover the valve collet groove on the valve
2. Using the special tools, remove the valve stem with a protective sleeve.
springs.
Using the special tool, install the valve seals.
• Remove the valve collets.
2007.50 Focus 3/2007 G323908en

303-01A-38 Duratec-HE (MI4) 303-01A-38
IN-VEHICLE REPAIR
• Remove the protective sleeve.
303-508
ELE0021637
3. Using the special tools, install the valve

springs.
• Install the valve spring retainer and the valve
spring.
• Compress the valve spring
• Install the valve collets.
303-361A
303-362
303-361-02
TIE0021829

5. Install the cylinder head.
For additional information, refer to Cylinder
Head - in this section.
2007.50 Focus 3/2007 G323908en

303-01A-39 Duratec-HE (MI4) 303-01A-39
IN-VEHICLE REPAIR
Camshafts(21 284 0)
Special Tool(s)
Alignment Plate, Camshaft Removal
303-376
21162B
Socket, Spark Plug

303-499
ES21202
TIE39686
Timing Peg, Crankshaft TDC 2. Disconnect the battery ground cable.

303-507
PZ21210 3. Disconnect the camshaft position (CMP)
General Equipment
M6 x 18 mm bolt
M6 x 25 mm bolt
Materials
Name Specification
Hypoid Gear Oil SQM-2C9002-AA
Adhesive - Loctite 243 WSK-M2G349-A7
TIE0036617
2007.50 Focus 3/2007 G388123en

303-01A-40 Duratec-HE (MI4) 303-01A-40
IN-VEHICLE REPAIR
4. Disconnect the positive crankcase ventilation 7. Remove the engine cover retaining brackets.
(PCV) hose from the valve cover.
TIE0038256
TIE0036618
8. Remove the valve cover.

TIE0036622
TIE0036619

6. Using the special tool, remove the spark For additional information, refer to: Lifting
plugs. (100-02 Jacking and Lifting, Description
and Operation).
303-499 normal direction of rotation.
Rotate the crankshaft until piston No. 1 is
approximately 45 degrees before top dead
center (BTDC).
ELE0017343
45
TIE0025437
2007.50 Focus 3/2007 G388123en

303-01A-41 Duratec-HE (MI4) 303-01A-41
IN-VEHICLE REPAIR
11. Remove the engine front cover lower 1. Using a suitable screwdriver, unlock the
blanking plug. timing chain tensioner ratchet.
2. Carefully rotate the exhaust camshaft by the
hexagon in the normal direction of rotation,
to detension the timing chain tensioner.
3. Install a suitable M6 x 25 mm bolt through
the blanking plug to secure the timing chain
guide in the detensioned position.
ELE0021906

plug and install the special tool.
303-507
1
ELE0017416

14. Remove the engine front cover upper ELE0022183
blanking plug.
16.
CAUTION: Hold the camshafts by the
hexagon with an open-ended wrench to
prevent them from rotating.
NOTE: Using a suitable piece of wire, prevent the
timing chain and the sprocket from dropping into
the timing case.
Loosen the camshaft sprockets retaining
bolts.
ELE0021302
15.
CAUTION: To detension the timing
chain, make sure the timing chain tensioner
ratchet is in the released position.
Detension the timing chain.
2007.50 Focus 3/2007 G388123en

303-01A-42 Duratec-HE (MI4) 303-01A-42
IN-VEHICLE REPAIR
• Detach the exhaust camshaft sprocket 2. CAUTIONS:
together with the timing chain from the
Install the camshafts approximately at
exhaust camshaft.
valve overlap position cylinder No. 4.
Install the camshafts and bearing caps

in their original location.
Install the camshafts.
• Working in several stages, evenly tighten the
camshaft bearing cap bolts in the sequence
shown, one half turn at a time.
• Coat the camshaft bearing caps with oil.
• Tighten the bolts in two stages:
• Stage 1: 7 Nm
ELE0021908
• Stage 2: 16 Nm
17.
CAUTION: Keep the camshaft bearing
3 1 2
caps, the camshafts and the camshaft
sprockets in order for installation.
NOTE: Working in several stages, release each 5 4
camshaft bearing cap retaining bolt two turns at a
time.
Remove the camshaft bearing caps in the
sequence shown. 10 9
8 6 7
ELE0014858
3 5 4
3. NOTE: Only carry out the following step
when new camshafts are installed.
1 2 Adjust the valve clearance.
For additional information, refer to: Valve
Clearance Adjustment (303-01 Engine - 2.0L
6 8 10 9 7 General Procedures).
ELE0014857
4. NOTE: Do not tighten the exhaust camshaft
sprocket retaining bolt at this stage.
18. NOTE: Using a suitable piece of wire, Attach the exhaust camshaft sprocket
prevent the timing chain and the sprocket together with the timing chain to the exhaust
from dropping into the cylinder block. camshaft.
Detach the intake camshaft sprocket from
the intake camshaft.
Installation
All vehicles
1. NOTE: Do not tighten the camshaft sprocket
retaining bolt at this stage.
Attach the intake camshaft sprocket together
with the timing chain to the intake camshaft
and insert the intake camshaft. TIE0025830
2007.50 Focus 3/2007 G388123en

303-01A-43 Duratec-HE (MI4) 303-01A-43
IN-VEHICLE REPAIR
5. Install the special tool. Tighten the camshaft sprocket retaining
bolts.
E0014880 72 Nm
TIE0021909
6. Coat the engine front cover upper blanking

plug with adhesive. 10. Remove the special tool.
7. Remove the M6 x 25 mm bolt, tension the
timing chain.
• Install the engine front cover upper blanking
plug.
10 Nm
E0014880

ELE0018260 (100-02 Jacking and Lifting, Description
and Operation).
8. NOTE: Only rotate the crankshaft in the 12. Remove the special tool.
Rotate the crankshaft until piston No. 1 is at
TDC.
9. NOTE: Hold the camshafts by the hexagon
with an open-ended wrench to prevent them
from rotating. 303-507
ELE0017416

2007.50 Focus 3/2007 G388123en

303-01A-44 Duratec-HE (MI4) 303-01A-44
IN-VEHICLE REPAIR
Rotate the crankshaft approximately one and Using a M6 x 18 mm bolt, check the position
three quarter revolutions, until piston No. 1 of the crankshaft pulley.
is 45 degrees before TDC.
ELE0018258
45
TIE0025437

14. Install the special tool.
18. NOTE: If it is not possible to install the
special tool, correct the valve timing.
Using the special tool, check the position of
the camshafts.
303-507
ELE0017416

E0014880
TDC.
16.
CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the valve timing.
E0014880

and Operation).
2007.50 Focus 3/2007 G388123en

303-01A-45 Duratec-HE (MI4) 303-01A-45
IN-VEHICLE REPAIR
21. Remove the crankshaft pulley securing bolt. 25. Install the engine front cover lower blanking
plug.
12 Nm
ELE0018258
ELE0021907

as shown.
303-507
ELE0017416
ELE0021634
23. Install the cylinder block lower blanking
plug.
necessary.
20 Nm
11 6 3 7 12
10
2 10 Nm1 1 13
ELE0021301
9 5
24. Coat the engine front cover lower blanking

plug with adhesive. 14
4 8
TIE0036679
2007.50 Focus 3/2007 G388123en

303-01A-46 Duratec-HE (MI4) 303-01A-46
IN-VEHICLE REPAIR
28. Install the engine cover retaining brackets. 31. Connect the positive crankcase ventilation
(PCV) hose to the valve cover.
TIE0038256
TIE0036618
29. Using the special tool, install the spark

plugs. 32. Connect the camshaft position (CMP)
303-499
12 Nm
12 Nm
TIE0017349
TIE0036617
30. Install the ignition coil-on-plug.

10 Nm 10 Nm Disconnect and Connect (414-01 Battery,
Procedures).
TIE0036620
TIE44765
2007.50 Focus 3/2007 G388123en

303-01A-47 Duratec-HE (MI4) 303-01A-47
IN-VEHICLE REPAIR
Procedures).
2007.50 Focus 3/2007 G388123en

303-01A-48 Duratec-HE (MI4) 303-01A-48
IN-VEHICLE REPAIR
Timing Chain(21 314 0)

Removal 4. Remove the timing chain guides.
1. Remove the engine front cover.

For additional information, refer to Engine
Front Cover - in this section.
2. Detension the timing chain.
1. Unlock the timing chain tensioner ratchet.
2. Apply pressure to the timing chain guide.
3. Fix the timing chain tensioner with a suitable
pin punch.
ELE0018002
1
3 2 5. Remove the timing chain tensioner.
ELE0014849

with an open-ended wrench to stop them
from rotating. TIE0024498
Loosen the camshaft sprocket retaining
bolts.
Installation
1. Install the timing chain tensioner.
ELE0018000 10 Nm
TIE0024499
2007.50 Focus 3/2007 G323910en

303-01A-49 Duratec-HE (MI4) 303-01A-49
IN-VEHICLE REPAIR
2. Install the timing chain guides. 5. NOTE: Hold the camshafts by the hexagon
with an open ended wrench to stop them
from rotating.
Tighten the camshaft sprocket retaining
bolts.
10 Nm
ELE0018003
3.
CAUTION: Do not tighten the camshaft
72 Nm
sprocket retaining bolts at this stage. Make
TIE0021909
sure the camshaft sprockets rotate on the
camshafts.
6. Install the engine front cover.
Install the camshaft sprockets.
For additional information, refer to Engine
• Install the timing chain.
Front Cover - in this section.
ELE0018000
4. Tension the timing chain.

• Apply pressure to the timing chain and
remove the securing pin.
ELE0022182
2007.50 Focus 3/2007 G323910en

303-01A-50 Duratec-HE (MI4) 303-01A-50
IN-VEHICLE REPAIR
Cylinder Head(21 163 0)

Special Tool(s) 4. Remove the air cleaner.
Remover/Installer, Hose For additional information, refer to: Air
Clamp Cleaner - 2.0L Duratec-HE (MI4)/1.8L
303-397 Duratec-HE (MI4) (303-12 Intake Air
Distribution and Filtering, Removal and
Installation).
24003
5. Remove the timing chain.
For additional information, refer to: Timing
Chain (303-01 Engine - 2.0L Duratec-HE
Materials (MI4)/1.8L Duratec-HE (MI4), In-vehicle
Name Specification Repair).
Hypoid Gear Oil SQM-2C9002-AA 6. Raise and support the vehicle.
Removal and Operation).
WARNING: Do not smoke or carry lighted 7. Remove the oil level indicator tube lower
tobacco or open flame of any type when retaining bolt.
working on or near any fuel related
components. Highly flammable vapors are
always present and may ignite. Failure to 10 Nm
personal injury.
1. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding
(303-03 Engine Cooling - 2.0L Duratec-HE
(MI4)/1.8L Duratec-HE (MI4), General
Procedures).
TIE0036815
8. Remove the intake manifold lower retaining

bolt.
18 Nm
TIE39686
3. Disconnect the battery. TIE0036813

2007.50 Focus 3/2007 G388116en

303-01A-51 Duratec-HE (MI4) 303-01A-51
IN-VEHICLE REPAIR
9. Detach the wiring harness from the intake 12. Disconnect the generator electrical
manifold. connector.
TIE0038268 TIE0038199
10. Disconnect the knock sensor (KS) electrical 13. Disconnect the thermostat electrical
connector for cylinder 3 and 4 (if equipped). connector.
• Detach the knock sensor (KS) electrical
connector for cylinder 3 and 4 from the intake
manifold.
TIE0038200
14. Disconnect the air conditioning (A/C)

TIE0038271
compressor electrical connector.
11. Disconnect the manifold absolute pressure

(MAP) sensor electrical connector.
TIE0038201
TIE45284
2007.50 Focus 3/2007 G388116en

303-01A-52 Duratec-HE (MI4) 303-01A-52
IN-VEHICLE REPAIR
15. Disconnect the crankshaft position (CKP) • Position the starter motor to one side.
ELE0015471
ELE0015349
16. Remove the exhaust manifold lower 20. Disconnect the brake booster vacuum line
retaining bolts. from the intake manifold.
TIE0036585 TIE0036580
17. Remove the wiring harness retaining 21. Disconnect the heated oxygen (HO2S)
bracket. sensor electrical connector.
ELE0015370 TIE0036574
18. Remove the starter motor.
2007.50 Focus 3/2007 G388116en

303-01A-53 Duratec-HE (MI4) 303-01A-53
IN-VEHICLE REPAIR
22. Disconnect the catalyst monitor sensor 25. Detach the engine wiring harness from the
electrical connector. intake manifold.
TIE45285 E0036819
23. Disconnect the evaporative emission 26. Disconnect the engine wiring harness
canister purge valve (EVAP) electrical interface connectors.
connector.
TIE0038269
TIE0038202
27. Remove the oil level indicator and oil level

24. Disconnect the engine coolant temperature indicator tube.
(ECT) sensor electrical connector.
10 Nm
TIE0036817
TIE0036678
2007.50 Focus 3/2007 G388116en

303-01A-54 Duratec-HE (MI4) 303-01A-54
IN-VEHICLE REPAIR
28. Disconnect the vacuum hose from the 31. Using the special tool, disconnect the
intake manifold. coolant hose from the coolant expansion
tank.
303-397
TIE0038216
TIE45287
29. Disconnect the knock sensor (KS) electrical

connector. 32. Remove the exhaust manifold heat shield
(engine shown removed for clarity).
• Detach the knock sensor (KS) electrical
connector from the intake manifold.
TIE0038213
30. Using the special tool, disconnect the

coolant hoses from the throttle body.
303-397
TIE0036581
33. Remove the exhaust manifold retaining

TIE45286 nuts (engine shown removed for clarity).
• Detach the exhaust manifold from the
cylinder head and position it to one side.
2007.50 Focus 3/2007 G388116en

303-01A-55 Duratec-HE (MI4) 303-01A-55
IN-VEHICLE REPAIR
• Discard the gaskets. 36. Detach the ground lead from the cylinder
head.
TIE0036583
TIE0024450
34. Disconnect the exhaust gas recirculation
(EGR) valve electrical connector. 37. Disconnect the fuel supply line.
For additional information, refer to: Quick
Release Coupling (310-00 Fuel System -
TIE0036741

coolant hoses from the coolant outlet ELE0022108
connector.
38. CAUTIONS:
303-397 Keep the camshaft bearing caps, valve
tappets and the camshafts in order for
installation.

sequence shown.
NOTE: Working in several stages, release each
time.
TIE0036742
Remove the camshaft.
2007.50 Focus 3/2007 G388116en

303-01A-56 Duratec-HE (MI4) 303-01A-56
IN-VEHICLE REPAIR
• Remove the valve tappets. • Stage 5: 90 degrees.
3 5 4 8 4 1 5 9
1 2
6 8 10 9 7 7 3 2 6 10
ELE0014857 ELE0014860
39. 3. Install the valve tappets.

CAUTION: Remove the cylinder head
bolts in the sequence shown. 4.
CAUTION: Working in several stages,
Remove the cylinder head. evenly tighten the camshaft bearing cap
bolts in the sequence shown, one half turn
• Discard the gasket.
at a time.
• Discard the bolts.
• Coat the camshaft bearing caps with hypoid
3 7 10 6 2
oil.
• Tighten the bolts in the sequence shown in
two stages:
• Stage 1: 7 Nm.
• Stage 2: 16 Nm.
4 8 9 5 1 3 1 2
ELE0014859
5 4
Installation
All vehicles
1. Check the cylinder head for distortion. 10 8 6 7 9
For additional information, refer to: Cylinder ELE0014858
Head Distortion (303-00 Engine System -

2. NOTE: Install new cylinder head bolts and
gasket.
Install the cylinder head.
• Tighten the cylinder head bolts in the
sequence shown in five stages:
• Stage 1: 5 Nm.
• Stage 2: 15 Nm.
• Stage 3: 45 Nm.
• Stage 4: 90 degrees.
2007.50 Focus 3/2007 G388116en

303-01A-57 Duratec-HE (MI4) 303-01A-57
IN-VEHICLE REPAIR
5. Connect the fuel supply line. 8. Using the special tool, connect the coolant
hoses to the coolant outlet connector.
303-397
TIE0036742
ELE0022108 9. Connect the exhaust gas recirculation (EGR)

valve electrical connector.
6. NOTE: Only carry out the following step
when a new cylinder head or new valves are
installed.
Adjust the valve clearance.
For additional information, refer to: Valve
Clearance Adjustment (303-01 Engine - 2.0L
7. Attach the ground lead to the cylinder head.
TIE0036741
15 Nm 10. NOTE: Install a new exhaust manifold

gasket.
NOTE: Do not tighten the exhaust manifold
retaining nuts at this stage.
Attach the exhaust manifold to the cylinder
head (engine shown removed for clarity).
TIE0024451
TIE0036583
2007.50 Focus 3/2007 G388116en

303-01A-58 Duratec-HE (MI4) 303-01A-58
IN-VEHICLE REPAIR
11. Raise and support the vehicle. 15. Install the exhaust manifold heat shield
and Operation).
12. Install the exhaust manifold lower retaining
bolts.
10 Nm
15 Nm
TIE0036586

14. Tighten the exhaust manifold retaining nuts
10 Nm
TIE0036582
16. Using the special tool, connect the coolant

hose to the coolant expansion tank.
51 Nm 51 Nm
E0036584
303-397
TIE45287
2007.50 Focus 3/2007 G388116en

303-01A-59 Duratec-HE (MI4) 303-01A-59
IN-VEHICLE REPAIR
17. Using the special tool, connect the coolant 20. Install the oil level indicator and oil level
hoses to the throttle body. indicator tube.
303-397
10 Nm
TIE45286 TIE0036817
18. Connect the knock sensor (KS) electrical 21. Connect the engine wiring harness
connector. interface connectors.
• Attach the knock sensor (KS) electrical
connector to the intake manifold.
TIE0038269
TIE0038213
22. Attach the engine wiring harness to the
intake manifold.
19. Connect the vacuum hose to the intake
manifold.
E0036819
TIE0038216
2007.50 Focus 3/2007 G388116en

303-01A-60 Duratec-HE (MI4) 303-01A-60
IN-VEHICLE REPAIR
23. Connect the engine coolant temperature 26. Connect the heated oxygen (HO2S) sensor
(ECT) sensor electrical connector. electrical connector.
TIE0036678 TIE0036574
24. Connect the evaporative emission canister 27. Connect the brake booster vacuum line to
purge valve (EVAP) electrical connector. the intake manifold.
TIE0038202 TIE0036580
25. Connect the catalyst monitor sensor 28. Raise and support the vehicle.
electrical connector. For additional information, refer to: Lifting
and Operation).
29. Install the starter motor.
35 Nm
TIE45285
ELE0015472
2007.50 Focus 3/2007 G388116en

303-01A-61 Duratec-HE (MI4) 303-01A-61
IN-VEHICLE REPAIR
30. Install the wiring harness retaining bracket. 33. Connect the thermostat electrical
connector.
ELE0015370
TIE0038200
31. Connect the crankshaft position (CKP)

sensor electrical connector. 34. Connect the generator electrical connector.
ELE0015349 TIE0038199
32. Connect the air conditioning compressor 35. Connect the manifold absolute pressure
electrical connector. (MAP) sensor electrical connector.
TIE0038201 TIE45284
36. Connect the knock sensor (KS) electrical

connector for cylinder 3 and 4 (if equipped).
2007.50 Focus 3/2007 G388116en

303-01A-62 Duratec-HE (MI4) 303-01A-62
IN-VEHICLE REPAIR
• Attach the knock sensor (KS) electrical 39. Install the oil level indicator tube lower
connector for cylinder 3 and 4 to the intake retaining bolt.
manifold.
10 Nm
TIE0036815
TIE0038271

37. Attach the wiring harness to the intake
manifold. 41. Install the timing chain.
(MI4)/1.8L Duratec-HE (MI4), In-vehicle
Repair).
42. Install the air cleaner.
For additional information, refer to: Air
Cleaner - 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4) (303-12 Intake Air
Installation).
TIE0038268 43. Connect the battery.
38. Install the intake manifold lower retaining Disconnect and Connect (414-01 Battery,
bolt. Mounting and Cables, General
Procedures).
44. Fill and bleed the cooling system.
18 Nm For additional information, refer to: Cooling
Procedures).
TIE0036813
2007.50 Focus 3/2007 G388116en

303-01A-63 Duratec-HE (MI4) 303-01A-63
IN-VEHICLE REPAIR
TIE44765

Procedures).
2007.50 Focus 3/2007 G388116en

303-01A-64 Duratec-HE (MI4) 303-01A-64
IN-VEHICLE REPAIR
Oil Pan(21 154 0)

General Equipment Vehicles with manual transaxle
Transmission jack 4. Loosen the transaxle upper retaining bolts
Materials
Name Specification
Removal
All vehicles
TIE0036566
All vehicles
indicator tube upper retaining bolt.
TIE39686
2. Remove the air cleaner.

Distribution and Filtering, Removal and TIE0036816
Installation).
Vehicles with 4-speed automatic transaxle 6. Raise and support the vehicle.
3. Loosen the transaxle upper retaining bolts For additional information, refer to: Lifting
approximately 10 mm. (100-02 Jacking and Lifting, Description
and Operation).
E52745
TIE0037660
2007.50 Focus 3/2007 G401889en

303-01A-65 Duratec-HE (MI4) 303-01A-65
IN-VEHICLE REPAIR
8. Drain the engine. 12. Disconnect the A/C compressor electrical
connector.
9. NOTE: Inspect the oil drain plug and seal for
damage. Install a new oil drain plug or seal
if necessary.
Install the oil drain plug.
TIE0037661
28 Nm 13. Remove the A/C compressor cover.
TIE0036668
10. Remove the engine support insulator.
TIE0036588
14. Detach the A/C compressor from the oil pan

and position it to one side.
TIE0036808
11. Remove the air conditioning (A/C)

compressor belt.
Conditioning (A/C) Compressor Belt - 2.0L
Duratec-HE (MI4)/1.8L Duratec-HE (MI4)
(303-05 Accessory Drive, Removal and
Installation).
TIE0036590
2007.50 Focus 3/2007 G401889en

303-01A-66 Duratec-HE (MI4) 303-01A-66
IN-VEHICLE REPAIR
15. Detach the A/C line bracket from the oil pan. 18. Remove the engine front cover lower
retaining bolts.
TIE0037656
TIE0036669

indicator tube. 19. Using a suitable transmission jack and a
suitable wooden block, support the engine.
TIE0036814
TIE0037659
17. Detach the wiring harness from the engine

front cover studs. Vehicles with 4-speed automatic transaxle
20. Loosen the transaxle right-hand retaining
bolts approximately 10 mm.
TIE0037658
E52746
2007.50 Focus 3/2007 G401889en

303-01A-67 Duratec-HE (MI4) 303-01A-67
IN-VEHICLE REPAIR
21. Loosen the transaxle lower retaining bolts 24. Loosen the transaxle left-hand retaining
approximately 10 mm. bolts approximately 10 mm.
E52747 TIE0037654
22. Loosen the transaxle left-hand retaining 25. Remove the transaxle lower retaining bolts.
bolt approximately 10 mm.
TIE0036858
E52748
All vehicles
Vehicles with manual transaxle 26. Slide the transaxle back approximately 8
23. Loosen the transaxle right-hand retaining mm, lower and remove the transmission
bolts approximately 10 mm. jack.
27. Remove the oil pan.
E48672
TIE0036671
2007.50 Focus 3/2007 G401889en

303-01A-68 Duratec-HE (MI4) 303-01A-68
IN-VEHICLE REPAIR
Installation Install the oil pan.
All vehicles
1. Clean the mating faces of the cylinder block
and the oil pan.
2. NOTE: Install the oil pan within 10 minutes
of applying the silicone sealant and tighten
the retaining bolts within a further 5 minutes.
Apply a 3 mm bead of sealant to the mating
face of the oil pan to the cylinder block.
TIE0036671
5. Install the engine front cover lower retaining

bolts.
10 Nm
ELE0017398

the retaining bolts within a further 5 minutes.
TIE0036670
face of the oil pan to the engine front cover.
6. Tighten the oil pan retaining bolts in the
sequence shown.
12 8 4 5 9
1
10
25 Nm
7 11
3 2 6
TIE0036665
TIE0036673
4. NOTE: Do not tighten the oil pan retaining
bolts at this stage.
2007.50 Focus 3/2007 G401889en

303-01A-69 Duratec-HE (MI4) 303-01A-69
IN-VEHICLE REPAIR
7. Using a suitable transmission jack and a 11. Install the transaxle lower retaining bolts.
suitable wooden block, support the engine.
44 Nm
TIE0036859
TIE0037659
Vehicles with 4-speed automatic transaxle

8. Slide the transaxle towards the engine.
12. Install the transaxle right-hand retaining
bolts.
9. Tighten the transaxle left-hand retaining
bolts.
48 Nm
44 Nm
E52752
13. Install the transaxle lower retaining bolts.

TIE0037655
10. Tighten the transaxle right-hand retaining

bolts.
44 Nm
48 Nm
E52753
TIE0037663
2007.50 Focus 3/2007 G401889en

303-01A-70 Duratec-HE (MI4) 303-01A-70
IN-VEHICLE REPAIR
14. Tighten the transaxle left-hand retaining 18. Attach the air conditioning (A/C) line
bolt. bracket to the oil pan.
48 Nm 25 Nm
E52754 TIE0037657
All vehicles 19. Attach the A/C compressor to the oil pan.
15. Remove the transmission jack and wooden
block.
16. Attach the wiring harness to the engine
front cover studs.
24 Nm
TIE0036591
20. Install the A/C compressor cover.
TIE0037658
15 Nm
17. Install the oil level indicator and oil level

indicator tube.
24 Nm
10 Nm
TIE0036589
TIE0036815
2007.50 Focus 3/2007 G401889en

303-01A-71 Duratec-HE (MI4) 303-01A-71
IN-VEHICLE REPAIR
21. Connect the A/C compressor electrical 26. Install the oil level indicator and oil level
connector. indicator tube upper retaining bolt.
10 Nm
TIE0037661 TIE0036817
22. Install the air A/C compressor belt. Vehicles with manual transaxle
For additional information, refer to: Air 27. Tighten the transaxle upper retaining bolts.
Installation).
23. Install the engine support insulator.
44 Nm
80 Nm
TIE0036567
80 Nm Vehicles with 4-speed automatic transaxle

28. Tighten the transaxle upper retaining bolts.
TIE0036809
48 Nm
E52751
TIE0037660
2007.50 Focus 3/2007 G401889en

303-01A-72 Duratec-HE (MI4) 303-01A-72
IN-VEHICLE REPAIR
All vehicles
Installation).
TIE44765
31. Fill the engine with engine oil.

2007.50 Focus 3/2007 G401889en

303-01A-73 Duratec-HE (MI4) 303-01A-73
IN-VEHICLE REPAIR
Oil Pump(21 714 0)

Special Tool(s) 4. Remove the oil pump chain tensioner.
Universal Flange Holding
Wrench
205-072 (15-030A)
15030A
Adapter for 205-072

205-072-01 (15-030A-01)
TIE0024480
20507201
5. Using the special tools, loosen the oil pump
sprocket retaining bolt.
Removal
205-072-01
Repair). 205-072
For additional information, refer to: Oil Pan
E0024482
(303-01 Engine - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4), In-vehicle Repair).
6. Remove the oil pump chain.
3. Remove the oil pump chain guide.
1. Remove the oil pump sprocket retaining bolt.
2. Remove the oil pump chain and the oil pump
sprocket.
TIE0024467
2
TIE0024483
7. Remove the oil pump.
2007.50 Focus 3/2007 G323913en

303-01A-74 Duratec-HE (MI4) 303-01A-74
IN-VEHICLE REPAIR
• Discard the gasket. 3. Using the special tools, tighten the oil pump
205-072-01
25 Nm
205-072
ELE0021905
E0024485
Installation
4. Install the oil pump chain tensioner.
1. NOTE: Install a new oil pump gasket.
Install the oil pump.
10 Nm
• Tighten the retaining bolts in the sequence
shown in two stages.
• Stage 1: 10 Nm.
• Stage 2: 23 Nm.
1 3
TIE0024481
5. Install the oil pump chain guide.
4 2
TIE0026145
10 Nm
2. Install the oil pump chain.
1. Install the oil pump chain and the oil pump
sprocket.
2. Install the oil pump sprocket retaining bolt.
TIE0024479
1 6. Install the oil pan.

For additional information, refer to: Oil Pan
(303-01 Engine - 1.8L Duratec-HE (MI4)/2.0L
Duratec-HE (MI4), In-vehicle Repair).
2
TIE0024484
2007.50 Focus 3/2007 G323913en

303-01A-75 Duratec-HE (MI4) 303-01A-75
IN-VEHICLE REPAIR
7. Install the timing chain.
Repair).
2007.50 Focus 3/2007 G323913en

303-01A-76 Duratec-HE (MI4) 303-01A-76
IN-VEHICLE REPAIR
Crankshaft Rear Seal(21 468 4)

Special Tool(s) Vehicles with manual transaxle
Locking Tool, Flywheel 3. Remove the clutch disc and pressure plate.
303-254 For additional information, refer to: Clutch
Disc and Pressure Plate (308-01 Clutch -
Vehicles With: 5-Speed Manual
Transmission (MTX-75), Removal and
21135 Installation)
/ Clutch Disc and Pressure Plate (308-01
Clutch - Vehicles With: 5-Speed Manual
Materials Transmission (iB5), Removal and
Installation).
Name Specification
Cleaner WSK-M5B401-A1 Vehicles with automatic transaxle
Silicone Sealant WSE-M4G323-A4 4. Remove the transaxle.
Engine Oil - 5W-30 WSS-M2C913-B For additional information, refer to: Transaxle
- 2.0L Duratec-HE (MI4) (307-01 Automatic
Removal 4-Speed Automatic Transmission (4F27E),
Removal).
All vehicles
1. Remove the engine cover. All vehicles
5. Drain the engine.
6. NOTE: Inspect the oil drain plug seal for
damage. Install a new drain plug and seal if
necessary.
TIE39686

28 Nm
TIE0036668
TIE0036816
2007.50 Focus 3/2007 G401891en

303-01A-77 Duratec-HE (MI4) 303-01A-77
IN-VEHICLE REPAIR
7. Remove the oil level indicator and oil level 11. Detach the A/C compressor from the oil pan
indicator tube. and secure it to one side.
TIE0036814 TIE0036590
8. Remove the air conditioning (A/C) 12. Using the special tool, lock the flywheel or
compressor belt. flexplate in position.
Conditioning (A/C) Compressor Belt - 2.0L 303-254
Installation).
9. Disconnect the A/C compressor electrical
connector.
TIE0024500
13. Remove the flywheel or flexplate.

303-254
TIE0037661
10. Remove the A/C compressor cover.
TIE0024668
TIE0036588
2007.50 Focus 3/2007 G401891en

303-01A-78 Duratec-HE (MI4) 303-01A-78
IN-VEHICLE REPAIR
15. Remove the engine front cover lower NOTE: A new crankshaft rear seal carrier is
retaining bolts. supplied preassembled with an installation sleeve
that must be removed following installation.
NOTE: Make sure that the dowel pins are correctly
seated.
Install the crankshaft rear seal carrier.
• Tighten the retaining bolts in the sequence
shown.
5 3
1
TIE0036669
10 Nm
2
4 6
ELE0014876
2. Clean the mating faces of the cylinder block,

the engine front cover and the oil pan with
cleaner.
TIE0036671 the retaining bolts within a further 5 minutes.
17. Remove the crankshaft rear seal carrier. face of the oil pan to the cylinder block.
• Discard the crankshaft rear seal carrier.
ELE0017398
ELE0014875

Installation the retaining bolts within a further 5 minutes.
All vehicles
1.
CAUTION: Do not remove the installation
sleeve before installation.
NOTE: Install a new crankshaft rear seal carrier.
2007.50 Focus 3/2007 G401891en

303-01A-79 Duratec-HE (MI4) 303-01A-79
IN-VEHICLE REPAIR
Apply a 3 mm bead of sealant to the mating 7. Tighten the oil pan retaining bolts in the
face of the oil pan to engine front cover. sequence shown.
12 8 4 5 9
1
10
25 Nm
7 11
3 2 6
TIE0036665 TIE0036673
5. NOTE: Do not tighten the oil pan retaining 8. NOTE: Install new flywheel or flexplate
bolts at this stage. retaining bolts.
Install the oil pan. Install the flywheel or flexplate.
TIE0036671 ELE0021911
6. Install the engine front cover lower retaining 9. Using the special tool, lock the flywheel or
bolts. flexplate in position.
303-254
10 Nm
TIE0036670 TIE0024500
10. Tighten the flywheel or flexplate retaining

bolts.
three stages.
• Stage 1: 50 Nm.
• Stage 2: 80 Nm.
2007.50 Focus 3/2007 G401891en

303-01A-80 Duratec-HE (MI4) 303-01A-80
IN-VEHICLE REPAIR
• Stage 3: 112 Nm. 15. Install the A/C compressor cover.
303-254 15 Nm
1
3
6
5
24 Nm
4
2
ELE0021912
TIE0036589
11. Remove the special tool. 16. Connect the A/C compressor electrical
connector.
12. Install the clutch disc and pressure plate.
For additional information, refer to: Clutch
Transmission (iB5), Removal and
Installation)
Installation).
TIE0037661
Vehicles with automatic transaxle

13. Install the transaxle. 17. Install the A/C compressor belt.
For additional information, refer to: For additional information, refer to: Air
Transaxle - 2.0L Duratec-HE (MI4) (307-01 Conditioning (A/C) Compressor Belt - 2.0L
Automatic Transmission/Transaxle - Duratec-HE (MI4)/1.8L Duratec-HE (MI4)
Vehicles With: 4-Speed Automatic (303-05 Accessory Drive, Removal and
Transmission (4F27E), Installation). Installation).
All vehicles indicator tube.
14. Attach the A/C compressor to the oil pan.
10 Nm
24 Nm
TIE0036815
TIE0036591
2007.50 Focus 3/2007 G401891en

303-01A-81 Duratec-HE (MI4) 303-01A-81
IN-VEHICLE REPAIR
10 Nm
TIE0036817
TIE44765

2007.50 Focus 3/2007 G401891en

303-01A-82 Duratec-HE (MI4) 303-01A-82
REMOVAL
Engine — Vehicles With: Manual Transaxle(21 134 0)

Special Tool(s) 1. Remove the engine cover.
Lifting Bracket, Engine
303-122
21068A
Remover/Installer, Hose
Clamp
303-397
TIE39686
24003
Disconnect Tool, Fuel Line Tray - 1.4L Duratec-16V (Sigma)/1.6L
(5/16”) Duratec-16V (Sigma)/1.8L Duratec-HE
310-040 (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery,
Mounting and Cables, Removal and
Installation).
23041 3. Disconnect the battery positive cable from
the battery positive cable terminal clamp.
General Equipment
Workshop table
Engine hoist
Retaining straps
Removal
All vehicles
WARNING: Do not smoke or carry lighted TIE0038244
tobacco or open flame of any type when
components. Highly flammable vapors are 4. Drain the cooling system.
always present and may ignite. Failure to For additional information, refer to: Cooling
follow these instructions may result in System Draining, Filling and Bleeding
personal injury. (303-03 Engine Cooling - 1.8L Duratec-HE
Procedures).
2007.50 Focus 3/2007 G420943en

303-01A-83 Duratec-HE (MI4) 303-01A-83
REMOVAL
5. Detach the ground cables from the wheel 8. Disconnect the heated oxygen sensor (HO2S)
housing. electrical connector.
TIE0036569 TIE0036574
6. Remove the central junction box (CJB) cover. 9. Disconnect the catalyst monitor sensor
TIE0036571
TIE45285
7. Disconnect the engine wiring harness

electrical connector. 10. Remove the radiator.
Radiator (303-03 Engine Cooling - 1.8L
coolant hose from the coolant outlet
connector.
303-397
TIE0036573
TIE0036592
2007.50 Focus 3/2007 G420943en

303-01A-84 Duratec-HE (MI4) 303-01A-84
REMOVAL
12. Disconnect the coolant hose. 15. Disconnect the brake booster vacuum line
from the intake manifold.
E49099
TIE0036580

coolant hose from the coolant expansion Vehicles with iB5 manual transaxle
tank.
(100-02, Description and Operation).
17. Remove the gearshift cables cover.
303-397
E49101
14. Remove the coolant expansion tank.
TIE0026646
18. Detach the gearshift cables from the

transaxle.
1. Detach the gearshift cables and the selector
cable from the selector levers.
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket.
E49102
TIE0026442
2007.50 Focus 3/2007 G420943en

303-01A-85 Duratec-HE (MI4) 303-01A-85
REMOVAL
19. Disconnect the reversing lamp switch 2. Press the locking tab and detach the
electrical connector. gearshift cable from the transaxle selector
lever.
TIE0026645
E44563
20.
CAUTION: If brake fluid is spilt on the 23. Detach the gearshift cables from the
paintwork, the affected area must be abutment.
1. Rotate the abutment sleeves
Disconnect the clutch slave cylinder supply counterclockwise and detach the selector
line. cable from the abutment.
• Remove the spring clip. 2. Rotate the abutment sleeves
counterclockwise and detach the gearshift
cable from the abutment.
TIE0026654 2
TIE44564
Vehicles with MTX-75 manual transaxle 24. Disconnect the reversing lamp switch
transaxle.
1. Press the locking tab and detach the selector
cable from the transaxle selector lever.
TIE0024487
2007.50 Focus 3/2007 G420943en

303-01A-86 Duratec-HE (MI4) 303-01A-86
REMOVAL
25. Detach the ground cable from the transaxle. All vehicles
27. Remove the exhaust manifold heat shield
TIE0036563
26. CAUTIONS:
If brake fluid is spilt on the paintwork,
the affected area must be immediately
washed down with cold water.
Close off the clutch slave cylinder supply

line to prevent fluid loss or dirt ingress.
Detach the clutch slave cylinder supply line
from the clutch slave cylinder.
• Remove the spring clip.
• Detach the clutch slave cylinder supply line
from the bracket.
TIE0036581

nuts (engine shown removed for clarity).
• Discard the nuts.
TIE0036726
TIE0036583
2007.50 Focus 3/2007 G420943en

303-01A-87 Duratec-HE (MI4) 303-01A-87
REMOVAL
29. Disconnect the evaporative emission 33. Remove the air conditioning (A/C)
(EVAP) valve vacuum line. compressor belt.
Installation).
34. Remove the A/C line retaining bracket.
TIE0038247
30. Using the special tool, disconnect the fuel

supply line.
TIE0037656
35. Remove the A/C compressor cover.
310-040
TIE0038248

TIE0036588
32. Remove the exhaust manifold lower
retaining nuts (engine shown removed for
clarity). 36. Disconnect the A/C compressor electrical
connector.
cylinder head and position it to one side.
TIE0038249
TIE0036585
2007.50 Focus 3/2007 G420943en

303-01A-88 Duratec-HE (MI4) 303-01A-88
REMOVAL
37. Detach the A/C compressor from the oil pan Position the workshop table under the
and position it to one side. vehicle and carefully lower the vehicle, until
the engine and transaxle assembly is in the
correct position to remove the engine
mounts.
TIE0036590
38. Remove the engine support insulator. ELE0016321
42. Detach the A/C compressor line retaining

bracket from the engine front mount.
TIE0036808
39. Remove the left-hand halfshaft.

For additional information, refer to: TIE0036666
Halfshaft LH (205-04 Front Drive
43. Remove the engine front mount retaining
40. Remove the right-hand halfshaft. nuts and bolts.
For additional information, refer to: • Discard the nuts.
Halfshaft RH (205-04 Front Drive
41. NOTE: Using suitable retaining straps to
secure the engine and the transaxle on the
workshop table.
TIE0038250
2007.50 Focus 3/2007 G420943en

303-01A-89 Duratec-HE (MI4) 303-01A-89
REMOVAL
44. Remove the engine front mount retaining 49. Remove the wiring harness retaining
studs. bracket.
TIE0038251 ELE0015370
45. Remove the engine front mount. 50. Remove the starter motor.
46. Remove the engine rear mount retaining • Detach the wiring harness from the retaining
bolt. bracket.
ELE0015471
TIE0037845
47. Raise and support the vehicle and remove 51. Remove the transaxle lower retaining bolts.
the engine and transaxle assembly.
48. Using a suitable engine hoist support the
engine and transaxle assembly and remove
the retaining straps.
303-122
TIE0036858
E0015369
2007.50 Focus 3/2007 G420943en

303-01A-90 Duratec-HE (MI4) 303-01A-90
REMOVAL
52. Remove the transaxle right-hand retaining
bolts.
E48672
53. Remove the transaxle left-hand retaining

bolts.
TIE0037654
54. Remove the transaxle upper retaining bolts.
TIE0036566
55. Remove the transaxle.
2007.50 Focus 3/2007 G420943en

303-01A-91 Duratec-HE (MI4) 303-01A-91
REMOVAL
Engine — Vehicles With: 4-Speed Automatic Transmission

(4F27E)(21 134 0)
303-122
21068A
Clamp
303-397
TIE39686
24003
3. Disconnect the battery positive cable from
Disconnect Tool, Fuel Line
(5/16”)
310-040
23041
General Equipment
Workshop table
Engine hoist TIE0038244
Retaining straps
Removal For additional information, refer to: Cooling

WARNING: Do not smoke or carry lighted (303-03 Engine Cooling - 2.0L Duratec-HE
tobacco or open flame of any type when (MI4)/1.8L Duratec-HE (MI4), General
working on or near any fuel related Procedures).
always present and may ignite. Failure to
personal injury.
and Installation).
2007.50 Focus 3/2007 G401893en

303-01A-92 Duratec-HE (MI4) 303-01A-92
REMOVAL
5. Detach the ground cables from the wheel 8. Disconnect the heated oxygen sensor (HO2S)
housing. electrical connector.
TIE0036569 TIE0036574
6. Remove the central junction box (CJB) cover. 9. Disconnect the catalyst monitor sensor
TIE0036571
TIE45285
7. Disconnect the engine wiring harness

electrical connector. 10. Disconnect the turbineshaft speed (TSS)
TIE0036573
ELE0008689
2007.50 Focus 3/2007 G401893en

303-01A-93 Duratec-HE (MI4) 303-01A-93
REMOVAL
11. Disconnect the automatic transaxle 14. Using the special tool, disconnect the
electrical connector. coolant hose from the coolant outlet
connector.
303-397
E50543
TIE0036592
12.
WARNING: Beware, risk of scalding
15. Disconnect the coolant hose.
when draining transmission fluid. Failure
to observe this instruction can lead to
injury.
CAUTION: Close off the transmission fluid
cooler feed and return lines to prevent fluid
loss or dirt ingress.
NOTE: Mark the position of the feed and return
lines as an aid to installation.
Detach the transmission fluid cooler feed
and return lines from the automatic
transmission.
E49099
container.
coolant hose from the coolant expansion
tank.
1 2
303-397
E50542
13. Remove the radiator.

E49101
Radiator (303-03 Engine Cooling - 2.0L
2007.50 Focus 3/2007 G401893en

303-01A-94 Duratec-HE (MI4) 303-01A-94
REMOVAL
17. Remove the coolant expansion tank. 19. Remove the exhaust manifold heat shield
E49102
18. Disconnect the brake booster vacuum line

from the intake manifold.
TIE0036581
TIE0036580

TIE0036583
2007.50 Focus 3/2007 G401893en

303-01A-95 Duratec-HE (MI4) 303-01A-95
REMOVAL
21. Disconnect the evaporative emission 25. Remove the air conditioning (A/C)
(EVAP) valve vacuum line. compressor belt.
Installation).
26. Remove the A/C line retaining bracket.
TIE0038247
22. Using the special tool, disconnect the fuel

supply line.
TIE0037656
27. Disconnect the transmission Range (TR)

310-040
TIE0038248

and Operation).
E50546
24. Remove the exhaust manifold lower
retaining nuts (engine shown removed for
clarity). 28. Detach the selector lever cable from the
transmission.
cylinder head and position it to one side. 1. Detach the selector lever cable from the
selector mechanism.
TIE0036585
2007.50 Focus 3/2007 G401893en

303-01A-96 Duratec-HE (MI4) 303-01A-96
REMOVAL
2. Press the locking pins together and detach 31. Disconnect the A/C compressor electrical
the selector lever cable from the abutment. connector.
E47354 TIE0038249
29. Disconnect the outputshaft speed (OSS) 32. Detach the A/C compressor from the oil pan
sensor electrical connector. and position it to one side.
ELE0007584 TIE0036590
30. Remove the A/C compressor cover. 33. Remove the engine support insulator.
TIE0036588
TIE0036808

2007.50 Focus 3/2007 G401893en

303-01A-97 Duratec-HE (MI4) 303-01A-97
REMOVAL
35. Remove the right-hand halfshaft. • Discard the nuts.
36. NOTE: Using suitable retaining straps to
secure the engine and the transaxle on the
workshop table.
Position the workshop table under the
vehicle and carefully lower the vehicle, until
correct position to remove the engine
mounts. TIE0038250

studs.
ELE0016321
37. Detach the A/C compressor line retaining

bracket from the engine front mount. TIE0038251
40. Remove the engine front mount.

41. Remove the engine rear mount retaining
bolt.
TIE0036666

nuts and bolts.
TIE0037845
42. Raise and support the vehicle and remove

the engine and transaxle assembly.
and Operation).
2007.50 Focus 3/2007 G401893en

303-01A-98 Duratec-HE (MI4) 303-01A-98
REMOVAL
43. Using a suitable engine hoist support the • Discard the torque converter nuts.
engine and transaxle assembly and remove
the retaining straps.
303-122
ELE0022082
E0015369 47. Remove the transaxle lower retaining bolts.
44. Remove the wiring harness retaining

bracket.
E52747

ELE0015370 bolts.

• Detach the wiring harness from the retaining
bracket.
E52746
ELE0015471
46. Remove the torque converter nuts (four

nuts).
2007.50 Focus 3/2007 G401893en

303-01A-99 Duratec-HE (MI4) 303-01A-99
REMOVAL
E52745

bolt.
E52748
2007.50 Focus 3/2007 G401893en

303-01A-100 Duratec-HE (MI4) 303-01A-100
DISASSEMBLY
Engine(21 134 8)
Universal Flange Holding Mounting Stand
Wrench 303-435
205-072
15030A
21187
Adapter for 205-072 Mounting Bracket for 303-435

205-072-01 303-435-06
20507201 21031B
Adapter for 205-072 Mounting Plate for

205-072-02 303-435-06
303-435-11A
21146C
20507202
Lifting Bracket, Engine 1. Using the special tools, mount the engine to
303-122 the mounting stand.
303-435
21068A
Locking Tool, Flywheel

303-254
303-435-1 1A
303-435-06
21135 TIE0017395
Clamp
303-397
24003
2007.50 Focus 3/2007 G323915en

303-01A-101 Duratec-HE (MI4) 303-01A-101
DISASSEMBLY
2. Remove the special tool. 6. Detach electrical connector bracket from the
thermostat housing.
303-122
ELE0017397
TIE0036625
3. Drain the engine.

indicator tube.
4. NOTE: Inspect the oil pan drain plug seal for
damage. Install a new drain plug and seal if
required.
Install the drain plug.
28 Nm
TIE0036627
TIE0036642

bracket.
TIE0036629
TIE0036623
2007.50 Focus 3/2007 G323915en

303-01A-102 Duratec-HE (MI4) 303-01A-102
DISASSEMBLY
9. Using the special tool, disconnect the 12. Remove the accessory drive belt tensioner.
coolant hose.
303-397
TIE0036636
TIE45288
13. Remove the generator.

TIE0036638
TIE0036632
14. Remove the coolant pump pulley.

ELE0021626
TIE0036634
2007.50 Focus 3/2007 G323915en

303-01A-103 Duratec-HE (MI4) 303-01A-103
DISASSEMBLY
15. Using the special tools, prevent the 3. Fix the timing chain tensioner with a suitable
crankshaft pulley from rotating and remove pin punch.
the crankshaft pulley.
1
3 2
205-072
205-072-02
ELE0014849
ELE0014846
16. Remove the engine front cover. with an open-ended wrench to stop them
from rotating.
Remove the camshaft sprockets and the
timing chain.
ELE0018000
19. Remove the timing chain guides.
ELE0014847

1. Unlock the timing chain tensioner ratchet. ELE0018002
2. Apply pressure to the timing chain guide.
2007.50 Focus 3/2007 G323915en

303-01A-104 Duratec-HE (MI4) 303-01A-104
DISASSEMBLY
20. Remove the timing chain tensioner. 23. Using the special tool, loosen the oil pump
205-072-01
205-072
TIE0024498
E0024482
21. Remove the oil pump chain guide.

24. Remove the oil pump chain.
1. Remove the oil pump sprocket retaining bolt.
2. Remove the oil pump chain and the oil pump
sprocket.
TIE0024467
22. Remove the oil pump chain tensioner. 2

TIE0024483
25. Remove the front friction washer.

• Discard the friction washer.
TIE0024480
TIE44677
2007.50 Focus 3/2007 G323915en

303-01A-105 Duratec-HE (MI4) 303-01A-105
DISASSEMBLY
26. Remove the crankshaft sprocket. • Remove the valve tappets.
3 5 4
1 2
6 8 10 9 7
ELE0014857
TIE44678
27. Remove the rear friction washer. 29.

CAUTION: Remove the cylinder head
• Discard the friction washer. bolts in the sequence shown.
Remove the cylinder head.
3 7 10 6 2
TIE44679
4 8 9 5 1
28. CAUTIONS: ELE0014859
Keep the camshaft bearing caps, valve

tappets and the camshafts in order for 30. Remove the coolant pump.
installation.
• Discard the O-ring.
sequence shown.
NOTE: Working in several stages, release each
time.
Remove the camshaft bearing caps.
• Remove the camshafts.
ELE0014861
31. Remove the thermostat housing.
2007.50 Focus 3/2007 G323915en

303-01A-106 Duratec-HE (MI4) 303-01A-106
DISASSEMBLY
• Discard the gasket. 34. Remove the crankcase ventilation oil
separator.
ELE0014863
ELE0021627
32. Remove the knock sensor (KS) for cylinder
1 and 2 and for cylinder 3 and 4. 35. Remove the oil filter adapter.
TIE0036640
ELE0014867
33. Remove the KS (if equipped).
36. Remove the clutch disc and pressure plate.
Transmission (F35M-R), Removal and
Installation)
Installation).
ELE0014865
2007.50 Focus 3/2007 G323915en

303-01A-107 Duratec-HE (MI4) 303-01A-107
DISASSEMBLY
37. Using the special tool, lock the flywheel in • Discard the gasket.
position.
303-254
ELE0014875
TIE0024500
42. Remove the oil pump.
38. Remove the flywheel. • Discard the gasket.
303-254
ELE0014879
TIE0024668

40. NOTE: Remove the oil pan by pulling it
downwards to prevent oil deposits or
abraded particles from entering the engine.
Remove the oil pan.
TIE0036643
41. Remove the crankshaft rear seal carrier.

• Discard the seal carrier.
2007.50 Focus 3/2007 G323915en

303-01A-108 Duratec-HE (MI4) 303-01A-108
ASSEMBLY
Engine(21 134 8)
Universal Flange Holding Remover/Installer, Hose
Wrench Clamp
205-072 303-397
24003
15030A
Adapter for 205-072 Timing Peg, Crankshaft TDC

205-072-01 303-507
20507201 PZ21210
Adapter for 205-072 General Equipment

205-072-02 Engine hoist
M6 x 18 mm bolt
Straight edge
20507202
Materials
Name Specification
303-122 Cleaner WSK-M5B401-A1
Hypoid Gear Oil SQM-2C9002-AA
21068A
Assembly
Locking Tool, Flywheel
1. NOTE: Install a new oil pump gasket.
303-254
Install the oil pump.
two stages.
21135 • Stage 1: 10 Nm.
Alignment Plate, Camshaft

303-376
21162B
2007.50 Focus 3/2007 G323916en

303-01A-109 Duratec-HE (MI4) 303-01A-109
ASSEMBLY
• Stage 2: 23 Nm. 5. NOTE: Do not tighten the oil pan retaining
Install the oil pan.
1 3
4 2
TIE0026145
2. NOTE: Install a new crankshaft rear seal TIE0036643

carrier.
NOTE: Install a new crankshaft rear seal carrier 6. Using a suitable straight edge, align the oil
gasket. pan to the mating face of cylinder block on
Install the crankshaft rear seal carrier. the timing chain side.
• Tighten the bolts in the sequence shown. 7. Tighten the oil pan retaining bolts.
5 3
1
10 Nm
12 8 4 5 9
2 1
10
25 Nm
4 6 11
7 3 2 6
ELE0014876
TIE0036673
and the oil pan with cleaner. 8. NOTE: Install new flywheel bolts.
4. NOTE: Install the oil pan within 10 minutes Install the flywheel.
of applying the sealer and tighten the
retaining bolts within a further 5 minutes.
Apply a 3 mm bead of sealant to the oil pan.
ELE0021911
ELE0017398
2007.50 Focus 3/2007 G323916en

303-01A-110 Duratec-HE (MI4) 303-01A-110
ASSEMBLY
9. Using the special tool, lock the flywheel in 12. Install the clutch disc and pressure plate.
position. For additional information, refer to: Clutch
303-254
Installation)
Installation).
13. NOTE: Install a new oil filter adapter gasket.
Install the oil filter adapter.
TIE0024500
10. Tighten the flywheel bolts.

25 Nm
three stages.
• Stage 1: 50 Nm
• Stage 2: 80 Nm
• Stage 3: 112 Nm
303-254
ELE0014868
1
3
6 14. Install the crankcase vent oil separator.
5
4
2
ELE0021912
10 Nm
303-254
ELE0021629
15. NOTE: Rotate the knock sensor (KS) as far

counter-clockwise as possible without
touching the PCV housing.
TIE0024500
2007.50 Focus 3/2007 G323916en

303-01A-111 Duratec-HE (MI4) 303-01A-111
ASSEMBLY
Install the KS (engine with one KS shown). Install the coolant pump.
20 Nm
10 Nm
ELE0014866 ELE0014862
16. Install the KS for cylinder 1 and 2 and 19. NOTE: Only rotate the crankshaft in the
cylinder 3 and 4 (engine with two KS normal direction of rotation.
shown).
Using the crankshaft pulley retaining bolt,
rotate the crankshaft until piston No. 1 is
approximately 20 mm before top dead center
20 Nm (TDC).
TIE0036641
17. NOTE: Install a new thermostat housing

gasket. TIE0025442
Install the thermostat housing.

20. Remove the crankshaft pulley bolt.
21. NOTE: Install new cylinder head bolts and
10 Nm
cylinder head gasket.
Install the cylinder head.
• Tighten the cylinder head bolts in the
sequence shown in five stages.
• 1. Stage: 5 Nm.
• 2. Stage: 15 Nm.
• 3. Stage: 45 Nm.
• 4. Stage: 90 degrees.
ELE0014864
18. NOTE: Install a new coolant pump O-ring

seal.
2007.50 Focus 3/2007 G323916en

303-01A-112 Duratec-HE (MI4) 303-01A-112
ASSEMBLY
• 5. Stage: 90 degrees. 24. Install the special tool.
8 4 1 5 9
7 3 2 6 10
ELE0014860
E0014880
22. Install the valve tappets. 25. NOTE: Install a new rear friction washer.
23. CAUTIONS: Install the rear friction washer.
Install the camshafts approximately at
valve overlap position cylinder No. 4.
Working in several stages, evenly tighten

the camshaft bearing caps in the sequence
shown, tightening the bolts one half turn at
a time.
• Coat the camshaft bearing caps with hypoid
oil.
• Tighten the camshaft bearing caps in the
TIE44679
sequence shown, tighten the bolts in two
stages:
• Stage 1: 7 Nm. 26. Install the crankshaft sprocket.
• Stage 2: 16 Nm.
3 1 2
5 4
10 8 6 7 9
TIE44678
ELE0014858
27. NOTE: Install a new front friction washer.
2007.50 Focus 3/2007 G323916en

303-01A-113 Duratec-HE (MI4) 303-01A-113
ASSEMBLY
Install the front friction washer. 30. Install the oil pump chain tensioner.
10 Nm
TIE44677 TIE0024481
28. Install the oil pump chain. 31. Install the oil pump chain guide.
1. Install the oil pump chain and the oil pump
sprocket.
2. Install the oil pump sprocket retaining bolt.
10 Nm
TIE0024479
2
32. Install the timing chain tensioner.
TIE0024484
29. Using the special tool, tighten the oil pump

205-072-01
25 Nm 10 Nm
TIE0024499
205-072
E0024485
2007.50 Focus 3/2007 G323916en

303-01A-114 Duratec-HE (MI4) 303-01A-114
ASSEMBLY
33. Install the timing chain guides. 36.
CAUTION: Hold the camshafts by the
hexagon with an open-ended wrench to
stop them from rotating.
Tighten the camshaft sprockets retaining
bolts.
10 Nm
ELE0018003 72 Nm
34.
CAUTION: Do not fully tighten the
camshaft sprocket retaining bolts at this
stage. TIE0016861
NOTE: Make sure the camshaft sprockets rotate

on the camshafts. 37. Clean the mating faces of the engine front
cover with cleaner.
Install the camshaft sprockets.
38. NOTE: Install the engine front cover within
• Install the timing chain.
10 minutes of applying the sealer.
Apply a 3 mm bead of sealant to the engine
front cover.
ELE0018000
35. Tension the timing chain.

• Apply pressure to the timing chain and
remove the securing pin.
ELE0022182 ELE0014850
39. Install the engine front cover.
2007.50 Focus 3/2007 G323916en

303-01A-115 Duratec-HE (MI4) 303-01A-115
ASSEMBLY
• Tighten the bolts in the sequence shown in Using the crankshaft pulley retaining bolt,
four stages: rotate the crankshaft against the special tool
• Stage 1: Tighten bolts 1 through 8 to 10 Nm. until piston No. 1 is at TDC.
• Stage 2: Tighten bolt 9: 48 Nm.
• Stage 3: Tighten bolts 10 through 19 to 10
Nm.
• Stage 4: Tighten bolts 20 through 22 to 48
Nm.
22
19
TIE0025442
18 20
12
42. Remove the crankshaft pulley retaining
21 8 bolt.
11
7 43.
4 CAUTION: Only tighten the crankshaft
1 5 NOTE: Install a new crankshaft pulley retaining
3 bolt.
9 Install the crankshaft pulley onto the
6
2 crankshaft and secure the crankshaft pulley
10 13 to the front cover using a M6 x 18 mm bolt.
14
15
16
17
E0014848

plug from the cylinder block and install the
special tool.
ELE0014884
303-507 44. Using the special tools, tighten the

crankshaft pulley retaining bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.
ELE0014882

2007.50 Focus 3/2007 G323916en

303-01A-116 Duratec-HE (MI4) 303-01A-116
ASSEMBLY
• Stage 2: 90 degrees. 47. Remove the special tool.
303-507
205-072
205-072-02
ELE0014846
ELE0017420
45. Remove the crankshaft pulley securing bolt. 48. NOTE: Only rotate the crankshaft in the
Rotate the crankshaft two revolutions.
303-507
ELE0014884
ELE0017420

TDC.
51.
CAUTION: Only tighten the crankshaft
NOTE: If it is not possible to install the crankshaft
E0014880
pulley securing bolt, correct the engine timing.
2007.50 Focus 3/2007 G323916en

303-01A-117 Duratec-HE (MI4) 303-01A-117
ASSEMBLY
Using a M6 x 18 mm bolt, check the position 54. Remove the crankshaft pulley securing bolt.
of the crankshaft pulley.
ELE0014884
ELE0014884

52. NOTE: If it is not possible to install the
special tool, correct the engine timing.
Using the special tool, check the position of
the camshafts. 303-507
ELE0017420
56. Install the cylinder block lower blanking

plug.
E0014880
20 Nm
ELE0022464
57. NOTE: When installing a new crankshaft

E0014880 pulley or engine front cover, the crankshaft
position (CKP) sensor must be aligned
using the tool supplied with the new
component.
NOTE: Do not tighten the bolts at this stage.
Align the CKP sensor.
1. Loosen the CKP sensor retaining bolts.
2007.50 Focus 3/2007 G323916en

303-01A-118 Duratec-HE (MI4) 303-01A-118
ASSEMBLY
2. Insert the tool supplied, so that its hooked in 60. Install the generator.
the crankshaft pulley teeth.
1 48 Nm
2
TIE0036639
TIE0017984
61. Install the accessory drive belt tensioner.

58. Install the CKP sensor.
1. Tighten the CKP sensor retaining bolts.
2. Remove the tool.
7 Nm 1
18 Nm
TIE0036637
2
TIE0017985
as shown.
59. Install the coolant pump pulley.
25 Nm
ELE0021634
ELE0021628
necessary.
2007.50 Focus 3/2007 G323916en

303-01A-119 Duratec-HE (MI4) 303-01A-119
ASSEMBLY
Install the valve cover. 66. Install the intake manifold.
18 Nm
10 Nm
18 Nm
TIE0036635 TIE0036630
64. Install the ignition coil-on-plug. 67. Attach the electrical connector bracket to
the thermostat housing.
10 Nm 10 Nm
6 Nm
TIE0036633
TIE0036626
65. Using the special tool, install the coolant

hoses. 68. Install the oil level indicator and oil level
indicator tube.
6 Nm
303-397
TIE45288
TIE0036628
2007.50 Focus 3/2007 G323916en

303-01A-120 Duratec-HE (MI4) 303-01A-120
ASSEMBLY
69. Install the exhaust manifold retaining
bracket.
20 Nm
TIE0036624

Specifications (303-01 Engine - 1.8L
Specifications).
71. Using the special tool and an engine hoist,
support the engine.
303-122
ELE0017397
303-435
303-435-1 1A
303-435-06
TIE0017395
2007.50 Focus 3/2007 G323916en

303-01A-121 Duratec-HE (MI4) 303-01A-121
INSTALLATION

Special Tool(s) 4. Install the transaxle left-hand retaining bolts.
Clamp
303-397
24003
44 Nm
General Equipment
Workshop table
Retaining straps TIE0037655
Engine hoist
bolts.
Installation
All vehicles
WARNING: Do not smoke or carry lighted 44 Nm
personal injury.
1. NOTE: Using suitable retaining straps,
secure the engine on the workshop table. E48673
Support the engine with wooden blocks.

2. Install the transaxle.
3. Install the transaxle upper retaining bolts.
44 Nm
44 Nm
TIE0036859
TIE0036567
2007.50 Focus 3/2007 G420944en

303-01A-122 Duratec-HE (MI4) 303-01A-122
INSTALLATION
7. Install the starter motor. Install the engine rear mount retaining bolt.
35 Nm
ELE0015472 TIE0037845
8. Install the wiring harness retaining bracket. 11. Install the engine front mount.
• Attach the wiring harness to the retaining 12. Install the engine front mount retaining
bracket. studs.
20 Nm
12 Nm
ELE0015470
TIE0038252
9. Position the workshop table under the 13. NOTE: Install new engine front mount
vehicle and carefully lower the vehicle until retaining nuts.
correct position to install the engine mounts. NOTE: Do not tighten the engine front mount
retaining nuts and retaining bolts at this stage.
Install the engine front mount retaining nuts
and bolts.
ELE0016321
10. NOTE: Do not tighten the engine rear mount

retaining bolt at this stage. TIE0038250
2007.50 Focus 3/2007 G420944en

303-01A-123 Duratec-HE (MI4) 303-01A-123
INSTALLATION
14. Attach the air conditioning compressor 19. Install the right-hand halfshaft.
(A/C) line retaining bracket to the engine For additional information, refer to:
front mount. Halfshaft RH (205-04 Front Drive
20. Install the left-hand halfshaft.
80 Nm
TIE0036667
15. Remove the retaining straps from the

transaxle.
16. Connect the fuel supply line. 80 Nm
TIE0036809
22. Attach the air conditioning (A/C)

compressor to the oil pan.
TIE0038315
24 Nm
17. Connect the evaporative emission (EVAP)
valve vacuum line.
TIE0036591
23. Connect the A/C compressor electrical

connector.
TIE0038247

TIE0038249
2007.50 Focus 3/2007 G420944en

303-01A-124 Duratec-HE (MI4) 303-01A-124
INSTALLATION
24. Install the A/C compressor belt. 29. Tighten the engine rear mount retaining
bolt.
Installation).
148 Nm
15 Nm
E0037846
24 Nm
30. Tighten the engine front mount retaining
nuts and retaining bolts.
TIE0036589 80 Nm
26. Install the A/C line retaining bracket.
25 Nm 90 Nm
E0038253
31. NOTE: Install a new exhaust manifold

gasket.
TIE0037657 Tighten the exhaust manifold retaining nuts
27. Install the exhaust manifold lower retaining
51 Nm 51 Nm
15 Nm
E0036584
TIE0036586
2007.50 Focus 3/2007 G420944en

303-01A-125 Duratec-HE (MI4) 303-01A-125
INSTALLATION
32. Install the exhaust manifold heat shield NOTE: Make sure the spring clip is correctly
(engine shown removed for clarity). seated.
Connect the clutch slave cylinder supply
line.
• Install the spring clip.
10 Nm
TIE0026655
36. Attach the gearshift cables to the bracket

and turn the abutment sleeves
counterclockwise.
10 Nm
TIE0036582
Vehicles with iB5 manual transaxle

(100-02, Description and Operation). TIE0026568
34. Connect the reversing lamp switch

electrical connector. 37. Attach the gearshift cables to the selector
levers.
TIE0026645
TIE0028774
35.
2007.50 Focus 3/2007 G420944en

303-01A-126 Duratec-HE (MI4) 303-01A-126
INSTALLATION
38. Install the gearshift cables cover. 42. Connect the reversing lamp switch
TIE0026646
TIE0024487

43. Attach the gearshift cables to the abutment.
Vehicles with MTX-75 manual transaxle 1. Rotate the abutment sleeves clockwise and
40. attach the gearshift cable to the abutment.
2. Rotate the abutment sleeves clockwise and
attach the selector cable to the abutment.
Connect the clutch slave cylinder supply line
to the clutch slave cylinder.
• Attach the clutch slave cylinder supply line
to the bracket. 2
TIE44565
44. Attach the gearshift cables to the transaxle.

1. Press the locking tab and attach the gearshift
cable to the transaxle selector lever.
TIE0036726
2. Press the locking tab and attach the selector
cable to the transaxle selector lever.
41. Attach the ground cable to the transaxle. 2
1
18 Nm
E44566
TIE0036564
2007.50 Focus 3/2007 G420944en

303-01A-127 Duratec-HE (MI4) 303-01A-127
INSTALLATION
All vehicles 48. Connect the coolant hose.
45. Connect the brake booster vacuum line to
the intake manifold.
E49099
TIE0036580 49. Using the special tool, connect the coolant

hose to the coolant outlet connector.
46. Install the coolant expansion tank.
303-397
TIE0036592
E49163
50. Connect the catalyst monitor sensor
hose to the coolant expansion tank.
303-397
TIE45285
E49101
2007.50 Focus 3/2007 G420944en

303-01A-128 Duratec-HE (MI4) 303-01A-128
INSTALLATION
51. Connect the heated oxygen (HO2S) sensor 54. Attach the ground cables to the wheel
electrical connectors. housing.
8 Nm
10 Nm
TIE0036574 E0036570
52. Connect the engine wiring harness 55. Adjust the gearshift cables.
electrical connector. For additional information, refer to:
Gearshift Cable Adjustment - Vehicles
With: 5-Speed Manual Transaxle (iB5)
(308-00 Manual Transmission/Transaxle
and Clutch - General Information, General
Procedures)
/ Gearshift Cable Adjustment - Vehicles
With: 5-Speed Manual Transaxle (MTX-75)
Procedures).
56. Bleed the hydraulic clutch system.
TIE0036573
System Bleeding (308-00 Manual
53. Install the central junction box (CJB) cover. Transmission/Transaxle and Clutch -
57. Install the battery tray.
Tray - 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)/1.8L Duratec-HE
and Installation).
TIE0036571
2007.50 Focus 3/2007 G420944en

303-01A-129 Duratec-HE (MI4) 303-01A-129
INSTALLATION
58. Connect the battery positive lead to the
battery positive cable terminal clamp.
12 Nm
E0038245
59. Fill and bleed the cooling system.

Procedures).
TIE44765

Procedures).
2007.50 Focus 3/2007 G420944en

303-01A-130 Duratec-HE (MI4) 303-01A-130
INSTALLATION
Engine — Vehicles With: Automatic Transaxle(21 134 0)

Special Tool(s) 2. Measure the correct installation depth
between the automatic transmission flange
and the torque converter guide collar.
Clamp
303-397
1
24003
General Equipment
Workshop table
Retaining straps
Engine hoist
15 mm 2
Installation
All vehicles
WARNING: Do not smoke or carry lighted
personal injury.
1. NOTE: Using suitable retaining straps,
TIE0008159
secure the engine on the workshop table.
Support the engine with wooden blocks.
4. Install the transaxle.
2.
CAUTION: The torque converter must 5. Install the transaxle upper retaining bolts.
remain at the correct installation depth
during the entire installation.
NOTE: Before installing the bolts in the
transmission, the torque converter studs must be
aligned with the holes in the drive plate.
Install the torque converter.
3.
CAUTION: The torque converter hub must
engage fully with the oil pump drive gear.
Check the installation depth of the torque
converter. 48 Nm
E52751
1. Position the steel straightedge on the
transmission flange.
2007.50 Focus 3/2007 G401895en

303-01A-131 Duratec-HE (MI4) 303-01A-131
INSTALLATION
6. Install the transaxle left-hand retaining bolt. Install the torque converter nuts (4 nuts).
36 Nm
48 Nm
E52754 ELE0022083
7. Install the transaxle right-hand retaining 10. Install the starter motor.
bolts.
48 Nm
35 Nm
ELE0015472
E52752
11. Install the wiring harness retaining bracket.

• Attach the wiring harness to the retaining
bracket.
20 Nm
48 Nm
E52753
ELE0015470
9. NOTE: Install new torque converter nuts.
2007.50 Focus 3/2007 G401895en

303-01A-132 Duratec-HE (MI4) 303-01A-132
INSTALLATION
12. Position the workshop table under the NOTE: Do not tighten the engine front mount
vehicle and carefully lower the vehicle until retaining nuts and retaining bolts at this stage.
Install the engine front mount retaining nuts
correct position to install the engine
and bolts.
mounts.
TIE0038250
ELE0016321
17. Attach the air conditioning compressor

13. NOTE: Do not tighten the engine rear mount
(A/C) line retaining bracket to the engine
retaining bolt at this stage.
front mount.
Install the engine rear mount retaining bolt.
TIE0036667
TIE0037845
18. Remove the retaining straps from the

14. Install the engine front mount. transaxle.
15. Install the engine front mount retaining 19. Connect the fuel supply line.
studs.
12 Nm
TIE0038315
TIE0038252
16. NOTE: Install new engine front mount

retaining nuts.
2007.50 Focus 3/2007 G401895en

303-01A-133 Duratec-HE (MI4) 303-01A-133
INSTALLATION
20. Connect the evaporative emission (EVAP) 25. Attach the air conditioning (A/C)
valve vacuum line. compressor to the oil pan.
24 Nm
TIE0038247 TIE0036591
21. Raise and support the vehicle. 26. Connect the A/C compressor electrical
connector.
and Operation).
Halfshafts, Removal and Installation). TIE0038249
27. Install the A/C compressor belt.
80 Nm Conditioning (A/C) Compressor Belt - 2.0L
Installation).
80 Nm
15 Nm
TIE0036809
24 Nm
TIE0036589
2007.50 Focus 3/2007 G401895en

303-01A-134 Duratec-HE (MI4) 303-01A-134
INSTALLATION
29. Install the A/C line retaining bracket. 32. Connect the transmission range (TR)
25 Nm
TIE0037657
E50546
30. Connect the output shaft speed (OSS)

sensor electrical connector. 33. Install the exhaust manifold lower retaining
15 Nm
ELE0007584
TIE0036586
31. Attach the selector lever cable to the

transmission. 34. Lower the vehicle.
1. Press the locking pins together and attach 35. Tighten the engine rear mount retaining
the selector lever cable to the abutment bolt.
2. Attach the selector lever cable to the selector
mechanism.
1
148 Nm
2
E0037846
E47355
2007.50 Focus 3/2007 G401895en

303-01A-135 Duratec-HE (MI4) 303-01A-135
INSTALLATION
36. Tighten the engine front mount retaining 38. Install the exhaust manifold heat shield
nuts and retaining bolts. (engine shown removed for clarity).
80 Nm
90 Nm
10 Nm
E0038253
37. NOTE: Install a new exhaust manifold

gasket.
Tighten the exhaust manifold retaining nuts
10 Nm
TIE0036582
51 Nm 51 Nm
39. Connect the brake booster vacuum line to
the intake manifold.
E0036584
TIE0036580
2007.50 Focus 3/2007 G401895en

303-01A-136 Duratec-HE (MI4) 303-01A-136
INSTALLATION
40. Install the coolant expansion tank. 43. Using the special tool, connect the coolant
hose to the coolant outlet connector.
303-397
E49163
TIE0036592

hose to the coolant expansion tank. 44. Connect the automatic transaxle electrical
connector.
303-397
E49101
E50543
42. Connect the coolant hose.

45. NOTE: The transmission fluid cooler feed
and return lines connectors are color
coded.
Attach the transmission fluid cooler feed and
return lines to the automatic transaxle.
E49099
E50552
2007.50 Focus 3/2007 G401895en

303-01A-137 Duratec-HE (MI4) 303-01A-137
INSTALLATION
46. Connect the turbine shaft speed (TSS) 49. Connect the engine wiring harness
sensor electrical connector. electrical connector.
ELE0008689 TIE0036573
47. Connect the catalyst monitor sensor 50. Install the central junction box (CJB) cover.
TIE0036571
TIE45285
51. Attach the ground cables to the wheel

48. Connect the heated oxygen (HO2S) sensor housing.
8 Nm
10 Nm
E0036570
TIE0036574
52. Adjust the gearshift cables.

With: 5-Speed Manual Transmission (iB5)
2007.50 Focus 3/2007 G401895en

303-01A-138 Duratec-HE (MI4) 303-01A-138
INSTALLATION
(308-00 Manual Transmission/Transaxle 58. Fill and bleed the cooling system.
and Clutch - General Information, General For additional information, refer to: Cooling
Procedures) System Draining, Filling and Bleeding
/ Gearshift Cable Adjustment - Vehicles (303-03 Engine Cooling - 2.0L Duratec-HE
With: 5-Speed Manual Transmission (MI4)/1.8L Duratec-HE (MI4), General
(MTX-75) (308-00 Manual Procedures).
Transmission/Transaxle and Clutch -
General Information, General Procedures). 59. Install the engine cover.
53. Bleed the hydraulic clutch system.
Battery, Mounting and Cables, Removal TIE44765
and Installation).
55. Connect the battery positive lead to the Vehicles with global closing
battery positive cable terminal clamp. 60. Initialize the door window motors.
Procedures).
12 Nm
E0038245
56. Connect the battery.

Procedures).
Installation).
2007.50 Focus 3/2007 G401895en

303-01B-1 Engine — 1.6L (Z6) 303-01B-1
.
SECTION 303-01B Engine — 1.6L (Z6)

CONTENTS PAGE
SPECIFICATIONS
Engine Data.................................................................................................................... 303-01B-2
Engine Oil Capacity........................................................................................................ 303-01B-2
Cylinder Block................................................................................................................. 303-01B-2
Crankshaft....................................................................................................................... 303-01B-2
Camshaft......................................................................................................................... 303-01B-2
Valves............................................................................................................................. 303-01B-3
Cylinder Head................................................................................................................. 303-01B-3
Oil Pressure Specifications............................................................................................. 303-01B-3
GENERAL PROCEDURES
Valve Clearance Adjustment............................................................................................... 303-01B-6
IN-VEHICLE REPAIR
Intake Manifold............................................................................................... (21 183 0) 303-01B-10
Valve Cover.................................................................................................... (21 140 0) 303-01B-15
Crankshaft Front Seal..................................................................................... (21 467 0) 303-01B-18
Valve Seals......................................................................................................................... 303-01B-20
Camshafts...................................................................................................... (21 284 0) 303-01B-24
Timing Chain................................................................................................... (21 314 0) 303-01B-29
Exhaust Manifold............................................................................................ (21 187 0) 303-01B-34
Cylinder Head................................................................................................. (21 163 0) 303-01B-35
Oil Pan............................................................................................................ (21 154 0) 303-01B-42
Oil Pump......................................................................................................... (21 714 0) 303-01B-44
Crankshaft Rear Seal..................................................................................... (21 468 4) 303-01B-45
REMOVAL
Engine — Vehicles With: Manual Transaxle................................................... (21 134 0) 303-01B-48
DISASSEMBLY
Engine............................................................................................................ (21 134 8) 303-01B-61
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head................................................................................................. (21 165 6) 303-01B-71
ASSEMBLY
Engine............................................................................................................ (21 134 8) 303-01B-75
INSTALLATION
Engine — Vehicles With: Manual Transaxle................................................... (21 134 0) 303-01B-86
303-01B-2 Engine — 1.6L (Z6) 303-01B-2
SPECIFICATIONS
Engine Data
Description
Engine code G9
Firing order 1-3-4-2
Emission level Stage III
Bore 78 mm
Stroke 83.6mm
Cubic capacity 1598 cm³
Power output at 6000 rpm 77 kW (105 PS)
Torque at 4000 rpm 145 Nm
Maximum engine speed (intermittent) 6850 rpm
Maximum engine speed (continuous) 6500 rpm
Idle speed - vehicles with manual transaxle 700 ± 50 rpm
Idle speed - vehicles with automatic transaxle FN4AL 750 ± 50 rpm
Oil consumption 0.1L /1000 Km

Item Specification
Engine oil WSS-M2C913-B
Coolant WSS-M97B44-D
Sealant WSE-M4G323-A4
Engine Oil Capacity

Description Liters
Initial fill including oil filter 4.2
Service fill including oil filter 3.9
Service fill without oil filter 3.7
Cylinder Block
Description mm
Maximum distortion 0.10
Cylinder bore diameter 78.000 - 78.013
Crankshaft
Description mm
Crankshaft end play 0.080 - 0.282
Camshaft
Description mm
Camshaft runout 0.030
Camshaft lobe lift - intake 41.373
2007.50 Focus 5/2007 G384590en

303-01B-3 Engine — 1.6L (Z6) 303-01B-3
SPECIFICATIONS
Description mm
Camshaft lobe lift - exhaust 41.495
Camshaft bearing journal diameter 25.940 - 25.965
Camshaft bearing journal clearance 0.035 - 0.081
Valves
Description mm
Valve clearance 0.270 - 0.330
Valve stem diameter - intake valve 5.470 - 5.485
Valve stem diameter - exhaust valve 5.465 - 5.480
Valve head diameter - intake valve 27.8
Valve head diameter - exhaust valve 24.7
Valve guide inner diameter 5.510 - 5.530
Valve stem to valve guide clearance — intake valve 0.025 - 0.060
Valve stem to valve guide clearance — exhaust valve 0.030 - 0.065
Valve tappet bore diameter 30.000 - 30.025
Valve tappet diameter 29.959 - 29.975
Valve tappet clearance 0.025 - 0.066
Cylinder Head
Description mm
Maximum distortion — measured longitudinally and diagonally 0.10
Oil Pressure Specifications

Description bar
Oil pressure at 3000 rpm 3.3 - 3.8
Transaxle wiring harness bracket retaining bolts 23 17 -
Engine rear mount retaining nuts 48 35 -
Engine rear mount center bolt 80 59 -
Engine front mount retaining bolts 80 59 -
Engine front mount retaining nuts 53 39 -
Ground cable to engine front mount retaining nut 10 - 89
Engine roll restrictor to transaxle bracket bolt 80 59 -
Engine roll restrictor to front axle crossmember bolts 80 59 -
2007.50 Focus 5/2007 G384590en

303-01B-4 Engine — 1.6L (Z6) 303-01B-4
SPECIFICATIONS

Thermostat housing retaining nuts 22 16 -
Crankshaft pulley retaining bolt 162 119 -
Flywheel retaining bolts 100 74 -
Crankcase vent oil separator retaining bolts 9 - 80
Power steering pump fluid reservoir retaining bolt 10 - 89
Power steering pump lower retaining bolt 35 26 -
Power steering pump upper retaining bolt 35 26 -
Power steering pump to steering gear pressure line 33 25 -
retaining bolt
Valve cover retaining bolts 9 - 80
Ignition coil-on-plug retaining bolts 9 - 80
Camshaft bearing caps retaining bolts 13 10 -
Camshaft sprocket retaining bolts 55 41 -
Camshaft position (CMP) sensor retaining bolt 9 - 80
Variable camshaft timing (VCT) solenoid retaining 9 - 80
bolt
VCT solenoid oil filter retaining bolt 39 29 -
Timing chain tensioner retaining bolt 9 - 80
Timing chain tensioner arm retaining bolt 22 16 -
Timing chain guide retaining bolt 22 16 -
Engine front cover retaining bolts a) - -
Engine front cover blanking plugs 4 - 35
Engine wiring harness bracket retaining 22 16 -
Idler pulley retaining nut 46 34 -
Accessory drive belt tensioner retaining bolt 46 34 -
Coolant pump retaining bolts 22 16 -
Coolant outlet connector retaining bolts 22 16 -
Oil pump pickup tube retaining bolts 9 - 80
Oil pump retaining bolts 22 16 -
Oil pan drain plug 15 11 -
Oil pan retaining bolts 9 - 80
Oil pressure switch 35 26 -
Oil filter 25 18 -
Oil level indicator pipe retaining bolt 9 - 80
Cylinder head retaining bolts a) - -
2007.50 Focus 5/2007 G384590en

303-01B-5 Engine — 1.6L (Z6) 303-01B-5
SPECIFICATIONS

Catalytic converter heat shield retaining bolts 9 - 80
Catalytic converter support bracket retaining bolts 23 17 -
Catalytic converter to muffler and tailpipe muffler 45 33 -
retaining bolts
Exhaust manifold studs 35 - 89
Exhaust manifold retaining nuts 42 31 -
Floor panel brace retaining bolts 30 22 -
EGR valve tube to exhaust manifold retaining nuts 9 - 80
EGR valve tube bracket to exhaust manifold 9 - 80
retaining nuts
EGR valve tube to exhaust manifold retaining nut 39 29 -
Exhaust gas recirculation (EGR) pipe to intake 9 - 80
manifold retaining bolts
EGR pipe retaining bracket retaining bolts 9 - 80
EGR valve retaining bracket retaining bolts 22 16 -
EGR pipe to EGR valve retaining nut 39 29 -
Generator lower retaining bolts 45 33 -
Generator upper retaining bolts 45 33 -
Air conditioning (A/C) compressor retaining bolts 25 18 -
Intake manifold retaining bolts 44 32 -
Crankshaft position (CKP) sensor retaining bolt 8 - 71
Knock sensor (KS) 27 20 -
Spark plugs 18 13 -
Torque converter retaining nuts 37 27 -
Crash box retaining bolts 40 30 -
Battery positive lead retaining nut 6 - 53
2007.50 Focus 5/2007 G384590en

303-01B-6 Engine — 1.6L (Z6) 303-01B-6
GENERAL PROCEDURES
Valve Clearance Adjustment

Special Tool(s)
4. Disconnect the ignition coil-on-plug electrical
Remover/Installer, Hose connectors.
Clamp
303-397
General Equipment
Feeler gauges
Materials
Name Specification
5. Disconnect the positive crankcase ventilation
All vehicles (PCV) hose from the valve cover.

3. Disconnect the camshaft position (CMP)
2007.50 Focus 5/2007 G384594en

303-01B-7 Engine — 1.6L (Z6) 303-01B-7
GENERAL PROCEDURES
7. Remove the spark plugs. Rotate the crankshaft until each piston is at
12. NOTE: Only carry out the following steps
when the valve clearance(s) require
adjustment.
Specifications (303-01 Engine - 1.6L (Z6),
Specifications).
Remove the camshafts.
Camshafts (303-01 Engine - 1.6L (Z6),
In-vehicle Repair).
13. NOTE: The number on the valve tappet is
8. Remove the valve cover. the valve tappet thickness, however only
the decimal places are marked (for example
.650 = 3.650).
Determine the valve tappet thickness
required:
1. Remove the valve tappet and read the
thickness from the underside.
2. Calculate the valve tappet thickness required
(thickness of currently installed valve tappet,
+ the measured valve clearance, - the
required valve clearance).
Specifications (303-01 Engine - 1.6L (Z6),
9. NOTE: Only rotate the crankshaft in the Specifications).
normal direction of rotation. 3. Install the correct valve tappet.
Rotate the crankshaft until piston No. 1 is at 14. NOTE: Do not install the valve cover at this
top dead center (TDC). stage.
10. NOTE: Note down each cylinder number Install the camshafts.
and the valve clearances measured. For additional information, refer to:
Using a suitable set of feeler gauges, Camshafts (303-01 Engine - 1.6L (Z6),
measure the valve clearances. In-vehicle Repair).
16. Repeat this procedure as necessary until
all valve clearances are within the specified
tolerance.

2007.50 Focus 5/2007 G384594en

303-01B-8 Engine — 1.6L (Z6) 303-01B-8
GENERAL PROCEDURES
17. Apply a small bead of sealant to the areas 20. Install the ignition coil-on-plug.
as shown.
21. Connect the positive crankcase ventilation

18. NOTE: Install a new valve cover gasket if (PCV) hose to the valve cover.
necessary.
22. Connect the ignition coil-on-plug electrical

connectors.
2007.50 Focus 5/2007 G384594en

303-01B-9 Engine — 1.6L (Z6) 303-01B-9
GENERAL PROCEDURES
23. Connect the camshaft position (CMP)

Procedures).

26. Initialize the door window regulator motors.
Procedures).
2007.50 Focus 5/2007 G384594en

303-01B-10 Engine — 1.6L (Z6) 303-01B-10
IN-VEHICLE REPAIR
Intake Manifold(21 183 0)

Special Tool(s)
2. Disconnect the battery.
Clamp For additional information, refer to: Battery
303-397 Disconnect and Connect (414-01 Battery,
Cleaner - 1.6L (Z6) (303-12 Intake Air
1. Remove the engine cover. Distribution and Filtering, Removal and
Installation).
table(s).
2007.50 Focus 5/2007 G384710en

303-01B-11 Engine — 1.6L (Z6) 303-01B-11
IN-VEHICLE REPAIR

1 Positive crankshaft ventilation (PCV) hose 9 Swirl plate servo motor electrical
See Removal Detail connector
10 Engine wiring harness clip
2 Evaporative emission (EVAP) vacuum
hose 11 Throttle body coolant hose
3 Fuel injectors electrical connector 12 Brake booster vacuum hose

See Removal Detail
4 Manifold absolute pressure (MAP) sensor See Installation Detail
13 EVAP hose
5 Knock sensor (KS) electrical connector See Removal Detail
6 Intake manifold runner control (IMRC)
electrical connector 14 Accelerator cable
See Removal Detail
7 Idle air control (IAC) electrical connector See Installation Detail
8 Throttle position sensor electrical 15 Fuel supply line
connector See Removal Detail
18 39 Nm
21
20 44 Nm
19 9 Nm 17
9 Nm 16
E51942
2007.50 Focus 5/2007 G384710en

303-01B-12 Engine — 1.6L (Z6) 303-01B-12
IN-VEHICLE REPAIR

16 Exhaust gas recirculation (EGR) pipe 19 EGR pipe gasket
retaining bolts
20 Intake manifold retaining bolts
17 EGR pipe bracket retaining bolt
21 Intake manifold gaskets
18 EGR pipe retaining bolt
Removal Details
Item 1 Positive crankshaft ventilation (PCV) Item 12 Brake booster vacuum hose
hose 1. Using the special tool, disconnect the brake
1. Detach the PCV hose from the bracket. booster vacuum hose from the intake
manifold.
Item 2 Evaporative emission (EVAP) vacuum
hose
1. Detach the EVAP vacuum hose from the
bracket. 303-397
Item 11 Throttle body coolant hose

coolant hose from the throttle body.
E51944
Item 13 EVAP hose

1. Using the special tool, disconnect the EVAP
hose from the intake manifold.
303-397
303-397
E51943
E51945
2007.50 Focus 5/2007 G384710en

303-01B-13 Engine — 1.6L (Z6) 303-01B-13
IN-VEHICLE REPAIR
Item 14 Accelerator cable 2. Detach the accelerator cable from the throttle
lever.
1. Detach the accelerator cable retaining
bracket from the intake manifold.
1
E51948
E51946
Item 15 Fuel supply line
2. Detach the accelerator cable from the throttle 1. Disconnect the fuel supply line quick
body. connector.
1. Detach the accelerator cable from the For additional information, refer to: Quick
bracket. Release Coupling (310-00 Fuel System -
Item 15 Fuel supply line 2. Attach the accelerator cable retaining bracket
to the intake manifold.
1. Connect the fuel supply line quick connector.
Item 14 Accelerator cable

1. Attach the accelerator cable to the throttle
body.
lever.
2. Attach the accelerator cable to the bracket.
E51947
E51949
2007.50 Focus 5/2007 G384710en

303-01B-14 Engine — 1.6L (Z6) 303-01B-14
IN-VEHICLE REPAIR
Item 13 EVAP hose Item 1 Positive crankshaft ventilation (PCV)
1. Using the special tool, connect the EVAP hose
hose to the intake manifold. 1. Attach the PCV hose from the bracket.
303-397
E51945
Item 12 Brake booster vacuum hose

1. Using the special tool, connect the brake
booster vacuum hose to the intake manifold.
303-397
E51944
Item 11 Throttle body coolant hose

hose to the throttle body.
303-397
E51943
Item 2 Evaporative emission (EVAP) vacuum

hose
1. Attach the EVAP vacuum hose to the bracket.
2007.50 Focus 5/2007 G384710en

303-01B-15 Engine — 1.6L (Z6) 303-01B-15
IN-VEHICLE REPAIR
Valve Cover(21 140 0)

Clamp
303-397
Materials
Name Specification
2. Disconnect the battery.

table(s).
2007.50 Focus 5/2007 G384714en

303-01B-16 Engine — 1.6L (Z6) 303-01B-16
IN-VEHICLE REPAIR

1 Positive crankcase ventilation (PCV) hose 3 Ignition coil-on-plug electrical connector
See Removal Detail
See Installation Detail 4 Camshaft position (CMP) sensor electrical
connector
2 Engine wiring harness clips
5 9 Nm
E51461
5 Ignition coil-on-plug retaining bolts 7 Valve cover retaining bolts

6 Ignition coil-on-plug
8 Valve cover gasket
Removal Details
2007.50 Focus 5/2007 G384714en

303-01B-17 Engine — 1.6L (Z6) 303-01B-17
IN-VEHICLE REPAIR
Item 1 Positive crankcase ventilation (PCV) hose
1. Using the special tool, disconnect the PCV
hose from the valve cover.
303-397
E51292
Item 7 Valve cover retaining bolts Item 1 Positive crankcase ventilation (PCV) hose
1. Apply a small bead of sealant to the areas 1. Using the special tool, connect the PCV hose
as shown. to the valve cover.
303-397
E51293 E51292
2. NOTE: Install a new valve cover gasket.

3 2 9 8
7
10 11
9 Nm 1 5 6
E51297
2007.50 Focus 5/2007 G384714en

303-01B-18 Engine — 1.6L (Z6) 303-01B-18
IN-VEHICLE REPAIR
Crankshaft Front Seal(21 467 0)

Universal Flange Holding Remover, Timing Cover Seal
Wrench 303-501
205-072
15030A ES21204
Adapter for 205-072 1. Disconnect the battery.

205-072-01 For additional information, refer to: Battery
20507201 2. Remove the accessory drive belt.
Accessory Drive Belt - 1.6L (Z6) (303-05
Remover, Seal Accessory Drive, Removal and Installation).
303-112
table(s).
303112
E51380
2007.50 Focus 5/2007 G384720en

303-01B-19 Engine — 1.6L (Z6) 303-01B-19
IN-VEHICLE REPAIR

1 Crankshaft pulley retaining bolt See Removal Detail
2 Crankshaft front seal
Removal Details
Item 1 Positive crankcase ventilation (PCV) hose Item 2 Crankshaft front seal
1. Using the special tool, remove the crankshaft 1. Using the special tool, remove the crankshaft
pulley retaining bolt. front seal.
205-072-01
303-112
205-072
E51381
E51382
Item 2 Crankshaft front seal Item 1 Positive crankcase ventilation (PCV) hose
1. NOTE: Install a new crankshaft front seal 1. Using the special tool, install the crankshaft
pulley retaining bolt.
Using the special tool and the crankshaft
pulley retaining bolt, install the crankshaft
front seal.
162 Nm
205-072-01
205-072
303-501
E51384
E51383
2007.50 Focus 5/2007 G384720en

303-01B-20 Engine — 1.6L (Z6) 303-01B-20
IN-VEHICLE REPAIR
Valve Seals
Compressor, Valve Spring Pliers, Valve Stem Seal
303-361A 303-508
21211
21155
Adapter for 303-361A Connector, Air Supply

303-361-04 (Cylinder Head)
303-363
21157
2115504
Adapter for 303-361A WARNING: Do not smoke or use any kind

303-361-05 of naked flame when working on or near
any fuel-related components. Highly
flammable vapors are always present and
may ignite. Failure to observe this
2115505 instruction can lead to injury.
1. Remove the camshafts.
Installer, Valve Stem Collets For additional information, refer to:
303-362 Camshafts (303-01 Engine - 1.6L (Z6),
In-vehicle Repair).
2. Position the appropriate piston at top dead
center (TDC).
21156
table(s).
2007.50 Focus 5/2007 G384730en

303-01B-21 Engine — 1.6L (Z6) 303-01B-21
IN-VEHICLE REPAIR
E51511
1 Valve collets 3 Valve spring

See Installation Detail 4 Valve seals
2 Valve spring retainer See Removal Detail
Removal Details
Item 1 Valve collets
2. Using the special tool, apply compressed air
1. Install the special tools. (7-10 bar) to the cylinder.
3. Using the special tools, compress the valve
springs.
303-361-04
303-361-05
303-363
303-361A
TIE45023
2007.50 Focus 5/2007 G384730en

303-01B-22 Engine — 1.6L (Z6) 303-01B-22
IN-VEHICLE REPAIR
4. Using the special tool, remove the valve Item 3 Valve spring
collets.
CAUTION: Keep the valve springs in order
for installation.
Item 4 Valve seals

1. Using the special tool, remove the valve
seals.
• Discard the valve seals.
303-362
TIE45024
Item 2 Valve spring retainer 303-508

CAUTION: Keep the valve spring retainers
in order for installation.
ELE0001753
Item 4 Valve seals Using the special tool, install the valve seals.
1. Cover the valve collet grooves on the valve
stem with a protective sleeve (valve shown
303-508
ELE0001753
ELE0016924
2. NOTE: Install new valve seals.
2007.50 Focus 5/2007 G384730en

303-01B-23 Engine — 1.6L (Z6) 303-01B-23
IN-VEHICLE REPAIR
springs.
303-361-04
303-361-05
303-363
303-361A
TIE45023
2. Using the special tool, install the valve

collets.
303-362
TIE45024
2007.50 Focus 5/2007 G384730en

303-01B-24 Engine — 1.6L (Z6) 303-01B-24
IN-VEHICLE REPAIR
Camshafts(21 284 0)
General Equipment 2. Remove the valve cover.
M10 x 6 mm bolt For additional information, refer to: Valve
Cover (303-01 Engine - 1.6L (Z6), In-vehicle
M10 x 25 mm bolt Repair).
1. Disconnect the battery. 3. Remove the components in the order
For additional information, refer to: Battery indicated in the following illustration(s) and
Disconnect and Connect (414-01 Battery, table(s).
6
5
E51699
1 Exhaust camshaft sprocket retaining bolt 5 Camshaft bearing caps

2 Exhaust camshaft sprocket 6 Exhaust camshaft

See Installation Detail 7 Intake camshaft
3 Intake camshaft sprocket retaining bolt See Installation Detail
4 Camshaft bearing caps retaining bolts
See Removal Detail
2007.50 Focus 5/2007 G384742en

303-01B-25 Engine — 1.6L (Z6) 303-01B-25
IN-VEHICLE REPAIR
Removal Details
Item 1 Exhaust camshaft sprocket retaining bolt 2. Carefully rotate the crankshaft
counterclockwise to detension the timing
NOTE: Hold the camshaft by the hexagon with an
chain tensioner.
open-ended wrench to prevent it from rotating.
NOTE: Do not remove the exhaust camshaft
sprocket retaining bolt at this stage.
1. Loosen the exhaust camshaft sprocket
retaining bolt.
Item 2 Exhaust camshaft sprocket 1

1. Remove the engine front cover blanking
plugs.
E51700
2. Install a bolt M10 x 25 mm (service hole 10 E51702

mm) or bolt M6 x 25 mm (service hole 7 mm)
to the right-hand blanking plug hole.
• Loosen the bolt M10 x 25 mm or bolt M6 x 4. NOTE: Fingertighten the M10 x 25mm or M6
25 mm by two turns. x 25mm bolt.
Tighten the bolt M10 x 25 mm or bolt M6 x
25 mm until it stops on the left-hand timing
chain tensioner arm.
E51701

1. Using a suitable screwdriver on the left-hand E51703
blanking plug hole, unlock the timing chain
tensioner ratchet.
5. Remove the exhaust camshaft sprocket
retaining bolt and the exhaust camshaft
sprocket.
2007.50 Focus 5/2007 G384742en

303-01B-26 Engine — 1.6L (Z6) 303-01B-26
IN-VEHICLE REPAIR
Item 4 Camshaft bearing caps retaining bolts Item 5 Camshaft bearing caps
1. Remove the camshaft bearing cap retaining NOTE: Keep the camshaft bearing caps in order
bolts in the sequence shown. for installation.
10 12 18 20 14 16 6 8
2
1
11
9 19 17 13 15 5 7
E51704
Item 7 Intake camshaft
Item 5 Camshaft bearing caps
1. Rotate the crankshaft in the normal direction
of rotation until piston No. one is at top dead 1. Install the camshaft bearing caps.
center (TDC).
1
4
5
E51707
E51705
Item 4 Camshaft bearing caps retaining bolts
2. Install the intake camshaft approximately in 1. NOTE: Working in several stages, evenly
the valve overlap position cylinder No. 4. tighten the camshaft bearing cap retaining
bolts one half turn at a time.
Item 6 Exhaust camshaft
1. Install the exhaust camshaft approximately
in the valve overlap position cylinder No. 4.
2007.50 Focus 5/2007 G384742en

303-01B-27 Engine — 1.6L (Z6) 303-01B-27
IN-VEHICLE REPAIR
Tighten the camshaft bearing caps retaining Install the exhaust camshaft sprocket
bolts in the sequence shown. together with the timing chain.
11 9 3 13 Nm 1 7 5
19
15
17
13
18
20
10 E51708
12 2 4 8 6 16 14
E51706
Item 3 Intake camshaft sprocket retaining bolt 2. Remove the bolt M10 x 25 mm or bolt M6 x
25 mm from the right-hand blanking plug
1.
CAUTION: The timing mark of the intake hole.
camshaft sprocket must align with the upper
surface of the engine front cover.
open-ended wrench to stop it from rotating.
Install the intake camshaft sprocket together
with the timing chain.
E51701

Rotate the crankshaft two revolutions, check
E51708 the valve timing and correct as necessary.
4. Install the engine front cover blanking plugs.
Item 2 Exhaust camshaft sprocket

1. 4 Nm
CAUTION: The timing mark of the exhaust
camshaft sprocket must align with the upper
surface of the engine front cover.
E51709
2007.50 Focus 5/2007 G384742en

303-01B-28 Engine — 1.6L (Z6) 303-01B-28
IN-VEHICLE REPAIR
Item 1 Exhaust camshaft sprocket retaining bolt
open-ended wrench to prevent it from rotating.
2007.50 Focus 5/2007 G384742en

303-01B-29 Engine — 1.6L (Z6) 303-01B-29
IN-VEHICLE REPAIR
Timing Chain(21 314 0)

Special Tool(s) 3. Attach the special tool on both sides
(right-hand side shown).
Support Bar, Engine
303-290A
303290A

303-290-03A
303-290-13
TIE0036685
30329003A
Adapter for 303-290A For additional information, refer to: Jacking
303-290-13 (100-02 Jacking and Lifting, Description
and Operation)
30329013
5. Install the special tools.
303-290-13 303-290-03A
Adapter for 303-290A 303-290A
303-290-15
E42950

303-290A-15 303-290-13
For additional information, refer to: Valve E50547
Cover (303-01 Engine - 1.6L (Z6), In-vehicle
Repair). 6. Remove the crankshaft front seal.
2. Remove the headlamp assembly on both For additional information, refer to:
sides. Crankshaft Front Seal (303-01 Engine - 1.6L
For additional information, refer to: (Z6), In-vehicle Repair).
Headlamp Assembly (417-01 Exterior 7. Lower the vehicle.
2007.50 Focus 5/2007 G401932en

303-01B-30 Engine — 1.6L (Z6) 303-01B-30
IN-VEHICLE REPAIR
8. Detach the coolant expansion tank and 11. Remove the engine front mount.
secure it to one side.
80 Nm
53 Nm
E51977
E51974
12. Disconnect the variable camshaft timing

9. Detach the power steering pump fluid (VCT) intake solenoid electrical connector.
reservoir and secure it to one side.
10 Nm
E51978
E51975
13. Disconnect the crankshaft position (CKP)

10. Detach the ground cable from the engine sensor electrical connector.
front mount.
10 Nm
E51979
E51976
14. Detach the power steering pump from the

cylinder block.
1. Remove the power steering pump upper
retaining bolt.
2007.50 Focus 5/2007 G401932en

303-01B-31 Engine — 1.6L (Z6) 303-01B-31
IN-VEHICLE REPAIR
2. Loosen the power steering pump lower 15. Remove the components in the order
retaining bolt. indicated in the following illustration(s) and
table(s).
23 Nm 1
23 Nm 2
E51992
10 11
9 12
3 46 Nm
1 9 Nm 9 Nm 16
4 39 Nm
9
5
6 46 Nm 9 Nm 7
8
14 22 Nm
13
15 22 Nm
E52005
1 VCT intake solenoid retaining bolt 7 Oil level indicator pipe retaining bolt
2 VCT intake solenoid O-ring seal 8 Oil level indicator pipe O-ring seal
3 Idler pulley retaining nut 9 Engine front cover retaining bolts

4 VCT intake solenoid oil filter retaining bolt
10 Engine front cover retaining bolt seal
5 VCT intake solenoid oil filter washer
11 Engine front cover
6 Accessory drive belt tensioner retaining See Installation Detail
bolts
12 Engine front cover O-ring seals
2007.50 Focus 5/2007 G401932en

303-01B-32 Engine — 1.6L (Z6) 303-01B-32
IN-VEHICLE REPAIR

13 Timing chain 15 Timing chain guide retaining bolt
See Removal Detail
See Installation Detail 16 Timing chain tensioner retaining bolt
14 Timing chain tensioner arm retaining bolt 16. To install, reverse the removal procedure.
Removal Details
Item 13 Timing chain 2. Detension the timing chain.
1. Rotate the crankshaft in the normal direction 1. Unlock the timing chain tensioner ratchet.
of rotation until piston No. one is at top dead 2. Apply pressure to the timing chain guide.
center (TDC). 3. Fix the timing chain tensioner with a suitable
pin punch.
1
2
3
E52000
E52001
Item 13 Timing chain 2. Rotate the camshafts until the camshaft
timing marks align with the upper surface of
the engine front cover.
of rotation until piston No. one is at top dead
center (TDC).
E51708
E52000
3. Install the timing chain.
2007.50 Focus 5/2007 G401932en

303-01B-33 Engine — 1.6L (Z6) 303-01B-33
IN-VEHICLE REPAIR
4. Remove the suitable pin punch, tension the • Bolts 7, 11, 16: 45 Nm.
timing chain.
2 1 7
6
11
12 16
15
3
8 9
13
18
17
5 10 4 14
E51999
E52003
Item 5 VCT intake solenoid oil filter
5. NOTE: Only rotate the crankshaft in the 1. Inspect the VCT intake solenoid oil filter and
normal direction of rotation. clean if necessary.
the valve timing and correct as necessary.
Item 11 Engine front cover

and of the front cover with cleaner.
2.
CAUTION: Install the engine front cover
within four minutes of applying the sealer.
Apply a bead of sealant to the areas as
shown.
E51997
E51998
Item 9 Engine front cover retaining bolts

1. Tighten the engine front cover retaining bolts
in the sequence shown.
• Bolt 9: 9 Nm.
• Bolts 1 through 6, 8, 10, 12 through 15, 17,
18: 22 Nm.
2007.50 Focus 5/2007 G401932en

303-01B-34 Engine — 1.6L (Z6) 303-01B-34
IN-VEHICLE REPAIR
Exhaust Manifold(21 187 0)

1. NOTE: The exhaust manifold and catalytic
converter are serviced as one component
and can not be renewed separately.
Remove the catalytic converter.
For additional information, refer to: Catalytic
Converter - 1.6L (Z6) (309-00 Exhaust
System, Removal and Installation).
2007.50 Focus 5/2007 G405612en

303-01B-35 Engine — 1.6L (Z6) 303-01B-35
IN-VEHICLE REPAIR

Special Tool(s) 5. Drain the cooling system.
Remover/Installer, Hose For additional information, refer to: Cooling
Clamp System Draining, Filling and Bleeding
303-397 (303-03 Engine Cooling - 1.6L (Z6), General
Procedures).
24003
6. Disconnect the heated oxygen (H02S) sensor
Gauge, Bolt Angle

303-174
21540

For additional information, refer to: Air E52079
7. Disconnect the catalyst monitor sensor
Installation).
Tray - 1.6L (Z6) (414-01 Battery, Mounting
and Cables, Removal and Installation).
For additional information, refer to: Intake
Manifold (303-01 Engine - 1.6L (Z6),
In-vehicle Repair).
E52080
Chain (303-01 Engine - 1.6L (Z6), In-vehicle
Repair).
table(s).
2007.50 Focus 5/2007 G384760en

303-01B-36 Engine — 1.6L (Z6) 303-01B-36
IN-VEHICLE REPAIR
2
1
E52081
1 Engine coolant temperature (ECT) sensor 3 Engine wiring harness bracket

electrical connector. 4 Heater core coolant hose
2 Engine wiring harness bracket retaining See Removal Detail
bolts See Installation Detail
2007.50 Focus 5/2007 G384760en

303-01B-37 Engine — 1.6L (Z6) 303-01B-37
IN-VEHICLE REPAIR
E52082
Item Description
5 Coolant outlet connector retaining bolts
6 Coolant outlet connector gasket
2007.50 Focus 5/2007 G384760en

303-01B-38 Engine — 1.6L (Z6) 303-01B-38
IN-VEHICLE REPAIR
20 11
7
21
13
10 14
12
15 9
16
19
22
18 17
E52083
7 Exhaust manifold to exhaust gas 12 EGR valve retaining bolts

recirculation (EGR) valve tube retaining 13 Wiring harness clip retaining bolt
nuts
14 Wiring harness clip
8 Exhaust manifold to EGR valve tube
bracket retaining nut 15 Catalytic converter heat shield upper
retaining nuts
retaining nut 16 Catalytic converter heat shield lower
retaining nuts
gasket 17 Catalytic converter to muffler and tailpipe
assembly retaining nuts
11 EGR valve electrical connector
2007.50 Focus 5/2007 G384760en

303-01B-39 Engine — 1.6L (Z6) 303-01B-39
IN-VEHICLE REPAIR

18 Exhaust hanger insulators 21 Exhaust manifold gasket
19 Catalytic converter support bracket 22 Catalytic converter
retaining bolts See Removal Detail
20 Exhaust manifold retaining nuts
23
24
25
E52029
2007.50 Focus 5/2007 G384760en

303-01B-40 Engine — 1.6L (Z6) 303-01B-40
IN-VEHICLE REPAIR

23 Camshaft bearing cap retaining bolts See Removal Detail
25 Cylinder head gasket
24 Cylinder head retaining bolts
Removal Details
Item 4 Heater core coolant hose
Item 23 Camshaft bearing cap retaining bolts
1. Using the special tool, disconnect the heater
core coolant hose from the cylinder head. 1. Remove the camshaft bearing cap retaining
bolts in the sequence shown.
10 12 18 20 14 16 6 8
2
303-397
4
1
11
E52084 9 19 17 13 15 5 7
E51704
Item 22 Catalytic converter

Item 24 Cylinder head retaining bolts
NOTE: The catalytic converter remains on the
vehicle. 1. Remove the cylinder head retaining bolts in
the sequence shown.
3 7 10 6 2
4 8 9 5 1
E52027
1.
CAUTION: Do not reuse the cylinder head
bolts if the length is more than 130.2 mm.
2007.50 Focus 5/2007 G384760en

303-01B-41 Engine — 1.6L (Z6) 303-01B-41
IN-VEHICLE REPAIR
Measure the cylinder head bolts. 2. NOTE: Working in several stages, evenly
tighten the camshaft bearing cap retaining
Tighten the camshaft bearing cap retaining
11 9 3 13 Nm 1 7 5
19
15
17
E56536 13
18
2. 20
CAUTION: Install new cylinder head bolts 10
as necessary. 12 2 4 8 6 16 14
E51706
Tighten the cylinder head retaining bolts in
the sequence shown in three stages.
Item 20 Exhaust manifold retaining nuts
1. Stage 1: 20 Nm.
1. NOTE: Install new exhaust manifold retaining
2. Stage 2: 90 degrees.
nuts.
8 4 1 5 9 in the sequence shown.
4 42 Nm 1
5
7 3 2 6 10
2
E52028 3
Item 23 Camshaft bearing cap retaining bolts E52085
1. Install the camshaft bearing caps.

Item 4 Heater core coolant hose
1. Using the special tool, connect the heater
core coolant hose to the cylinder head.
1
303-397
5
E51707
E52084
2007.50 Focus 5/2007 G384760en

303-01B-42 Engine — 1.6L (Z6) 303-01B-42
IN-VEHICLE REPAIR
Oil Pan(21 154 0)

Special Tool(s) Materials
Separator, Oil Pan Name Specification
303-428
Cleaner WSK-M5B401-A1
21179 Engine Oil - 5W-30 WSS-M2C913-A
table(s).
9 Nm 3
1
E51506
1 Oil pan retaining bolts 3 Oil pick-up pipe retaining bolts

See Removal Detail 4 Oil pick-up pipe O-ring seal
2 Oil pan
See Removal Detail
Removal Details
2007.50 Focus 5/2007 G384771en

303-01B-43 Engine — 1.6L (Z6) 303-01B-43
IN-VEHICLE REPAIR
Item 1 Oil pan retaining bolts Item 2 Oil pan
1. Raise and support the vehicle. 1. Using the special tool, remove the oil pan.
and Operation)
2. Drain the engine. 303-428
3. NOTE: Inspect the oil drain plug and seal for
damage. Install a new oil drain plug as
necessary.
E51507
15 Nm
E52288
Item 2 Oil pan Item 1 Oil pan retaining bolts
1. Clean the mating faces of the oil pan and the 1. Install the oil pan.
cylinder block with cleaner.
• Tighten the oil pan retaining bolts in the
2. sequence shown.
CAUTION: Install the oil pan within five
minutes of applying the sealant.
8 4 9 Nm 1 5 9
Apply a 3 mm bead of sealant to the mating 11
face of the oil pan. 12
13
16
14
15
7 3 2 6 10
E51509

E51508 3. Fill the engine with engine oil.
2007.50 Focus 5/2007 G384771en

303-01B-44 Engine — 1.6L (Z6) 303-01B-44
IN-VEHICLE REPAIR
Oil Pump(21 714 0)

For additional information, refer to: Timing table(s).
Chain (303-01 Engine - 1.6L (Z6), In-vehicle
Repair).
1 22 Nm
E51516
Item Description
1 Oil pump retaining bolts
2 Oil pump gasket
2007.50 Focus 5/2007 G384774en

303-01B-45 Engine — 1.6L (Z6) 303-01B-45
IN-VEHICLE REPAIR
Crankshaft Rear Seal(21 468 4)

Special Tool(s) 1. Remove the transaxle.
Locking Tool, Flywheel For additional information, refer to: Transaxle
303-254 (308-03 Manual Transmission/Transaxle -
Vehicles With: 5-Speed Manual Transaxle
(F35M-R), Removal)
/ Transaxle (307-01 Automatic
21135
4-Speed Automatic Transmission
(FN4A-EL), Removal).
303-293
21143 Transmission (iB5), Removal and
Installation)
Installer, Crankshaft Rear Clutch - Vehicles With: 5-Speed Manual
Seal Transmission (MTX-75), Removal and
303-347 Installation).
21188 table(s).
E51220
2007.50 Focus 5/2007 G384779en

303-01B-46 Engine — 1.6L (Z6) 303-01B-46
IN-VEHICLE REPAIR

1 Flywheel/ Flexplate retaining bolts 3 Crankshaft rear seal
2 Flywheel/ Flexplate 4. To install, reverse the removal procedure.
Removal Details
Item 3 Crankshaft rear seal
1.
engages correctly.
303-293
NOTE: Only rotate the engine in the normal
Using the special tool, lock the flywheel/
flexplate.
303-254
E51223

rear seal.
E51221
Item 3 Crankshaft rear seal Item 1 Positive crankcase ventilation (PCV) hose
1. NOTE: Install a new crankshaft rear seal. 1.
Using the special tool, install the crankshaft engages correctly.
rear seal.
303-437
E51224
2007.50 Focus 5/2007 G384779en

303-01B-47 Engine — 1.6L (Z6) 303-01B-47
IN-VEHICLE REPAIR
flexplate.
303-254
E51221
2. Tighten the flywheel/ flexplate retaining bolts

100 Nm 1
6
4
3 303-254
5
2
E51225
2007.50 Focus 5/2007 G384779en

303-01B-48 Engine — 1.6L (Z6) 303-01B-48
REMOVAL

Special Tool(s) 3. Disconnect the battery positive cable from
303-122
Clamp
303-397

WARNING: Do not smoke or carry lighted
(303-03F Engine Cooling - 1.6L (Z6),
follow these instructions may result in 5. Remove the accessory drive belt.
personal injury. For additional information, refer to:
1. Remove the engine cover. Accessory Drive Belt - 1.6L (Z6) (303-05
6. Detach the ground cables from the wheel
housing.

2007.50 Focus 5/2007 G384845en

303-01B-49 Engine — 1.6L (Z6) 303-01B-49
REMOVAL
7. Remove the central junction box (CJB) cover. 11. Remove the floor panel brace.
TIE0036571 E47216
8. Disconnect the engine wiring harness 12. Remove the engine support insulator.
TIE0036808
TIE0036573

9. Remove the cooling fan motor and shroud. For additional information, refer to:
For additional information, refer to: Cooling Halfshaft LH (205-04 Front Drive
Fan Motor and Shroud (303-03F Engine Halfshafts, Removal and Installation).
Cooling - 1.6L (Z6), Removal and
14. Remove the right-hand halfshaft in unit with
Installation).
the intermediate shaft.
10. Raise and support the vehicle. For additional information, refer to:
For additional information, refer to: Lifting Halfshaft RH (205-04 Front Drive
(100-02 Jacking and Lifting, Description Halfshafts, Removal and Installation).
and Operation).
table(s).
2007.50 Focus 5/2007 G384845en

303-01B-50 Engine — 1.6L (Z6) 303-01B-50
REMOVAL
3
E52825
Item Description
1 Air conditioning (A/C) compressor
2 A/C compressor retaining bolts
3 A/C compressor
See Removal Detail
2007.50 Focus 5/2007 G384845en

303-01B-51 Engine — 1.6L (Z6) 303-01B-51
REMOVAL
8
17
4
18 10
7 11
5
6
12
13
16
19
14
15
E52826
4 Exhaust manifold to exhaust gas 9 EGR valve retaining bolts

recirculation (EGR) valve tube retaining 10 Wiring harness clip retaining bolt
nuts
bracket retaining nut 12 Catalytic converter heat shield upper
retaining nuts
retaining nut 13 Catalytic converter heat shield lower
retaining nuts
gasket 14 Catalytic converter to muffler and tailpipe
assembly retaining nuts
8 EGR valve electrical connector
2007.50 Focus 5/2007 G384845en

303-01B-52 Engine — 1.6L (Z6) 303-01B-52
REMOVAL

15 Exhaust hanger insulators 18 Exhaust manifold gasket
16 Catalytic converter support bracket 19 Catalytic converter
retaining bolts See Removal Detail
20
21
22
E52827
Item Description
20 Power steering line
See Removal Detail
21 Power steering fluid supply hose
See Removal Detail
22 Coolant hose
See Removal Detail
2007.50 Focus 5/2007 G384845en

303-01B-53 Engine — 1.6L (Z6) 303-01B-53
REMOVAL
28
29
32
25
31
24
27
30
26
23
E52828
23 Radiator lower coolant hose 28 Heated oxygen sensor (HO2S) electrical

24 Coolant outlet connector to coolant 29 Catalyst monitor sensor electrical

expansion tank hose connector
See Removal Detail 30 Brake booster vacuum line
25 Cylinder head to heater core coolant hose See Removal Detail
See Removal Detail 31 Accelerator cable
26 Coolant outlet connector to radiator upper See Removal Detail
coolant hose 32 Fuel supply line
27 Gearshift cables
See Removal Detail
2007.50 Focus 5/2007 G384845en

303-01B-54 Engine — 1.6L (Z6) 303-01B-54
REMOVAL
35
34
33
E52829
Item Description
33 Clutch slave cylinder supply line
See Removal Detail
34 Engine rear mount retaining bolt
See Removal Detail
35 Engine front mount retaining nuts
See Removal Detail
2007.50 Focus 5/2007 G384845en

303-01B-55 Engine — 1.6L (Z6) 303-01B-55
REMOVAL
36 37
39
38
E52860
36 Vehicle speed (VSS) sensor electrical 38 Reversing lamp switch electrical connector
connector 39 Transaxle wiring harness bracket retaining
37 Neutral switch electrical connector bolts
2007.50 Focus 5/2007 G384845en

303-01B-56 Engine — 1.6L (Z6) 303-01B-56
REMOVAL
42
41
40
E52861
Item Description
40 Starter motor retaining bolts
41 Starter motor
See Removal Detail
42 Transaxle
See Removal Detail
Removal Details
Item 3 A/C compressor Cap the power steering pump connection
1. Detach the A/C compressor from the bracket to prevent fluid loss or dirt ingress.
and secure it to one side.

NOTE: The catalytic converter remains on the
vehicle.
Item 20 Power steering line

1. CAUTIONS:
Cap the power steering line to prevent
2007.50 Focus 5/2007 G384845en

303-01B-57 Engine — 1.6L (Z6) 303-01B-57
REMOVAL
Remove and discard the power steering line Item 22 Coolant hose
union washers.
coolant hose from the cylinder block.
E52519
303-397
E52896
Item 21 Power steering fluid supply hose
1. CAUTIONS: Item 23 Radiator lower coolant hose
Cap the power steering fluid supply hose 1. Using the special tool, disconnect the
to prevent fluid loss or dirt ingress. coolant hose from the cylinder block.

to prevent fluid loss or dirt ingress. 303-397
Using the special tool, disconnect the power
steering fluid supply hose from the power
steering pump.
container.
303-397
E52928
Item 24 Coolant outlet connector to coolant

expansion tank hose
connector.
E52694
303-397
E52897
2007.50 Focus 5/2007 G384845en

303-01B-58 Engine — 1.6L (Z6) 303-01B-58
REMOVAL
Item 25 Cylinder head to heater core coolant 2. Press the locking pins together and detach
hose the gearshift cables from the bracket.
coolant hose from the cylinder head.
2
1
E52917
303-397
E52898
Item 30 Brake booster vacuum line
1. Using the special tool, disconnect the brake
booster vacuum hose from the intake
Item 26 Coolant outlet connector to radiator
manifold.
upper coolant hose
connector.
303-397
303-397
E51944

E52899 1. Detach the accelerator cable retaining
bracket from the intake manifold.
Item 27 Gearshift cables
transaxle.
1. Detach the gearshift and selector cables from
the selector mechanism.
E51946
2. Detach the accelerator cable from the throttle

body.
1. Detach the accelerator cable from the
bracket.
2007.50 Focus 5/2007 G384845en

303-01B-59 Engine — 1.6L (Z6) 303-01B-59
REMOVAL
2. Detach the accelerator cable from the throttle Item 34 Engine rear mount retaining bolt
lever.
1. NOTE: Support the engine and transaxle with
suitable wooden blocks.
1
Secure the engine and transaxle assembly
on the workshop table using suitable
retaining straps.
E51948

1. Disconnect the fuel supply line quick
connector.
TIE45738
Release Coupling (310-00A Fuel System - Item 35 Engine front mount retaining nuts
1. Remove the engine ground cable.
Item 33 Clutch slave cylinder supply line
1. CAUTIONS:
If brake fluid comes into contact with the
paintwork, rinse off the affected areas with
cold water without delay.
Close off the clutch slave cylinder

pressure line to prevent fluid loss or dirt
ingress.
Detach the clutch slave cylinder pressure
line from the clutch slave cylinder. E52862
• Detach the clutch slave cylinder pressure

line from the bracket. 2. Remove the engine front mount retaining
• Remove the spring clip. nuts.
E53287 E52863
2007.50 Focus 5/2007 G384845en

303-01B-60 Engine — 1.6L (Z6) 303-01B-60
REMOVAL
3. Raise and support the vehicle. 2. Remove the transaxle left-hand retaining
bolts.
and Operation).
4. Remove the engine and transaxle assembly.
303-122
E52870
ELE0001115
Item 41 Starter motor

1. Remove the starter motor cable shield.
E51777
Item 42 Transaxle
bolts.
E52869
2007.50 Focus 5/2007 G384845en

303-01B-61 Engine — 1.6L (Z6) 303-01B-61
DISASSEMBLY
Engine(21 134 8)
Universal Flange Holding Mounting Stand
Wrench 303-435
205-072
15030A
21187
Adapter for 205-072 Mounting Bracket for 303-435

205-072-01 303-435-06
20507201 21031B
Remover, Seal Mounting Plate for

303-112 303-435-06
303-435-11A
30343511A
303112
Locking Tool, Flywheel 1. Install the special tool.

303-254
21135

303-293
303-435-11A
E53427
21143
Separator, Oil Pan

303-428
21179
2007.50 Focus 5/2007 G384846en

303-01B-62 Engine — 1.6L (Z6) 303-01B-62
DISASSEMBLY
2. Install the special tool. 4. Remove the special tool.
303-122
303-435-06
ELE0017397
E53428
3. Mount the engine on the mounting stand. 5. Drain the engine.

6. Install the oil drain plug.
303-435
15 Nm
E53429
E52288

table(s).
2007.50 Focus 5/2007 G384846en

303-01B-63 Engine — 1.6L (Z6) 303-01B-63
DISASSEMBLY
10
9 19
3
18
12
1 17
16
11
2
8
15
7
4
14
5 13
E53274
1 Power steering pump electrical connector 10 Ignition coil-on-plug electrical connectors
2 Variable camshaft timing (VCT) solenoid 11 Fuel injector electrical connectors

electrical connector 12 Wiring harness clips
3 Wiring harness clip 13 Oil pressure switch electrical connector
4 Crankshaft position (CKP) sensor 14 Battery to generator cable electrical
electrical connector connector
5 Wiring harness clip See Disassembly Detail
6 Generator electrical connector 15 Evaporative emission (EVAP) solenoid

8 Manifold absolute pressure (MAP) sensor
electrical connector 17 Wiring harness clip
9 Camshaft position (CMP) sensor electrical 18 Intake manifold runner control (IMRC)
connector electrical connector
2007.50 Focus 5/2007 G384846en

303-01B-64 Engine — 1.6L (Z6) 303-01B-64
DISASSEMBLY
26
24
25
27 23
22
20
21
E53275
20 Knock sensor (KS) electrical connector 24 Heated oxygen (HO2S) sensor electrical
connector
21 Idle air control (IAC) electrical connector
25 Catalyst monitor sensor electrical
22 Throttle position (TP) electrical connector connector
23 Engine coolant temperature (ECT) 26 Positive crankshaft ventilation hose
27 EVAP solenoid vacuum line
2007.50 Focus 5/2007 G384846en

303-01B-65 Engine — 1.6L (Z6) 303-01B-65
DISASSEMBLY
30
33
32
31
28 29
E53276
Item Description
28 Exhaust gas recirculation (EGR) pipe 34
retaining bolts
29 EGR pipe bracket retaining bolt
30 EGR pipe retaining nut
35
31 EGR pipe gasket
32 Intake manifold retaining bolts
33 Intake manifold gaskets E53277
Item Description
34 Generator upper retaining bolt
35 Generator lower retaining bolt
2007.50 Focus 5/2007 G384846en

303-01B-66 Engine — 1.6L (Z6) 303-01B-66
DISASSEMBLY
Item Description
36
36 Power steering pump upper retaining bolt
37 Power steering pump lower retaining bolt
37
E53278
46 39 40 41
38
54
55
56 42
53
47
45
48 60
49 53
43
44
51
50 58
59 52
57
E53314
38 CMP sensor retaining bolt 46 VCT intake solenoid O-ring seal
39 CMP sensor O-ring seal 47 Idler pulley retaining nut
40 Spark plug 48 VCT intake solenoid oil filter retaining bolt
41 Valve cover 49 VCT intake solenoid oil filter
42 Valve cover gasket 50 Accessory drive belt tensioner retaining

bolts
43 Crankshaft pulley retaining bolt
See Disassembly Detail 51 Oil level indicator pipe retaining bolt
44 Crankshaft front seal 52 Oil level indicator pipe O-ring seal

See Disassembly Detail 53 Engine front cover retaining bolts
45 VCT intake solenoid retaining bolt
2007.50 Focus 5/2007 G384846en

303-01B-67 Engine — 1.6L (Z6) 303-01B-67
DISASSEMBLY

54 Engine front cover retaining bolt seal 57 Timing chain
washer See Disassembly Detail
55 Engine front cover 58 Timing chain tensioner arm retaining bolt
56 Engine front cover O-ring seals 59 Timing chain guide retaining bolt
60 Timing chain tensioner retaining bolt
61
62
63
64
65
E53315
2007.50 Focus 5/2007 G384846en

303-01B-68 Engine — 1.6L (Z6) 303-01B-68
DISASSEMBLY

61 Camshaft bearing cap retaining bolts 63 Valve tappets
See Disassembly Detail See Disassembly Detail
62 Camshaft bearing caps 64 Cylinder head retaining bolts
65 Cylinder head gasket
66
67
68
81 69
80 70
71
77
72
79 76
73
74
78 75
E53333
66 Flywheel/ Flexplate retaining bolts 73 Thermostat housing retaining bolts

See Disassembly Detail 74 Oil pan retaining bolts
67 Flywheel/ Flexplate 75 Oil pan
68 Spacer plate See Disassembly Detail
69 Crankshaft rear seal 76 Oil pick-up pipe retaining bolts

See Disassembly Detail 77 Oil pick-up pipe O-ring seal
70 Crankcase vent oil separator retaining 78 Oil pump retaining bolts
bolts
79 Oil pump gasket
71 Crankcase vent oil separator O-ring seal
80 Coolant pump retaining bolt
72 Knock sensor (KS)
81 Coolant pump O-ring seal
Disassembly Details
2007.50 Focus 5/2007 G384846en

303-01B-69 Engine — 1.6L (Z6) 303-01B-69
DISASSEMBLY
Item 14 Battery to generator cable electrical Item 57 Timing chain
connector 1. Rotate the crankshaft in the normal direction
1. Remove the Battery to generator cable of rotation until piston No. one is at top dead
electrical connector. center (TDC).
E53279 E52000
Item 43 Crankshaft pulley retaining bolt 2. Detension the timing chain.

1. Using the special tools, remove the 1. Unlock the timing chain tensioner ratchet.
crankshaft pulley retaining bolt. 2. Apply pressure to the timing chain guide.
3. Fix the timing chain tensioner with a suitable
pin punch.
1
205-072-01
2
3
205-072
E51381
E52001
Item 44 Crankshaft front seal
1. Using the special tool, remove the crankshaft Item 61 Camshaft bearing cap retaining bolts
front seal.
1. Remove the camshaft bearing cap retaining
• Discard the seal. bolts in the sequence shown.
10 12 18 20 14 16 6 8
2
303-112 4
1
11
E51382 9 19 17 13 15 5 7
E51704
2007.50 Focus 5/2007 G384846en

303-01B-70 Engine — 1.6L (Z6) 303-01B-70
DISASSEMBLY
Item 62 Camshaft bearing caps • Discard the seal.
NOTE: Keep the camshaft bearing caps in order
for installation.
303-293
Item 63 Valve tappets
NOTE: Keep the valve tappets in order for
installation.

1. Remove the cylinder head retaining bolts in
the sequence shown.
E51223
3 7 10 6 2
Item 75 Oil pan
1. Using the special tool, remove the oil pan.
4 8 9 5 1
303-428
E52027
Item 66 Flywheel/ Flexplate retaining bolts

1.
CAUTION: Make sure that the special tool E51507
engages correctly.
flexplate.
303-254
E51221
Item 69 Crankshaft rear seal

rear seal.
2007.50 Focus 5/2007 G384846en

303-01B-71 Engine — 1.6L (Z6) 303-01B-71

Compressor, Valve Spring Installer, Valve Stem Collets
303-361A 303-362
21155 21156
Adapter for 303-361A Pliers, Valve Stem Seal

303-361-04 303-508
21211
2115504
Adapter for 303-361A 1. Disassemble the components in the order

303-361-05 indicated in the following illustration(s) and
table(s).
2115505
E51511
2007.50 Focus 5/2007 G384847en

303-01B-72 Engine — 1.6L (Z6) 303-01B-72

1 Valve collets 3 Valve spring
4 Valve seals
2 Valve spring retainer See Removal Detail
35 Nm 7
5
6
E53581

procedure.
5 Exhaust valve
6 Intake valve
7 Exhaust manifold studs
Disassembly Details
2007.50 Focus 5/2007 G384847en

303-01B-73 Engine — 1.6L (Z6) 303-01B-73
Item 1 Valve collets Item 2 Valve spring retainer
1. Install the special tools. CAUTION: Keep the valve spring retainers
in order for installation.
Item 3 Valve spring

CAUTION: Keep the valve springs in order
for installation.
303-361-04
303-361-05
Item 4 Valve seals
303-363 1. Using the special tool, remove the valve
seals.
• Discard the valve seals.
303-361A
TIE45023

springs.
3. Using the special tool, remove the valve
collets.
303-508
ELE0001753
303-362
TIE45024
Assembly Details
Item 4 Valve seals 2. NOTE: Install new valve seals.
1. Cover the valve collet grooves on the valve Using the special tool, install the valve seals.
stem with a protective sleeve (valve shown
303-508
ELE0001753
ELE0016924
2007.50 Focus 5/2007 G384847en

303-01B-74 Engine — 1.6L (Z6) 303-01B-74
springs.
303-361-04
303-361-05
303-363
303-361A
TIE45023
2. Using the special tool, install the valve

collets.
303-362
TIE45024
2007.50 Focus 5/2007 G384847en

303-01B-75 Engine — 1.6L (Z6) 303-01B-75
ASSEMBLY
Engine(21 134 8)
Universal Flange Holding Mounting Bracket for 303-435
Wrench 303-435-06
205-072
15030A 21031B
Adapter for 205-072 Mounting Plate for

205-072-01 303-435-06
303-435-11A
30343511A
20507201
Locking Tool, Flywheel Remover, Timing Cover Seal

303-254 303-501
21135 ES21204
Installer, Crankshaft Rear Materials

Seal
303-347 Name Specification
Cleaner WSK-M5B401-A1
21188
1. Assemble the components in the order
Mounting Stand table(s).
303-435
21187
2007.50 Focus 5/2007 G384848en

303-01B-76 Engine — 1.6L (Z6) 303-01B-76
ASSEMBLY
16
15
14
13
1
11
22 Nm 2
9 Nm 12
5 27 Nm 10
7 22 Nm 9
8
22 Nm 4 9 Nm 6
E53448
1 Coolant pump O-ring seal 9 Thermostat housing retaining bolts
2 Coolant pump retaining bolt 10 Knock sensor (KS)
3 Oil pump gasket 11 Crankcase vent oil separator O-ring seal
4 Oil pump retaining bolts 12 Crankcase vent oil separator retaining

bolts
5 Oil pick-up pipe O-ring seal
13 Crankshaft rear seal
6 Oil pick-up pipe retaining bolts See Assembly Detail
7 Oil pan 14 Spacer plate
See Assembly Detail
15 Flywheel/ Flexplate
8 Oil pan retaining bolts
See Assembly Detail 16 Flywheel/ Flexplate retaining bolts
See Assembly Detail
2007.50 Focus 5/2007 G384848en

303-01B-77 Engine — 1.6L (Z6) 303-01B-77
ASSEMBLY
21
20
19
18
17
E53449
17 Cylinder head gasket 20 Camshaft bearing caps

See Assembly Detail
18 Cylinder head retaining bolts
See Assembly Detail 21 Camshaft bearing cap retaining bolts
See Assembly Detail
19 Valve tappets
2007.50 Focus 5/2007 G384848en

303-01B-78 Engine — 1.6L (Z6) 303-01B-78
ASSEMBLY
45 9 Nm 44 19 Nm 43
36
42
28 27
26 41
29
35 46 Nm 40
37 9 Nm
22 9 Nm
34 39 Nm
33 29
39
38 9 Nm 31
32 46 Nm
24 22 Nm
30
25
23 22 Nm
E53450
22 Timing chain tensioner retaining bolt 35 Idler pulley retaining nut
23 Timing chain guide retaining bolt 36 VCT intake solenoid O-ring seal
24 Timing chain tensioner arm retaining bolt 37 VCT intake solenoid retaining bolt
25 Timing chain 38 Crankshaft front seal

See Assembly Detail See Assembly Detail
26 Engine front cover O-ring seals 39 Crankshaft pulley retaining bolt

See Assembly Detail
27 Engine front cover
See Assembly Detail 40 Valve cover gasket
28 Engine front cover retaining bolt seal 41 Valve cover

washer See Assembly Detail
29 Engine front cover retaining bolts 42 Valve cover retaining bolt

30 Oil level indicator pipe O-ring seal 43 Spark plug
31 Oil level indicator pipe retaining bolt 44 Camshaft position (CMP) sensor O-ring
seal
32 Accessory drive belt tensioner retaining
bolts 45 CMP sensor retaining bolt
33 Variable camshaft timing (VCT) intake

solenoid oil filter
See Assembly Detail
34 VCT intake solenoid oil filter retaining bolt
2007.50 Focus 5/2007 G384848en

303-01B-79 Engine — 1.6L (Z6) 303-01B-79
ASSEMBLY
47 23 Nm
49 45 Nm
46 23 Nm 48 45 Nm
E53451 E53452

46 Power steering pump lower retaining bolt 48 Generator lower retaining bolt
47 Power steering pump upper retaining bolt 49 Generator upper retaining bolt
53 39 Nm
50
52
51 44 Nm
9 Nm 54
9 Nm 55
E53453
50 Intake manifold gaskets 53 EGR pipe retaining nut
51 Intake manifold retaining bolts 54 EGR pipe bracket retaining bolt
52 Exhaust gas recirculation (EGR) pipe 55 EGR pipe retaining bolts

gasket
2007.50 Focus 5/2007 G384848en

303-01B-80 Engine — 1.6L (Z6) 303-01B-80
ASSEMBLY
57
56
59
58
60
61
63
62
E53454
56 Evaporative emission (EVAP) solenoid 60 Engine coolant temperature (ECT)

vacuum line electrical connector
57 Positive crankshaft ventilation hose 61 Throttle position (TP) electrical connector
58 Catalyst monitor sensor electrical 62 Idle air control (IAC) electrical connector
connector 63 Knock sensor (KS) electrical connector
59 Heated oxygen (HO2S) sensor electrical
connector
2007.50 Focus 5/2007 G384848en

303-01B-81 Engine — 1.6L (Z6) 303-01B-81
ASSEMBLY
73
74 64
80
65
71
81 66
67
72
82
75
68
76
77
79
69
78 70
E53455
64 Wiring harness clip 79 Crankshaft position (CKP) sensor

65 Intake manifold runner control (IMRC)
electrical connector 80 Wiring harness clip
66 Wiring harness clip 81 Power steering pump electrical connector
67 Wiring harness clip 82 VCT solenoid electrical connector
68 EVAP solenoid electrical connector 2. Install the special tool.

69 Battery to generator cable electrical
See Assembly Detail
303-122
70 Oil pressure switch electrical connector
71 Wiring harness clips
72 Fuel injector electrical connectors
73 Ignition coil-on-plug electrical connectors
74 CMP sensor electrical connector
75 Manifold absolute pressure (MAP) sensor ELE0017397
77 Generator electrical connector
2007.50 Focus 5/2007 G384848en

303-01B-82 Engine — 1.6L (Z6) 303-01B-82
ASSEMBLY
3. Remove the engine from the mounting stand. 5. Remove the special tool.
303-435
303-435-11A
E53429 E53427
303-435-06
E53428
Assembly Details
Item 7 Oil pan Item 13 Crankshaft rear seal
1. 1. NOTE: Install a new crankshaft rear seal.
CAUTION: Install the oil pan within five
minutes of applying the sealant. Using the special tool, install the crankshaft
rear seal.
face of the oil pan.
303-437
E51224
E51508
Item 8 Oil pan retaining bolts
1. Install the oil pan.
2007.50 Focus 5/2007 G384848en

303-01B-83 Engine — 1.6L (Z6) 303-01B-83
ASSEMBLY
• Tighten the oil pan retaining bolts in the Item 18 Cylinder head retaining bolts
sequence shown.
1.
CAUTION: Do not reuse the cylinder head
8 4 9 Nm 1 5 9 bolts if the length is more than 130.2 mm.
11
Measure the cylinder head bolts.
12
13
16
14
15
7 3 2 6 10
E51509
Item 16 Flywheel/ Flexplate retaining bolts E56536

1.
engages correctly.
2.
NOTE: Only rotate the engine in the normal CAUTION: Install new cylinder head bolts
direction of rotation. as necessary.
Using the special tool, lock the flywheel or Tighten the cylinder head retaining bolts in
flexplate. the sequence shown in three stages.
1. Stage 1: 20 Nm.
303-254 3. Stage 3: 90 degrees.
8 4 1 5 9
E51221
7 3 2 6 10
2. Tighten the flywheel or flexplate retaining
bolts in the sequence shown. E52028
100 Nm 1
6
4
3 303-254
5
2
E51225
2007.50 Focus 5/2007 G384848en

303-01B-84 Engine — 1.6L (Z6) 303-01B-84
ASSEMBLY
Item 20 Camshaft bearing caps 2. Rotate the camshafts until the camshaft
timing marks align with the upper surface of
1. Install the camshaft bearing caps.
1 the engine front cover.
4
5
E51707 E51708
Item 21 Camshaft bearing cap retaining bolts 3. Install the timing chain.
1. NOTE: Working in several stages, evenly 4. Remove the suitable pin punch, tension the
tighten the camshaft bearing cap retaining timing chain.
Tighten the camshaft bearing cap retaining
11 9 3 13 Nm 1 7 5
19
15
17
13
18
E52003
20
10
12 2 4 8 6 16 14 5. NOTE: Only rotate the crankshaft in the
E51706
Item 25 Timing chain the valve timing and correct as necessary.
of rotation until piston No. one is at top dead Item 27 Engine front cover
center (TDC).
and of the front cover with cleaner.
2.
CAUTION: Install the engine front cover
within four minutes of applying the sealer.
E52000
2007.50 Focus 5/2007 G384848en

303-01B-85 Engine — 1.6L (Z6) 303-01B-85
ASSEMBLY
Apply a bead of sealant to the areas as Item 41 Valve cover
shown.
as shown.
E51998
E51293
Item 29 Engine front cover retaining bolts
1. Tighten the engine front cover retaining bolts Item 42 Valve cover retaining bolt
1. NOTE: Install a new valve cover gasket.
• Bolt 9: 9 Nm.
• Bolts 1 through 6, 8, 10, 12 through 15, 17,
18: 22 Nm. • Tighten the bolts in the sequence shown.
• Bolts 7, 11, 16: 45 Nm.
3 2 9 8
2 1 7 7
6
11
12 4
16
15
3 10 11
8 9
13 9 Nm 1
18 5 6
17 E51297
5 10 4 14
E51999
Item 33 Variable camshaft timing (VCT) intake

solenoid oil filter
1. Inspect the VCT intake solenoid oil filter and
clean if necessary.
E51997
2007.50 Focus 5/2007 G384848en

303-01B-86 Engine — 1.6L (Z6) 303-01B-86
INSTALLATION

Lifting Bracket, Engine Remover/Installer, Hose
303-122 Clamp
303-397
24003
21068A
1. Install the components in the order indicated

in the following illustration(s) and table(s).
45 Nm 3
E52959
Item Description
1 Transaxle
2 Starter motor
3 Starter motor retaining bolts
2007.50 Focus 5/2007 G384849en

303-01B-87 Engine — 1.6L (Z6) 303-01B-87
INSTALLATION
23 Nm 4
5
E52962
4 Transaxle wiring harness bracket retaining 6 Neutral switch electrical connector

bolts 7 Vehicle speed (VSS) sensor electrical
5 Reversing lamp switch electrical connector connector
2007.50 Focus 5/2007 G384849en

303-01B-88 Engine — 1.6L (Z6) 303-01B-88
INSTALLATION
53 Nm 8
9 80 Nm
10
E52965
Item Description
8 Engine front mount retaining nuts
9 Engine rear mount retaining bolt
10 Clutch slave cylinder supply line
2007.50 Focus 5/2007 G384849en

303-01B-89 Engine — 1.6L (Z6) 303-01B-89
INSTALLATION
15
14
18
11
12
13
16
19
17
20
E52966
11 Fuel supply line 16 Gearshift cables

12 Accelerator cable 17 Coolant outlet connector to radiator upper

See Installation Detail coolant hose
13 Brake booster vacuum line
See Installation Detail 18 Cylinder head to heater core coolant hose
14 Catalyst monitor sensor electrical
connector 19 Coolant outlet connector to coolant
expansion tank coolant hose
15 Heated oxygen sensor (HO2S) electrical See Installation Detail
connector
20 Radiator lower coolant hose
2007.50 Focus 5/2007 G384849en

303-01B-90 Engine — 1.6L (Z6) 303-01B-90
INSTALLATION
23 33 Nm
22
21
E53108
Item Description
21 Coolant hose
22 Power steering fluid supply hose
pressure line
2007.50 Focus 5/2007 G384849en

303-01B-91 Engine — 1.6L (Z6) 303-01B-91
INSTALLATION
26 35
39
25
33
36 32
38
34
31 37
30
27
24
28 29
E52981
24 Catalytic converter 30 Catalytic converter heat shield lower

retaining nuts
25 Exhaust manifold gasket
31 Catalytic converter heat shield upper
26 Exhaust manifold retaining nuts retaining nuts
27 Catalytic converter support bracket
retaining bolts 33 Wiring harness clip retaining bolt
28 Exhaust hanger insulators 34 Exhaust gas recirculation (EGR) valve

retaining bolts
29 Catalytic converter to muffler and tailpipe
assembly retaining nuts 35 EGR valve electrical connector
2007.50 Focus 5/2007 G384849en

303-01B-92 Engine — 1.6L (Z6) 303-01B-92
INSTALLATION

36 Exhaust manifold to EGR valve tube 38 Exhaust manifold to EGR valve tube
gasket bracket retaining nut
37 Exhaust manifold to EGR valve tube 39 EGR valve tube retaining nuts
retaining nut
42
41 25 Nm
40
E52982

Item Description
40 Air conditioning (A/C) compressor
41 A/C compressor retaining bolts
42 A/C compressor electrical connector
All vehicles
105 Nm
Halfshaft RH (205-04 Front Drive Halfshafts,
Removal and Installation). E52954

2007.50 Focus 5/2007 G384849en

303-01B-93 Engine — 1.6L (Z6) 303-01B-93
INSTALLATION
5. Install the floor panel brace. 9. Attach the ground cables to the wheel
housing.
8 Nm
10 Nm
30 Nm
E47580
E0036570

10. Install the accessory drive belt.
7. Connect the engine wiring harness electrical
connector. For additional information, refer to:
Accessory Drive, Removal and
Installation).
With: 5-Speed Manual Transmission
(F35M-R) (308-00 Manual
TIE0036573 12. Fill and bleed the clutch system.
8. Install the central junction box (CJB) cover. System Bleeding (308-00 Manual
13. Connect the battery positive lead to the
battery positive cable terminal clamp.
12 Nm
TIE0036571
E0038245

2007.50 Focus 5/2007 G384849en

303-01B-94 Engine — 1.6L (Z6) 303-01B-94
INSTALLATION
15. Fill and bleed the cooling system. Vehicles with global closing
For additional information, refer to: Cooling 17. Initialize the window regulator motors.
(303-03 Engine Cooling - 1.6L (Z6),
16. Install the engine cover. Procedures).
Item 1 Transaxle 3. Install the transaxle right-hand retaining
bolts.
1. Attach the engine to the workshop hoist
using the special tool.
4. NOTE: Support the engine and transaxle

assembly with suitable wooden blocks.
2.
CAUTION: Ensure that the two guide
sleeves are installed.
Attach the transaxle to the engine.
2007.50 Focus 5/2007 G384849en

303-01B-95 Engine — 1.6L (Z6) 303-01B-95
INSTALLATION
Secure the engine and transaxle assembly Item 8 Engine front mount retaining nuts
on the workshop table using suitable
1. Position the workshop table under the
retaining straps.
vehicle and lower the vehicle until the engine
mounts can be installed.
303-122
ELE0001115
ELE0016321

6. Install the transaxle left-hand retaining bolts. 2. NOTE: Install new engine front mount
retaining nuts.
Install the engine front mount retaining nuts.
53 Nm
45 Nm
E52960
Item 2 Starter motor E52963
1. Install the starter motor cable shield.

3. Install the engine ground cable.
10 Nm
E51777
E52964
Item 9 Engine rear mount retaining bolt

NOTE: Remove the retaining strap.
2007.50 Focus 5/2007 G384849en

303-01B-96 Engine — 1.6L (Z6) 303-01B-96
INSTALLATION
Item 10 Clutch slave cylinder supply line 2. Attach the accelerator cable retaining bracket
to the intake manifold.
1.
Attach the clutch slave cylinder line to the
clutch slave cylinder.
E51947
Item 13 Brake booster vacuum line

1. Using the special tool, disconnect the brake
booster vacuum hose from the intake
manifold.
E53294

1. Connect the fuel supply line quick connector.
303-397

body. E51944

lever. Item 16 Gearshift cables
2. Attach the accelerator cable to the bracket.
1. Attach the gearshift cables to the bracket.
2
2. Attach the gearshift cable to the selector
mechanism.
1
1
E51949
2
E52918
2007.50 Focus 5/2007 G384849en

303-01B-97 Engine — 1.6L (Z6) 303-01B-97
INSTALLATION
Item 17 Coolant outlet connector to radiator Item 20 Radiator lower coolant hose
upper coolant hose 1. Using the special tool, connect the coolant
1. Using the special tool, connect the coolant hose to the thermostat housing.
hose from the coolant outlet connector.
303-397
303-397
E52928
E52899
Item 21 Coolant hose

Item 18 Cylinder head to heater core coolant 1. Using the special tool, connect the coolant
hose hose to the cylinder block.
hose the cylinder head.
303-397
E52896
303-397
E52898 Item 22 Power steering fluid supply hose
1. Using the special tool, connect the power
Item 19 Coolant outlet connector to coolant steering fluid supply hose to the power
expansion tank coolant hose steering pump.
1. Using the special tool, connect the to the
coolant outlet connector.
303-397
E52694
303-397
E52897
2007.50 Focus 5/2007 G384849en

303-01B-98 Engine — 1.6L (Z6) 303-01B-98
INSTALLATION
pressure line
NOTE: Install new washers to the power steering
pump pressure line union.
Item 26 Exhaust manifold retaining nuts

1. NOTE: Install new exhaust manifold retaining
nuts.
4 42 Nm 1
5
2
3
E52085
2007.50 Focus 5/2007 G384849en

Engine Cooling — 2.0L Duratec-HE (MI4)/1.8L
303-03A-1 Duratec-HE (MI4) 303-03A-1
.
SECTION 303-03A Engine Cooling — 2.0L Duratec-HE

CONTENTS PAGE
SPECIFICATIONS

Engine Cooling................................................................................................................... 303-03A-3
1.8L Duratec HE (MI4) engine............................................................................................ 303-03A-3

Engine Cooling................................................................................................................... 303-03A-4
Symptom Chart................................................................................................................... 303-03A-4
Component Tests................................................................................................................ 303-03A-8
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding.............................................. (24 122 0) 303-03A-12
Draining.............................................................................................................................. 303-03A-12
Filling and Bleeding ........................................................................................................... 303-03A-12

Thermostat Housing........................................................................................................... 303-03A-13
Coolant Pump................................................................................................. (24 404 0) 303-03A-16
Radiator.............................................................................................................................. 303-03A-18
Cooling Fan Motor and Shroud.......................................................................................... 303-03A-21
Coolant Outlet Connector................................................................................................... 303-03A-24
303-03A-2 Duratec-HE (MI4) 303-03A-2
SPECIFICATIONS
Item Specification
Motorcraft Super Plus Antifreeze WSS-M97B44–D
Antifreeze
Specific Gravity Approximate Remains Fluid to Solidifies at
(providing no other percentage of Anti-
additive is in coolant) Freeze (by volume)
1.061 at +15°C 50% –25°C (–13°F) –37°C (–35°F)
Cooling System Refill Capacities

Description Liters
Cooling system and heater - Vehicles with 1.8L engine 6.51
Cooling system and heater - Vehicles with 2.0L engine 6.31
Cooling System Pressure Specification

Description Pressure kpa (psi)
Radiator pressure test 138 (20)
Coolant expansion tank cap release pressure 130 to 150 (18 to 21)
Radiator support bracket retaining bolts 25 18 -
Thermostat housing retaining bolts 10 - 89
Coolant pump pulley retaining bolts 25 18 -
Coolant pump retaining bolts 10 - 89
Coolant outlet connector retaining bolts 10 - 89
Vacuum solenoid valve retaining bracket screws 6 - 53
Cooling fan motor retaining bolts 10 - 89
Radiator upper coolant hose retaining clamp 9 - 80
Block heater 55 - 41
2007.50 Focus 3/2007 G165299en

303-03A-3 Duratec-HE (MI4) 303-03A-3
Engine Cooling
Thermostat housing
E42991
Item Description
1 Thermostat housing
2 Bypass coolant hose
Due to the greater space requirements of the
alternator it was necessary to modify the thermostat
housing. The connection piece now has a different
angle and is longer overall.
The coolant hose from the thermostat housing to
the coolant distributor is routed closer to the
cylinder block and has different bending radii.
The previously used electrically heated thermostat
has been replaced with a thermostat with an
expansion element.
2007.50 Focus 3/2007 G183855en

303-03A-4 Duratec-HE (MI4) 303-03A-4
Engine Cooling
Pressure Tester, Cooling Mechanical Electrical
System
303-396 (24-001 A) • Coolant leak(s) • Fuse(s)
• Gasket(s) or seal(s) • Wiring harness
• Hose(s) or hose • Electrical
IA24001A joints connector(s)
• Coolant expansion • Engine coolant
tank cap and seal temperature (ECT)
Adaptor for 303-396 sensor
• Coolant expansion
303-396-09
tank • Cooling fan
• Radiator • Powertrain control
• Coolant pump module (PCM)
• Thermostat housing
E55030
• Heater core
General Equipment • Accessory drive belt
• Coolant outlet
Ford approved diagnostic tool
connector
Inspection and Verification 3. If an obvious cause for an observed or reported

1. Verify the customer concern. before proceeding to the next step
2. Visually inspect for obvious signs of mechanical 4. If the cause is not visually evident, verify the
or electrical damage. symptom and refer to the Symptom Chart.
Symptom Chart

• Loss of coolant • Hose(s) or hose joint(s). • INSPECT the hoses and hose
joints. INSTALL a new hose(s)
as necessary.
• Radiator. • INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03
Engine Cooling - 2.0L
Duratec-HE (MI4), Removal
and Installation).
2007.50 Focus 3/2007 G165301en

303-03A-5 Duratec-HE (MI4) 303-03A-5

• Coolant pump. • INSPECT the coolant pump for
leaks. CARRY OUT the Pres-
sure Test Component Test in
this section. INSTALL a new
coolant pump or coolant pump
gasket as necessary.
REFER to: Coolant Pump (303-
03 Engine Cooling - 2.0L
and Installation).
• Thermostat housing. • INSPECT the thermostat
housing for leaks. CARRY OUT
the Pressure Test Component
Test in this section. INSTALL
a new thermostat housing and
thermostat housing gasket as
necessary.
REFER to: Thermostat (303-03
and Installation).
• Coolant expansion tank cap or • CHECK the coolant expansion
seal(s). tank cap for tightness and
damage. INSTALL a new
coolant expansion cap as
necessary.
• Coolant expansion tank. • INSPECT the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary.
• Heater core. • CHECK the heater core for
leaks.
• Engine. • INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket. REFER
to:
Cylinder Head (303-01 Engine
- 2.0L Duratec-HE (MI4),
2007.50 Focus 3/2007 G165301en

303-03A-6 Duratec-HE (MI4) 303-03A-6

• The engine overheats (signs of • Cooling system does not hold • INSPECT the coolant expan-
coolant boiling) pressure. sion tank for damage. INSTALL
as necessary.
• INSPECT the coolant pump or
coolant pump gasket for
coolant pump or coolant pump
gasket as necessary.
and Installation).
• INSPECT the engine, cylinder
to:
• Air in cooling system. • BLEED the cooling system.
REFER to: Cooling System
Draining, Filling and Bleeding
Procedures).
• Coolant expansion tank cap or • CHECK the coolant expansion
seal(s). tank cap for tightness and
necessary.
• Coolant expansion tank. • INSPECT the coolant expan-
sion tank for damage. INSTALL
as necessary.
2007.50 Focus 3/2007 G165301en

303-03A-7 Duratec-HE (MI4) 303-03A-7

• Coolant level or condition. • CHECK the coolant level.
REFILL the cooling system as
necessary.
Procedures).
• CHECK the coolant condition.
If the coolant is in poor condi-
tion drain and refill with new
coolant.
Procedures).
• Coolant concentration. • REFER to: Specifications (303-
Duratec-HE (MI4), Specifica-
tions).
• Radiator grille. • INSPECT the radiator grille for
air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
• Coolant pump. • CARRY OUT the Pressure Test
INSPECT the coolant pump for
leaks. INSTALL a new coolant
pump or coolant pump gasket
as necessary.
and Installation).
• Thermostat. • CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat housing and thermostat
housing gasket as necessary.
and Installation).
2007.50 Focus 3/2007 G165301en

303-03A-8 Duratec-HE (MI4) 303-03A-8

• Accessory drive belt. • CHECK the condition of the
accessory drive belt. REFER
to: (303-05 Accessory Drive)
Accessory Drive (Diagnosis
and Testing),
Accessory Drive (Diagnosis
and Testing).
• Cooling fan. • CHECK the operation of the
cooling fan. REFER to the Ford
approved diagnostic tool.
to:
• The engine does not reach • Thermostat. • CARRY OUT the Thermostat
normal operating temperature. Test Component Test in this
mostat housing and thermostat
housing gasket as necessary.
and Installation).
Component Tests 3. Install the special tools 303-396 and 303-396-09

to the coolant expansion tank.
4. Pressurize the cooling system to the coolant
Pressure Test expansion tank cap release pressure.
WARNING: When releasing the cooling REFER to: Specifications (303-03 Engine
system pressure, cover the coolant Cooling - 2.0L Duratec-HE (MI4)/2.3L
expansion tank cap with a thick cloth to Duratec-HE (MI4), Specifications).
prevent the possibility of coolant scalding. 5. Observe the cooling system pressure tester
Failure to follow this instruction may result gauge reading for approximately two minutes.
in personal injury. The pressure should not drop during this time.
If the cooling system holds pressure, proceed
NOTE: If the coolant expansion tank cap is rotated
to Step 7. If the cooling system does not hold
counterclockwise by ½ a full turn, the pressurized
pressure, check it thoroughly for coolant leaks.
coolant will be vented to the underside of the
coolant expansion tank cap.
1. Slowly remove the coolant expansion tank cap
to release the cooling system pressure.
2. Install the coolant expansion tank cap.
2007.50 Focus 3/2007 G165301en

303-03A-9 Duratec-HE (MI4) 303-03A-9
6. Check the engine for coolant leaks. Drain the 5. If the pressure test gauge readings are not
cooling system, repair any coolant leaks found within the acceptable gauge reading limits,
and fill and bleed the cooling system as INSTALL a new coolant expansion tank cap.
necessary.
REFER to: Cooling System Draining, Filling and
Bleeding (303-03 Engine Cooling - 2.0L
Thermostat Test
1. Connect the Ford approved diagnostic tool to
the data link connector (DLC).
7. Recheck the cooling system by repeating Steps
2. Using the Ford approved diagnostic tool
3 and 4 at least twice.
datalogger function, SELECT the following
sensors (as applicable to the application):
Radiator Leak Test, Removed From Vehicle • IAT - intake air temperature (IAT) sensor
• ECT - engine coolant temperature (ECT) sensor
CAUTION: Radiator internal pressure must • CHT - cylinder head temperature (CHT) sensor
not exceed 130 kpa (20 psi) or damage may
• LOAD - engine load
result.
• VSS - vehicle speed sensor (VSS)
Clean the radiator thoroughly before leak testing
• RPM - engine speed
it, to prevent contamination of the water in the test
tank. Leak test the radiator in clean water with 138 • DSRPM - desired engine speed
kpa (20 psi) air pressure. Check it thoroughly for The IAT sensor output is useful if the engine being
air leaks. INSTALL a new radiator if necessary. tested is cold or after an over-night cold soak. The
REFER to: Radiator (303-03 Engine Cooling - 2.0L ECT sensor or CHT sensor and the IAT sensor
Duratec-HE (MI4)/2.3L Duratec-HE (MI4), should either indicate the same value or be within
Removal and Installation). 1 to 2 degrees Celsius of each other.
The ECT sensor output is important to display as
it indicates the engine warm-up and opening
Coolant Expansion Tank Cap Pressure Test temperature for the thermostat. It will initially
indicate a slightly higher reading just before the
WARNING: When releasing the cooling thermostat opens and then drops back before
system pressure, cover the expansion tank settling to a near flat line output (see graphic
cap with a thick cloth to prevent the below).
possibility of coolant scalding, Failure to
personal injury.
1. Remove the coolant expansion tank cap.
2. Use water to clean the area of the rubber seal
and pressure relief valve. Install the pressure
tester and adapter and immerse the coolant
expansion tank cap in water .
NOTE: If the plunger of the pump is depressed too
quickly, an erroneous pressure reading will result.
3. Slowly depress the plunger of the pressure test A B
E62640
pump until the pressure gauge reading stops
increasing, and note the highest pressure
Item Description
reading obtained.
4. Release pressure by turning the pressure relief A Thermostat opens
screw counterclockwise. Tighten the pressure B Thermostat settles into a cyclic open and
relief screw and repeat step 3 at least twice to closure pattern
make sure the pressure test reading is
repeatable and within acceptable gauge reading CAUTION: If the ECT sensor output
limits of the coolant expansion tank cap. reaches the 120ºC default line under
normal cooling system pressure, internal
2007.50 Focus 3/2007 G165301en

303-03A-10 Duratec-HE (MI4) 303-03A-10
damage may be caused to the engine and 3.
WARNING: Make sure that the Ford
a diagnostic trouble code (DTC) will be set
approved diagnostic tool is placed in the
in the PCM. The test should be stopped
vehicle so that it does not interfere with the
and the cause located and corrected. If the
safe operation of the vehicle. Do not place
cooling system does not pressurize, the
the Ford approved diagnostic tool in the
coolant will boil at 100ºC which may also
deployment path of any air bag. Failure to
damage the engine. CARRY OUT the
Coolant Expansion Tank Cap Pressure Test
personal injury.
NOTE: The road test is best carried out with the
If the Ford approved diagnostic tool only allows the
aid of another technician in the vehicle to enable
ECT sensor to be displayed in volts, refer to the
the vehicle to be driven safely while the sensor
following table for corresponding Celsius values:
outputs are monitored within datalogger. If there
is only one technician available, the Ford approved
Volts ºCelsius
diagnostic tool can be set up (using the
1.33 60 record/capture mode camera icon) before leaving
the workshop to record a 16 km (10 mile) test.
1.02 70
NOTE: The results from the test are more
0.78 80 conclusive if the engine is cold when the test is
0.60 90 started.
0.46 100 Carry out a road test.

REFER to: Road/Roller Testing (100-00 General
0.35 110
0.27 120 4. Drive the vehicle at a constant throttle opening
and set speed until the ECT value settles into
The CHT sensor output is useful to examine the a shallow rise and fall signal, close to a straight
cylinder head temperature rise during the warm-up line. This indicates that the thermostat is
cycle and later during the normal light throttle cruise functioning correctly.
test. This sensor output may vary between vehicles
with manual transmission and vehicles with NOTE: Some thermostats indicate the
automatic transmission and should be used for temperature(s) in Celsius and Fahrenheit.
reference only. The graphic below shows the location and an
The LOAD display is used for reference as it is example of the opening temperature (88ºC) and
necessary to maintain a stable load line during the fully open temperature (102ºC) of a thermostat.
test. It is necessary to carry out the test under
normal light throttle cruise driving conditions and
average loads, typically 40% to 70% of the load
value.
The VSS output is used for reference but can help
to identify misfires and sensors which fail during
the warm-up cycle.
The RPM display indicates the engine speed and
can be compared with the DSRPM.
The DSRPM is the desired or calculated idle speed
which the PCM commands the engine to reach. If E63922
the thermostat opens too early (before the correct
opening temperature has been reached), the The graphic below shows an alternative method
engine will not reach this value. used to show the opening temperature (88ºC) and
fully open temperature (112ºC) of a thermostat.
When using the Ford approved diagnostic tool in
datalogger mode, the signals recorded should
remain within the DEFAULT values set by the Ford
approved diagnostic tool.
2007.50 Focus 3/2007 G165301en

303-03A-11 Duratec-HE (MI4) 303-03A-11
B
E63879
Item Description
A Opening temperature
B Fully open temperature
NOTE: Generally, most thermostats maintain a
coolant temperature between 88ºC (190ºF) and
92ºC (198ºF) although dual stage electric
thermostats may increase the coolant temperature
up to 100ºC (212ºF) under light engine load
conditions.
The engine should start cleanly and the ECT value
will rise quite quickly with smooth progression. If
the ECT signal appears unstable or erratic, the
ECT sensor, electrical connector and wiring
harness to the PCM need to be visually inspected
for damage, chafing or water ingress.
The temperature should rise to approximately 90ºC
for a thermostat that has an 88ºC value. The signal
value will then fall as cooler coolant enters the
engine.
If the ECT value fails to maintain a constant value
and falls back to lower figures, typically between
60ºC (140ºF) and 70ºC (150ºF), the thermostat
and its sealing function within the thermostat
housing must be checked.
5. INSTALL a new thermostat.
REFER to: Thermostat (303-03 Engine Cooling
- 2.0L Duratec-HE (MI4)/2.3L Duratec-HE
(MI4), Removal and Installation).
6. Carry out another road test from step 1 using
the same criteria to confirm that the concern
has been rectified.
7. Using the Ford approved diagnostic tool, clear
the PCM keep alive memory (KAM) or
electrically erasable programmable read only
memory (EEPROM) so that new drive values
can be learnt.
2007.50 Focus 3/2007 G165301en

303-03A-12 Duratec-HE (MI4) 303-03A-12
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding(24 122 0)

Draining NOTE: If the cooling system has been drained from
any coolant system hose(s) other than the radiator
1.
WARNING: When releasing the cooling drain plug. Fill the coolant expansion tank to the
system pressure, cover the coolant top of the coolant expansion tank filler neck.
expansion tank cap with a thick cloth to
3. Install the coolant expansion tank cap.
prevent the possibility of scalding. Failure
to follow this instruction may result in 4. Start the engine, maintain the engine speed
personal injury. at 2500 revolutions per minute (RPM) for
eight minutes or until the engine reaches
NOTE: The cooling system pressure will be vented
normal operating temperature.
to the underside of the coolant expansion tank.
5. Maintain the engine speed at 2500 RPM for
Release the cooling system pressure by
three minutes after the engine has reached
slowly turning the coolant expansion tank
normal operating temperature.
cap between 2 and 3 turns.
6. Increase the engine speed to 4000 RPM for
2. Remove the coolant expansion tank cap.
five seconds.
7. Decrease the engine speed to 2500 RPM for
three minutes.
and Lifting].
8. Switch the engine off.
4. NOTE: To avoid the removal of an excessive
volume of coolant, the cooling system 9. Check the cooling system for leaks.
should only be drained from the radiator 10. Allow the engine to cool.
drain plug.
11. Fill the coolant expansion tank to the MAX
Drain the cooling system. mark.
• Allow the coolant to drain into a suitable
container.
E39447
5. Install the radiator drain plug.

Filling and Bleeding

NOTE: Make sure the interior heater temperature
control switch is in the hot position.
1. Switch the interior heater blower off.
2. Fill the coolant expansion tank 15 mm over
the MAX mark.
2007.50 Focus 3/2007 G293545en

303-03A-13 Duratec-HE (MI4) 303-03A-13
Thermostat Housing
Remover/Installer, Coolant For additional information, refer to Cooling
Hose Clamp System Draining, Filling and Bleeding - in
303-397 this section.
2. Remove the accessory drive belt tensioner.
24003 For additional information, refer to
Section 303-05A [Accessory Drive] /
303-05B [Accessory Drive -- 2.5L Duratec-ST
(VI5)].
table(s).
2007.50 Focus 3/2007 G295583en

303-03A-14 Duratec-HE (MI4) 303-03A-14
10 Nm
E39338

1 Thermostat housing to coolant expansion
tank and heater core return coolant hose
See Removal Detail
2 Radiator lower to thermostat housing
coolant hose
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G295583en

303-03A-15 Duratec-HE (MI4) 303-03A-15
Item 1 Thermostat housing to coolant expansion
tank and heater core return coolant hose
thermostat housing to coolant expansion
tank and heater core return coolant hose.
E39414
Item 2 Radiator lower to thermostat housing

coolant hose
radiator lower to thermostat housing coolant
hose.
E40433
2007.50 Focus 3/2007 G295583en

303-03A-16 Duratec-HE (MI4) 303-03A-16
Coolant Pump(24 404 0)

3. Loosen the coolant pump pulley retaining
Materials
bolts.
Name Specification
Merpol grease ESE-M99M144-B
For additional information, refer to Cooling
System Draining, Filling and Bleeding - in
this section.
25 Nm
E39141
4. Remove the accessory drive belt. For

(VI5)].
E39140
table(s).
2007.50 Focus 3/2007 G295584en

303-03A-17 Duratec-HE (MI4) 303-03A-17
2
1
10 Nm
E39129
Item Description
1 Coolant pump pulley
2 Coolant pump
2007.50 Focus 3/2007 G295584en

303-03A-18 Duratec-HE (MI4) 303-03A-18
Radiator
Remover/Installer, Coolant For additional information, refer to: Cooling
Hose Clamp System Draining, Filling and Bleeding
303-397 (303-03 Engine Cooling - 2.0L Duratec-HE
Procedures).
24003
3. Remove the cooling fan motor and shroud.
Fan Motor and Shroud (303-03 Engine
1. Secure the air conditioning (A/C) condenser
Cooling - 2.0L Duratec-HE (MI4)/1.8L
to the front panel (if equipped).
Duratec-HE (MI4), Removal and
Installation).
table(s).
2007.50 Focus 3/2007 G295585en

303-03A-19 Duratec-HE (MI4) 303-03A-19
10
10
1 9 Nm
9 6
E39148
1 Radiator upper coolant hose retaining 6 Radiator lower coolant hose

clamp 7 Radiator support bracket
2 Radiator upper coolant hose See Removal Detail
3 Radiator degas coolant hose retaining
clamp 8 Radiator
4 Radiator degas coolant hose 9 Radiator lower insulators

5 Radiator lower coolant hose retaining
clamp 10 Radiator upper insulators
See Removal Detail
2007.50 Focus 3/2007 G295585en

303-03A-20 Duratec-HE (MI4) 303-03A-20
Removal Details
Item 3 Radiator degas coolant hose retaining Item 5 Radiator lower coolant hose retaining
clamp clamp
1. Using the special tool, disconnect the 1. Using the special tool, disconnect the
radiator degas coolant hose retaining clamp. radiator lower coolant hose.
E40470 E40472
Item 7 Radiator support bracket

1. With the aid of another technician, support
the radiator.
Item 8 Radiator
damage the cooling fins of the coolant
radiator and the A/C condenser when
removing the radiator. Failure to follow this
instruction could result in coolant leaks or
engine overheat.
Item 9 Radiator lower insulators
CAUTION: Inspect the radiator lower
insulators for signs of cracking, splitting
or damage. Install new radiator lower
insulators as necessary. Failure to follow
this instruction may result in damage to
the radiator.
Item 7 Radiator support bracket

1. With the aid of another technician, install the
radiator support bracket.
• Install the 30mm M8 bolts leaving 15mm of
thread exposed.
2007.50 Focus 3/2007 G295585en

303-03A-21 Duratec-HE (MI4) 303-03A-21
Cooling Fan Motor and Shroud

WARNING: The cooling fan motor is under 1. Disconnect the battery ground cable.
the control of the powertrain control For additional information, refer to: Battery
module (PCM) and the cooling fan can Disconnect and Connect (414-01 Battery,
become active after the ignition key has Mounting and Cables, General Procedures).
been removed. Before working on or near
the cooling fan, disconnect the battery 2. Raise and support the vehicle.
ground cable. Failure to follow these For additional information, refer to: Lifting.
table(s).
E39803
Item Description
1 Engine under shield
See Removal Detail
2 Radiator splash shield
2007.50 Focus 3/2007 G295586en

303-03A-22 Duratec-HE (MI4) 303-03A-22
25 Nm 4
4 25 Nm
3 25 Nm
25 Nm 3
E39145
3 Radiator support bracket front retaining 6 Cooling fan motor electrical connector
bolts 7 Cooling fan motor and shroud
4 Radiator support bracket rear retaining
bolts 5. Initialize the door window motors.
5 Air conditioning (A/C) condenser For additional information, refer to: Door
See Removal Detail Window Motor Initialization.
Removal Details
Item 1 Engine under shield • Rotate the locking tang counterclockwise.
1. Release the locking tangs.
E40327
2007.50 Focus 3/2007 G295586en

303-03A-23 Duratec-HE (MI4) 303-03A-23
Item 3 Radiator support bracket front retaining 2. Slide the A/C condenser upwards
bolts
1. Install temporary radiator support bracket 2
front retaining bolts.
• Remove the radiator support bracket front
retaining bolts.
• Install 30mm M8 bolts leaving 15mm of 1
thread exposed.
15 mm E39311
Item 7 Cooling fan motor and shroud

1. Press in the cooling fan motor and shroud
retaining clips. Lift up the cooling fan shroud
until clear of the retaining brackets. Remove
the cooling fan motor and shroud.
E47481
Item 5 Air conditioning (A/C) condenser

1. Detach the A/C condenser from the radiator
(if equipped).
1. Press in the radiator A/C condenser retaining
clip.
E39048
Item 3 Radiator support bracket front retaining
bolts
1. Install the radiator support bracket front
retaining bolts.
• Remove the temporary radiator support
bracket 30mm M8 retaining bolts.
• Install the radiator support bracket front
retaining bolts.
2007.50 Focus 3/2007 G295586en

303-03A-24 Duratec-HE (MI4) 303-03A-24
Coolant Outlet Connector

Special Tool(s)
3. Disconnect the engine coolant temperature
Remover/Installer, Coolant (ECT) sensor electrical connector and the
Hose Clamp vacuum solenoid valve electrical connectors.
303-397
24003

For additional information, refer to Cooling
System Draining, Filling and Bleeding - in
this section.
E39143

table(s).
E39140
2007.50 Focus 3/2007 G307342en

303-03A-25 Duratec-HE (MI4) 303-03A-25
6 Nm
6
3
5 10 Nm
E39144
1 Vacuum solenoid valve retaining bracket 4 Radiator lower to coolant outlet connector
coolant hose
2 Coolant expansion tank to coolant outlet See Removal Detail
connector coolant hose
See Removal Detail 5 Thermostat housing to coolant outlet
connector coolant hose
3 Coolant outlet connector to heater core
coolant hose 6 Coolant outlet connector
See Removal Detail
2007.50 Focus 3/2007 G307342en

303-03A-26 Duratec-HE (MI4) 303-03A-26
Removal Details
Item 2 Coolant expansion tank to coolant outlet Item 4 Radiator lower to coolant outlet
connector coolant hose connector coolant hose
coolant expansion tank to coolant outlet radiator lower to coolant outlet connector
connector coolant hose. coolant hose.
E39415 E40685
Item 3 Coolant outlet connector to heater core

coolant hose
coolant outlet connector to heater core
coolant hose.
E40684
2007.50 Focus 3/2007 G307342en

303-03B-1 Engine Cooling — 1.6L (Z6) 303-03B-1
.
SECTION 303-03B Engine Cooling — 1.6L (Z6)

CONTENTS PAGE
SPECIFICATIONS

Engine Cooling................................................................................................................... 303-03B-3
Coolant Flow Diagram........................................................................................................ 303-03B-6

Engine Cooling................................................................................................................... 303-03B-7
Inspection and Verification.................................................................................................. 303-03B-7
Symptom Chart................................................................................................................... 303-03B-7
Component Tests................................................................................................................ 303-03B-9
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding.............................................. (24 122 0) 303-03B-11
Draining.............................................................................................................................. 303-03B-11
Filling and Bleeding............................................................................................................ 303-03B-11

Thermostat..................................................................................................... (24 454 0) 303-03B-12
Coolant Pump................................................................................................. (24 404 0) 303-03B-14
Radiator.......................................................................................................... (24 254 0) 303-03B-16
Cooling Fan Motor and Shroud...................................................................... (24 222 0) 303-03B-20
Coolant Outlet Connector................................................................................................... 303-03B-22
SPECIFICATIONS
Description Specification
Motorcraft Super Plus Anti-freeze 3M81-97B44-AA
Anti-freeze
Specific Gravity Approximate Remains fluid to Solidifies at
(providing no other percentage of anti-
additive is in coolant) freeze (by volume)
1.061 at +15°C 50% -25°C (-13°F) -37°C (-35°F)
Cooling System Refill Capacities

Description Liters
Cooling system and heater 6.5
Cooling system pressure specification

Description Pressure Kpa (Psi)
Radiator pressure test 138 (20)
Coolant expansion tank cap pressure release 135 to 155 (19.6 to 22.5)
Item Nm lb-ft lb-in
Coolant pump retaining bolts 22 16 -
Thermostat cover retaining bolts 22 16 -
Radiator support bracket front retaining bolts 25 18 -
Radiator support bracket rear retaining bolts 25 18 -
2007.50 Focus 4/2007 G384868en

Engine Cooling
Item Description
1 Coolant outlet connector
2007.50 Focus 4/2007 G385277en

Item Description
2 Coolant pump
2007.50 Focus 4/2007 G385277en

Item Description
4 Radiator
5 Cooling fan motor and shroud
2007.50 Focus 4/2007 G385277en

Coolant Flow Diagram
8
6
5
2 4
Item Description
1 Coolant reservoir
2 Radiator
3 Thermostat
4 Coolant pump
5 Engine block
6 Cylinder head
7 Heater
8 Idle air control (IAC) valve
2007.50 Focus 4/2007 G385277en

Engine Cooling
Pressure Tester, Cooling Mechanical Electrical
System
303-396 (24-001 A) – Coolant leaks – Fuse(s)
– Gaskets/seals – Wiring harness
– Core plug(s) – Electrical
IA24001A
– Hose(s)/hose joints connector(s)
– Coolant expansion – Engine coolant
tank pressure cap temperature (ECT)
Adaptor for 303-396 sensor
and seal(s)
303-396-05 (24-001A-05)
– Coolant expansion – Cooling fan motor
tank – Auxiliary Heater
– Radiator – Powertrain control
24001A05 – Water pump module (PCM)
– Thermostat housing
General Equipment – Heater core
– Heater control valve
Worldwide Diagnostic System (WDS) (418-F224)
– Accessory drive belt
– Cooling Fan
2. Visually inspect for obvious signs of mechanical before proceeding to the next step
Symptom Chart
Symptom Chart
• Loss of coolant • Coolant expansion tank pres- • CHECK the coolant expansion
sure cap or seal(s). tank pressure cap for tightness
and damage. INSTALL a new
necessary.
• Cooling system. • INSPECT the cooling system
for leaks. CARRY OUT the
Pressure Test Component Test
in this section. INSTALL new
component(s) as necessary.
REFER to: Cylinder Head (303-
01 Engine - 1.6L (Z6), In-
vehicle Repair).
2007.50 Focus 4/2007 G384872en


• The engine overheats (signs of • Air in cooling system. • BLEED the cooling system.
coolant boiling) REFER to: Cooling System
1.6L (Z6), General Proced-
ures).
• Cooling system does not hold • CHECK the coolant expansion
pressure. tank pressure cap for tightness
and damage. INSTALL a new
necessary.
• INSPECT the engine, cylinder
01 Engine - 1.6L (Z6), In-
vehicle Repair).
• Coolant level/condition. • CHECK the coolant level.
REFILL the cooling system as
necessary.
ures).
• CHECK the coolant condition
and concentration. If the
coolant is contaminated or the
concentration is below
specifications, drain and refill
with new coolant.
ures).
• Radiator grille. • INSPECT the radiator grille for
air restrictions/damage.
as necessary.
• Cooling fan. • CHECK the operation of the
cooling fan. REFER to WDS.
mostat as necessary.
Engine Cooling - 1.6L (Z6),
2007.50 Focus 4/2007 G384872en


• Coolant pump. • REMOVE AND INSPECT the
coolant pump/impeller.
INSTALL a new coolant
pump/coolant pump gasket as
necessary.
(Z6), Removal and Installa-
tion).
01 Engine - 1.6L (Z6), In-
vehicle Repair).
• The engine does not reach • ECT sensor. • CHECK the engine coolant
normal operating temperature. temperature. REFER to WDS.
• Temperature gauge. • CHECK the instrument cluster
engine temperature gauge.
REFER to: Instrument Cluster
(413-01 Instrument Cluster,
mostat as necessary.
Engine Cooling - 1.6L (Z6),
Component Tests 3. Pressurize the cooling system to the coolant

expansion tank cap release pressure.
REFER to: Specifications (303-03 Engine
Pressure Test Cooling - 1.6L (Z6), Specifications).
WARNING: When releasing the system 4. Observe the cooling system pressure tester
pressure, cover the expansion tank cap gauge reading for approximately two minutes.
with a thick cloth to prevent the possibility The pressure should not drop during this time.
of coolant scalding, Failure to follow this If the system holds pressure, Install a new
instruction may result in personal injury. coolant expansion tank pressure cap. If the
system does not hold pressure, check the
NOTE: If the coolant expansion tank pressure cap cooling system thoroughly for coolant leaks.
is rotated counterclockwise by between 2 and 3
5. Check the system by repeating steps 3 and 4
full turns, the pressurized coolant will be vented to
at least twice.
the underside of the coolant expansion tank.
6. If a coolant leak cannot be found, check the
1. Remove the coolant expansion tank pressure engine for cylinder leakage.
cap.
REFER to: Cylinder Head (303-01 Engine - 1.6L
2. Install the special tools 303-396 and 303-396-05
(Z6), In-vehicle Repair).
to the coolant expansion tank.
2007.50 Focus 4/2007 G384872en

Drain the cooling system, repair any coolant
leaks found and fill and bleed the cooling system
as necessary.
REFER to: Cooling System Draining, Filling and
Bleeding (303-03 Engine Cooling - 1.6L (Z6),
Thermostat Test
1. Remove the thermostat.

- 1.6L (Z6), Removal and Installation).
2. Immerse the thermostat in a water and
antifreeze mixture. Heat the fluid mixture to
above 88 ºC (190 ºF). At this temperature the
thermostat should begin to open. If it does not
begin to open, install a new thermostat.
- 1.6L (Z6), Removal and Installation).
2007.50 Focus 4/2007 G384872en

GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding(24 122 0)

Draining 2. Fill the cooling system to the MAX mark of
the coolant expansion tank.
1.
WARNING: When releasing the cooling
3. Install the coolant expansion tank cap
system pressure, cover the coolant
expansion tank cap with a thick cloth to CAUTIONS:
prevent the possibility of scalding. Failure
to follow this instruction may result in Do not allow the engine coolant
personal injury. temperature indicator to rise above the
normal working parameters of the engine.
NOTE: The cooling system pressure will be vented If the engine temperature rises above the
to the underside of the coolant expansion tank. upper limit of the normal working
Release the cooling system pressure by temperature, switch off the engine and
slowly turning the coolant expansion tank allow to cool.
cap between 2 and 3 turns. Do not allow the coolant level in the
2. Remove the coolant expansion tank cap. coolant expansion tank to fall below the
minimum mark.
4. Start the engine.
(100-02 Jacking and Lifting, Description 5. Allow the engine to idle until the engine
and Operation). coolant temperature indicator is mid scale.
4. NOTE: To avoid the removal of an excessive 6. Raise the engine speed to 2500 revolutions
volume of coolant, the cooling system per minute (RPM) and maintain for 5 minutes.
should only be drained from the radiator 7. Increase the engine speed to 3000 RPM and
drain plug. maintain for 5 seconds.
Drain the cooling system. 8. Decrease the engine speed to idle.
• Allow the coolant to drain into a suitable 9. Increase the engine speed to 3000 RPM and
container. maintain for 5 seconds.
10. Decrease the engine speed to idle.
11. Increase the engine speed to 3000 RPM and
maintain for 5 seconds.
12. Decrease the engine speed to idle.
13. Switch the engine off.
14. Check the cooling system for leaks.
15. Allow the engine to cool.
16. Top up the coolant expansion tank to the
MAX mark.
5. Install the radiator drain plug.

Filling and Bleeding

NOTE: Make sure the interior heater temperature
control switch is in the hot position.
1. Switch the interior heater blower off.
2007.50 Focus 4/2007 G384873en

Thermostat(24 454 0)
4. Detach the air conditioning (A/C) compressor
and secure to one side.
(303-03 Engine Cooling - 1.6L (Z6), General 25 Nm
Procedures).
table(s).
1 22 Nm
2007.50 Focus 4/2007 G384875en

1 Thermostat cover retaining bolts 8. Vehicles with global closing, initialize the
door window motors.
2 Thermostat cover
See Removal Detail
Window Motor Initialization.
3 Thermostat
4 Thermostat O-ring seal
Removal Details
Item 2 Thermostat cover
1. Detach the thermostat cover and position to
one side.
Item 3 Thermostat
1. Align the thermostat with the engine indent.
2007.50 Focus 4/2007 G384875en

Coolant Pump(24 404 0)

(303-03 Engine Cooling - 1.6L (Z6), General
Procedures).
5. Remove the generator.

Generator - 1.6L (Z6) (414-02 Generator and
Regulator, Removal and Installation).
table(s).
2007.50 Focus 4/2007 G384876en

Item Description
1 Coolant pump retaining bolts
2 Coolant pump
3 Coolant pump gasket
Procedures).
2007.50 Focus 4/2007 G384876en

Radiator(24 254 0)
Special Tool(s)
3. Secure the air conditioning (A/C) condenser
Remover/Installer, Cooling to the front panel (if equipped).
Hose Clamp
303-397 (24-003) 4. Drain the cooling system.
24003
Procedures).
5. Remove the cooling fan motor and shroud.
For additional information, refer to: Battery Fan Motor and Shroud (303-03 Engine
Disconnect and Connect (414-01 Battery, Cooling - 1.6L (Z6), Removal and
Mounting and Cables, General Procedures). Installation).
2. Remove the air deflector. 6. Remove the components in the order
table(s).
2007.50 Focus 4/2007 G384877en

6
11
11
4
1
3
5
8
2
12
7 7
10 12
1 Radiator lower coolant hose retaining 7 Temporary radiator support bracket front
clamp retaining bolts
2 Radiator lower coolant hose 8 Radiator support bracket

See Removal Detail
3 Radiator upper coolant hose retaining
clamp 9 A/C condenser (If equipped)
4 Radiator upper coolant hose 10 Radiator

See Removal Detail
5 Coolant expansion tank to radiator coolant See Installation Detail
hose retaining clamp
See Removal Detail 11 Radiator upper insulators
6 Coolant expansion tank to radiator coolant 12 Radiator lower insulators

hose See Installation Detail
Removal Details
2007.50 Focus 4/2007 G384877en

Item 1 Radiator lower coolant hose retaining Item 5 Coolant expansion tank to radiator
clamp coolant hose retaining clamp
radiator lower coolant hose. radiator degas coolant hose
Item 3 Radiator upper coolant hose retaining Item 8 Radiator support bracket
clamp 1. With the aid of another technician, support
1. Using the special tool, disconnect the the radiator.
radiator upper coolant hose.
Item 9 A/C condenser (If equipped)
1. Detach the radiator from the A/C condenser
(If equipped).
1. Press in the radiator A/C condenser retaining
tang.
2. Slide the radiator downwards.
E39311
Item 10 Radiator
damage the cooling fins of the coolant
radiator and the A/C condenser when
removing the coolant radiator. Failure to
follow this instruction could result in
coolant leaks or engine overheat.
2007.50 Focus 4/2007 G384877en

303-03B-19 Engine Cooling — 1.6L (Z6) 303-03BB-19
Item 12 Radiator lower insulators
CAUTION: Inspect the radiator lower
insulators for signs of cracking, splitting
or damage. Install new radiator lower
insulators as necessary. Failure to follow
this instruction may result in damage to
the radiator.
Item 10 Radiator
1. With the aid of another technician, support
the radiator.
Item 7 Temporary radiator support bracket front

retaining bolts
1. Install the radiator support bracket temporary
front 30mm M8 retaining bolts leaving 15mm
of thread exposed.
2007.50 Focus 4/2007 G384877en

Cooling Fan Motor and Shroud(24 222 0)

Mounting and Cables, General Procedures). 4. Remove the radiator splash shield.
2. Disconnect the cooling fan motor electrical
connector.
TIE40814

table(s).
25 Nm 2
2 25 Nm
25 Nm 1
1 25 Nm
2007.50 Focus 4/2007 G384878en

1 Radiator support bracket front retaining 7. Vehicles with global closing, initialize the
bolts door window motors.
See Removal Detail For additional information, refer to: Door
See Installation Detail Window Motor Initialization (501-11 Glass,
2 Radiator support bracket rear retaining
Procedures).
bolts
3 Cooling fan motor and shroud
See Removal Detail
Removal Details
bolts Item 3 Cooling fan motor and shroud
1. Install temporary radiator support bracket 1. Press in the cooling fan motor and shroud
front retaining bolts. retaining clips. Lift up the cooling fan shroud
until clear of the retaining bracket. Remove
• Remove the radiator support bracket front the cooling fan motor and shroud.
retaining bolts.
• Install 30mm M8 bolts leaving 15mm of
thread exposed.
15 mm
E39048
E47481
bolts
1. Install the radiator support bracket front
retaining bolts.
• Remove the temporary radiator support
bracket 30mm M8 retaining bolts.
• Install the radiator support bracket front
retaining bolts.
2007.50 Focus 4/2007 G384878en

Coolant Outlet Connector

Special Tool(s)
Hose Clamp For additional information, refer to: Air
303-397 (24-003) Cleaner - 1.6L (Z6) (303-12 Intake Air
Installation).
1. Disconnect the battery ground cable. System Draining, Filling and Bleeding
Procedures).
Mounting and Cables, General Procedures). 5. Lower the vehicle.
2. Remove the engine upper cover. 6. Remove the components in the order
table(s).
2007.50 Focus 4/2007 G384879en

4 20 Nm 3
E53004
1 Cylinder head temperature (CHT) sensor 4 Fuel charging wiring harness ground
electrical connector electrical connector
2 Coolant expansion tank coolant degas 5 Engine wiring harness and engine
hose retaining clip emission pipe support bracket
See Removal Detail
3 Engine wiring harness and engine
emission pipe support bracket retaining
bolts
2007.50 Focus 4/2007 G384879en

14 13 11
10
12
20 Nm 8
7 6
E53003
6 Radiator lower coolant hose to coolant 11 Coolant expansion tank to coolant outlet
outlet connector retaining clamp connector coolant hose retaining clamp
See Installation Detail 12 Coolant expansion tank to coolant outlet
7 Radiator lower coolant hose to coolant connector coolant hose
outlet connector 13 Coolant outlet connector
8 Coolant outlet connector retaining bolts 14 Coolant outlet connector O-ring seal
9 Throttle body to coolant outlet connector
coolant hose retaining clamp
8. Vehicles with global closing, initialize the
10 Throttle body to coolant outlet connector door window motors.
coolant hose
Removal Details
Item 5 Engine wiring harness and engine
emission pipe support bracket
1. Position the engine wiring harness and
engine emission pipe support bracket to one
side to gain access to the coolant outlet
connector.
2007.50 Focus 4/2007 G384879en

Item 3 Engine wiring harness and engine
emission pipe support bracket retaining bolts
1. Position the engine harness ground
connector under the upper engine wiring
harness and engine emission pipe support
bracket retaining bolt.
Item 6 Radiator lower coolant hose to coolant

outlet connector retaining clamp
1. Using the special tool, detach the radiator
lower coolant hose from the coolant outlet
connector.
303-397
2007.50 Focus 4/2007 G384879en

Fuel Charging and Controls — 2.0L
303-04A-1 Duratec-HE (MI4)/1.8L Duratec-HE (MI4) 303-04A-1
.
SECTION 303-04A Fuel Charging and Controls — 2.0L

CONTENTS PAGE
SPECIFICATIONS

Fuel Charging and Controls................................................................................................ 303-04A-3

Fuel Charging and Controls................................................................................................ 303-04A-5
Principles of Operation....................................................................................................... 303-04A-5
Symptom Chart................................................................................................................... 303-04A-9

Throttle Body...................................................................................................................... 303-04A-25
Fuel Injectors.................................................................................................. (23 455 0) 303-04A-28
Fuel Charging Wiring Harness........................................................................................... 303-04A-29
Fuel Injection Supply Manifold............................................................................................ 303-04A-32
SPECIFICATIONS
Throttle body retaining bolts 10 — 89
Fuel injection supply manifold retaining bolts 25 18 —
2007.50 Focus 3/2007 G37518en

4
E48342
Item Description Fuel Injection Supply Manifold

1 Fuel injection supply manifold The fuel injection supply manifold is retained to the
2 Fuel injector retaining clip engine by two bolts. The fuel injection supply
manifold has pressed steel cups to house the fuel
3 Fuel injector O-ring seals injectors.
4 Fuel injector The fuel injectors are fitted directly into the fuel
injection supply manifold and are retained by the
fuel injector retaining clips. Sealing between the
2007.50 Focus 3/2007 G385113en

fuel injector to fuel injection supply manifold and The fuel injectors are activated sequentially by the
the intake manifold is achieved by means of upper powertrain control module (PCM) which modifies
and lower O-ring seals. the fuel quantity by adjusting fuel injector opening
times according to the engine operating conditions.
E48343
The signal from the PCM is used to control a DC

Item Description
motor within the throttle body which is connected
1 Throttle body to the throttle butterfly through gears.
The throttle body also gives inputs back to the
Throttle Body PCM. This information allows the PCM to
The throttle butterfly position is controlled by a compensate for factors such as carbon build up
signal from the PCM which receives an input from within the throttle body and throttle body wear. The
the accelerator pedal position sensor. The system throttle body also provides information to the PCM
is fully electronic and does not use any cables. to enable the flagging of a DTC.
2007.50 Focus 3/2007 G385113en


General Equipment The introduction of Ethanol E85 has required some
major internal changes to the fuel supply and
delivery system. Some earlier vehicles used an
Ethanol mixture called Ethanol E15. This fuel was
Principles of Operation made up of 15% Ethanol and 85% gasoline. At this
mixture ratio, no changes to the fuel charging or
delivery system where required, as no degradation
Ethanol equipped vehicles would occur with the cylinder head valves or
material content of the components, although some
Ethanol, is derived from cellulose waste. A large performance loss would be noticeable.
proportion of Ethanol is distilled from corn, wheat The components used by vehicles running Ethanol
and sugar cane crops. The product that is to be appear to be the same in construction as those
used in this vehicle is called Ethanol E85. E85 is that use unleaded fuel only. The changes are
a mixture of 15% gasoline and 85% Ethanol. mainly to do with the materials used and increases
Ethanol is a clear liquid and when fully burnt the in fuel flow rates.
combustion gasses remaining are Carbon Dioxide
and water. This makes the use of Ethanol a good Ethanol has a much higher octane rating than
environmental proposition. One drawback with pure standard fuel which means that the ignition and
Ethanol is that it is corrosive to certain rubber and fuel injection calibrations for a vehicle that is
plastic materials. capable of using Ethanol E85 must be adapted
suitably.
2
3
4
6
E59684
1 Fuel injectors 3 Block heater
2 Fuel rail 4 Fuel pump module
2007.50 Focus 3/2007 G165371en

Item Description Fuel supply

5 Throttle body
6 Heated Oxygen sensor (HO2s)
7 Intake manifold
Fuel injectors
E59686
The fuel supply for all petrol fueled variants is

equipped with a return-less fuel system. This
means that the fuel delivery pressure at the fuel
injectors, is monitored and controlled by the fuel
tank module. This control is achived by switching
the fuel pump on and off.
E59688 The fuel pump module for both the Ethanol E85
variant vehicle and the unleaded fueled vehicle are
To maintain the same or similar power output to very similar. Visualy the only difference is the fuel
that of the unleaded fuel vehicle, the fuel injectors pump electrical connections which on the Ethanol
have been replaced with high flow fuel injectors. E85 variant is sealed. This is not the only
differance, both fuel pump modules have different
fuel level sensor resistor card values.
Fuel composition monitoring
Cold start
E59687
The quantity of Ethanol E85 in relation to the

E59683
quantity of unleaded fuel contained in the fuel tank
at any one time is not monitored at the fuel tank. To overcome the problems relating to cold start
The Ethanol percentage volume can only decrease inherent with Ethanol E85 vehicles (temperatures
from its maximum 85% (pure Ethanol E85), to zero down to -29 degrees centigrade), a block heater
(100% unleaded fuel). has been installed into the engine coolant system.
The fuel charging system compensates for the The block heater is located to the rear of the engine
changes in fuel composition using the signal under the exhaust manifold. The block heater is
received by the power train control module (PCM) fitted with a dedicated harness which terminates
from the HO2s. The PCM adapts the fueling and at an external plug connector fitted into the radiator
ignition calibrations to suit the current fuel tank grill.
content composition.
2007.50 Focus 3/2007 G165371en

The block heater can be connected to an external Throttle body
power supply, which will pre-heat the engine
coolant contained within the cylinder block. The
heated coolant will radiate heat to the fuel rail,
which will warm the contained fuel. Sufficient
warmed fuel is stored in the fuel rail to allow the
engine to start and continue running correctly, until
the engine combustion generates sufficient heat
to maintain correct operating conditions.
Fuel rail
E59690
The throttle body on Ethanol E85 vehicles is the

same as non Ethanol E85 variants. This is a fully
electronic controlled and monitored component.
The PCM adapts to the wear characteristics of the
throttle plate. If a new throttle body is installed, it
is necessary to teach the values of the new throttle
body to the PCM. If installing a new throttle body,
follow the initialization procedure.
REFER to: Throttle Body (303-04 Fuel Charging
E59685 and Controls - 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4), Removal and Installation).
The fuel rail on Ethanol E85 vehicles is the same
as non Ethanol E85 variants. The fuel rail function
is to supply a reservoir of fuel at equal pressure
for all four fuel injectors.
2007.50 Focus 3/2007 G165371en

Intake manifold
E59689
Item Description
1 Intake manifold tuning (IMT) swirl plates
2 Intake manifold runner control (IMRC) 1. Verify the customer concern.
throttle plates 2. Visually inspect for obvious signs of mechanical
The intake manifold for both Ethanol E85 and
standard unleaded fueled vehicles is the same Visual Inspection Chart
construction. Mechanical Electrical
Built into the intake manifold, are the IMRC throttle – Fuel leak(s) – Powertrain control
plates and IMT swirl plates. – Vacuum line(s) module (PCM)
Under low demand throttle conditions, the air – Gasket(s) – Wiring harness
charge is delivered to the cylinder head intake ports – Seal(s) – Electrical
through the primary air intake chambers. The clean connector(s)
flow of the air charge is disturbed by the IMT swirl – Fuel injector(s)
– Throttle body
plates to assist in the mixing of the air fuel mixture – Throttle body
at the fuel injectors. – Fuel injector(s)
– Fuel rail
During high demand throttle conditions, the IMRC – Fuel supply line
throttle plates are opened and the air charge is
allowed to use both primary and secondary intake 3. If an obvious cause for an observed or reported
chambers. This means a higher volume of air concern is found, correct the cause (if possible)
charge can be accommodated by the intake before proceeding to the next step.
manifold. During this high demand throttle
condition, the IMT swirl plates are fully open so as
not to restrict the air charge flow.
2007.50 Focus 3/2007 G165371en

Symptom Chart
Symptom Chart
• Engine does not crank • PATS. • CHECK the PATS LED extin-
guishes within 3 seconds when
the ignition is turned on.
REFER to: Anti-Theft - Passive
(419-01B, Diagnosis and
Testing).
• Starting system. • REFER to: Starting System
(303-06 Starting System,
• Ignition switch. • REFER to the Wiring
Diagrams.
• Powertrain control module • Carry out a full engine
(PCM). diagnosis using the guided
diagnostic menu in WDS.
• Engine cranks but does not • Inertia fuel shutoff (IFS) switch. • RESET the IFS switch.
start
• Low fuel system pressure. • Check the fuel system pres-
sure.
REFER to: Fuel System Pres-
sure Check (310-00 Fuel
tion, General Procedures).
• Fuel lines damaged or blocked. • INSPECT the fuel lines.
necessary. TEST the system
for normal operation.
• Fuel pump module. • REFER to: Fuel System - 2.0L
Duratec-HE (MI4) (310-00
Fuel System - General
Testing).
• Crankshaft position (CKP) • Carry out a full engine
sensor. diagnosis using the guided
• Camshaft position (CMP) • Carry out a full engine
sensor. diagnosis using the guided
• PCM. • Carry out a full engine
diagnosis using the guided
2007.50 Focus 3/2007 G165371en


• Fuel rail fuel pressure sensor. • Carry out a full engine
• Fuel injectors. • INSPECT the fuel injectors.
CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
• Incorrect valve timing. • CHECK the valve timing.
• Low cylinder compression. • TEST the cylinder compres-
sion.
• Poor starting • Low fuel system pressure. • Check the fuel system pres-
sure.
• Fuel system leak. • CHECK the system for fuel
leak(s). REPAIR the system as
necessary.
• Fuel system restriction. • INSPECT the fuel system.
• Air cleaner element blocked. • INSTALL a new air cleaner
element.
• Incorrect engine oil. • INSTALL a new engine oil filter
and engine oil.
• Incorrect power steering fluid. • DRAIN and REFILL the power
steering system with the correct
fluid.
System Flushing - Vehicles
With: Electro-Hydraulic Power
Steering (EHPS) (211-00,
• CKP sensor. • Carry out a full engine
• Engine coolant temperature • Carry out a full engine
(ECT) sensor. diagnosis using the guided
2007.50 Focus 3/2007 G165371en


• Fuel injector(s). • INSPECT the fuel injectors.
• Catalytic converter blocked. • REMOVE and visually
INSPECT the catalytic
converter as necessary.
REFER to: Catalytic Converter
Duratec-HE (MI4) (309-00,
• Low cylinder compression. • TEST the engine cylinder
compression.
• Engine starts but immediately • Air cleaner element blocked. • INSTALL a new air cleaner
stops element.
• CMP sensor. • Carry out a full engine
• PCM. • Carry out a full engine
sure.
• Fuel system restriction. • INSPECT the fuel system.
• Poor idling • Air cleaner element blocked. • INSTALL a new air cleaner
element.
2007.50 Focus 3/2007 G165371en


• Incorrect or contaminated fuel. • CHECK for signs of contamina-
tion such as strange odors from
the fuel tank.
• If contaminated fuel is found,
DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
Procedures).
INSTALL a new fuel filter.
• INSPECT the fuel injectors.
• INSTALL a new fuel rail.
REFER to: Fuel Injection
Supply Manifold (303-04C,
sure.
• EGR valve sticking open. • REFER to: Engine Emission
and Testing).
• Knock sensor (KS). • Carry out a full engine
• Fuel injection supply manifold • Carry out a full engine
fuel pressure sensor. diagnosis using the guided
2007.50 Focus 3/2007 G165371en


• Engine stumbling • Engine ignition. • REFER to: Engine Ignition
and Testing).
sure.
and Testing).
• Engine lacks power • Engine ignition. • REFER to: Engine Ignition
and Testing).
• Brakes binding. • CHECK the braking system.
Testing).
• Vehicle overloaded, or • ADVISE the customer about
excessive wind resistance (roof the effects of overloading the
racks, towing etc). vehicle and wind resistance on
the fuel consumption.
element as necessary.
sure.
2007.50 Focus 3/2007 G165371en


• Kinked or restricted fuel lines. • INSPECT the fuel lines.
the fuel tank.
Procedures).
• INSTALL a new rail.
and Testing).
• Vehicle speed sensor (VSS). • Carry out a full engine
• ECT sensor. • Carry out a full engine
2007.50 Focus 3/2007 G165371en


• Low cylinder compression. • CHECK the cylinder compres-
sion.
converter for damage.
INSTALL a new catalytic
• Black smoke at idle • Air cleaner element blocked. • INSTALL a new air cleaner
element as necessary.
• Excessive black smoke during • Air cleaner element blocked. • INSTALL a new air cleaner
acceleration element as necessary.
2007.50 Focus 3/2007 G165371en


the fuel tank.
Procedures).
and Testing).
• KS. • Carry out a full engine
2007.50 Focus 3/2007 G165371en


• Black smoke at cruising speeds • Air cleaner element blocked. • INSTALL a new air cleaner
element.
and Testing).
• Blue smoke • Engine burning oil. • CARRY OUT a controlled oil
consumption test over 1000 km
(600 miles). CONFIRM that the
oil consumption is less than 0.1
litre per 1000 km (600 miles).
2007.50 Focus 3/2007 G165371en


the fuel tank.
Procedures).
• Positive crankcase ventilation • INSPECT for visible signs of
(PCV) system. damage or blockage. CLEAN,
as necessary.
• Worn or damaged valve • REMOVE the cylinder head.
guide(s), piston ring(s), cylinder INSPECT the cylinder head,
bore(s), cylinder head or pistons and cylinder bores for
gasket. signs of wear or damage.
01C, In-vehicle Repair).
2007.50 Focus 3/2007 G165371en


• White smoke • Incorrect or contaminated fuel. • CHECK for signs of contamina-
the fuel tank.
Procedures).
• INSTALL a new fuel injection
supply manifold.
• Coolant in the combustion • CARRY OUT a cooling system
chamber. pressure test.
and Testing).
REMOVE the cylinder head.
INSPECT the cylinder head,
cylinder head gasket and
cylinder bores for wear or
damage.
2007.50 Focus 3/2007 G165371en


• Engine misfire • Engine ignition. • REFER to: Engine Ignition
and Testing).
the fuel tank.
Procedures).
sure.
and Testing).
• Engine operating temperature • REFER to: Engine Cooling
too high. (303-03 Engine Cooling -
and Testing).
2007.50 Focus 3/2007 G165371en


• CMP sensor. • Carry out a full engine
• Low cylinder compression. • CHECK the engine compres-
sion.
• Worn or damaged valve(s), • REMOVE the cylinder head.
tappet(s) or camshaft(s). INSPECT the cylinder head,
valves, tappets and camshafts
for signs of wear or damage.
• Damaged cylinder head gasket. • REMOVE the cylinder head.
INSPECT the cylinder head
gasket and cylinder bores for
wear or damage.
• Engine knock at idle • Low engine oil level. • CHECK the engine oil level.
REFILL as necessary.
2007.50 Focus 3/2007 G165371en


the fuel tank.
Procedures).
• Fuel injector(s). • INSPECT the fuel injectors.
• Excessive carbon build up. • REMOVE the cylinder head.
INSPECT the cylinder head
and pistons for signs carbon
build up.
• Worn or damaged oil pump. • INSPECT the engine compon-
• Worn or damaged timing chain ents.
or sprocket.
• Major mechanical engine
failure.
• Engine knock during accelera- • KS. • Carry out a full engine
tion diagnosis using the guided
2007.50 Focus 3/2007 G165371en


• Major mechanical engine • REFER to: Engine (303-01C,
failure. Diagnosis and Testing).
NOTE: Before proceeding with • Brakes binding. • CHECK the braking system.
any of the actions in relation to the REFER to: Brake System (206-
possible sources for excessive 00 Brake System - General
fuel consumption, a fuel Information, Diagnosis and
consumption test located in the Testing).
toolbox menu of WDS must be
performed.
• Excessive fuel consumption
• Vehicle overloaded, or • ADVISE the customer about
excessive wind resistance (roof the effects of overloading the
racks, towing etc). vehicle and wind resistance on
the fuel consumption.
element.
• Fuel system leak(s). • CHECK the system for fuel
leak(s). REPAIR or INSTALL
new parts as necessary.
• Incorrect engine oil. • INSTALL a new oil filter and
engine oil.
• Generator. • REFER to WDS.
and Testing).
• Slipping clutch. • REFER to: Manual Transaxle
and Clutch - 3-Door (308-00
Manual Transmis-
sion/Transaxle and Clutch -
2007.50 Focus 3/2007 G165371en


• PCM calibration. • Using WDS, CHECK for the
availability of a calibration
update.
• Low cylinder compression. • CHECK the engine compres-
sion.
• Engine cuts out during hard • CMP sensor. • Carry out a full engine
acceleration diagnosis using the guided
sure.
2007.50 Focus 3/2007 G165371en

Throttle Body
Special Tool(s)
3. Remove the air cleaner outlet pipe.
Hose Clamp
303-397 (24-003)
24003

(303-03 Engine Cooling - 2.0L Duratec-HE E39283
Procedures).
2. Remove the engine upper cover. indicated in the following illustration(s) and
table(s).
E39140
2007.50 Focus 3/2007 G295645en

10 Nm
4
1
2
N 3
E40748

Item Description
1 Throttle body electrical connector Window Motor Initialization (501-11 Glass,
2 Radiator to throttle body coolant hose Frames and Mechanisms, General
See Removal Detail Procedures).
3 Throttle body to exhaust gas recirculation 7. NOTE: Do not press the accelerator pedal
(EGR) valve coolant hose during the initialization period as this will
See Removal Detail prevent the complete initialization of the
throttle body.
4 Throttle body
Turn the ignition key to position II and wait
5. To install, reverse the removal procedure. for one minute to initialize the throttle body.
8. Turn the ignition key to the OFF position.
2007.50 Focus 3/2007 G295645en

Removal Details
Item 2 Radiator to throttle body coolant hose
radiator to throttle body coolant hose from
the throttle body.
303-397
E40749
Item 3 Throttle body to exhaust gas

recirculation (EGR) valve coolant hose
1. Using the special tool, remove throttle body
to EGR valve coolant hose from the throttle
body.
E40452
2007.50 Focus 3/2007 G295645en

Fuel Injectors(23 455 0)

1. Remove the fuel injection supply manifold.
For additional information, refer to Fuel
Injection Supply Manifold - in this section.
2007.50 Focus 3/2007 G307349en

Fuel Charging Wiring Harness

1. Disconnect the battery ground cable. For
Section 414-01 [Battery, Mounting and
Cables].
E39140

table(s).
2007.50 Focus 3/2007 G295647en

1
6 2 3
10
9 7
E41014
1 Powertrain control module (PCM) electrical 6 Ignition coil-on-plug electrical connectors

connector 7 Camshaft position (CMP) sensor electrical
2 Swirl plates solenoid valve electrical 8 Fuel injector electrical connectors
connector
9 Fuel charging wiring harness electrical
3 Air shut off solenoid valve electrical connectors
connector
10 Fuel charging wiring harness
4 Throttle body electrical connector See Removal Detail
5 Knock sensor (KS) electrical connector
2007.50 Focus 3/2007 G295647en

5. Initialize the door window motors. For Section 501-11 [Glass, Frames and
additional information, refer to Mechanisms].
Removal Details
Item 1 Powertrain control module (PCM)
1. Remove the PCM. For additional information,
refer to Section 303-14A [Electronic Engine
Controls] / 303-14B [Electronic Engine
Controls -- 2.5L Duratec-ST (VI5)].
Item 10 Fuel charging wiring harness

1. Disconnect the fuel charging wiring harness
retaining clips from the fuel injection supply
manifold and remove the fuel charging wiring
harness.
2007.50 Focus 3/2007 G295647en

Fuel Injection Supply Manifold

WARNINGS: 3. Remove the engine upper cover.
present and may ignite. Failure to follow
injury.
This procedure involves fuel handling. Be
prepared for fuel spillage at all times and
always observe fuel handling precautions.
Failure to follow these instructions may
result in personal injury. E39140
1. Release the fuel system pressure. For

additional information, refer to 4. Remove the components in the order
Section 310-00 [Fuel System - General indicated in the following illustration(s) and
Information]. table(s).

Cables].
2007.50 Focus 3/2007 G295648en

25 Nm
3
2 2
N
N
7 7
6 N N 6
N N
E40871
1 Fuel pulse damper vacuum line 6 Fuel injector retaining clips

See Removal Detail
2 Fuel injector(s) electrical connector(s)
7 Fuel injector(s)
3 Fuel charging wiring harness
4 Fuel injection supply manifold fuel supply WARNINGS:
line
See Removal Detail Do not smoke or carry lighted tobacco or
5 Fuel injection supply manifold and fuel or near any fuel related components.
injectors Highly flammable vapors are always
2007.50 Focus 3/2007 G295648en

present and may ignite. Failure to follow 6. Initialize the door window motors. For
these instructions may result in personal additional information, refer to
injury. Section 501-11 [Glass, Frames and
Mechanisms].
Removal Details
Item 3 Fuel charging wiring harness
1. Detach the fuel charging wiring harness
retaining clips from the fuel injection supply
manifold.
Item 4 Fuel injection supply manifold fuel

supply line
1. Disconnect the fuel supply line from the fuel
injection supply manifold. For additional
information, refer to Section 310-00 [Fuel
Item 6 Fuel injector retaining clips

1. Remove the fuel injector retaining clips.
• Discard the fuel injector retaining clips.
E40872
2007.50 Focus 3/2007 G295648en

303-04B-1 Fuel Charging and Controls — 1.6L (Z6) 303-04B-1
.
SECTION 303-04B Fuel Charging and Controls — 1.6L

(Z6)
CONTENTS PAGE
SPECIFICATIONS

Fuel Charging and Controls................................................................................................ 303-04B-3
Throttle body....................................................................................................................... 303-04B-3
Fuel injection supply manifold............................................................................................ 303-04B-4
Fuel injector........................................................................................................................ 303-04B-4

Fuel Charging and Controls................................................................................................ 303-04B-5

Throttle Body.................................................................................................. (29 280 0) 303-04B-6
Fuel Injectors.................................................................................................. (23 455 0) 303-04B-9
Fuel Injection Supply Manifold............................................................................................ 303-04B-10
Fuel Charging Wiring Harness........................................................................................... 303-04B-14
SPECIFICATIONS

Emission pipe support bracket retaining bolt 21 15 -
Throttle body retaining bolts 21 15 -
Idle air control (IAC) valve retaining bolts 5 - 44
Fuel injection supply manifold retaining bolts 20 15 -
2007.50 Focus 4/2007 G384902en

2
1
Item Description • Throttle position (TP) sensor

• Idle air control (IAC) valve
1 Throttle body
The throttle body is mounted to a plastic intake
2 Fuel injection supply manifold manifold and remote from the engine block. Engine
3 Fuel injectors coolant is piped through the throttle body to assist
with rapid warm up of the IAC valve intake air
temperature.
Throttle body The throttle body base idle settings are set during
manufacture and should not be adjusted during
the service life of the component.
1
The throttle body consists of:

• Throttle plate
• Accelerator cable cam
2007.50 Focus 4/2007 G424532en

Fuel injection supply manifold
The fuel injection supply manifold acts as a

reservoir of fuel supplying equal fuel pressure to
all four fuel injectors. The reservoir of fuel reduces
the pressure pulsing effect created by the operation
of the fuel injectors.
Fuel injector
The fuel injectors are individualy controled by the

powertrain control module (PCM) by switching the
ground connection of each fuel injector.
Fuel pressure to the fuel injectors is controlled by
the fuel pump. Excess fuel pressure is returned to
the fuel tank through a fuel bypass line located on
the fuel tank.
2007.50 Focus 4/2007 G424532en


General Equipment

• Fuel leaks • Loose or corroded
• Damaged fuel supply connector(s)
manifold • Wiring harness
• Damaged fuel line • Fuel injector(s)
connections
• Throttle body air
leaks

symptom and refer to WDS.
2007.50 Focus 4/2007 G384906en

Throttle Body(29 280 0)

General Equipment 1. Detach the accelerator cable locking nut.
Brake hose clamp 2. Pull the accelerator outer cable through the
accelerator cable grommet.
1. Remove the air cleaner. 3. Detach the accelerator cable grommet from
the accelerator cable support bracket.
Cleaner - 1.6L (Z6) (303-12 Intake Air 4. Rotate the throttle lever clockwise and detach
Distribution and Filtering, Removal and the accelerator inner cable from the throttle
Installation). lever.

3. Detach the accelerator cable. table(s).
2007.50 Focus 4/2007 G384907en


1 Idle Air Control (IAC) valve electrical 4 Throttle body retaining bolts
connector
5 Throttle body coolant hoses
2 Throttle Position (TP) Sensor electrical See Removal Detail
connector See Installation Detail
3 Evaporative emission pipe support bracket 6 Throttle body and IAC valve assembly
retaining bolt
7 Throttle body O-ring seal
1 5 Nm
3 N
3. Check the accelerator inner cable free play.

Item Description
The free play should not be less than 1mm
7 IAC valve and not exceed 3mm.
8 IAC valve gasket
6. Adjust the accelerator cable.
2 3
1. Make sure the throttle body linkage is against
the throttle stop screw.
2. Adjust the throttle cable using the throttle
cable locking nuts.
7. Top up the cooling system.
2007.50 Focus 4/2007 G384907en

Removal Details
Item 5 Throttle body coolant hoses
1. Detach the throttle body coolant hoses and
clamp the coolant hoses using a suitable
brake hose clamp.
E51893
Item 5 Throttle body coolant hoses
1. Connect the throttle body coolant hoses.
2. Remove the brake hose clamp.
2007.50 Focus 4/2007 G384907en

Fuel Injectors(23 455 0)

Removal
1. Remove the fuel injection supply manifold.
For additional information, refer to: Fuel
Injection Supply Manifold (303-04 Fuel
Charging and Controls - 1.6L (Z6), Removal
and Installation).
2007.50 Focus 4/2007 G413453en

Fuel Injection Supply Manifold

Materials Release the fuel system pressure.
Name Specification For additional information, refer to: Fuel
System Pressure Release (310-00 Fuel
Engine Oil - 5W-30 WSS-M2C911-A System - General Information, General
Procedures).
1. WARNINGS:
Do not smoke or carry lighted tobacco
or open flame of any type when working on For additional information, refer to: Battery
or near any fuel related components. Highly Disconnect and Connect (414-01 Battery,
flammable vapors are always present and Mounting and Cables, General Procedures).
may ignite. Failure to follow these 3. Remove the engine upper cover.
This procedure involves fuel handling.

Be prepared for fuel spillage at all times and
This procedure involves fuel handling.
Be prepared for fuel spillage at all times and

table(s).
2007.50 Focus 4/2007 G384909en

3 20 Nm
1 Fuel injector electrical connectors 3 Fuel injection supply manifold retaining

bolts
2 Fuel injection supply manifold fuel supply
line quick release coupling 4 Fuel injection supply manifold assembly
See Removal Detail 5 Fuel injector to intake manifold O-ring
seals
2007.50 Focus 4/2007 G384909en

N 8
8 N
7
E52911

6 Fuel injector retaining clips 6. Vehicles with global closing, initialize the
door window motors.
7 Fuel injectors
8 Fuel injector to fuel supply manifold O-ring Window Motor Initialization.
seals
Removal Details
2007.50 Focus 4/2007 G384909en

Item 2 Fuel injection supply manifold fuel For additional information, refer to: Quick
supply line quick release coupling Release Coupling (310-00 Fuel System -
1. Disconnect the fuel supply line from the fuel
injection supply manifold.
Item 8 Fuel injector to fuel supply manifold
O-ring seals
CAUTION: Do not use silicone grease to
lubricate O-ring seals as it will block the
fuel injectors.
1. Lubricate the fuel injector seals with clean
engine oil to assist with installation.
Item 5 Fuel injector to intake manifold O-ring

seals
CAUTION: Do not use silicone grease to
lubricate O-ring seals as it will block the
fuel injectors.
1. Lubricate the fuel injector seals with clean
engine oil to assist with installation.
2007.50 Focus 4/2007 G384909en

Fuel Charging Wiring Harness

1. Disconnect the battery ground cable. 3. Remove the air cleaner.
For additional information, refer to: Battery For additional information, refer to: Air
Disconnect and Connect (414-01 Battery, Cleaner - 1.6L (Z6) (303-12 Intake Air
Mounting and Cables, General Procedures). Distribution and Filtering, Removal and
2. Remove the engine upper cover. Installation).
table(s).
2007.50 Focus 4/2007 G426599en

5
2
4
E53067
1 Powertrain control module (PCM) upper 4 Catalyst monitor sensor wiring harness
cover electrical connector
See Removal Detail
2 Battery cable wiring harness to fuel
charging wiring harness electrical 5 Heated oxygen sensor (HO2S) wiring
connector harness electrical connector
See Removal Detail
3 PCM electrical connector
6 Fuel charging wiring harness retaining
clips
See Removal Detail
2007.50 Focus 4/2007 G426599en

7 Engine coolant temperature (ECT) sensor 11 Intake manifold tuning (IMT) valve
electrical connector electrical connector
8 Throttle position (TP) sensor electrical 12 Knock sensor (KS) wiring harness
9 Idle air control (IAC) valve electrical 13 Evaporative emissions canister vent
connector solenoid electrical connector
10 Intake manifold runner control (IMRC) 14 Fuel charging wiring harness retaining
actuator electrical connector clips
2007.50 Focus 4/2007 G426599en

20 20
15
18
20
19
16
21
20
17
22
23
E53069
15 Barometric pressure sensor electrical 20 Fuel charging wiring harness retaining

connector clips
21 Fuel charging wiring harness retaining clip
17 Air conditioning (A/C) compressor See Removal Detail
22 Crankshaft position (CKP) sensor wiring
18 Variable camshaft timing (VCT) oil control harness retaining clip
solenoid electrical connector See Installation Detail
19 Power steering pressure (PSP) switch 23 CKP sensor electrical connector
electrical connector See Installation Detail
2007.50 Focus 4/2007 G426599en

27
26
28
29
24 25
28 28
24 Camshaft position (CMP) sensor electrical 27 Exhaust gas recirculation (EGR) valve
See Removal Detail 28 Fuel charging wiring harness retaining
25 Fuel injector electrical connectors clips
26 Ignition coil-on-plug electrical connectors 29 Fuel charging wiring harness

Removal Details
Item 4 Catalyst monitor sensor wiring harness
Item 6 Fuel charging wiring harness retaining
clips
1. Disconnect the catalyst monitor sensor
wiring harness electrical connector and 1. Detach the fuel charging wiring harness from
detach the fuel charging wiring harness from the fuel charging wiring harness retaining
the connector support bracket. clips.
Item 5 Heated oxygen sensor (HO2S) wiring Item 21 Fuel charging wiring harness retaining
harness electrical connector clip
1. Disconnect the HO2S wiring harness 1. Raise and support the vehicle.
electrical connector and detach the fuel For additional information, refer to: Lifting
charging wiring harness from the connector (100-02 Jacking and Lifting, Description
support bracket. and Operation).
2007.50 Focus 4/2007 G426599en

2. Detach the fuel charging wiring harness Item 24 Camshaft position (CMP) sensor
retaining clip. electrical connector
2. Disconnect the CMP electrical connector.
Item 23 CKP sensor electrical connector
and Operation).
2. Connect the CKP sensor electrical
connector.
Item 22 Crankshaft position (CKP) sensor wiring

harness retaining clip
CAUTION: The CKP sensor wiring harness
retaining clip must be securely attached
to the CKP wiring harness. Failure to follow
this instruction will result in damage to the
CKP sensor wiring harness when it comes
in contact with the A/C compressor pulley.
Item 20 Fuel charging wiring harness retaining

clips
2. Install the fuel charging wiring harness
retaining clips to the engine components.
2007.50 Focus 4/2007 G426599en

303-05-1 Accessory Drive 303-05-1
.
SECTION 303-05 Accessory Drive

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 303-05-2
Specifications...................................................................................................................... 303-05-3

Accessory Drive — 1.8L Duratec-HE (MI4)........................................................................ 303-05-4
1.8L Duratec HE (MI4) engine............................................................................................ 303-05-4
Accessory Drive — 1.6L (Z6)............................................................................................. 303-05-5

Accessory Drive.................................................................................................................. 303-05-7
Accessory Drive Belt Concerns.......................................................................................... 303-05-7
Symptom Chart................................................................................................................... 303-05-9
Component Tests................................................................................................................ 303-05-12

Accessory Drive Belt — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)....... (21 567 0) 303-05-14
Accessory Drive Belt — 1.6L (Z6).................................................................. (21 567 0) 303-05-16
Accessory Drive Belt Tensioner — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE
(MI4)............................................................................................................. (21 569 0) 303-05-18
Accessory Drive Belt Tensioner — 1.6L (Z6)................................................. (21 569 0) 303-05-20
Air Conditioning (A/C) Compressor Belt — 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4).......................................................................................... (21 567 0) 303-05-21
SPECIFICATIONS
Torque Specifications - vehicles with 1.8L or 2.0L engine
Accessory drive belt tensioner 25 18 -
retaining bolt
Torque Specifications - vehicles with 1.6L diesel engine

Throttle body support bracket 10 - 89
retaining bolt
Throttle body retaining bolts 10 - 89
retaining bolts

retaining bolt

Accessory drive belt 27 20 -
tensioner lower retaining
bolt
Accessory drive belt 47 35 -
tensioner center
retaining bolt
2007.50 Focus 5/2007 G165385en

SPECIFICATIONS
Item Nm lb-ft lb-in
Accessory drive belt tensioner retaining bolts 25 18 -
2007.50 Focus 5/2007 G384919en

Accessory Drive — 1.8L Duratec-HE (MI4)

1.8L Duratec HE (MI4) engine The longer drive belt drives the alternator and the
coolant pump. A self-adjusting belt tensioner is
used to tension the belt.
1
1
7
2
E43047
Item Description
1 Crankshaft belt pulley
3 The crankshaft pulley has two running surfaces to
drive the multi-groove belts.
4
5
E43003
Item Description
1 Belt tensioner
2 Coolant pump
3 Alternator
4 Elastic multi-groove belt
5 Air Conditioning (A/C) compressor
6 Crankshaft belt pulley
7 Conventional multi-groove belt
NOTE: The elastic multi-groove belt must not be
re-used.
NOTE: The elastic multi-groove belt of the A/C
compressor is supplied in a service kit containing
the special tools required for installation.
The drive belts for the auxiliary systems are
multi-groove belts.
The short drive belt is an elastic multi-groove belt
which drives the A/C compressor without an
additional tensioning pulley.
2007.50 Focus 5/2007 G183920en

Accessory Drive — 1.6L (Z6)

Vehicles with air conditioning (A/C)
1 Accessory drive belt tensioner pulley 5 Accessory drive belt idler pulley
2 Power steering pump pulley 6 A/C compressor
3 Accessory drive belt idler pulley 7 Crankshaft pulley
4 Generator 8 Coolant pump pulley
2007.50 Focus 5/2007 G426417en

Vehicles without air conditioning (A/C)
Item Description
1 Accessory drive belt tensioner pulley
2 Power steering pump pulley
3 Accessory drive belt idler pulley
4 Generator
5 Accessory drive belt guide pulley
6 Crankshaft pulley
7 Coolant pump pulley
2007.50 Focus 5/2007 G426417en

Accessory Drive
Inspection and Verification 1. Check the accessory drive belt for cracks. If the
damage exceeds the acceptable limit, install a
1. Verify the customer concern. new accessory drive belt. REFER to:
2. Visually inspect for obvious signs of mechanical Accessory Drive Belt (303-05, Removal and
damage. Installation),
Accessory Drive Belt (303-05, Removal and
Installation),
Mechanical Accessory Drive Belt (303-05 Accessory Drive
– Damaged or contaminated accessory drive - 2.5L Duratec-ST (VI5), Removal and
belt Installation),
– Damaged or contaminated pulley(s) Installation),
– Incorrect accessory drive belt Accessory Drive Belt (303-05, Removal and
– Incorrect fitment of the accessory drive belt Installation).
– Accessory drive belt tensioner
Chunking
– Accessory drive belt idler pulley
Chunking describes the condition where long
– Generator
lengths of rubber become detached from the ribs
– Power steering pump of the accessory drive belt. This is considered to
– Power steering pump leakage be a failure of the accessory drive belt.
– Air conditioning (A/C) compressor
– Pulley(s)
– Loose hardware

Accessory Drive Belt Concerns

CAUTION: Do not lubricate the accessory MPZ9632071
drive belt, accessory drive belt tensioner
or idler pulley(s) as potential damage to 2. Check the accessory drive belt for damage. If
the accessory drive belt material any chunks are found to be missing, install a
construction, accessory drive belt new accessory drive belt. REFER to:
tensioner damping mechanism, accessory Accessory Drive Belt (303-05, Removal and
drive belt tensioner pulley bearing and idler Installation),
pulley(s) bearing may occur. Accessory Drive Belt (303-05, Removal and
Installation),
Cracking Accessory Drive Belt (303-05 Accessory Drive
Accessory drive belts are made from rubber which - 2.5L Duratec-ST (VI5), Removal and
hardens with time and can develop cracks. As the Installation),
accessory drive belt runs on the back of some of Accessory Drive Belt (303-05, Removal and
the pulleys, the cracks are opened up. Small cracks Installation),
are not considered to be a failure of the accessory Accessory Drive Belt (303-05, Removal and
drive belt. Only if the crack is deep enough to reach Installation).
the bottom of the groove to expose the cord or any
chunks are found to be missing from the accessory
drive belt, is the accessory drive belt condition
considered to be unacceptable.
2007.50 Focus 5/2007 G165389en

Pilling 3. Longer pills up to 50% of the rib height.
Possible noise concern. INSTALL a new
Pilling is dust that forms in between the ribs of the
accessory drive belt if noise is apparent.
accessory drive belt from rubber that is worn off
REFER to:
the accessory drive belt when it is new. There may
also be loose particles left on the accessory drive Accessory Drive Belt (303-05, Removal and
belt during the manufacturing process. These are Installation),
worn off and form into small balls of rubber that Accessory Drive Belt (303-05, Removal and
then get trapped in the grooves of the accessory Installation),
drive belt. This condition will usually clear itself Accessory Drive Belt (303-05 Accessory Drive
within 4800 km - 8000 km (3000 miles - 5000 miles) - 2.5L Duratec-ST (VI5), Removal and
of normal driving. Installation),
Installation),
Installation).
4. Longer pills up to 50% of the rib height.
Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
REFER to:
Installation),
Installation),
Accessory Drive Belt (303-05 Accessory Drive
- 2.5L Duratec-ST (VI5), Removal and
Installation),
Installation),
Installation).
5. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
accessory drive belt. REFER to:
Installation),
VUE0037805
Installation),
3. Check the accessory drive belt for pilling. The Accessory Drive Belt (303-05 Accessory Drive
condition of the accessory drive belt should be - 2.5L Duratec-ST (VI5), Removal and
compared against the illustration. Installation),
1. Small scattered pills. Not considered a
Installation),
concern. No action required.
2. Small scattered pills. Not considered a Installation).
concern. No action required.
2007.50 Focus 5/2007 G165389en

6. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
accessory drive belt. REFER to:
Installation),
Installation),
Accessory Drive Belt (303-05 Accessory Drive
- 2.5L Duratec-ST (VI5), Removal and
Installation),
Installation), VUE0037806

Installation).
Incorrect fitment
Accessory drive belt noise can be generated by
the accessory drive belt being incorrectly fitted on
the pulley as shown in the following illustration.
Make sure that all the V grooves on the accessory
drive belt contact correctly with the pulley.
Symptom Chart

• Accessory drive belt noise • Accessory drive system • CHECK the system with the
engine running and the
accessory drive belt removed
(only run the engine for a very
short period). If a noise is
apparent, the cause is not the
accessory drive system. If a
noise is not apparent, the
cause is the accessory drive
system. CHECK where the
noise is coming from. Use a
stethoscope or other listening
device to determine the source
of the noise. INSTALL new
TEST the system for normal
operation.
2007.50 Focus 5/2007 G165389en


• Accessory drive belt incorrectly • CHECK the accessory drive
installed. belt is correctly installed in the
pulley grooves. INSTALL a new
accessory drive belt as neces-
sary. REFER to:
Accessory Drive Belt (303-05,
Accessory Drive Belt (303-05
Accessory Drive - 2.5L
Duratec-ST (VI5), Removal
and Installation),
operation.
• Pulley(s). • CHECK the pulley(s) for
damage, freedom of rotation,
stone entrapment and align-
ment. INSTALL new compon-
ents as necessary. TEST the
• Lubricant or other contamina- • CHECK the accessory drive
tion. belt for contamination or
damage. RECTIFY the source
of the leak and INSTALL a new
accessory drive belt. REFER
to:
and Installation),
operation.
2007.50 Focus 5/2007 G165389en


NOTE: Squeal is defined as a • Accessory drive belt tensioner • CHECK the accessory drive
continuous shriek, most noticeable worn, damaged or contamin- belt tensioner for correct opera-
when the engine is being accelerated with oil. tion, damage or contamination.
ated or with electrical load. REFER to the Accessory Drive
Belt Tensioner Component
• Accessory drive belt squeal
Test in this procedure.
INSTALL a new accessory
drive belt tensioner as neces-
sary. TEST the system for
normal operation.
NOTE: Whine is defined as a • Poor surface finish on • REMOVE the accessory drive
continuous noise at the same accessory drive belt idler pulley belt. REFER to:
frequency, generally associated flat surface(s). Accessory Drive Belt (303-05,
with plastic pulleys. Removal and Installation),
• Accessory drive belt whine Accessory Drive Belt (303-05,
and Installation),
INSPECT the idler pulley(s) for
surface finish. INSTALL a new
idler pulley(s) as necessary.
operation.
• Accessory drive belt idler pulley • REMOVE the accessory drive
bearing failure. belt. REFER to:
and Installation),
INSPECT the idler pulley(s) for
smooth rotation. INSTALL a
new idler pulley(s) as neces-
normal operation.
2007.50 Focus 5/2007 G165389en


NOTE: Chirp is defined as a twit- • Pulley misalignment (usually • CHECK that the accessory
tering noise, often intermittent evident at idle). drive belt is running centrally
on the flat pulleys. TEST the
• Accessory drive belt chirp
• CHECK the pulleys for
excessive end float and bent
flanges.
• With the engine running at idle,
use a stethoscope to identify
the source of the noise.
NOTE: Rattle is defined as a • Accessory drive belt tensioner • CHECK the accessory drive
metallic knocking noise hitting the end stops. belt tensioner for correct opera-
tion or damage. REFER to the
• Accessory drive belt rattle
Accessory Drive Belt Tensioner
procedure. INSTALL a new
accessory drive belt tensioner
as necessary. TEST the
• Loose components or hard- • CHECK the components or
ware. hardware for correct installation
and tighten as necessary.
operation.
• Accessory drive belt fraying • Accessory drive belt. • CHECK the extent of the
• Pulley(s). fraying by referring to the illus-
trations shown in the Visual
Inspection section. Only
INSTALL a new accessory
drive belt if the fraying is within
the criteria quoted in the Visual
Inspection section. TEST the
• CHECK the pulley(s) for
damage, freedom of rotation
and alignment. INSTALL new
operation.
Component Tests 1. Inspect the area surrounding the accessory

drive belt tensioner for lubricant or other
contamination. Rectify any leaks before
Accessory Drive Belt Tensioner - Static installing a new accessory drive belt tensioner.
Check If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as the
The accessory drive belt tensioner may be checked damping mechanism inside may be damaged.
statically as follows:
2007.50 Focus 5/2007 G165389en

INSTALL a new accessory drive belt tensioner tensioner movement. Check the condition by
as necessary. TEST the system for normal installing a new accessory drive belt. REFER
operation. to:
2. Detach the accessory drive belt in the area of Accessory Drive Belt (303-05, Removal and
the accessory drive belt tensioner. Installation),
3. NOTE: The accessory drive belt tensioner Accessory Drive Belt (303-05, Removal and
has a damping feature, which is usually a Installation),
friction device, therefore some friction within Accessory Drive Belt (303-05 Accessory Drive
the system is normal. - 2.5L Duratec-ST (VI5), Removal and
Installation),
Using the correct tool, move the accessory drive Accessory Drive Belt (303-05, Removal and
belt tensioner from its relaxed position through Installation),
its full stroke and back to the relaxed position Accessory Drive Belt (303-05, Removal and
to make sure there is no excessive stick, grab Installation).
or bind, and to make sure there is tension on TEST the system for normal operation.
the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley
and check for damage, freedom of rotation and
alignment. INSTALL a new accessory drive belt
tensioner as necessary. TEST the system for
normal operation.
5. If the accessory drive belt tensioner meets the
above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the accessory
drive belt tensioner does not meet the above
criteria, INSTALL a new accessory drive belt
tensioner. TEST the system for normal
operation.
Accessory Drive Belt Tensioner - Dynamic

Check
The accessory drive belt tensioner may be checked

dynamically as follows:
1. With the engine running, observe the accessory
drive belt tensioner movement. The accessory
drive belt tensioner should move (respond)
when the engine is accelerated rapidly or when
the A/C clutch cycles ON and OFF (the degree
of movement can be up to 4 mm). If the
accessory drive belt tensioner movement is not
constant without engine acceleration or A/C
clutch cycling, a pulley or shaft is possibly bent,
out of round, or the damping mechanism inside
the accessory drive belt tensioner may be
damaged. INSTALL a new accessory drive belt
tensioner as necessary. TEST the system for
normal operation.
2. Excessive accessory drive belt rideout (uneven
depth of grooves in the accessory drive belt)
may cause excessive accessory drive belt
2007.50 Focus 5/2007 G165389en

Accessory Drive Belt — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE

(MI4)(21 567 0)
Removal
Vehicles with air conditioning 1. Rotate the accessory drive belt tensioner
counterclockwise.
compressor belt. 2. Remove the accessory drive belt.
For additional information, refer to Air 1

Conditioning (A/C) Compressor Belt in this
section.
All vehicles
E39279
Installation
1. NOTE: Vehicles without A/C shown, vehicles
with A/C similar.
E39140
2007.50 Focus 5/2007 G165390en

E39280
2007.50 Focus 5/2007 G165390en

Accessory Drive Belt — 1.6L (Z6)(21 567 0)

Removal and Installation 3. Rotate the accessory drive belt tensioner
clockwise and remove the accessory drive
All vehicles belt.
Vehicles without air conditioning

2. Raise and support the vehicle. 4. To install, reverse the removal procedure.
and Operation).
Vehicles with air conditioning

2007.50 Focus 5/2007 G384923en

2007.50 Focus 5/2007 G384923en

Accessory Drive Belt Tensioner — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4)(21 569 0)
3. Detach the engine wiring harness retaining
clips from the engine.
2. Detach the fuel charging wiring harness and
position to one side.
• Detach the fuel charging wiring harness from
the retaining clip.
• Disconnect the fuel charging wiring harness
4. Detach the engine wiring harness electrical

connector from the retaining clip and
position the engine wiring harness one side.

table(s).
2007.50 Focus 5/2007 G295698en

Item Description
1 Accessory drive belt tensioner
2007.50 Focus 5/2007 G295698en

Accessory Drive Belt Tensioner — 1.6L (Z6)(21 569 0)

For additional information, refer to: table(s).
1 25 Nm
E52652
Item Description
1 Accessory drive belt tensioner retaining
bolts
2 Accessory drive belt tensioner
2007.50 Focus 5/2007 G384924en

Air Conditioning (A/C) Compressor Belt — 2.0L Duratec-HE

(MI4)/1.8L Duratec-HE (MI4)(21 567 0)
General Equipment • Rotate the locking tangs counterclockwise.
Knife
Removal
CAUTIONS:
The A/C compressor belt must not be
reused as it is designed to be stretched
onto the pulleys only once. Failure to
follow this instruction may lead to
premature failure of the belt.
E40677
It is not necessary to remove the A/C
compressor cover to remove the A/C
compressor belt. Failure to follow this 4. Using a suitable knife, cut the A/C
instruction may result in damage to the compressor belt and remove.
A/C compressor.
1. Remove the right-hand front wheel and tire. Installation
For additional information, refer to: Wheel NOTE: Install a new A/C compressor belt.
and Installation). 1. Wipe clean both of the pulleys to make sure
that the A/C compressor belt does not slip
2. Remove the right-hand front splash shield. during installation.
2. Install the installation tool (supplied in the
parts kit) to the crankshaft pulley at the 9
o'clock position (A/C compressor cover
E44900
E40680
3. Install the A/C compressor belt (A/C

compressor cover shown removed for
clarity).
1. Install the belt around the A/C compressor
pulley.
2007.50 Focus 5/2007 G319986en

2. Install the belt around the installation tool. Turn the engine until the installation tool is
at the 6 o'clock position (A/C compressor
cover shown removed for clarity).
2
1
E40681
4. Install the belt guide tool (supplied in the E40682

parts kit) to the A/C compressor belt (engine
shown removed for clarity). 7. Remove the installation tool.
• The curved end of the tool fits around the 8. NOTE: Only turn the engine in the normal
belt and the flat end of the tool fits between direction of rotation.
the A/C compressor and the oil pan.
Turn the engine through 360 degrees.
9. Check that the A/C compressor belt is
correctly positioned in the grooves of the
pulleys.
• Repeat the installation procedure if the A/C
compressor belt is misaligned.
• Discard the installation tool if the A/C
compressor belt is fitted correctly.
10. Remove the belt guide tool from the A/C
compressor belt.
E43551
• Discard the belt guide tool.
5. Make sure that the A/C compressor belt is
correctly positioned in the grooves of the • Rotate the locking tangs clockwise.
A/C compressor pulley.
6. NOTE: Only turn the engine in the normal
NOTE: Guide the A/C compressor belt onto the
pulleys as the engine is rotated.
E40677
2007.50 Focus 5/2007 G319986en

12. Install the right-hand front splash shield.
E44900
13. Install the right-hand front wheel and tire.

2007.50 Focus 5/2007 G319986en

303-06-1 Starting System 303-06-1
.
SECTION 303-06 Starting System

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 303-06-2
Torque Specifications - vehicles with 1.8L or 2.0L engine.............................................. 303-06-2

Starting System.................................................................................................................. 303-06-4
Symptom Chart................................................................................................................... 303-06-4
Pinpoint Tests..................................................................................................................... 303-06-7

Starter Motor — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)................... (26 204 0) 303-06-19
Starter Motor — 1.6L (Z6).............................................................................. (26 204 0) 303-06-22
SPECIFICATIONS
Ignition switch to starter motor cable 7 - 62
retaining nut
Starter motor positive cable retaining 12 9 -
nut

retaining nut
nut
Starter motor wiring harness support 20 15 -
bracket retaining nuts
Starter motor retaining studs 25 18 -

retaining nut
nut

retaining nut
nut
Torque Specifications - vehicles with 1.6L (Z6) engine

Starter motor positive cable retaining 10 - 89
nut

Ignition switch to starter 7 5 -
motor cable retaining nut
2007.50 Focus 5/2007 G165414en

SPECIFICATIONS

Starter motor positive 12 9 -
cable retaining nut
Starter motor retaining 35 26 -
bolts
2007.50 Focus 5/2007 G165414en

Starting System
Refer to Wiring Diagrams Section 303-06, for
Inspection and Verification • Starter motor • Fuse(s)

• Battery
1. Verify the customer concern. • Starter relay
2. Visually inspect for obvious signs of mechanical • Start inhibit relay
or electrical damage. • Wiring harness(es)
• Loose or corroded
connector(s)

Symptom Chart
Symptom Chart
• The engine does not crank and • Battery • GO to Pinpoint Test A.
the relay does not click • Starter motor
• Starter relay
• Start inhibit relay
• Battery junction box (BJB)
• Powertrain control module
(PCM)
• Circuit(s)
• The engine does not crank but • Battery • GO to Pinpoint Test B.
the relay clicks • Starter relay
• Circuit(s)
• Starter motor
• Ignition switch
• The engine cranks slowly • Battery • GO to Pinpoint Test C.
• Circuit(s)
• Starter motor
2007.50 Focus 5/2007 G165416en


• Unusual starter motor noise • Starter motor • CHECK the flywheel ring gear.
• Flywheel ring gear • INSPECT the starter motor for
alignment or cracked casing.
Make sure the mounting bolts
are tightened. If necessary,
INSTALL a new starter motor.
REFER to: Starter Motor - 1.4L
Duratec-16V (Sigma) (303-06
Starting System, Removal
and Installation)
/ Starter Motor - 2.0L Duratec-
(MI4) (303-06 Starting
System, Removal and
Installation)
/ Starter Motor - 1.6L Duratorq-
and Installation)
and Installation).
operation.
2007.50 Focus 5/2007 G165416en


• The starter spins but the engine • Starter motor • INSPECT the flywheel ring
does not crank • Flywheel ring gear gear for missing teeth.
REFER to: Flywheel Inspection
(303-00 Engine System -
Procedures).
CHECK the starter motor for
correct mounting. If the concern
persists, INSTALL a new
starter motor.
REFER to: Starter Motor - 1.4L
Duratec-16V (Sigma) (303-06
and Installation)
/ Starter Motor - 2.0L Duratec-
(MI4) (303-06 Starting
System, Removal and
Installation)
and Installation)
and Installation).
operation.
2007.50 Focus 5/2007 G165416en

Pinpoint Tests
PINPOINT TEST A : THE ENGINE DOES NOT CRANK AND THE RELAY DOES NOT CLICK
A1: CHECK THE BATTERY
1 CHECK the battery voltage using WDS.
• Is the battery OK?
→ Yes
Vehicles with manual transaxle. GO to A13.
Vehicles with automatic transaxle. GO to A2.
→ No
CHARGE the battery.
REFER to: Battery Charging (414-00 Charging
Procedures).
TEST the system for normal operation. If the
concern persists, INSTALL a new battery.
REFER to: Battery - 1.6L Duratorq-TDCi (DV)
A2: CHECK THE STARTER RELAY FOR VOLTAGE
1 Disconnect Starter Relay C1013.
3 Measure the voltage between the starter relay
C1013 pin 1, circuit 50-BB16C (GY/BK), harness
V
side and ground.
→ Yes
GO to A3.
→ No
GO to A8.
E60181
A3: CHECK THE STARTER RELAY

2007.50 Focus 5/2007 G165416en


2 Carry out the relay component test on starter
relay C1013. For additional information, REFER
to the Wiring Diagrams.
• Does the starter relay pass the component
test?
→ Yes
Vehicles with 1.6L engine. GO to A4.
Vehicles with 1.8L or 2.0L engine. GO to A5.
Vehicles with 1.6L diesel engine. GO to A6.
→ No
INSTALL a new starter relay. TEST the
A4: CHECK CIRCUIT 31S-BB16 (BK/RD) FOR OPEN
1 Disconnect PCM C594.
2 Measure the resistance between the starter
relay C1013 pin 2, circuit 31S-BB16 (BK/RD),
harness side and PCM C594 pin F30, circuit
31S-BB16 (BK/RD), harness side.
→ Yes
INSTALL a new PCM.
REFER to: Powertrain Control Module (PCM)
- 1.6L Duratec-16V (Sigma) (303-14 Elec-
E45213 tronic Engine Controls, Removal and
Installation).
→ No
REPAIR the circuit. TEST the system for
normal operation.
2007.50 Focus 5/2007 G165416en


harness side and PCM C690 pin 4, circuit 31S-
BB16 (BK/RD), harness side.
→ Yes
INSTALL a new PCM.
- 2.0L Duratec-HE (MI4)/1.8L Duratec-HE
E45214 (MI4), Vehicles Without: PCM Security
Shield (303-14 Electronic Engine Controls,
/ Powertrain Control Module (PCM) - 2.0L
Vehicles With: PCM Security Shield (303-14
Electronic Engine Controls, Removal and
Installation).
→ No
normal operation.
harness side and PCM C419 pin A1, circuit 31S-
→ Yes
INSTALL a new PCM.
- 1.6L Duratorq-TDCi (DV) Diesel/1.8L
E45215 Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-
TDCi (DW) Diesel (303-14 Electronic Engine
Controls, Removal and Installation).
→ No
normal operation.
2007.50 Focus 5/2007 G165416en


harness side and PCM C418 pin D1, circuit 31S-
→ Yes
INSTALL a new PCM.
E45216 Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-
TDCi (DW) Diesel (303-14 Electronic Engine
→ No
normal operation.
A8: CHECK CIRCUIT 15-BB16 (GN/OG) FOR VOLTAGE
2 Disconnect Start inhibit relay C1001.
4 Measure the voltage between the start inhibit
relay C1001 pin 1, circuit 15-BB16 (GN/OG),
V
→ Yes
GO to A9.
→ No
normal operation.
E60182
A9: CHECK CIRCUIT 50-BB16A (GY/BK) FOR VOLTAGE

2007.50 Focus 5/2007 G165416en


2 Measure the voltage between the start inhibit
relay C1001 pin 3, circuit 50-BB16A (GY/BK),
V
→ Yes
GO to A10.
→ No
normal operation.
E60183
A10: CHECK CIRCUIT 31S-TA36 (BK/GN) FOR OPEN

2 Disconnect Transmission control unit C812.
3 Measure the resistance between the start inhibit
relay C1001 pin 2, circuit 31S-TA36 (BK/GN),
harness side and the transmission control unit
C812 pin 10, circuit 31S-TA36 (BK/GN), harness
side.
→ Yes
GO to A11.
→ No
E45210 REPAIR the circuit. TEST the system for
normal operation.
A11: CHECK THE START INHIBIT RELAY

1 Carry out the relay component test on start
inhibit relay C1001. For additional information,
REFER to Wiring Diagrams.
• Does the start inhibit relay pass the component
test?
→ Yes
GO to A12.
→ No
INSTALL a new start inhibit relay. TEST the
2007.50 Focus 5/2007 G165416en


A12: CHECK CIRCUIT 50-BB16A (GY/BK) FOR OPEN
1 Measure the resistance between the start inhibit
relay C1001 pin 5, circuit 50-BB16A (GY/BK),
V
harness side and the starter relay C1013 pin 1,
circuit 50-BB16C (GY/BK), harness side.
→ Yes
INSTALL a new transmission control unit.
→ No
normal operation.
A13: CHECK THE STARTER RELAY FOR VOLTAGE

1 Disconnect Starter relay C1013.
3 Measure the voltage between the starter relay
C1013 pin 1, circuit 50-BB16 (GY/BK), harness
V
side and ground.
→ Yes
GO to A3.
→ No
REPAIR circuit 50-BB16 (GY/BK). TEST the
E60181
PINPOINT TEST B : THE ENGINE DOES NOT CRANK AND THE RELAY CLICKS
B1: CHECK THE STARTER MOTOR FOR SWITCHED VOLTAGE
1 Disconnect Starter Motor C110B.
2007.50 Focus 5/2007 G165416en


3 Measure the voltage between the starter motor
C110B, circuit 50-BB12 (GY), harness side and
ground.
V • Is the voltage greater than 10 volts?
→ Yes
GO to B2.
→ No
Vehicles with manual transaxle. GO to A3.
Vehicle with automatic transaxle. GO to B3.
E45217
B2: CHECK THE STARTER MOTOR FOR BATTERY VOLTAGE

1 Connect Starter Motor C110B.
2 Disconnect Starter Motor 110A.
2007.50 Focus 5/2007 G165416en


C110A, circuit 30-BB10 (RD), harness side and
ground.
→ Yes
REFER to: Starter Motor - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma) (303-06
Starting System, Removal and Installation)
E45217 / Starter Motor - 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4) (303-06 Starting System,
/ Starter Motor - 1.6L Duratorq-TDCi (DV)
Diesel (303-06 Starting System, Removal
and Installation)
/ Starter Motor - 1.8L Duratorq-TDCi (Lynx)
and Installation).
→ No
CLEAN and TIGHTEN all positive battery
cable connections. TEST the system for
normal operation. If the concern persists.
INSTALL a new battery to starter motor cable.
REFER to: Battery Cables - 1.4L Duratec-16V
Battery, Mounting and Cables, Removal and
Installation)
/ Battery Cables - 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4) (414-01 Battery, Mounting
and Cables, Removal and Installation)
/ Battery Cables - 1.6L Duratorq-TDCi (DV)
Diesel (414-01 Battery, Mounting and
Cables, Removal and Installation)
/ Battery Cables - 2.0L Duratorq-TDCi (DW)
Cables, Removal and Installation).
B3: CHECK CIRCUIT 50-BB12 (GY) FOR OPEN
1 Disconnect Gearshift Mode Switch C438.
2007.50 Focus 5/2007 G165416en


2 Measure the resistance between the gearshift
mode switch C438 pin 9, circuit 50-BB12 (GY),
harness side and the starter motor C110B,
circuit 50-BB12 (GY), harness side.
→ Yes
GO to B4.
→ No
E60185 normal operation.
B4: CHECK CIRCUITS 50-BB12 (GY) AND 50-BB14 (GY/RD) FOR OPEN
relay C1013 pin 5, circuit 50-BB12 (GY),
harness side and the gearshift mode switch
C438 pin 6, circuit 50-BB14 (GY/RD), harness
side.
→ Yes
GO to B5.
→ No
E60186 REPAIR the circuit(s). TEST the system for
normal operation.
B5: CHECK THE GEARSHIFT MODE SWITCH

1 Select PARK.
mode switch C438 pin 6, component side and
the gearshift mode switch C438 pin 9,
component side.
E60187
3 Select NEUTRAL.
2007.50 Focus 5/2007 G165416en


mode switch C438 pin 6, component side and
the gearshift mode switch C438 pin 9,
component side.
• Are the resistances 0 ohms?
→ Yes
GO to B6.
→ No
INSTALL a new gearshift mode switch. TEST
E60187 the system for normal operation.
B6: CHECK THE STARTER RELAY

3 Carry out the relay component test on starter
relay C1013. For additional information, REFER
to the Wiring Diagrams.
• Does the starter relay pass the component
test?
→ Yes
REPAIR circuit 50-BB12 (GY). TEST the
system for normal operation. If the concern
persists, INSTALL a new CJB.
→ No
INSTALL a new starter relay. TEST the
2007.50 Focus 5/2007 G165416en

PINPOINT TEST C : THE ENGINE CRANKS SLOWLY
C1: CHECK THE STARTER MOTOR LOAD
1 Carry out the starter motor Component Test
using WDS.
• Is the starter motor OK?
→ Yes
GO to C2.
→ No
REFER to: Starter Motor - 1.4L Duratec-16V
Starting System, Removal and Installation)
/ Starter Motor - 2.0L Duratec-HE (MI4)/1.8L
/ Starter Motor - 1.6L Duratorq-TDCi (DV)
and Installation)
/ Starter Motor - 1.8L Duratorq-TDCi (Lynx)
and Installation).
2007.50 Focus 5/2007 G165416en


C2: CHECK FOR VOLTAGE DROP
pin 30, component side and the battery positive
V terminal with the ignition switch in position III.
• Is the voltage less than 0.5 volts?
→ Yes
GO to C3.
→ No
CLEAN and TIGHTEN all positive battery
VUV2601160 normal operation. If the concern persists.
INSTALL a new battery to starter motor cable.
REFER to: Battery Cables - 1.4L Duratec-16V
Battery, Mounting and Cables, Removal and
Installation)
/ Battery Cables - 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4) (414-01 Battery, Mounting
and Cables, Removal and Installation)
/ Battery Cables - 1.6L Duratorq-TDCi (DV)
Cables, Removal and Installation)
/ Battery Cables - 2.0L Duratorq-TDCi (DW)
Cables, Removal and Installation).
C3: CHECK FOR GROUND CONNECTION
case and battery negative terminal with the
ignition switch in position III.
V • Is the voltage less than 0.5 volts?

→ Yes
DIAGNOSE the battery and charging system.
VUV9510063
→ No
CLEAN and TIGHTEN all battery negative
connections, starter motor mounting and body
to engine ground straps. TEST the system for
normal operation. If the concern persists,
INSTALL a new battery negative cable. TEST
2007.50 Focus 5/2007 G165416en

Starter Motor — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE

(MI4)(26 204 0)
Cables].
and Lifting].
E40677

table(s).
2007.50 Focus 5/2007 G295706en

1
2
20 Nm
25 Nm
N 3
E41141

1 Starter motor electrical connectors 6. Initialize the door window motors. For
See Removal Detail additional information, refer to
See Installation Detail Section 501-11 [Glass, Frames and
Mechanisms].
2 Starter motor wiring harness support
bracket
3 Starter motor
See Removal Detail
2007.50 Focus 5/2007 G295706en

Removal Details
Item 1 Starter motor electrical connectors Item 3 Starter motor
1. Disconnect the ignition switch and battery 1. Discard the starter motor gasket.
to starter motor solenoid cables.
VUE0023772
E41142
Item 1 Starter motor electrical connectors Item 3 Starter motor
1. Connect the ignition switch and battery to 1. Install a new starter motor gasket into the
starter motor solenoid cables. transaxle housing prior to installing the
starter motor.
6 Nm
12 Nm
E41143
VUE0023772
2007.50 Focus 5/2007 G295706en

Starter Motor — 1.6L (Z6)(26 204 0)

and Operation).
table(s).
2
3
45 Nm 5
4 10 Nm
6
1
E51776
1 Ignition switch to starter motor solenoid 5 Starter motor retaining bolts

cable electrical connector See Installation Detail
2 Battery to starter motor solenoid cable 6 Starter motor

electrical connector shield
See Removal Detail
5. Vehicles with global closing, initialize the
3 Battery to starter motor solenoid cable door window motors.
retaining clips
4 Battery to starter motor solenoid cable Window Motor Initialization (501-11 Glass,
electrical connector retaining nut Frames and Mechanisms, General
Procedures).
Removal Details
2007.50 Focus 5/2007 G384937en

Item 2 Battery to starter motor solenoid cable
1. Unclip the battery to starter motor solenoid
electrical connector shield.
E51777
Item 5 Starter motor retaining bolts
NOTE: Make sure that the engine earth cable
bracket is installed behind the starter motor lower
retaining bolt.
E51778
2007.50 Focus 5/2007 G384937en

Engine Ignition — 2.0L Duratec-HE (MI4)/1.8L
303-07A-1 Duratec-HE (MI4) 303-07A-1
.
SECTION 303-07A Engine Ignition — 2.0L Duratec-HE

CONTENTS PAGE
SPECIFICATIONS

Engine Ignition.................................................................................................................... 303-07A-3
1.8l Duratec HE (MI4) engine............................................................................................. 303-07A-3

Engine Ignition.................................................................................................................... 303-07A-4
Symptom Chart................................................................................................................... 303-07A-4

Ignition Coil-On-Plug — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)........................... 303-07A-5
303-07A-2 Duratec-HE (MI4) 303-07A-2
SPECIFICATIONS
Item Nm lb-ft lb-in
Ignition coil-on-plug retaining bolt(s) 10 - 89
Spark plug(s) 12 10 -
2007.50 Focus 3/2007 G319988en

303-07A-3 Duratec-HE (MI4) 303-07A-3
Engine Ignition
1.8l Duratec HE (MI4) engine
Ignition system
E42995
The ignition system requires this information in

Item Description
order to synchronise the ignition sparks of the
1 Direct ignition coil individual ignition coils.
An ignition system with direct ignition coils is used. If the CMP sensor should fail, the system uses the
signal from the CKP and ignites cylinders "1" and
This provides a more stable combustion process "4" or "2" and "3" together. Here ignition takes place
with reduced exhaust gas emissions. in the working cycle of one cylinder and in the
On this ignition system, a direct ignition coil is exhaust cycle of the other.
needed for each spark plug, and this is located WDS can be used to diagnose the system.
directly on the spark plug.
Only one ignition spark is generated for each direct
ignition coil in the compression stroke.
To do this, the Powertrain Control Module (PCM)
evaluates the signals from the Camshaft Position
(CMP) sensor and the Crankshaft Position (CKP)
sensor.
The CMP sensor identifies cylinder "1" by scanning
the camshaft timing pulley.
2007.50 Focus 3/2007 G187618en

303-07A-4 Duratec-HE (MI4) 303-07A-4
Engine Ignition
General Equipment Visual Inspection Chart
Worldwide Diagnostic System (WDS) Electrical
• Circuit(s)
Inspection and Verification • Wiring harness
• Electrical connector(s)
• Spark plug(s)
2. Visually inspect for obvious signs of electrical
• Ignition coil-on-plug(s)
damage.
• Powertrain control module (PCM)

Symptom Chart
Symptom Chart
• Engine misfire • Spark plug(s). • CARRY OUT a KV test using
WDS.
• Circuit(s) • REFER to WDS.
• PCM.
• PCM calibration.
• Engine stumbling • Spark plug(s). • CARRY OUT a KV test using
WDS.
• PCM.
• PCM calibration.
• Engine lacks power • Spark plug(s). • CARRY OUT a KV test using
WDS.
2007.50 Focus 3/2007 G323557en

303-07A-5 Duratec-HE (MI4) 303-07A-5
Ignition Coil-On-Plug — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE

(MI4)
1. Remove the engine upper cover. 2. Remove the components in the order
table(s).
E39140
2007.50 Focus 3/2007 G295712en

303-07A-6 Duratec-HE (MI4) 303-07A-6
10 Nm
E39285
Item Description
1 Ignition coil-on-plug electrical connector(s)
2 Ignition coil-on-plug(s)
2007.50 Focus 3/2007 G295712en

303-07B-1 Engine Ignition — 1.6L (Z6) 303-07B-1
.
SECTION 303-07B Engine Ignition — 1.6L (Z6)

CONTENTS PAGE
SPECIFICATIONS

Engine Ignition.................................................................................................................... 303-07B-3
Ignition coil.......................................................................................................................... 303-07B-4

Engine Ignition.................................................................................................................... 303-07B-5
Symptom Chart................................................................................................................... 303-07B-5
SPECIFICATIONS
Spark plugs
Description mm
Spark plug gap 1.0
Ignition coil retaining bolt 9 - 80
Spark plug 18 13 -
2007.50 Focus 3/2007 G384938en

Engine Ignition
E53515
Item Description
1 Ignition coils
2 Spark plugs
2007.50 Focus 3/2007 G385278en

Ignition coil
Each engine cylinder has its own ignition coil. The

ignition coil is bolted to the camshaft cover and the
ignition coil retaining bolt makes up part of the high
tension ignition circuit. By using four ignition coils,
the work load on the coils is reduced. The ignition
coil is connected to the spark plug by an integrated
high tension plug cap. The close proximity of the
ignition coil to the spark plug reduces the losses
of energy from the high tension circuit.
2007.50 Focus 3/2007 G385278en

Engine Ignition
1. Verify the customer concern. before proceeding to the next step.
Electrical
• Wiring harness
• Electrical connector(s)
• Spark plug(s)
• Ignition coil pack(s)
• Powertrain control module (PCM)
Symptom Chart
Symptom Chart
• Engine cranks but does not • Spark plug(s). • CARRY OUT a Power Balance
start • Ignition coil pack(s) spark plug test using WDS. INSTALL a
connection. new spark plug(s) or ignition
coil pack(s) as necessary.
operation.
• Ignition coil pack(s). • CARRY OUT an engine
• PCM. diagnostic using WDS.
INSTALL new ignition
operation.
• Engine misfire • Spark plug(s). • CARRY OUT a Power Balance
• Ignition coil pack(s) spark plug test using WDS. INSTALL a
operation.
2007.50 Focus 3/2007 G384942en


• Ignition coil pack(s). NOTE: Only install an updated
• PCM. module calibration if the vehicle
• PCM calibration. exhibits a concern related to the
calibration update.
• CARRY OUT an engine
diagnostic using WDS.
CARRY OUT a module
programming routine using
WDS. TEST the system for
normal operation.
• Low fuel pressure. • CHECK the fuel pressure.
• Fuel pump. INSTALL new fuel system
operation.
• Low cylinder compression. • CARRY OUT an engine
compression check.
• Worn or damaged vale(s), • REMOVE the cylinder head.
valve tappet(s) or camshaft(s). INSPECT the cylinder head,
01 Engine - 1.6L (Z6), In-
vehicle Repair).
• Engine stumbling • Spark plugs. • CARRY OUT a Power Balance
operation.
• Ignition coil pack(s). NOTE: Only install an updated
• PCM. module calibration if the vehicle
• PCM calibration. exhibits a concern related to the
calibration update.
• CARRY OUT an engine
CARRY OUT a module
programming routine using
WDS. TEST the system for
normal operation.
operation.
2007.50 Focus 3/2007 G384942en


compression check.
01 Engine - 1.6L (Z6), In-
vehicle Repair).
• Engine lacks power • Spark plugs. • CARRY OUT a Power Balance
operation.
• Ignition coil pack(s). • CARRY OUT an engine
operation.
operation.
compression check.
01 Engine - 1.6L (Z6), In-
vehicle Repair).
2007.50 Focus 3/2007 G384942en

Engine Emission Control — 2.0L Duratec-HE
303-08A-1 (MI4)/1.8L Duratec-HE (MI4) 303-08A-1
.
SECTION 303-08A Engine Emission Control — 2.0L

CONTENTS PAGE
SPECIFICATIONS

Engine Emission Control.................................................................................................... 303-08A-3
Symptom Chart................................................................................................................... 303-08A-3

Exhaust Gas Recirculation (EGR) Valve............................................................................ 303-08A-5
Crankcase Vent Oil Separator............................................................................................ 303-08A-8
SPECIFICATIONS
Exhaust gas recirculation (EGR) valve bolts 25 18 –
EGR valve outlet tube union 55 41 –
Crankcase vent oil separator retaining bolts 10 – 89
2007.50 Focus 3/2007 G37567en

Engine Emission Control

Worldwide Diagnostic System (WDS) Mechanical Electrical
– Hose(s)/hose joints – Electrical
Inspection and Verification – Gasket(s) connector(s)
– Positive crankcase – Wiring harness
1. Verify the customer concern. ventilation (PCV) – Fuse(s)
2. Visually inspect for obvious signs of mechanical valve – Relay
or electrical damage. – PCV separator – EGR valve
– Exhaust gas recircu- – Powertain control
lation (EGR) valve module (PCM)

4. If the concern is not visually evident, verify the
Symptom Chart
Symptom Chart
• Poor engine performance • EGR valve. • Using WDS, CHECK the EGR
Valve Duty Cycle input signal
to the EGR vacuum regulator
valve. If the result is 0%,
REMOVE the EGR valve.
REFER to Exhaust Gas Recir-
culation (EGR) Valve - in this
section.
INSPECT the EGR valve and
valve seat for damage. Make
sure that the EGR valve is in
the closed position. If the EGR
valve is not closed. INSTALL a
new EGR valve. TEST the
system for normal operation. If
the result is not 0% continue
the engine diagnostic using
WDS.
• Excessive crankcase pressure • Blocked or damaged PCV • CHECK the PCV system
hose(s). components for blockages,
• Blocked crankcase vent oil CLEAN or INSTALL new
separator. components as necessary.
2007.50 Focus 3/2007 G334290en


• Worn or damaged engine • REFER to Section 303-01A
components. [Engine -- 1.4L Duratec-16V
(Sigma)] / 303-01B [Engine --
(Sigma)] / 303-01C [Engine --
Duratec-HE (MI4)] / 303-01D
[Engine -- 2.5L Duratec-ST
(VI5)] / 303-01E [Engine --
Diesel] / 303-01F [Engine --
Diesel] / 303-01G [Engine --
Diesel] / 303-01H [Engine --
1.6L (Z6)].
2007.50 Focus 3/2007 G334290en

Exhaust Gas Recirculation (EGR) Valve

Special Tool(s) 3. Remove the upper engine cover.
Remover/Installer, Coolant
Hose Clamp
303-397
24003
1. Drain the cooling system. For additional

information, refer to Section 303-03A
[Engine Cooling -- 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma)] / 303-03B E39140
[Engine Cooling -- 1.6L Duratec-16V Ti-VCT
(Sigma)] / 303-03C [Engine Cooling -- 2.0L 4. Remove the air cleaner outlet pipe.
Duratec-HE (MI4)/1.8L Duratec-HE (MI4)] /
303-03D [Engine Cooling -- 2.5L Duratec-ST
(VI5)] / 303-03E [Engine Cooling -- 1.6L
Duratorq-TDCi (DV) Diesel] / 303-03F [Engine
Cooling -- 1.8L Duratorq-TDCi (Lynx) Diesel]
/ 303-03G [Engine Cooling -- 2.0L
Duratorq-TDCi (DW) Diesel] / 303-03H
[Engine Cooling -- 1.6L (Z6)].
Cables].
E39283

table(s).
2007.50 Focus 3/2007 G295718en

25 Nm
E40451

1 EGR valve electrical connector 7. Initialize the door window motors. For
2 Throttle body to EGR valve coolant hose Section 501-11 [Glass, Frames and
See Removal Detail Mechanisms].
3 EGR valve
Removal Details
2007.50 Focus 3/2007 G295718en

Item 2 Throttle body to EGR valve coolant hose
1. Using the special tool, remove the throttle
body to EGR valve coolant hose from the
throttle body.
E40452
2. Using the special tool, remove the throttle

body to EGR valve coolant hose from the
EGR valve.
E40453
2007.50 Focus 3/2007 G295718en

Crankcase Vent Oil Separator

Removal
For additional information, refer to: Intake
Manifold (303-01 Engine - 2.0L Duratec-HE 10 Nm
Repair).
2. Disconnect the positive crankcase ventilation
(PCV) hose from the PCV valve.
VUE0015064
Installation
1. NOTE: Install a new crankcase vent oil
separator gasket.
NOTE: Make sure that the PCV hose is clean and
VUE0017647
free from any oil residue as this will reduce the
installation grip of the PCV hose.
3. Remove the PCV valve from the crankcase To install, reverse the removal procedure.
vent oil separator.
1. Push in the locking tangs.
2. Twist the PCV valve to remove.
2
1
VUE0017648
4. Remove the crankcase vent oil separator.
2007.50 Focus 3/2007 G319990en

303-08B-1 Engine Emission Control — 1.6L (Z6) 303-08B-1
.
SECTION 303-08B Engine Emission Control — 1.6L

(Z6)
CONTENTS PAGE
SPECIFICATIONS

Engine Emission Control.................................................................................................... 303-08B-3

Engine Emission Control.................................................................................................... 303-08B-4
Symptom Chart................................................................................................................... 303-08B-4

Exhaust Gas Recirculation (EGR) Valve............................................................................ 303-08B-6
Crankcase Vent Oil Separator............................................................................................ 303-08B-8
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube................................... 303-08B-9
Exhaust Gas Recirculation (EGR) Valve Outlet Tube......................................................... 303-08B-12
SPECIFICATIONS
Item Nm lb-ft lb-in
Windshield wiper arm retaining nuts 15 11 -
Exhaust manifold to exhaust gas recirculation 9 - 80
(EGR) vale tube support bracket retaining nut
Exhaust manifold to EGR vale tube, EGR valve 9 - 80
retaining nuts
EGR valve retaining nuts 21 15 -
Exhaust manifold to EGR valve tube, exhaust 39 29 -
manifold union
EGR outlet valve tube union 39 29 -
EGR valve outlet tube support bracket retaining bolt 9 - 80
EGR outlet tube to intake manifold retaining bolts 9 - 80
Crankcase vent oil seperator retaining bolts 9 - 80
Oil level indicator tube retaining bolt 9 - 80
2007.50 Focus 3/2007 G384956en

3
2
Item Description
1 Exhaust gas recirculation (EGR) valve
bracket to intake manifold EGR tube
2 EGR valve bracket
3 EGR valve
4 Exhaust manifold to EGR valve bracket
EGR tube
The EGR system consists of an EGR valve, the
EGR tubes and an EGR valve bracket to which
they are all connected.
The recirculated quantity of exhaust gas is
regulated by the EGR valve which allows for
accurate adjustment.
The EGR valve is actuated directly by the PCM
(Powertrain control module) using pulse-width
modulated signals. The PCM determines the
position of the EGR valve using data from various
other electronic engine controls. The EGR valve
also provides a feedback signal to the PCM which
is used to determine any EGR system fault.
2007.50 Focus 3/2007 G385279en


Worldwide Diagnostic System (WDS) Mechanical Electrical
• Exhaust gas recircu- • EGR valve
Inspection and Verification lation (EGR) valve • EGR valve electrical
• EGR valve gasket connector
1. Verify the customer concern. • Exhaust manifold to • EGR valve wiring
2. Visually inspect for obvious signs of mechanical EGR valve tube harness
or electrical damage. • EGR valve to intake
manifold tube
• Positive crankcase
ventilation (PCV)
valve
• Crankcase vent oil
separator
• PCV hose

Symptom Chart
Symptom Chart
• Excessive exhaust black • EGR valve • CHECK the operation of the
smoke EGR valve using WDS. If the
EGR valve is operating
correctly, REMOVE and
INSPECT the EGR valve and
valve seat for signs of damage.
INSTALL a new EGR valve if
necessary.
REFER to: Exhaust Gas Recir-
culation (EGR) Valve (303-08
Engine Emission Control -
1.6L (Z6), Removal and
Installation).
operation. If the EGR valve is
OK, continue the diagnostic
using WDS.
2007.50 Focus 3/2007 G384960en


• Excessive crankcase pressure • Blocked PCV valve. • CLEAN or INSTALL new PCV
• Blocked crankcase vent oil components as necessary.
separator. TEST the system for normal
• Blocked PCV hose. operation.
• Blocked intake manifold PCV
hose union.
• Worn or damaged engine • REFER to: Engine (303-00
components. Engine System - General
Testing).
• Oil in the air intake system • Restriction in the PCV crank- • CLEAN the PCV crankcase
case vent oil separator. vent oil separator.
REFER to: Crankcase Vent Oil
Separator (303-08 Engine
Emission Control - 1.6L (Z6),
operation.
• PCV valve permanently open. • INSTALL a new PCV valve.
operation.
• Worn or damaged engine • REFER to: Engine (303-00
components. Engine System - General
Testing).
2007.50 Focus 3/2007 G384960en

Exhaust Gas Recirculation (EGR) Valve

1. NOTE: Make sure that the windshield wiper 5. Remove the cowl panel grille.
motor is in the park position.
1. Detach the cowl panel grille retaining clips.
Disconnect the battery ground cable. 2. Detach the cowl panel grille from the
For additional information, refer to: Battery windshield glass lower weatherstrip and
Disconnect and Connect (414-01 Battery, remove.
6. Remove the bulkhead extension panel.

1. Remove the bulkhead extension panel
3. Detach the brake fluid reservoir from the retaining screws.
bulkhead extension panel. 2. Detach the bulkhead extension panel
retaining clips.
4. Remove the windshield wiper arms. 7. Remove the components in the order
table(s).
2007.50 Focus 3/2007 G384961en

3 5
6
9 Nm 1
9 Nm 2 21 Nm 4
support bracket retaining nut gasket
2 Exhaust manifold to EGR valve tube, EGR 7 EGR valve gasket

valve retaining nuts
3 EGR valve electrical connector 9. Vehicles with global closing, initialize the
4 EGR valve retaining nuts door window motors.
5 EGR valve For additional information, refer to: Door
Removal Details
Item 5 EGR valve
CAUTION: When removing the EGR valve,
do not place excessive strain on the EGR
valve to exhaust manifold tube. Failure to
follow this instruction could result in
damage and leaks to the EGR valve to
exhaust manifold tube.
2007.50 Focus 3/2007 G384961en

Crankcase Vent Oil Separator

3. Remove the engine oil level indicator tube.
For additional information, refer to: Intake 1
In-vehicle Repair).
2
2. Remove the engine oil level indicator and
tube.
1. Remove the engine oil level indicator.
2. Remove the engine oil level indicator tube
retaining bolt. 3

table(s).
1 9 Nm

1 Crankcase vent oil seperator retaining
bolts
2 Crankcase vent oil seperator
3 Crankcase vent oil seperator seal
2007.50 Focus 3/2007 G384962en

Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube


retaining clips.
table(s).
2007.50 Focus 3/2007 G413472en

1
5 2
support bracket retaining nut 5 Exhaust manifold to EGR valve tube
See Installation Detail gasket
2 Exhaust manifold to EGR valve tube, EGR
valve retaining nuts
See Installation Detail 9. Vehicles with global closing, initialize the
door window motors.
3 Exhaust manifold to EGR valve tube,
exhaust manifold union For additional information, refer to: Door
Removal Details
Item 3 Exhaust manifold to EGR valve tube,
exhaust manifold union
and Operation).
2007.50 Focus 3/2007 G413472en

Item 3 Exhaust manifold to EGR valve tube, 4. Tighten the exhaust manifold to EGR valve
exhaust manifold union tube, exhaust manifold union.
1. Install the exhaust manifold to EGR valve
tube, exhaust manifold union finger tight.
Item 2 Exhaust manifold to EGR valve tube,

EGR valve retaining nuts
1. Install the exhaust manifold to EGR valve 39 Nm
tube, EGR valve retaining nuts finger tight.
Item 1 Exhaust manifold to EGR valve tube

support bracket retaining nut
1. Install the exhaust manifold to EGR valve
tube support bracket retaining nut finger 5. Lower the vehicle.
tight.
2. Tighten the exhaust manifold to EGR valve
tube, EGR valve retaining nuts and the
exhaust manifold to EGR valve tube support
bracket retaining nut in the order indicated.
9 Nm 1
2 9 Nm

and Operation).
2007.50 Focus 3/2007 G413472en

Exhaust Gas Recirculation (EGR) Valve Outlet Tube


retaining clips.
table(s).
2007.50 Focus 3/2007 G413473en

5 N
2
3
1 EGR valve outlet tube union 4 EGR valve outlet tube

2 EGR valve outlet tube support bracket 5 EGR valve outlet tube to intake manifold
retaining bolt O-ring seal
3 EGR valve outlet tube to intake manifold 9. Vehicles with global closing, initialize the
retaining bolts door window motors.
Removal Details
Item 4 EGR valve outlet tube valve outlet tube. Failure to follow this
instruction may result in engine coolant
CAUTION: Do not place excessive strain
leaks or poor engine run characteristics.
on the fuel charging wiring harness or
coolant hoses when removing the EGR
2007.50 Focus 3/2007 G413473en

Item 3 EGR valve outlet tube to intake manifold
retaining bolts
1. Install the EGR valve outlet tube to intake
manifold retaining bolts finger tight.
Item 2 EGR valve outlet tube support bracket

retaining bolt
1. Install the EGR valve outlet tube support
bracket retaining bolt finger tight.
Item 1 EGR valve outlet tube union

1. Install the EGR valve outlet tube union finger
tight.
2. Tighten the EGR valve outlet tube in the
order indicated.
39 Nm 2
9 Nm 1
9 Nm 3
2007.50 Focus 3/2007 G413473en

303-12-1 Intake Air Distribution and Filtering 303-12-1
.
SECTION 303-12 Intake Air Distribution and Filtering

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 303-12-2

Intake Air Distribution and Filtering — 1.8L Duratec-HE (MI4)........................................... 303-12-3
1.8L Duratec HE (MI4) engine............................................................................................ 303-12-3
Intake Air Distribution and Filtering — 1.6L (Z6)................................................................ 303-12-6
Intake manifold................................................................................................................... 303-12-7
Intake air resonator............................................................................................................. 303-12-7
Air cleaner.......................................................................................................................... 303-12-8

Intake Air Distribution and Filtering..................................................................................... 303-12-9
Symptom Chart................................................................................................................... 303-12-9

Air Cleaner — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)...................... (23 174 0) 303-12-20
Air Cleaner — 1.6L (Z6)................................................................................. (23 174 0) 303-12-23
SPECIFICATIONS
Item Nm lb-ft lb-in
Charge air cooler retaining bolts 5 - 44
Air cleaner outlet tube retaining clips (vehicles with 4 - 35
1.4L or 1.6L engines)
2007.50 Focus 5/2007 G165567en

Intake Air Distribution and Filtering — 1.8L Duratec-HE (MI4)
Intake manifold and ancillary components
3
2
1
E43000
The solenoid valves are actuated by the powertrain

Item Description
control module (PCM). The engine speed and
1 Throttle Position (TP) sensor engine load are used as input signals.
2 Electronic intake manifold valve An electronic intake manifold valve is also used.
3 Central vacuum supply The housing of the electronic intake manifold valve
is heated by the coolant circuit by means of a
4 Solenoid valve - intake manifold connection above the base of the air shutoff
switchover system throttle. This prevents the intake manifold valve
5 Swirl valve solenoid valve from icing up.
The coolant connection of the exhaust gas
The intake manifold is made of plastic and is fitted recirculation (EGR) stepper motor is connected to
with swirl valves and an intake manifold switchover the housing of the electronic intake manifold valve.
system. At the other end of the electronic intake manifold
Each plate is actuated by its own dedicated valve housing, the coolant connection is connected
vacuum motor. The required vacuum is switched with the feed pipe to the heat exchanger.
by a solenoid valve.
2007.50 Focus 5/2007 G334185en

Swirl valves
E42999
The improved swirl of the fuel/air mixture makes

Item Description
the fuel/air mixture easier to ignite. Fuel
1 Swirl valves consumption and exhaust emissions are reduced
as a result.
The swirl valve system from the Mondeo remains
unchanged. The plates are adjusted by means of a vacuum
motor on the intake manifold.
The swirl valves reduce the cross section of the
intake ports in the lower engine speed range, The swirl valves are closed when the engine is not
thereby swirling the intake air. running.
2007.50 Focus 5/2007 G334185en

Intake manifold switchover system
E42998
When engine speed is reduced to around 4300

Item Description
rpm, the flaps of the intake manifold switchover
1 Flaps - intake manifold switchover system system are closed.
2 Intake manifold switchover vacuum motor This allows the inlet air to flow out of the other
intake pipes, via the cylinder specific intake pipe
3 Swirl valve vacuum motor and the cylinder specific flap of the intake manifold
switchover system.
The flaps of the intake manifold switchover system
allow the length of the inlet tract to be varied in
order to allow engine speed dependent resonance
charging of the cylinder.
are open when the engine is not running.
When the engine is started the vacuum generated
is applied via the solenoid to the vacuum motor of
the intake manifold switchover flaps.
are closed.
Now the inlet air is exclusively obtained through
the cylinder specific inlet port from the intake
manifold.
When engine speed is increased to around 4500
rev/min, the flaps of the intake manifold switchover
system are opened.
2007.50 Focus 5/2007 G334185en

Intake Air Distribution and Filtering — 1.6L (Z6)
3 4
E53695
1 Intake manifold 3 Air cleaner
2 Intake air resonator 4 Air cleaner outlet hose
2007.50 Focus 5/2007 G424533en

Intake manifold
2
3 5
E53698
charge can be accommodated by the intake

Item Description
manifold. During this high demand throttle
1 Throttle body condition, the IMT swirl plates are fully open so as
not to restrict the air charge flow.
2 Primary air intake chambers
Built into the intake manifold body, positioned just
3 Intake manifold runner control (IMRC) behind the throttle body is the EGR and the fuel
throttle plates evaporative emissions inlet ports. By having these
4 Intake manifold tuning (IMT) swirl plates two ports at the beginning of the intake manifold,
the gasses entering the intake manifold have time
5 Exhaust gas recirculation (EGR) intake to mix with the air charge from the air cleaner.
port
6 Fuel evaporative emissions intake port Intake air resonator
Clean air from the air cleaner enters the intake
manifold through the throttle body. The volume of
air is controlled by the throttle body throttle plate. 2
Under low demand throttle conditions, the air

charge is delivered to the cylinder head intake ports
via the primary air intake chambers. The charge is
then mixed by the IMT swirl plates to assist in the
mixing of the air fuel mixture at the fuel injectors.
During high demand throttle conditions, the IMRC
throttle plates are opened and the air charge is
allowed to use both primary and secondary intake
chambers. This means a higher volume of air E53696
2007.50 Focus 5/2007 G424533en

The intake air resonator is fitted under the left hand
fender and extracts intake air from behind the left
hand headlamp. The air from the air intake
resonator is then passed to the air cleaner through
a solid pipe which exits through the inner fender.
Air cleaner
E53697
The air cleaner is made up of:

• Air cleaner base
• Air cleaner filter
• Air cleaner cover
The dirty air enters from the air resonator into the
air cleaner base, through the air filter and clean air
passes out through the air cleaner cover. The air
cleaner cover has a secondary filter gauze fitted
to the outlet. Fitted into the air cleaner cover outlet
pipe, is the manifold absolute pressure (MAP)
sensor.
2007.50 Focus 5/2007 G424533en

Intake Air Distribution and Filtering

– Air cleaner element – Mass air flow (MAF)
– Air cleaner intake sensor
hose – Manifold absolute
– Air cleaner outlet pressure (MAP)
hose sensor (Vehicles with
1.6L Diesel and 2.0L
– Charge air cooler
Diesel engine)
(Vehicles with 1.6L
Diesel and 2.0L – Electrical
Diesel engine) connector(s)
intake hose
(Vehicles with 1.6L
Diesel and 2.0L
Diesel engine)
outlet hose (Vehicles
with 1.6L Diesel and
2.0L Diesel engine)
Symptom Chart

• Excessive intake air noise • Detached air cleaner hose(s). • CHECK the hose(s) for security
• Detached turbocharger hose(s) and leaks to atmosphere.
(Vehicles with 1.6L Diesel and INSTALL new intake air
2.0L Diesel engine). components as necessary.
• Detached charge air cooler TEST the system for normal
hose(s) (Vehicles with 1.6L operation.
Diesel and 2.0L Diesel engine).
2007.50 Focus 5/2007 G165569en


• Oil in the air intake system • Blocked or damaged positive
crankcase ventilation (PCV)
valve.
• Blocked or damaged PCV
pipe(s)/hose(s).
• Blocked or damaged crankcase
vent oil separator.
2007.50 Focus 5/2007 G165569en


• Vehicles with 1.6L engine.
REFER to Section 303-08A
[Engine Emission Control --
Duratec-16V Ti-VCT (Sigma)]
/ 303-08B [Engine Emission
Control -- 2.0L Duratec-HE
(MI4)/1.8L Duratec-HE (MI4)] /
303-08C [Engine Emission
Control -- 1.6L Duratorq-TDCi
(DV) Diesel] / 303-08D [Engine
Emission Control -- 2.0L
Duratorq-TDCi (DW) Diesel] /
303-08E [Engine Emission
Control -- 1.6L (Z6)] / 303-08F
Diesel] / 303-08G [Engine
Duratec-ST (VI5)].
• Vehicles with 1.8L/2.0L engine.
Control -- 1.6L (Z6)] / 303-08F
Duratec-ST (VI5)].
• Vehicles with 1.6L Diesel
engine. REFER to
Section 303-08A [Engine
2007.50 Focus 5/2007 G165569en


Control -- 1.6L (Z6)] / 303-08F
Duratec-ST (VI5)].
engine. REFER to
Section 303-08A [Engine
Control -- 1.6L (Z6)] / 303-08F
Duratec-ST (VI5)].
2007.50 Focus 5/2007 G165569en


• Turbocharger (Vehicles with • Vehicles with 1.6L and 2.0L
1.6L Diesel and 2.0L Diesel Diesel engine. REFER to
engine). Section 303-04A [Fuel Char-
ging and Controls -- 1.4L
Duratec-16V (Sigma)] / 303-
04B [Fuel Charging and
Controls -- 1.6L Duratec-16V
Ti-VCT (Sigma)] / 303-04C
[Fuel Charging and Controls --
2.5L Duratec-ST (VI5)] / 303-
04E [Fuel Charging and
Controls - Turbocharger -- 2.5L
Duratec-ST (VI5)] / 303-04F
Diesel] / 303-04G [Fuel Char-
Duratorq-TDCi (Lynx) Diesel] /
303-04H [Fuel Charging and
Controls -- 2.0L Duratorq-TDCi
(DW) Diesel] / 303-04I [Fuel
Charging and Controls -
Turbocharger] / 303-04J [Fuel
Charging and Controls -- 1.6L
(Z6)].
• Water in the air cleaner • Air intake pipe splash shield. • CHECK the air intake pipe
splash shield for correct install-
ation and alignment.
REPAIR/INSTALL the air intake
pipe splash shield as neces-
normal operation.
• Blocked air cleaner drain. • CHECK the air cleaner drain
for blockage. TEST the system
• Engine lacks power • Air cleaner element blocked. • INSPECT the air cleaner for
signs of blockage. INSTALL a
new air cleaner element as
necessary.
• Charge air cooler pipe(s) • INSPECT the charge air cooler
(Vehicles with 1.6L Diesel and pipes for damage. INSTALL a
2.0L Diesel engine). new charge air cooler pipe(s)
as necessary.
2007.50 Focus 5/2007 G165569en


• Charge air cooler blocked • INSPECT the charge air cooler
(Vehicles with 1.6L Diesel and for blockage. INSTALL a new
2.0L Diesel engine). charge air cooler as necessary.
REFER to Charge Air Cooler -
1.6L Diesel/2.0L Diesel in this
section.
2007.50 Focus 5/2007 G165569en


• Fuel charging and controls
2007.50 Focus 5/2007 G165569en


• Vehicles with 1.6L engine.
(Z6)].
• Vehicles with 1.8L/2.0L engine.
2007.50 Focus 5/2007 G165569en


(Z6)].
engine. REFER to
Section 303-04A [Fuel Char-
(Z6)].
2007.50 Focus 5/2007 G165569en


engine. REFER to
Section 303-04A [Fuel Char-
(Z6)].
2007.50 Focus 5/2007 G165569en


• Turbocharger (Vehicles with • Vehicles with 1.6L and 2.0L
1.6L Diesel and 2.0L Diesel Diesel engine. REFER to
engine). Section 303-04A [Fuel Char-
(Z6)].
2007.50 Focus 5/2007 G165569en

Air Cleaner — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE

(MI4)(23 174 0)
1. Remove the upper engine cover. 2. Remove the components in the order
table(s).
E39140
2007.50 Focus 5/2007 G295769en

1 4
3
2
E39282
1 Air cleaner outlet pipe 3 Air cleaner quick release retainer

2 Positive crankcase ventilation (PCV) hose 4 Air cleaner

quick release coupling See Installation Detail
Removal Details
2007.50 Focus 5/2007 G295769en

Item 1 Air cleaner outlet pipe Item 3 Air cleaner quick release retainer
1. Release the air cleaner outlet pipe retaining 1. Detach the air cleaner quick release retainer
clips. from the air cleaner.
E39283 E39284
Item 4 Air cleaner
NOTE: Make sure the two locating pegs on the air
cleaner are located into the rubber grommets on
the support bracket.

quick release coupling
NOTE: Make sure that the PCV hose quick release
coupling and air cleaner are clean and free from
any oil residue.
2007.50 Focus 5/2007 G295769en

Air Cleaner — 1.6L (Z6)(23 174 0)

table(s).
2
6
3
E51894
1 Mass air flow (MAF) sensor electrical 4 Air cleaner outlet hose to throttle body
connector retaining clamp
2 Evaporative emissions control valve

3 Crankcase ventilation hose
2007.50 Focus 5/2007 G384973en

Item Description NOTE: Make sure that the inside of the air cleaner
outlet hose is clean and free from any oil residue,
5 Air cleaner quick release retainer as this will reduce the installation grip of the hose
See Removal Detail to the throttle body.
6 Air cleaner NOTE: Make sure the positive crankcase
See Installation Detail ventilation (PCV) hose is clean and free from any
oil residue.
Removal Details
Item 5 Air cleaner quick release retainer
1. Detach the air cleaner quick release retainer
from the air cleaner.
E39284
Item 6 Air cleaner
NOTE: Make sure the two locating pegs on the air
cleaner are located into the rubber grommets on
the support bracket.
2007.50 Focus 5/2007 G384973en

303-13-1 Evaporative Emissions 303-13-1
.
SECTION 303-13 Evaporative Emissions

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 303-13-2

Evaporative Emissions....................................................................................................... 303-13-3

Evaporative Emission Canister........................................................................................... 303-13-4
SPECIFICATIONS
Item Nm lb-ft lb-in
Evaporative emission canister retaining bolts 9 - 80
2007.50 Focus 3/2007 G165590en

Evaporative Emissions
– Vacuum line(s) – Fuse(s)
– Evaporative emis- – Wiring harness
sion canister – Electrical
– Evaporative emis- connector(s)
sion system hose(s)
– Evaporative emis-
sion canister purge
valve

symptom and refer to WDS to diagnose the
system.
2007.50 Focus 3/2007 G165592en

Evaporative Emission Canister

table(s).
and Lifting].
9 Nm 1
E41175
1 Evaporative emission canister retaining 4 Evaporative emission canister breather

bolts hose
2 Fuel tank vent pipe to evaporative 5 Evaporative emission canister

emission canister quick release coupling See Installation Detail
See Removal Detail
3 Evaporative emission purge valve pipe to
evaporative emission canister quick
release coupling
See Removal Detail
Removal Details
Item 2 Fuel tank vent pipe to evaporative
emission canister quick release coupling
1. Disconnect the fuel tank vent pipe to
evaporative emission canister. For additional
information, refer to Section 310-00 [Fuel
2007.50 Focus 3/2007 G295783en

Item 3 Evaporative emission purge valve pipe valve pipe to evaporative emission canister.
to evaporative emission canister quick release For additional information, refer to
coupling Section 310-00 [Fuel System - General
Information].
1. Disconnect the evaporative emission purge
Item 5 Evaporative emission canister
1. Make sure the evaporative emission canister
locating tang is positioned correctly on to
the rear crossmember .
E41185
2007.50 Focus 3/2007 G295783en

303-14-1 Electronic Engine Controls 303-14-1
.
SECTION 303-14 Electronic Engine Controls

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 303-14-3

Electronic Engine Controls — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4).................. 303-14-6
System overview, 1.8L Duratec HE (MI4) engine............................................................... 303-14-6
Components....................................................................................................................... 303-14-8
Electronic Engine Controls — 1.6L (Z6)............................................................................. 303-14-13
IMT valve............................................................................................................................ 303-14-14
PCM.................................................................................................................................... 303-14-15
ECT sensor......................................................................................................................... 303-14-15
TP sensor........................................................................................................................... 303-14-15
IAC valve............................................................................................................................ 303-14-15
EOP sensor........................................................................................................................ 303-14-16
IMRC actuator.................................................................................................................... 303-14-16
Knock sensor...................................................................................................................... 303-14-16
CMP sensor........................................................................................................................ 303-14-16
Barometric pressure sensor............................................................................................... 303-14-17
VCT oil control solenoid...................................................................................................... 303-14-17
CKP sensor........................................................................................................................ 303-14-17
PSP switch......................................................................................................................... 303-14-17
HO2S.................................................................................................................................. 303-14-18
Catalyst monitor sensor...................................................................................................... 303-14-18
MAF sensor........................................................................................................................ 303-14-18

Electronic Engine Controls................................................................................................. 303-14-19

Powertrain Control Module (PCM) — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE
(MI4), Vehicles Without: PCM Security Shield.............................................. (29 200 0) 303-14-20
Powertrain Control Module (PCM) — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE
(MI4), Vehicles With: PCM Security Shield................................................... (29 200 0) 303-14-22
Powertrain Control Module (PCM) — 1.6L (Z6)............................................. (29 200 0) 303-14-25
Knock Sensor (KS) — 1.6L (Z6)..................................................................... (29 222 0) 303-14-26
Front Knock Sensor (KS) — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)..................... 303-14-27
Rear Knock Sensor (KS) — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)..................... 303-14-30
Brake Pedal Position (BPP) Switch................................................................ (33 501 0) 303-14-33
Engine Coolant Temperature (ECT) Sensor — 1.6L (Z6).............................. (21 190 0) 303-14-36
Variable Camshaft Timing (VCT) Oil Control Solenoid — 1.6L (Z6)................................... 303-14-38
Intake Manifold Tuning (IMT) Valve — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)..... 303-14-41
Idle Air Control (IAC) Valve — 1.6L (Z6)........................................................ (23 323 0) 303-14-44
Clutch Pedal Position (CPP) Switch............................................................... (25 247 0) 303-14-45
.
Throttle Position (TP) Sensor — 1.6L (Z6)..................................................... (23 325 0) 303-14-48
SPECIFICATIONS
Torque Specifications - vehicles with 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.6L
Duratec-16V Ti-VCT (Sigma) engine
Crankshaft position (CKP) sensor 7 - 62
retaining bolt
Heated oxygen (HO2S) sensor 42 31 -
Camshaft position (CMP) sensor 7 - 89
retaining bolt
Engine coolant temperature (ECT) 12 - 53
sensor
Variable camshaft timing (VCT) oil 10 - 89
control solenoid retaining bolt
(vehicles with 1.6L Duratec-16V Ti-
VCT (Sigma) engine)
Torque Specifications - vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine

Engine timing belt upper cover 4 - 35
retaining bolts
Engine timing belt lower cover 6 - 53
retaining bolts
Crankshaft pulley retaining bolt a - -
retaining bolt
retaining bolt
a)
For additional information, refer to: Crankshaft Position (CKP) Sensor - 1.6L Duratorq-TDCi (DV) Diesel (303-14 Electronic Engine

retaining bolt
retaining bolt
Engine coolant temperature (ECT) 20 15 -
sensor
Knock Sensor (KS) 26 19 -
Variable camshaft timing (VCT) oil 10 - 89
control solenoid retaining bolt
Heated oxygen (HO2S) sensor 40 30 -
Intake manifold tuning (IMT) valve 5 - 44
retaining bolts
2007.50 Focus 5/2007 G165602en

SPECIFICATIONS

Throttle position (TP) sensor retaining 2 - 18
bolts
Idle air control (IAC) valve 5 - 44
Engine oil pressure (EOP) sensor 15 11 -
Intake manifold runner control (IMRC) 9 - 80
actuator retaining bolts
Catalyst monitor sensor 40 30 -
Torque Specifications - vehicles with 1.8L Duratorq-TDCi (Kent) Diesel engine

Turbocharger oil supply pipe retaining 18 13 -
nut
Knock Sensor (KS) heat shield 23 17 -
retaining stud
KS retaining bolt 20 15 -
retaining bolt
retaining bolt
Fuel filter crash protection top shield 9 - 80
retaining bolts
Cylinder head temperature (CHT) 20 15 -
sensor
Torque Specifications - vehicles with 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) engine
Front Knock Sensor (KS) retaining 20 15 -
bolt
Rear KS retaining bolt 20 15 -
retaining bolt
ECT sensor 12 9 -
retaining bolt
Torque Specifications - vehicles with 2.0L Duratorq-TDCi (DW) Diesel engine

Engine timing belt cover retaining 7 - 62
bolts
Crankshaft pulley retaining bolt a - -
retaining bolt
2007.50 Focus 5/2007 G165602en

SPECIFICATIONS

retaining bolt
a)
For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.0L Duratorq-TDCi (DW) Diesel (303-14 Electronic
Engine Controls, Removal and Installation).
2007.50 Focus 5/2007 G165602en

Electronic Engine Controls — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4)
System overview, 1.8L Duratec HE (MI4) engine
2007.50 Focus 5/2007 G183973en

1 20 21
19
2
22
3
23
4
24
18
25
6
7 26
27
8
9 28
11
10 29
12
30
17
13 31
32
14
15 16
E43368
2007.50 Focus 5/2007 G183973en


1 Temperature and Manifold Absolute 31 Electronic air shutoff throttle
Pressure (T-MAP) sensor
32 Instrument cluster
2 Throttle Position (TP) sensor in the
electronic intake manifold valve
Components
3 Engine Coolant Temperature (ECT)
sensor
4 Crankshaft Position (CKP) sensor PCM
5 Camshaft Position (CMP) sensor
6 Ambient air temperature sensor
7 Heated Oxygen Sensor (HO2S), pre- and
post-cat
8 Power Steering Pressure (PSP) switch
9 Stoplamp switch
10 Clutch Pedal Position (CPP) switch
11 Brake Pedal Position (BPP) switch
E43279
12 Accelerator Pedal Position (APP) sensor
The powertrain control module is housed in the
13 Generator (input signal)
engine compartment next to the battery.
14 Knock Sensor (KS) sensors The PCM is a Visteon Electronic Management
15 Power supply relay System 7.
16 Battery It has two connections for the wiring harness.
17 Malfunction Indicator Lamp (MIL) A comprehensive diagnosis can be performed

through the DLC using the WDS diagnostic
18 Powertrain Control Module (PCM) equipment.
19 Data Link Connector (DLC)
20 Fuel pump relay
21 Fuel pump
22 Fuel injectors
23 Passive Anti-theft System (PATS) LED
24 Exhaust Gas Recirculation (EGR) stepper
motor
25 Solenoid valve - inlet manifold switching
system
26 Swirl plate solenoid valve
27 Air Conditioning (A/C) compressor
28 Generator (output signal)
29 Direct ignition coils
30 EVAP solenoid valve
2007.50 Focus 5/2007 G183973en

KS sensors Then the PCM calculates a new ignition angle and
the ignition timing of the corresponding cylinder is
retarded.
1 Electronic throttle flap
4
2
E42997 3
Item Description
1 Coolant connection, outlet
2 Coolant connection, intake
E42994 3 Electronic throttle flap electric motor

4 TP sensor
NOTE: The stop of the throttle flap must never be
Item Description adjusted.
1 Knock sensors The APP sensor sends the data containing the
driver's acceleration request to the PCM. This
Two knock sensors are used. The knock sensors information depends directly on the movement of
are located on the cylinder block between cylinders the accelerator pedal.
1 and 2 and between cylinders 3 and 4.
The PCM processes this information and sends
As a result, it is possible to maximise the ignition output signals for the electronic throttle valve, the
timing advance, which in turn provides even more ignition system and the injected fuel quantity.
torque at lower engine speeds.
The electric motor moves the throttle flap shaft
If the combustion noise exceeds the permissible using a set of gears.
limits, then the CKP sensor and the CMP sensor
The position of the throttle flap is set and monitored
first determine which cylinder is affected.
in a closed loop control circuit. The TP sensor
supplies the PCM with the current throttle flap
position information.
Should a fault appear at the electronic throttle flap,
a substitute function is performed. This substitute
function allows the throttle flap to be opened by a
defined amount.
For this purpose, there is an throttle flap adjustment
screw on the throttle housing. The return spring
closes the throttle flap until the stop of the toothed
wheel touches the stop screw. In this way a defined
throttle flap gap is formed for limp home mode.
2007.50 Focus 5/2007 G183973en

With the throttle flap kept in a constant position, Direct ignition coils
the ignition angle and the injected fuel quantity are
varied according to the position of the APP sensor
in order to enable restricted operation of the
engine.
The vehicle then drives with a limited top speed.
The stop screw of the throttle flap has a
spring-loaded pin which permits the throttle flap to
be closed beyond the emergency running position
(e.g. idle speed control or engine overrun shutoff).
Intake manifold switchover solenoid and E43364

swirl valve solenoid
The direct ignition coils are pushed onto the
relevant spark plug and are bolted onto the valve
cover.
The PCM actuates each direct ignition coil directly.
Each direct ignition coil is actuated individually by
the PCM.
Because of the direct ignition coils the specification
of the spark plugs has been changed. Irridium
coated spark plugs are now used.
E43366 BPP switch and brake light switch

NOTE: The vacuum line leading to the vacuum
motor of the intake manifold switchover system
must not be swapped with the vacuum line leading
to the vacuum motor of the swirl valves.
The solenoid for the intake manifold switching
system is located together with the swirl valve
solenoid on the transmission side of the cylinder
head.
Vacuum is supplied by a central vacuum
connection from the intake manifold.
The solenoid for the intake manifold switching E43363
system is supplied with either the maximum voltage
or zero voltage, i.e. the valves are either fully open NOTE: Please refer to the current service literature
or fully closed. for the exact procedures for servicing the stop lamp
switch and the BPP switch.
Actuation depends on the engine speed and the
engine load. The BPP switch and the stop lamp switch are
located on the pedal box and provide the PCM with
the information that the vehicle is being
decelerated.
The BPP switch is connected to the instrument
cluster via a CAN bus. In its rest state the switch
is closed and sends a ground signal to the PCM .
2007.50 Focus 5/2007 G183973en

The stop lamp switch is connected to the PCM and When the brake pedal is pressed again the engine
is open in its rest state. When the switch is closed speed drops to idle speed. When the brake pedal
it connects 12V to the PCM . returns to its rest position the engine speed is
increased again.
The signals from the BPP switch and the stop lamp
switch are used in the event of failure of the APP
sensor for the emergency operating mode.
Error messages from the APP sensor
In this instance, the PCM compares the signals of
the BPP switch and brake light switch.
APP sensor
1 2
E43369
Item Description
1 Driver information system
2 Malfunction Indicator Lamp (MIL)
If one of the sensors of the APP sensor fails then
the engine runs with reduced power. However, it
is still possible to reach top speed.
If the vehicle is equipped with a driver information
system, the fault message: "REDUCED
ACCELERATION" will be displayed.
If both sensors of the APP sensor fail, the driver
information system displays the fault message:
"LIMITED MAXIMUM SPEED".
In the event of failure of the electronic throttle flap
the error message "LIMITED MAXIMUM SPEED"
E43365 is also displayed.
The PCM requires the pedal position from the APP
sensor in order to regulate the power output of the
engine according to the driver's request for power.
The APP sensor is a double contactless inductive
sensor.
If a fault of the APP sensor occurs while driving
then a trouble code is stored in the PCM.
If both sensors of the APP sensor fail then, after a
single operation of the BPP switch and the stop
lamp switch and a subsequent comparative
plausibility test, the engine is regulated to a
maximum engine speed of up to 4000 rev/min. The
vehicle can be accelerated to a maximum speed
of 56 km/h.
2007.50 Focus 5/2007 G183973en

1 2
E43370
Item Description
1 Engine system fault warning lamp
2 Malfunction Indicator Lamp (MIL)
If the vehicle is not fitted with a driver information
system, the "engine system fault" warning light will
come on to indicate a system fault.
2007.50 Focus 5/2007 G183973en

Electronic Engine Controls — 1.6L (Z6)
9 1
8
4
7 6 5
E53235
1 Intake manifold tuning (IMT) valve 6 Engine oil pressure (EOP) sensor
2 Powertrain control module (PCM) 7 Intake manifold runner control (IMRC)

actuator
3 Engine coolant temperature (ECT) sensor
8 Knock sensor (KS)
4 Throttle position (TP) sensor
9 Camshaft position (CMP) sensor
5 Idle air control (IAC) valve
2007.50 Focus 5/2007 G426418en

16 9
10
11
15
14 13 12
E53236
Item Description
9 Camshaft position (CMP) sensor IMT valve
10 Barometric pressure sensor
11 Variable camshaft timing (VCT) oil control 1
solenoid
12 Crankshaft position (CKP) sensor
13 Power steering pressure (PSP) switch
14 Heated oxygen sensor (HO2S)
15 Catalyst monitor sensor
16 Mass air flow (MAF) sensor
E53431
The IMT valve controls swirl plates within the intake

manifold which are positioned close to the union
of the intake manifold and cylinder head intake
ports. The function of the swirl plates is to reduce
the cross-section of the intake ports at low speeds.
The IMT valve is controlled by a pulse-width
modulated signal from the PCM. Output from the
IMT valve is transmitted to the swirl plates by a
transfer gear in the IMT valve working directly on
to the swirl plate shaft.
2007.50 Focus 5/2007 G426418en

PCM TP sensor
This engine installation uses a Denso PCM. The The TP sensor measures the current position of
PCM is attached to the battery tray and shielded the throttle body throttle plate using a swept
from direct engine temperatures. variable resistor. The variable voltage output
generated by the TP sensor is used by the PCM
to calculate the drivers demand. The TP sensor
ECT sensor requires no setup or adjustment. But care must be
taken to install the sensor to the correct torque
value to avoid distortion of the sensor body and
subsequent failure.
IAC valve
The ECT sensor is fitted directly into the cylinder

head next to the coolant outlet connector. The ECT
sensor is a resistor with a negative temperature
coefficient (NTC resistor). Using the voltage drop
across the ECT sensor, the PCM calculates the
coolant temperature. The signal from the ECT is
used by the PCM to control the cooling fan motor The IAC valve is attached to the underside of the
and to determine the precise fueling and ignition throttle body. By locating the IAC so close to the
characteristics for the current engine condition. throttle body throttle plate, the length of the IAC
The ECT output is also used for the instrument inlet and outlet tracks have been kept to a
cluster temperature gauge input. minimum. This results in a more precise control of
the engine Idle with a smooth transition between
open and closed throttle.
2007.50 Focus 5/2007 G426418en

EOP sensor Knock sensor
The EOP sensor is located in the engine oil filter The knock sensor is screwed directly into the
housing above the engine oil cooler. The EOP engine block and is located under the intake
sensor provides a ground connection to the manifold. The knock sensor registers increased
instrument cluster oil pressure indicator lamp if the vibration in the engine block developed during
oil pressure drops below a predetermined pressure. increased combustion noise. The PCM uses the
knock sensor signal to adjust the ignition and
fueling characteristics to prevent fuel
IMRC actuator pre-detonation.
CMP sensor
The IMRC actuator controls a set of throttle plates

located in the intake manifold, which in turn control
the volume of air allowed to pass through the intake
manifold dependant on engine demand. The IMRC The CMP sensor is a hall effect sensor located in
actuator is controlled by a pulse-width modulated the camshaft cover. The CMP sensor signal is
signal from the PCM. Output from the IMRC taken from a intake camshaft lobe on cylinder
actuator is transmitted to the throttle plates by a number 1. The CMP sensor is non adjustable and
transfer gear in the IMRC actuator working directly requires no setup procedure when installed.
on to the throttle plate shaft. With the engine at
idle, the IMRC throttle plates would normally be in
the closed position.
2007.50 Focus 5/2007 G426418en

Barometric pressure sensor CKP sensor
10 12
E53437 E53438
The barometric pressure sensor is clipped to the The CKP sensor is a hall effect sensor located on
intake manifold. The signal from the barometric the engine timing belt cover. The CKP sensor
pressure sensor is used by the PCM to adjust the signal is taken from a toothed wheel attached to
ignition and fueling characteristics for changes in the rear of the crankshaft pulley. The CKP sensor
atmospheric pressure in relation to altitude. is non adjustable and requires no setup procedure
when installed.
VCT oil control solenoid
PSP switch
11
13
E53239
E53504
The VCT oil control solenoid controls the camshaft
timing by adjusting the oil flow being delivered to The PSP switch is fitted into the body of the power
the camshaft VCT elements. The VCT oil solenoid steering pump. The signal from the PSP switch is
is controlled by a duty cycle signal from the PCM. used to control the idle speed when the steering
The oil gallery slots in the VCT oil control solenoid wheel is rotated with the engine at idle.
are calibrated to give optimum positioning of the
Intake camshaft in relation to the exhaust camshaft
to achieve an optimized engine torque output.
2007.50 Focus 5/2007 G426418en

HO2S MAF sensor
14 16
E53506 E53238
The HO2S is located in the exhaust manifold before The MAF sensor is located at the outlet of the air
the exhaust catalyst and monitors the Oxygen filter. The MAF sensor is used to calculate the
content of the gasses produced after detonation mass of air being demanded by the engine and so
of the fuel air mixture in the combustion chamber. the engine load conditions. Combined with the MAF
The signal from the HO2S is received by the PCM sensor is the air intake temperature (IAT) sensor,
and is used to adjust the fuel injector pulse width. which takes the form of a hot wire sensor. As the
intake air flows across the IAT sensor the
resistance changes and the voltage output is
Catalyst monitor sensor changed proportionately.
15
E53507
The catalyst monitor sensor measures the Oxygen

content of the exhaust gases after the gases have
passed through the exhaust catalyst. If the
measured amount of Oxygen content, is not
significantly different from the measured quantity
of Oxygen seen at the HO2S, with the engine at
working temperature, a diagnostic trouble code
(DTC) will be generated and the malfunction
indicator lamp (MIL) will be illuminated.
2007.50 Focus 5/2007 G426418en

Electronic Engine Controls

Electrical
– Fuse(s)
– Wiring harness
– Electrical connector(s)
– Relay(s)
– Sensor(s)
– Switch(es)
– Powertrain control module (PCM)

before proceeding to the next step
symptom and refer to WDS to diagnose the
system.
2007.50 Focus 5/2007 G165604en

Powertrain Control Module (PCM) — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4), Vehicles Without: PCM Security
Shield(29 200 0)
NOTE: If a new PCM is being installed connect 2. Remove the engine upper cover.
WDS. Upload the PCM configuration information
using the programmable modules installation
routine prior to commencing the removal of the
PCM.
Cables].
E39140

table(s).
1 3
E39527
2007.50 Focus 5/2007 G295792en

Item Description NOTE: If a new PCM is being installed connect

WDS. Download the PCM configuration information
1 PCM cover using the programmable modules installation
See Removal Detail routine after the installation of the PCM.
2 PCM electrical connectors 5. Initialize the door window motors. For
3 PCM
Section 501-11 [Glass, Frames and
4. To install, reverse the removal procedure. Mechanisms].
Removal Details
Item 1 PCM cover
1. Release the locking tang and remove the
PCM cover.
E39528
2007.50 Focus 5/2007 G295792en

Powertrain Control Module (PCM) — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4), Vehicles With: PCM Security
Shield(29 200 0)
NOTE: If a new PCM is being installed connect the 2. Remove the engine upper cover.
Worldwide Diagnostic System (WDS). Upload the
PCM configuration information using the
programmable modules installation routine prior to
commencing the removal of the PCM.
Cables].
E39140

table(s).
N 1 4
2
N 1 3
N 5
E39530
2007.50 Focus 5/2007 G295793en

1 PCM security bracket shear bolts NOTE: If a new PCM is being installed connect
See Removal Detail WDS. Download the PCM configuration information
using the programmable modules installation
2 PCM security shield routine after the installation of the PCM.
5. Initialize the door window motors. For
3 PCM electrical connectors additional information, refer to
4 PCM Mechanisms].
See Removal Detail
5 PCM security bracket
Removal Details
Item 1 PCM security bracket shear bolts
Item 4 PCM
1. Remove the PCM security bracket shear
bolts (battery tray shown removed for 1. Remove the PCM from the PCM security
clarity). bracket.
• Drill a 3mm pilot hole in the center of the
PCM security bracket shear bolts.
• Drill a 8mm hole in the PCM security bracket
shear bolts and remove the PCM security
shield.
E39532
E39538
2007.50 Focus 5/2007 G295793en

Item 2 PCM security shield
1. Install the PCM security shield locating tangs
into the PCM security bracket (battery tray
E39531
2007.50 Focus 5/2007 G295793en

Powertrain Control Module (PCM) — 1.6L (Z6)(29 200 0)

Removal
2007.50 Focus 5/2007 G426600en

Knock Sensor (KS) — 1.6L (Z6)(29 222 0)

For additional information, refer to: Intake table(s).
In-vehicle Repair).
26 Nm 1
E53285
Item Description
1 KS
2007.50 Focus 5/2007 G384979en

Front Knock Sensor (KS) — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4)
2. Disconnect the front KS electrical connector.
Materials
Name Specification
Metal Surface Cleaner WSE-M5B392-A
1. Remove the intake manifold. For additional
[Engine -- 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)] / 303-01B [Engine --
1.6L Duratec-16V Ti-VCT (Sigma)] / 303-01C
[Engine -- 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4)] / 303-01D [Engine -- 2.5L
Duratec-ST (VI5)] / 303-01E [Engine -- 1.6L E42385
-- 1.8L Duratorq-TDCi (Lynx) Diesel] /
303-01G [Engine -- 2.0L Duratorq-TDCi (DW) 3. Remove the components in the order
Diesel] / 303-01H [Engine -- 1.6L (Z6)]. indicated in the following illustration(s) and
table(s).
2007.50 Focus 5/2007 G338639en

20 Nm
E42384

1 Front KS
See Removal Detail
Removal Details
Item 1 Front KS
NOTE: Make a note of the position of the front KS
and make sure it is positioned in the same position
when installed.
2007.50 Focus 5/2007 G338639en

Item 1 Front KS
NOTE: Prior to installing the front KS, clean the
engine block and front KS mating surfaces with
metal surface cleaner.
NOTE: Make sure the front KS is installed in the
same position as removed
2007.50 Focus 5/2007 G338639en

Rear Knock Sensor (KS) — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4)
2. Disconnect the rear KS electrical connector.
Materials
Name Specification
Metal Surface Cleaner WSE-M5B392-A
1. Remove the intake manifold. For additional
[Engine -- 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)] / 303-01B [Engine --
1.6L Duratec-16V Ti-VCT (Sigma)] / 303-01C
[Engine -- 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4)] / 303-01D [Engine -- 2.5L
Duratec-ST (VI5)] / 303-01E [Engine -- 1.6L E42387
-- 1.8L Duratorq-TDCi (Lynx) Diesel] /
303-01G [Engine -- 2.0L Duratorq-TDCi (DW) 3. Remove the components in the order
Diesel] / 303-01H [Engine -- 1.6L (Z6)]. indicated in the following illustration(s) and
table(s).
2007.50 Focus 5/2007 G338640en

20 Nm
E42386

1 Rear KS
See Removal Detail
Removal Details
Item 1 Rear KS
NOTE: Make a note of the position of the rear KS
and make sure it is positioned in the same position
when installed.
2007.50 Focus 5/2007 G338640en

Item 1 Rear KS
NOTE: Prior to installing the rear KS, clean the
engine block and rear KS mating surfaces with
metal surface cleaner.
NOTE: Make sure the rear KS is installed in the
same position as removed
2007.50 Focus 5/2007 G338640en

Brake Pedal Position (BPP) Switch(33 501 0)

table(s).
Cables].
3 1
E40395
2007.50 Focus 5/2007 G341783en


1 Instrument panel lower trim panel 3 Instrument panel lower trim panel retaining
clips.
2 Instrument panel insulation pad. See Installation Detail
E40396

4 BPP switch electrical connector 4. Initialize the door window motors. For
5 BPP switch Section 501-11 [Glass, Frames and
See Removal Detail Mechanisms].
Removal Details
Item 5 BPP switch
1.
CAUTION: Make sure that the brake pedal
is kept in the rest position and is not pressed
or moved during the removal of the BPP
switch. Failure to follow this may result in
damage to the BPP switch.
Remove the BPP switch.
2007.50 Focus 5/2007 G341783en

• Rotate the BPP switch counter clockwise and
remove.
E40397
Item 5 BPP switch
1.
CAUTION: Make sure that the brake pedal
or moved during the installation of the BPP
switch. Failure to follow this may result in
damage to the BPP switch.
Install the BPP switch.
1. Install the BPP switch.
2. Rotate the BPP switch.
2
E40398
Item 3 Instrument panel lower trim panel

retaining clips.
1. Install the instrument panel lower trim panel
retaining clips to the instrument panel lower
trim panel.
2007.50 Focus 5/2007 G341783en

Engine Coolant Temperature (ECT) Sensor — 1.6L (Z6)(21 190 0)

1. Remove the exhaust gas recirculation (EGR)
valve outlet tube.
table(s).
For additional information, refer to: Exhaust
Gas Recirculation (EGR) Valve Outlet Tube
(303-08 Engine Emission Control - 1.6L
(Z6), Removal and Installation).
1 2 20 Nm
3 N
E52680

1 ECT sensor electrical connector
2 ECT sensor
See Removal Detail
3 ECT sensor sealing washer
Removal Details
Item 2 ECT sensor
NOTE: Make sure the plastic body of the ECT
sensor is not damaged during removal.
2007.50 Focus 5/2007 G424992en

Item 2 ECT sensor
NOTE: Make sure the plastic body of the ECT
sensor is not damaged during installation.
2007.50 Focus 5/2007 G424992en

Variable Camshaft Timing (VCT) Oil Control Solenoid — 1.6L (Z6)

Special Tool(s) 3. Detach the brake fluid reservoir and secure
to one side.
Support Bar, Engine
303-290A

303-290-13

303-290-15 4. Unclip the throttle cable and power assisted
steering (PAS) hose.
5. Detach the PAS reservoir and secure to one

side.
2. Remove the headlamps on both sides.

2007.50 Focus 5/2007 G426549en

6. Attach the special tool on both sides 9. Lower the vehicle.
10. Detach the ground cable from the engine
front mount.
10 Nm
303-290-13
TIE0036685
E51976
For additional information, refer to: Lifting 11. Remove the components in the order
(100-02 Jacking and Lifting, Description indicated in the following illustration(s) and
and Operation). table(s).
303-290-13 303-290-03A
303-290A
303-290A-15 303-290-13
E50547
2007.50 Focus 5/2007 G426549en

2 53 Nm
53 Nm 2
1 80 Nm
4 80 Nm 1
5 10 Nm
E53072
1 Engine front mount to chassis retaining 4 VCT oil control solenoid electrical
bolts. connector.
2 Engine front mount to engine retaining 5 VCT oil control solenoid retaining bolt.
nuts. 6 VCT oil control solenoid O-ring seal.
3 Engine front mount.
Item 2 Engine front mount to engine retaining
nuts.
NOTE: Hand tighten the front engine mount to
engine retaining nuts, install and tighten the front
engine mount to chassis retaining bolts and then
tighten the front engine mount to engine retaining
nuts.
2007.50 Focus 5/2007 G426549en

Intake Manifold Tuning (IMT) Valve — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4)
2. Detach the vacuum lines from the IMT valve
1. Remove the throttle Body. For additional
(intake manifold shown removed for clarity).
information, refer to Section 303-04A [Fuel
Charging and Controls -- 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma)] / 303-04B
[Fuel Charging and Controls -- 1.6L
Duratec-16V Ti-VCT (Sigma)] / 303-04C [Fuel
Charging and Controls -- 2.0L Duratec-HE
(MI4)/1.8L Duratec-HE (MI4)] / 303-04D [Fuel
Charging and Controls -- 2.5L Duratec-ST
(VI5)] / 303-04E [Fuel Charging and Controls
- Turbocharger -- 2.5L Duratec-ST (VI5)] /
303-04F [Fuel Charging and Controls -- 1.6L
Duratorq-TDCi (DV) Diesel] / 303-04G [Fuel
Charging and Controls -- 1.8L Duratorq-TDCi E41498
(Lynx) Diesel] / 303-04H [Fuel Charging and
Controls -- 2.0L Duratorq-TDCi (DW) Diesel]
/ 303-04I [Fuel Charging and Controls - 3. Remove the components in the order
Turbocharger] / 303-04J [Fuel Charging and indicated in the following illustration(s) and
Controls -- 1.6L (Z6)]. table(s).
2007.50 Focus 5/2007 G295911en

1 3
E41497

1 IMT valve vacuum pipe
2 IMT valve retaining screws
3 IMT valve
See Removal Detail
Removal Details
2007.50 Focus 5/2007 G295911en

Item 3 IMT valve
1. Detach the IMT valve actuator rod from the
intake manifold (intake manifold shown
E41499
2007.50 Focus 5/2007 G295911en

Idle Air Control (IAC) Valve — 1.6L (Z6)(23 323 0)

For additional information, refer to: Lifting table(s).
N 4
5 Nm 2
E52012
1 IAC valve electrical connector 3 IAC valve
2 IAC valve retaining bolts 4 IAC valve gasket

Item 2 IAC valve retaining bolts
CAUTION: Do not overtighten the IAC valve
retaining bolts. Failure to follow this
instruction may result in damage to the
brass inserts in the throttle body.
2007.50 Focus 5/2007 G413459en

Clutch Pedal Position (CPP) Switch(25 247 0)

table(s).
3 1
E40395
Item Description
1 Instrument panel lower trim panel
2 Instrument panel insulation pad
3 Instrument panel lower trim panel retaining
clips
2007.50 Focus 5/2007 G414676en

7
4
E51887
4 CPP switch wiring harness retaining clip 6 CPP switch locking tang
5 CPP switch electrical connector 7 CPP switch

Removal Details
Item 4 CPP switch wiring harness retaining clip 1. Release the locking tang.
1. Detach the CPP switch wiring harness 2. Slide the CPP downwards.
retaining clip from the clutch pedal support
bracket.
1
Item 6 CPP switch locking tang

1.
CAUTION: Make sure that the clutch pedal
or moved during the removal of the CPP 2
switch. Failure to follow this instruction may
result in damage to the CPP switch.
Detach the CPP switch from the clutch pedal
E51888
support bracket.
2007.50 Focus 5/2007 G414676en

Item 7 CPP switch
1.
CAUTION: Make sure that the clutch pedal
or moved during the installation of the CPP
switch. Failure to follow this instruction may
result in damage to the CPP switch.
Install the CPP switch.
E51889

retaining clips
retaining clips to the instrument panel lower
trim panel before installation.
2007.50 Focus 5/2007 G414676en

Throttle Position (TP) Sensor — 1.6L (Z6)(23 325 0)

1. Remove the engine upper cover. 2. Remove the air cleaner.
Installation).
table(s).
Item Description
1 TP sensor electrical connector
2 TP sensor retaining bolts
3 TP sensor
2007.50 Focus 5/2007 G417011en

Automatic Transmission/Transaxle —
Vehicles With: 4-Speed Automatic
307-01-1 Transmission (4F27E) 307-01-1
.
SECTION 307-01 Automatic Transmission/Transaxle

— Vehicles With: 4-Speed Automatic Transmission
(4F27E)
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 307-01-3
Differential Shaft Shim Selection Chart.......................................................................... 307-01-3
Clutch Plate Usage and Clearance Specification Chart................................................. 307-01-4
Intermediate/Overdrive Band Bolt Chart......................................................................... 307-01-5
Line Pressure Chart........................................................................................................ 307-01-6
Stall Speed Chart............................................................................................................ 307-01-6

Transaxle Description......................................................................................................... 307-01-8
Transmission Control System............................................................................................. 307-01-34
Electronic Synchronous Shift Control (ESSC).................................................................... 307-01-34

Preliminary Inspection........................................................................................................ 307-01-38
Know and Understand the Concern................................................................................... 307-01-38
Verification of Condition...................................................................................................... 307-01-38
Shift Point Road Test.......................................................................................................... 307-01-41
Torque Converter Diagnosis............................................................................................... 307-01-42
Torque Converter Operation Test....................................................................................... 307-01-42
Transaxle Drive Cycle Test................................................................................................. 307-01-43
After On-Board Diagnostics................................................................................................ 307-01-43
Before Pinpoint Tests.......................................................................................................... 307-01-43
Diagnostic Trouble Code Charts......................................................................................... 307-01-44
Transmission/Transaxle Connector Layouts...................................................................... 307-01-100
Special Testing Procedures................................................................................................ 307-01-104
Engine Idle Speed Check................................................................................................... 307-01-104
Line Pressure Test.............................................................................................................. 307-01-104
Stall Speed Test.................................................................................................................. 307-01-105
Air Pressure Tests.............................................................................................................. 307-01-107
Leakage Inspection............................................................................................................. 307-01-108
Fluid Leakage in Torque Converter Area............................................................................ 307-01-109
Leak Check Test................................................................................................................. 307-01-110
Leak Check Test With Black Light...................................................................................... 307-01-110
Diagnosis By Symptom....................................................................................................... 307-01-111
Diagnosis by Symptom Directions...................................................................................... 307-01-111
Diagnosis by Symptom Index............................................................................................. 307-01-112
Diagnostic Routines............................................................................................................ 307-01-114
307-01-2 Transmission (4F27E) 307-01-2
.
GENERAL PROCEDURES
Transmission Fluid Drain and Refill.................................................................................... 307-01-194
IN-VEHICLE REPAIR
Transmission Fluid Pan, Gasket and Filter......................................................................... 307-01-197
Main Controls...................................................................................................................... 307-01-198
Turbine Shaft Speed (TSS) Sensor.................................................................................... 307-01-201
Output Shaft Speed (OSS) Sensor..................................................................................... 307-01-202
Halfshaft Seal LH................................................................................................................ 307-01-203
Halfshaft Seal RH............................................................................................................... 307-01-205
Transmission Range (TR) Sensor.................................................................. (17 705 0) 307-01-207
REMOVAL
Transaxle — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)......................... (17 214 0) 307-01-210
DISASSEMBLY
Transaxle........................................................................................................ (17 214 8) 307-01-217

Final Drive Carrier and Differential Assembly..................................................................... 307-01-228
Pump Assembly.................................................................................................................. 307-01-230
Transfer Shaft..................................................................................................................... 307-01-232
Forward Clutch................................................................................................................... 307-01-234
Direct and Reverse Clutch Assembly................................................................................. 307-01-237
Direct Clutch....................................................................................................................... 307-01-240
Reverse Clutch................................................................................................................... 307-01-243
Planetary Assembly............................................................................................................ 307-01-246
Main Control Valve Body.................................................................................................... 307-01-251
Transaxle Case................................................................................................................... 307-01-255
Torque Converter................................................................................................................ 307-01-258
Torque Converter Leak Check............................................................................................ 307-01-259
Torque Converter End Play Check..................................................................................... 307-01-260
ASSEMBLY
Transaxle........................................................................................................ (17 214 8) 307-01-261
INSTALLATION
Transaxle — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)......................... (17 214 0) 307-01-278
307-01-3 Transmission (4F27E) 307-01-3
SPECIFICATIONS
Item Specification
Automatic transmission fluid WSS-M2C202-B
Thread sealer SD-M4G9107-A
Loctite 5699 WSS-M4G320-A3
Capacities
Litres
Transmission fluid (including cooler and tubes) 6.7
Transfer Shaft Shim Selection Chart

Tool Reading mm Shim Thickness mm (in)
0.34 - 0.39 0.48 - 0.52 (0.0188 - 0.0204)
0.39 - 0.44 0.53 - 0.57 (0.0208 - 0.0224)
0.44 - 0.49 0.58 - 0.62 (0.0228 - 0.0244)
0.49 - 0.54 0.63 - 0.67 (0.0248 - 0.0263)
0.54 - 0.59 0.68 - 0.72 (0.0267 - 0.0283)
0.59 - 0.64 0.73 - 0.77 (0.0287 - 0.0303)
0.64 - 0.69 0.78 - 0.82 (0.0307 - 0.0322)
0.69 - 0.74 0.83 - 0.87 (0.0326 - 0.0342)
0.74 - 0.79 0.88 - 0.92 (0.0346 - 0.0362)
0.79 - 0.84 0.93 - 0.97 (0.0366 - 0.0381)
0.84 - 0.89 0.98 - 1.02 (0.0381 - 0.0401)
0.89 - 0.94 1.03 - 1.07 (0.0405 - 0.0421)
0.94 - 0.99 1.08 - 1.12 (0.0425 - 0.0440)
0.99 - 1.04 1.13 - 1.17 (0.0444 - 0.0460)
1.04 - 1.09 1.18 - 1.22 (0.0464 - 0.0480)
1.09 - 1.14 1.23 - 1.27 (0.0488 - 0.0500)
1.14 - 1.19 1.28 - 1.32 (0.0503 - 0.0519)
Differential Shaft Shim Selection Chart

0.28 - 0.33 0.48 - 0.52 (0.0188 - 0.0204)
0.33 - 0.38 0.53 - 0.57 (0.0208 - 0.0224)
0.38 - 0.43 0.58 - 0.62 (0.0228 - 0.0244)
0.43 - 0.48 0.63 - 0.67 (0.0248 - 0.0263)
0.48 - 0.53 0.68 - 0.72 (0.0267 - 0.0283)
0.53 - 0.58 0.73 - 0.77 (0.0287 - 0.0303)
0.58 - 0.63 0.78 - 0.82 (0.0307 - 0.0322)
2007.50 Focus 3/2007 G420724en

307-01-4 Transmission (4F27E) 307-01-4
SPECIFICATIONS

0.63 - 0.68 0.83 - 0.87 (0.0326 - 0.0342)
0.68 - 0.73 0.88 - 0.92 (0.0346 - 0.0362)
0.73 - 0.78 0.93 - 0.97 (0.0366 - 0.0381)
0.78 - 0.83 0.98 - 1.02 (0.0385 - 0.0401)
0.83 - 0.88 1.03 - 1.07 (0.0405 - 0.0421)
0.88 - 0.93 1.08 - 1.12 (0.0425 - 0.0440)
0.93 - 0.98 1.13 - 1.17 (0.0444 - 0.0460)
0.98 - 1.03 1.18 - 1.22 (0.0464 - 0.0480)
1.03 - 1.08 1.23 - 1.27 (0.0484 - 0.0500)
1.08 - 1.13 1.28 - 1.32 (0.0503 - 0.0519)
1.13 - 1.18 1.33 - 1.37 (0.0523 - 0.0539)
1.18 - 1.23 1.38 - 1.42 (0.0543 - 0.0559)
1.23 - 1.28 1.43 - 1.47 (0.0562 - 0.0578)
1.28 - 1.33 1.48 - 1.52 (0.0582 - 0.0598)
1.33 - 1.38 1.53 - 1.57 (0.0602 - 0.0618)
Clutch Plate Usage and Clearance Specification Chart

Clutch Steel Friction Clearance mm (in) Selective Snap Ring
Plates Plates Thickness mm (in)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.15 - 1.25 (0.0452 -
0.0492)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.35 - 1.45 (0.0531 -
0.0570)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.55 - 1.65 (0.0610 -
0.0649)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.75 - 1.85 (0.0688 -
0.0728)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 1.95 - 2.05 (0.0767 -
0.0807)
Forward 4 4 1.5 - 1.8 (0.0590 - 0.0708 2.15 - 2.25 (0.0846 -
0.0885)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.15 - 1.25 (0.0452 -
0.0492)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.35 - 1.45 (0.0531 -
0.0570)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.55 - 1.65 (0.0610 -
0.0649)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.75 - 1.85 (0.0688 -
0.0728)
2007.50 Focus 3/2007 G420724en

307-01-5 Transmission (4F27E) 307-01-5
SPECIFICATIONS
Clutch Steel Friction Clearance mm (in) Selective Snap Ring

Plates Plates Thickness mm (in)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 1.95 - 2.05 (0.0767 -
0.0807)
Direct 3 3 1.0 - 1.3 (0.393 - 0.0511) 2.15 - 2.25 (0.0846 -
0.0885)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.15 - 1.25 (0.0452 -
0.0492)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.35 - 1.45 (0.0531 -
0.0570)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.55 - 1.65 (0.0610 -
0.0649)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.75 - 1.85 (0.0688 -
0.0728)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 1.95 - 2.05 (0.0767 -
0.0807)
Reverse 2 2 1.0 - 1.3 (0.0393 - 0.0511) 2.15 - 2.25 (0.0846 -
0.0885)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 1.75 - 1.85 (0.0688 -
0.0728)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 1.95 - 2.05 (0.0767 -
0.0807)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.15 - 2.25 (0.0846 -
0.0885)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.35 - 2.45 (0.0925 -
0.0964)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.55 - 2.65 (0.1003 -
0.1043)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.75 - 2.85 (0.1082 -
0.1122)
Low/Reverse 5 5 2.2 - 2.5 (0.0866 - 0.0984) 2.95 - 3.05 (0.1161 -
0.1200)
Intermediate/Overdrive Band Bolt Chart

Bolt Length Bolt Head Number
39.0 mm 7
38.5 mm 6
38.0 mm 5
37.5 mm 4
37.0 mm 3
36.5 mm 2
36.0 mm 1
2007.50 Focus 3/2007 G420724en

307-01-6 Transmission (4F27E) 307-01-6
SPECIFICATIONS
Line Pressure Chart
Transmission Range Idle (kPa) Idle (psi) Stall (kPa) Stall (si)
4F27E P. N 345 - 450 50 - 65 1240 - 1450 180 - 210
4F27E R 450 - 585 65 - 85 1930 - 2310 280 - 335
4F27E D. 2. 1 345 - 450 50 - 65 1240 - 1450 180 - 210
Stall Speed Chart

Engine rpm
1.8L 2300 - 2650
Description Nm lb - ft lb - in
Transaxle flange bolts 48 35 -
Torque converter to flexplate 36 27 -
Main control lever 22 16 -
Floor panel brace 30 22 -
Crashbox 40 30 -
Radiator support bracket 25 18 -
Starter motor bracket retaining nuts 20 15 -
Engine rear mount bracket bolts 90 66 -
Rear engine mount nut 133 98 -
Engine support insulator 80 59 -
Front exhaust pipe flange 47 35 -
Output shaft speed (OSS) sensor 10 - 89
Oil pan to transaxle 7 - 62
Transmission range (TR) sensor 10 - 89
Turbine shaft speed (TSS) sensor 10 - 89
Intermediate/overdrive servo piston cover 13 10 -
Manual lever shaft locking shaft 13 10 -
Final drive input gear bearing retaining nut rotational 0.6 - 0.9 - 5.3 - 8.1
torque
Final drive input gear bearing retaining nut preload 400 - 450 256 - 332 -
Parking pawl 13 10 -
Torque converter housing 22 16 -
Main control assembly 9 - 80
Solenoid cable clip 10 - 89
Intermediate/overdrive band anchor 45 33 -
2007.50 Focus 3/2007 G420724en

307-01-7 Transmission (4F27E) 307-01-7
SPECIFICATIONS
Transaxle housing cover 22 16 -
Fluid pump to transaxle 22 16 -
2007.50 Focus 3/2007 G420724en

307-01-8 Transmission (4F27E) 307-01-8
Transaxle Description
The 4F27E automatic transmission is an The individual ratios are achieved through two
electronically controlled four-speed transmission planetary gear sets connected one behind the
designed for front wheel drive vehicles. other.
4F27E stands for: The individual components of the planetary gear
sets are driven or held by means of three multiplate
– 4 - 4 forward drive gears
clutches, a multiplate brake, a brake band and a
– F - front-wheel drive roller one-way clutch.
– 27 - maximum input torque of 365 Nm (270 lb-ft)
The torque is transmitted to the final drive assembly
– E - fully electronic control through an intermediate gear stage.
The automatic transmission fluid is changed as
directed by the Scheduled Maintenance Guide that
is supplied with the vehicle.
The manual selector lever gives the driver a choice
of "P" (PARK), "R" (REVERSE), "N" (NEUTRAL),
"D" (DRIVE), "M" (MANUAL MODE), "+" (TIP UP)
and "-" (TIP DOWN).
The transmission has electronic synchronous shift
control (ESSC) which guarantees extremely
smooth gear shifting over the entire life of the
transmission.
The transmission can be diagnosed and tested
using worldwide diagnostic system (WDS) through
the data link connector (DLC), in the passenger
compartment.
Transmission ratios in the individual gears:
Gear Transmission ratio
1st gear 2.816
2nd gear 1.498
3rd gear 1.000
ELE0008127 4th gear 0.726
Reverse gear 2.649
2007.50 Focus 3/2007 G457140en

307-01-9 Transmission (4F27E) 307-01-9
Torque Converter Housing with Torque Converter Assembly and Transmission Fluid Pump Assembly
3
7
9
8
2
6
5
ELE0007782
1 Torque converter assembly 6 Transmission fluid pump seal
2 Transmission differential seal assembly 7 Transmission fluid pump assembly
3 Output shaft speed (OSS) sensor 8 Forward clutch cylinder seal
4 Torque converter housing 9 Transmission fluid pump support thrust

washer
5 Transmission fluid pump seal assembly
2007.50 Focus 3/2007 G457140en

307-01-10 Transmission (4F27E) 307-01-10
Forward Clutch
10
9
8
6
6
4 5
3
2
1
7
7
ELE0007780
1 Transmission turbine shaft assembly 6 Transmission forward clutch separator

steel plates
2 Transmission forward clutch piston
assembly 7 Transmission forward clutch friction plate
assembly
3 Transmission forward piston return spring
assembly 8 Transmission forward/direct clutch
pressure plate
4 Transmission forward clutch balance
piston 9 Forward clutch retaining ring
5 Transmission forward clutch balance 10 Transmission forward clutch cylinder hub

piston snap ring
2007.50 Focus 3/2007 G457140en

307-01-11 Transmission (4F27E) 307-01-11
Differential Assembly and Final Drive Input
8 7
9 10
11
9
10
12
8 7
3 2
6
5
2 3
1
18
4 14
15
17
15
14
13
16
16 25
20
21
24
19 23
21
20
22
22
TIE0029108
2007.50 Focus 3/2007 G457140en

307-01-12 Transmission (4F27E) 307-01-12

1 Differential bearing shim 14 Transfer shaft roller bearing cup
2 Differential bearing cup 15 Transfer shaft taper roller bearing
3 Differential taper roller bearing 16 Transfer shaft bearing assemblies
4 Differential bearing assembly 17 Transfer shaft gear assembly
5 Output shaft speed (OSS) sensor ring 18 Transfer shaft oil funnel
6 Differential gear assembly 19 Transmission final drive gear
7 Pinion thrust washers 20 Final drive taper roller bearing
8 Differential pinion gears 21 Final drive bearing cup
9 Differential side gears 22 Final drive bearing assemblies
10 Differential side gear thrust washer 23 Final drive spacer
11 Retaining pin 24 Final drive snap ring
12 Differential pinion shaft 25 Final drive retaining nut
13 Transfer shaft roller bearing shim
2007.50 Focus 3/2007 G457140en

307-01-13 Transmission (4F27E) 307-01-13
Low/Reverse Clutch and Planetary Gears
9
6 8
6
4
2 3
1
7
7
20
19
18
17
14
15 16
13
12
11
10
ELE0007783
2007.50 Focus 3/2007 G457140en

307-01-14 Transmission (4F27E) 307-01-14

1 Low/reverse clutch piston 11 Low OWC assembly
2 Low/reverse clutch return spring 12 Snap ring
3 Low one-way clutch (OWC) inner race 13 Front ring gear
4 Low OWC snap ring 14 Front planetary gear assembly
5 Low/reverse clutch wave spring 15 Front planetary carrier thrust bearing
assembly
6 Low/reverse clutch separator plate
assembly 16 Snap ring
7 Low/reverse clutch friction plate assembly 17 Front planetary sun gear assembly
8 Low/reverse clutch pressure plate 18 Front sun gear thrust bearing assembly
9 Low/reverse clutch selective plate snap 19 Rear planetary gear assembly
ring
20 Snap ring
10 Low gear OWC retainer
2007.50 Focus 3/2007 G457140en

307-01-15 Transmission (4F27E) 307-01-15
Clutches and Band
14
12
13
8 10 11
6 9
5
2 4
1 3
24
23
22
21
17 20
19
16
15
18
ELE0007784
2007.50 Focus 3/2007 G457140en

307-01-16 Transmission (4F27E) 307-01-16

1 Reverse clutch snap ring 12 Direct clutch piston assembly
2 Rear sun gear assembly 13 Direct clutch thrust bearing assembly
3 Rear sun gear thrust bearing assembly 14 Direct clutch cylinder assembly
4 Direct clutch hub assembly 15 Reverse clutch pressure plate snap ring
5 Snap ring 16 Reverse clutch pressure plate
6 Forward/direct clutch pressure plate 17 Reverse clutch separator plate
7 Forward/direct clutch friction plate 18 Reverse clutch friction plate assembly
assembly
19 Reverse clutch spring retainer snap ring
8 Direct clutch separator plates
20 Reverse clutch spring retainer
9 Direct clutch balance piston snap ring
21 Reverse clutch piston return spring
10 Direct clutch balance piston
22 Reverse clutch piston assembly
11 Forward/direct clutch piston return spring
assembly 23 Intermediate drum assembly
24 Intermediate band assembly
2007.50 Focus 3/2007 G457140en

307-01-17 Transmission (4F27E) 307-01-17
Transmission Main Control Assembly
9 7
8 1
7
9
10
4
3
11 21
6 22
2 5 2
23
6
12
2
13 3
24
14
2
16 17 18 3
4
15
25 2
20 3
19 24
2 32
7 31
26
28
30
28
27
29
TIE0018307
2007.50 Focus 3/2007 G457140en

307-01-18 Transmission (4F27E) 307-01-18

1 Manual control valve assembly 18 Main fluid pressure regulator valve
2 Spring retainer plates 19 Solenoid regulator valve spring
3 Bypass clutch control springs 20 Solenoid regulator valve
4 Bypass clutch control valves 21 Intermediate servo accumulator spring
5 Modulation valve spring 22 Intermediate servo accumulator piston
6 Pressure line modulator valves 23 Converter regulator valve spring
7 Control valve body retaining bolts M6 x 50 24 Valve - lock up control and 3-4 shift (2)
8 Control valve body retaining bolts M6 x 63 25 Solenoid body gasket
9 Control valve body seal 26 Solenoid body shift control valves
10 Control valve body retaining bolts M6 x 60 27 Solenoid body electrical pressure control
valve
11 Control valve upper body
28 Solenoid body valve retaing bolts M6 x 12
12 Control valve body gasket
29 Solenoid body valve retaing bolts M6 x 14
13 Control valve body separator gasket
30 Solenoid shift control throttle pressure
14 Control valve lower body body
15 Main regulator valve stop 31 Solenoid body shift control valve assembly
16 Main regulator valve retaining plate 32 Solenoid shift control bracket
17 Main fluid pressure regulator valve spring
2007.50 Focus 3/2007 G457140en

307-01-19 Transmission (4F27E) 307-01-19
Transmission Housing Assembly
7
9
2
1 6 12
8 11
4 5 14
13
3
15
33
32 10
21
16
17
31
4 18
30
26
18 29
19
25
28
20
27 23
24
22
21
TIE0018278
2007.50 Focus 3/2007 G457140en

307-01-20 Transmission (4F27E) 307-01-20

1 Parking pawl shaft 18 Fluid pan dowels
2 Parking pawl brake 19 Servo piston return spring
3 Parking pawl return spring 20 Intermediate servo piston and seal
assembly
4 Transmission housing dowels
21 Intermediate band servo cover retaining
5 Transmission housing bolt M6 x 20
6 Transmission housing orifice plug 22 Intermediate band servo cover
7 Service identification tag 23 Intermediate band servo cover seal
8 Turbine shaft speed (TSS) sensor 24 N/D shift accumulator piston
9 TSS sensor retaining bolt M6-1 x 20 25 N/D shift accumulator outer spring
10 TSS sensor o-ring 26 N/D shift accumulator inner spring
11 Transmission rear mount retaining stud 27 1/2 shift accumulator piston
12 Transmission ventilation cap 28 1/2 shift accumulator outer spring
13 Breather tube 29 1/2 shift accumulator inner spring
14 Intermediate band anchor stud 30 Line tap plug
15 Differential seal 31 Fluid transfer pipe
16 1/8-27 Hex socket 32 Parking pawl actuating adjustment
17 Connector ¼ x 5/8 x 22.9 33 Parking pawl actuating plate
2007.50 Focus 3/2007 G457140en

307-01-21 Transmission (4F27E) 307-01-21
Seals, O-rings and Gaskets
2 3 4 6 7
1
8
8
21
20
9
19
10
11
18
17 15 14
13
16 11
12
TIE0018309
2007.50 Focus 3/2007 G457140en

307-01-22 Transmission (4F27E) 307-01-22

1 Reverse clutch piston assembly 12 Output shaft speed (OSS) sensor o-ring
2 Direct clutch piston assembly 13 Valve body seals
3 Direct clutch balance piston 14 Manual shaft fluid seals
4 Low/reverse clutch piston 15 Fluid filter seal
5 Turbine shaft speed (TSS) sensor o-ring 16 Intermediate band servo cover seal
6 Forward clutch balance piston 17 Iintermediate band servo piston and seal
assembly
7 Forward clutch piston assembly
18 Solenoid body gasket
8 Forward and direct clutch cylinder seals
19 Control valve body gasket
9 Fluid pump seal assembly
20 Transmission housing cover seals
10 Fluid pump seal
21 Reverse clutch cylinder seals
11 Differential seal assembly
2007.50 Focus 3/2007 G457140en

307-01-23 Transmission (4F27E) 307-01-23
Snap Rings
1 2 5
13
3
4
12
11
10
9
8
7
6
TIE0018308
2007.50 Focus 3/2007 G457140en

307-01-24 Transmission (4F27E) 307-01-24

1 Reverse clutch snap ring 7 Low one-way clutch (OWC) snap ring
2 Low/reverse clutch selective plate snap 8 Reverse clutch snap ring
ring
9 DC balance piston snap ring
3 Final drive retainer snap ring
10 Ring - forward/direct clutch planet retaining
4 Forward clutch balance piston snap ring
11 Reverse clutch spring snap ring
5 Forward/direct clutch selective plate snap
ring 12 Forward/direct clutch selective plate snap
ring
6 Front sun gear snap ring
13 Rear planetary assembly snap ring
2007.50 Focus 3/2007 G457140en

307-01-25 Transmission (4F27E) 307-01-25
Bearings, Bushings and Thrust Washers
1 2 4 5 6
3
13
15
14
12
11 10 9 8
TIE0018310
2007.50 Focus 3/2007 G457140en

307-01-26 Transmission (4F27E) 307-01-26

1 Rear sun gear bearing assembly 9 Differential side gear thrust washers
2 Front sun gear bearing assembly 10 Pinion thrust washers
3 Front planetary carrier bearing assembly 11 Transfer shaft bearing cups
4 Input shaft taper roller bearings 12 Transfer shaft taper roller bearings
5 Input shaft bearing cups 13 Rear planetary carrier bearing assembly
6 Fluid pump support thrust washer 14 Rear sun gear bearing assembly
7 Differential taper roller bearings 15 Direct clutch cylinder bearing assembly
8 Differential bearing cups
2007.50 Focus 3/2007 G457140en

307-01-27 Transmission (4F27E) 307-01-27
Overview of Construction and Function
1 2 3 4 5
13 12 11 10
TIE0018312
2007.50 Focus 3/2007 G457140en

307-01-28 Transmission (4F27E) 307-01-28

1 Intermediate/overdrive band 3 Stator
2 Front ring gear planetary gear sets 4 Torque converter lock-up clutch
3 Low/reverse clutch 5 Transmission input shaft
4 Forward clutch The torque converter transmits the engine torque
5 Fluid pump and stator support hydraulically to the transmission input shaft.
The stator boosts the torque to the input shaft
6 Torque converter
(approximately 85 % difference in speed between
7 Transmission input shaft the impeller and the turbine).
8 Differential The stator is made of synthetic resin to reduce
weight.
9 Transfer shaft assembly
To increase the efficiency of the automatic
10 Final drive input gear transmission, the torque converter has a lock-up
clutch. When the torque converter lock-up clutch
11 Low one-way clutch
is closed, the torque is transmitted directly from
12 Reverse clutch the crankshaft through the torque converter
housing to the transmission input shaft.
13 Direct clutch
Transmission Fluid Pump and Stator Support
Torque Converter and Torque Converter Lock-up
Clutch
2
1
3 1
3
5 4
4
TIE0008102
ELE0008101
Item Description
Item Description 1 Stator support
1 Converter housing and impeller 2 Transmission fluid pump
2 Turbine
2007.50 Focus 3/2007 G457140en

307-01-29 Transmission (4F27E) 307-01-29
Item Description Planetary gear sets
3 Converter impeller hub The individual gears are shifted by means of two
planetary gear sets connected one behind the
4 Stator other.
The transmission fluid pump is a crescent gear Clutches and bands
pump and is driven directly from the crankshaft by
means of drivers on the converter impeller hub. The individual ratios are selected by means of four
The transmission fluid pump is bolted to the multiplate clutches, a brake band and a roller
transmission housing. one-way clutch.
The stator support is part of the transmission fluid The components are controlled by the transmission
pump. Splines on the support locate and hold the control module (TCM) through pulse width
converters stator. modulation (PWM) solenoid valves.
Valve Body
ELE0008103
Item Description The valve body contains six solenoid valves:

1 Solenoid body shift control valve assembly – three solenoid body shift control valves (pulse
width modulation solenoid valves),
2 Solenoid body shift control (on/off) valves – two solenoid body shift control (on/off) valves,
3 Solenoid body electrical pressure control – one solenoid body electrical pressure control
valve valve (variable force solenoid).
The individual clutches and bands are supplied
pressure from the solenoid body shift control valves
and the solenoid body shift control (on/off) valves
and thus the gears are shifted.
2007.50 Focus 3/2007 G457140en

307-01-30 Transmission (4F27E) 307-01-30
The solenoid body shift control valves allow direct Solenoid body shift control (on/off) valves
actuation of the clutches and bands to ensure
The solenoid body shift control (on/off) valves
extremely smooth gear shifting through precise
switch the different oil passages in the valve body
pressure regulation.
to direct the pressure to the individual clutches and
The solenoid body electrical pressure control valve bands.
(variable force solenoid) ensures that sufficient
hydraulic pressure is available in all operating Solenoid body electrical pressure control valve
conditions. (VFS)
The solenoid body electrical pressure control valve
Solenoid body shift control valves
(variable force solenoid) controls the required main
The solenoid body shift control valves control the line pressure for the individual transmission ranges.
pressure to the bands and clutches.
The main line pressure is dependent on engine
load.
2007.50 Focus 3/2007 G457140en

307-01-31 Transmission (4F27E) 307-01-31
Internal Shift Mechanism
1 2
ELE0008104
Item Description The shift lever is secured on a square on the

manual shaft. Axial movement of the selector lever
1 Lever on manual shaft cable is changed into rotational movement of the
2 Manual shaft manual shaft.
3 Parking pawl engaging lever The manual shaft operates the parking pawl
engaging lever and the actuating lever of the
4 Lever and bracket assembly manual valve.
5 Manual valve The manual valve, a valve operated entirely
manually, is moved by means of the manual valve
actuating lever in the valve body.
2007.50 Focus 3/2007 G457140en

307-01-32 Transmission (4F27E) 307-01-32
The manual valve guarantees the functions during Manual selector lever position "R"
hydraulic emergency operation.
In manual selector lever position "R" reverse gear
External Shift Mechanism is selected. REVERSE allows the vehicle to be
operated in a rearward direction, at a reduced gear
ratio.
Manual selector lever position "N"

1
In manual selector lever position "N" no gear is
selected. The drive line is not locked, so the wheels
3 are free to rotate.
2
The vehicle may be started in NEUTRAL.
Manual selector lever position "D"

In manual selector lever position "D" the
E57353 transmission control allows all the gears to be
selected.
Item Description
Manual selector lever position "M"
1 Manual release mechanism
In manual selector lever position "M" the gears can
2 Shift selector gate
be selected manually by moving the selector lever
3 Automatic shift gate to the "-" or "+" positions.
The transmission control only allows the up or
Range selection downshift to take place when the corresponding
The transaxle range selector has seven positions: vehicle speed has been reached.
"P", "R", "N", "D", "M", "-" and "+". The selector levers allow for manual shifting of the
transmission.
Manual selector lever position "P"
Changing from automatic mode to manual mode
NOTE: For safety reasons always apply the parking
is achieved by moving the selector lever from
brake whenever the vehicle is parked.
position "D" in the automatic shift gate to position
In manual selector lever position "P" no gear is "M" in the select shift gate.
selected. The parking pawl is engaged manually
In select shift mode, gears can be selected
by the manual selector lever cable and the shift
manually by moving the selector lever to the "-" or
shaft.
"+" positions.
2007.50 Focus 3/2007 G457140en

307-01-33 Transmission (4F27E) 307-01-33
E55728
At the selector lever end the cable is clipped onto

Item Description
a pin.
1 Selector lever cable - transaxle end
2 Gearshift cable bushing retaining nuts
3 Selector lever cable - selector lever end
The selector lever adjustment mechanism is
connected to the transaxle selector lever pin, which
is located above the transmission range (TR)
sensor.
The selector lever cable adjustment mechanism is
locked at the transaxle end of the selector lever
cable.
2007.50 Focus 3/2007 G457140en

307-01-34 Transmission (4F27E) 307-01-34
Intermediate Gear Stage and Final Drive Assembly Transmission Control System
1
2
3
E52212
The transmission control module (TCM) is separate

from the PCM mounted on the firewall on the
left-hand side in the vehicle's direction of travel.
4 During routine servicing, the TCM must be

calibrated using the WDS.
Together with the new TCM, numerous modes
were changed or added in the transmission control
system of the 4F27E:
•Select Shift mode
TIE0018311 •Fast-off mode
•Kick down mode
Item Description In select shift mode, the gears can be selected
1 Final drive input gear manually using the gear selector lever.
2 Transfer shaft input gear Fast-off mode prevents the transmission from
shifting to a higher gear when the driver suddenly
3 Transfer shaft output gear takes his foot off the accelerator. By staying in the
4 Differential lower gear, the engine braking effect can be better
taken advantage of.
The final drive input gear is splined to the planet The kick down mode allows the transmission
carrier of the front planetary gear set and drives control system to differentiate between kick down
the transfer shaft input gear of the intermediate and wide open throttle (WOT).
gear stage.
The transfer shaft output gear of the intermediate
gear stage drives the final drive assembly.
Electronic Synchronous Shift Control
(ESSC)
The torque is transmitted to the halfshafts through
the final drive assembly. Control of shift operations
The differential offsets differences in the speed of During a shift operation certain elements are
rotation of the halfshafts. released while others are actuated. Ideally this
The intermediate gear stage is designed so that process takes place simultaneously
the final drive ratio can be adapted to requirements (synchronously) to avoid jerky gear shifting.
when the automatic transmission is used in The time for the shift operation should remain
conjunction with different engines. within the time limits provided.
2007.50 Focus 3/2007 G457140en

307-01-35 Transmission (4F27E) 307-01-35
When the shift operation is controlled In both cases a jerk will be felt during the shift
conventionally, the pressure build up and reduction operation.
at the shift elements are set and defined for ideal
In addition, wear in the shift elements leads to a
conditions (synchronous shifting).
lengthening of the shift operation. Therefore,
As there is no way of influencing the control in the shifting takes longer when the transmission has
event of different levels of wear in the shift accumulated a higher mileage.
elements, when the transmission has been used
for a fairly high mileage, it is possible that the Control of shift operations with ESSC
pressure build up and reduction may no longer be ESSC monitors the shift operations and is able to
synchronous. adapt to the wear in the shift elements over the life
The result or premature pressure reduction at the of the transmission.
element to be switched off is an unwanted rise in The system monitors the shift time whether the
the turbine shaft speed as the element to be shift operation is synchronous.
switched on cannot transmit the input torque.
If the TCM detects a deviation from the stored
The result of delayed pressure reduction at the values for the shift time and synchronization of the
element to be switched off is an unwanted shift operation, the pressure build up or reduction
decrease in the turbine shaft speed as both shift is adapted accordingly.
elements transmit the input torque. In the process
the torque is transmitted to the transmission
housing through internal locking.
Turbine Shaft Speed (TSS) Sensor
E57658
The TSS sensor is located on the transmission If the TSS sensor fails, the signal of the output shaft
housing over the transmission input shaft. speed (OSS) sensor is used as a substitute signal.
The TSS sensor is an inductive sensor which
senses the speed of rotation of the transmission
input shaft.
2007.50 Focus 3/2007 G457140en

307-01-36 Transmission (4F27E) 307-01-36
Output Shaft Speed (OSS) Sensor
ELE0008125
The OSS sensor is located on the transmission

housing above the rotor in the differential.
The OSS sensor is an inductive sensor which
detects the vehicle speed by means of a rotor on
the differential.
If the OSS sensor fails, the signal of the TSS
sensor is used as a substitute signal.
2007.50 Focus 3/2007 G457140en

307-01-37 Transmission (4F27E) 307-01-37
Transmission Range (TR) Sensor When the ignition is switched on, the manual
selector lever shift lock solenoid is actuated by
depressing the brake pedal (signal from the
stoplamp switch). This retracts the locking pin so
that the manual selector lever can be moved out
of position "P".
Substitute Function
ELE0008126
The TR sensor is located on the manual shaft on

the transmission housing.
If the connection is cut the vehicle cannot be
started.
Manual Selector Lever Shift Lock Solenoid TIE45383
Item Description
1 1 Manual release mechanism cover
If the brake signal should fail, due to a malfunction,
manual unlocking is possible.
NOTE: If position "P" is selected again the manual
selector lever is locked again.
3 2 Remove the manual release mechanism cover and
using a suitable object (ignition key) press into the
ELE0008129 opening until the manual selector lever can be
moved out of position "P".
Item Description
1 Solenoid
2 Retaining pin
3 Manual release mechanism
2007.50 Focus 3/2007 G457140en

307-01-38 Transmission (4F27E) 307-01-38
Preliminary Inspection
General Equipment
Worldwide Diagnostic System (WDS) Determine the Customer Concern
NOTE: Some transmission conditions can cause

Know and Understand the Concern engine concerns. For example the torque converter
clutch not disengaging will stall the engine.
The following items must be checked before
The concern must be fully understood before
beginning the diagnostic procedures:
commencing any fault diagnosis. Detailed
• Know and understand the customer concen, information from the customer may be needed for
REFER to Determine the Customer Concern in this.
this procedure.
Ask the customer under which condition(s) the
• Check for any technical service bulletin (TSB) concern occurs. For example:
or online automotive service information system
(OASIS) messages regarding the concern. • Cold or warm engine?
• Check for non-factory installed components. • Hot or cold ambient temperatures?
• Check for additional aftermarket systems; for • On what road surface(s)?
example air conditioning, cellular phone, speed • Was the vehicle laden or unladen?
control system, which are not approved, or • In what driving situation:
which have not been professionally installed. – while accelerating?
• Check for electronic engine control (EEC) and – on overrun?
engine tuning, which may have an effect on the
engine and transmission management. – when gear changing up or down?
• Check the transmission fluid condition. REFER • What is the quality of the gear change?
to Check the Transmission Fluid Condition in • Noise and vibration:
this procedure. – At what engine speed, vehicle speed or load?
• Check the selector lever cable adjustment. – In which gear or gear range?
REFER to: Selector Lever Cable Adjustment • Does the gear engaged correspond to the
(307-05 Automatic Transmission/Transaxle display?
External Controls - Vehicles With: 4-Speed • When the incorrect operation occurred, did a
Automatic Transmission (4F27E), General warning lamp illuminate in the instrument
Procedures). cluster?
• Verify the concern by operating the vehicle.
• Carry out the WDS quick test, for both key on
engine off (KOEO) and key on engine running
Road Test the Vehicle.
(KOER), and record any diagnostic trouble
1. Connect WDS and carry out the quick test.
codes (DTCs). If no DTCs are present,
2. Carry out the transmission drive cycle test,
REFER to: Diagnosis By Symptom (307-01
Automatic Transmission/Transaxle - Vehicles REFER to: Transaxle Drive Cycle Test (307-01
With: 4-Speed Automatic Transmission Automatic Transmission/Transaxle - Vehicles
(4F27E), Diagnosis and Testing). With: 4-Speed Automatic Transmission
(4F27E), Diagnosis and Testing).
3. Record and then erase the quick test DTCs.
Verification of Condition
4. Make sure that the transmission fluid level is
correct.
This section provides information that must be used
in both determining the actual cause of the 5. With the transmission in the "D" (DRIVE)
customer concern(s) and executing the appropriate position, moderately accelerate from stationary
procedures. to 80 km/h (50 mph). This allows the
2007.50 Focus 3/2007 G526634en

307-01-39 Transmission (4F27E) 307-01-39
transmission to shift into 4th gear. Hold the approximately 30 minutes to allow the transmission
vehicle speed and throttle position steady for a fluid to cool before carrying out the transmission
minimum of 15 seconds. fluid level check.
6. With the transmission in 4th gear and NOTE: Incorrect transmission fluid level may affect
maintaining a steady vehicle speed and throttle the transmission operation and could result in
position, lightly apply and release the brake transmission damage.
pedal to operate the stop lamps. Then hold the
vehicle speed and throttle position steady for a 1. Drive the vehicle 30 km (20 miles) or until the
minimum of five seconds. vehicle reaches normal operating temperature.
7. Brake to a halt and remain stationary for a 2. Stop the vehicle on a level surface and engage
minimum of 20 seconds. the parking brake.
8. Repeat steps 4 through 6 at least 5 times. 3. Depress and hold the brake pedal in the applied
position. Start the engine. Move the selector
9. Carry out the WDS quick test and record the lever through all the gear positions, allowing
continuous DTCs. sufficient time for each gear to engage.
1. Carry out the on-board diagnostic procedures 4. Move the selector lever to the "P" (PARK)
for both KOEO and KOER. position and leave the engine running.
2. Record all DTCs.
5. Check the transmission fluid level. The fluid
3. Repair all non-transmission DTCs. should be within the designated areas.
4. Repair all transmission DTCs.
5. Erase all continuous DTCs and repeat the
WDS quick test.
6. Repair all continuous DTCs. 1
7. If no DTCs are obtained, 2
3
REFER to: Diagnosis By Symptom (307-01
Automatic Transmission/Transaxle -
Transmission (4F27E), Diagnosis and
Testing).
TIE0029717
Check the Transmission Fluid Level
Item Description
Under normal operating conditions, there is no
requirement to check the transmission fluid level. 1 Maximum transmission fluid level
However, if the transmission is not functioning 2 Transmission fluid level range at
correctly, the transmission may slip, shift slowly or normal operating temperature
there may be some sign of fluid leakage, the fluid (66°C-77°C)
level should be checked.
3 Minimum transmission fluid level
CAUTION: The vehicle should not be driven
if the fluid level is below the bottom line
on the fluid level indicator and the ambient
temperature is above 10°C. High Transmission Fluid Level
NOTE: Transmission fluid expands when warmed. A high transmission fluid level may cause the
To obtain an accurate fluid level check, drive the transmission fluid to become aerated due to the
vehicle until normal operating temperature has churning action of the rotating internal parts. This
been reached, approximately 30 km (20 miles). will cause erratic control pressure, foaming, loss
NOTE: If the vehicle has been operated for an of transmission fluid from the vent tube and
extended period at high speeds, in city traffic during
hot weather, or pulling a trailer, the vehicle should
be parked with the engine switched off for
2007.50 Focus 3/2007 G526634en

307-01-40 Transmission (4F27E) 307-01-40
possible transmission damage. If an overfill reading 5. If transmission fluid contamination or
is indicated, adjust the transmission fluid to the transmission failure is confirmed by the
correct fluid level. sediment in the bottom of the transmission fluid
REFER to: Transmission Fluid Drain and Refill pan, the transmission must be disassembled
(307-01 Automatic Transmission/Transaxle - and completely cleaned,
Vehicles With: 4-Speed Automatic Transmission REFER to: Transaxle (307-01 Automatic
(4F27E), General Procedures). Transmission/Transaxle - Vehicles With:
For fluid type, refer to 4-Speed Automatic Transmission (4F27E),
REFER to: Specifications (307-01 Automatic Disassembly).
Transmission/Transaxle - Vehicles With: 4-Speed
Automatic Transmission (4F27E), Specifications).
Low Transmission Fluid Level
A low transmission fluid level could result in poor

transmission engagement, slipping or possible
transmission damage. If a low fill reading is
indicated, adjust the transmission fluid to the
correct fluid level.
REFER to: Transmission Fluid Drain and Refill
(307-01 Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic Transmission
(4F27E), General Procedures).
For fluid type, refer to
REFER to: Specifications (307-01 Automatic
Check the Transmission Fluid Condition
1. Check the transmission fluid level. For additional

information, refer to Check Transmission Fluid
Level in this procedure.
2. Observe the transmission fluid color. The color
under normal operating conditions should be
reddish, not brown or black.
3. Check the transmission fluid odor for signs of
overheaing.
4. Allow the transmission fluid to drip onto a tissue
and examine the stain. If evidence of solid
material is found, the transmission fluid pan
should be removed for further inspection,
REFER to: Transmission Fluid Pan, Gasket and
Filter (307-01 Automatic
In-vehicle Repair).
2007.50 Focus 3/2007 G526634en

307-01-41 Transmission (4F27E) 307-01-41
Shift Point Road Test

This test verifies that the shift control system is 5. Select manual shift mode and make sure that
operating correctly. the transmission will manually upshift each gear
1. Bring the engine and transaxle up to normal to 4th gear and downshift each gear to 1st gear
operating temperature. dependent on vehicle speed.
2. Operate the vehicle with the selector lever in 6. Manually select 3rd gear at approximately 90
the "D" (DRIVE) position. km/h (56 mph). Gently accelerate to 110 km/h
(68 mph) and hold that speed. A slight drop in
3. Apply minimum throttle and observe the speeds
engine speed should be observed.
at which upshift occurs.
7. If the transaxle fails to upshift or downshift, or
4. Press the accelerator pedal rapidly to the floor
the torque converter clutch does not apply or
(kickdown). The transaxle should shift from:
release,
• 4th to 3rd, or 4th to 2nd, dependent on
vehicle speed REFER to: Diagnosis By Symptom (307-01
Automatic Transmission/Transaxle - Vehicles
• 3rd to 2nd, or 3rd to 1st, dependent on
With: 4-Speed Automatic Transmission
vehicle speed
• 2nd to 1st
Shift Speeds Chart - Vehicles with 1.6L Duratec-16V (Sigma) engine
Throttle Position Shift Final Drive Ratio 4.2:1
km/h mph
Closed 4-3 35 22
Closed 3-2 19 12
Closed 2-1 12 7
WOT 1-2 57 35
WOT 2-3 108 67
WOT 3-4* 180 112
* To attain maximum speed the vehicle must be in 3rd gear. The 3 - 4 upshift will not occur with wide open throttle (WOT). Upshift
is achieved by releasing the throttle slightly at maximum speed.
Shift Speeds Chart - Vehicles with 2.0L Duratec-HE (MI4) engine

NOTE: The transmission will downshift directly from 3-1 with a closed throttle.
Throttle Position Shift Final Drive Ratio 4.2:1

km/h mph
Closed 4-3 28 17
Closed 3-1 14 9
WOT 1-2 57 35
WOT 2-3 108 67
WOT 3-4 154 96
2007.50 Focus 3/2007 G528301en

307-01-42 Transmission (4F27E) 307-01-42
Torque Converter Diagnosis

General Equipment
Worldwide Diagnostic System (WDS) Torque Converter Operation Test
NOTE: To prevent the unnecessary installation of 1. Run on-board diagnostics, REFER to WDS.
a new torque converter all diagnostic procedures Check the DTCs,
must be followed before installing a new torque
converter. Only after a complete diagnostic REFER to: Diagnostic Trouble Code Charts
evaluation should the decision be made to install (307-01 Automatic Transmission/Transaxle -
a new torque converter. Vehicles With: 4-Speed Automatic
1. Carry out the torque converter preliminary Testing).
inspection, 2. Bring the engine and transaxle up to normal
REFER to: Preliminary Inspection (307-01 operating temperature.
Automatic Transmission/Transaxle - Vehicles 3. When normal operating temperature has been
With: 4-Speed Automatic Transmission reached, maintain a constant vehicle speed of
(4F27E), Diagnosis and Testing). approximately 80 km/h (50 mph) and tap the
2. Carry out the torque converter Diagnostic brake pedal with the left foot.
Procedures. 4. The engine speed should increase when the
1. Run on-board diagnostics, REFER to WDS. brake pedal is tapped and decrease
• Repair all non-transaxle related diagnostic approximately 5 seconds later. If this does not
trouble codes (DTCs) first. occur, REFER to Torque Converter Operation
2. Carry out the transmission line pressure test, Concerns.
REFER to: Special Testing Procedures REFER to: Diagnosis By Symptom (307-01
(307-01 Automatic Transmission/Transaxle Automatic Transmission/Transaxle - Vehicles
- Vehicles With: 4-Speed Automatic With: 4-Speed Automatic Transmission
Transmission (4F27E), Diagnosis and (4F27E), Diagnosis and Testing).
Testing). 5. If the vehicle stalls in "D" (DRIVE) at engine idle
3. Carry out the transmission stall speed test, speed with vehicle at a stop, move the selector
lever to manual 1 position. If the vehicle stalls
REFER to: Special Testing Procedures again, REFER to Torque Converter Operation
(307-01 Automatic Transmission/Transaxle Concerns.
- Vehicles With: 4-Speed Automatic
Transmission (4F27E), Diagnosis and REFER to: Diagnosis By Symptom (307-01
Testing). Automatic Transmission/Transaxle - Vehicles
4. Carry out a diagnosis by symptom, With: 4-Speed Automatic Transmission
REFER to: Diagnosis By Symptom (307-01 Repair as necessary. TEST for normal
Automatic Transmission/Transaxle - operation.
Testing).
• Use the index to locate the appropriate
routine that best describes the symptom(s).
The routine will list all possible components
which may cause or contribute to the
symptom. Check each component listed;
diagnose and repair as necessary before
installing a new torque converter.
3. Carry out the Torque Converter Operation Test;
REFER to Torque Converter Operation Test in
this procedure.
2007.50 Focus 3/2007 G526637en

307-01-43 Transmission (4F27E) 307-01-43
Transaxle Drive Cycle Test

NOTE: Always drive the vehicle in a safe manner to the correct manual(s) and aids in diagnosing
according to driving conditions and obey all traffic internal transaxle concerns and external
laws. non-transaxle inputs. The pinpoint tests are used
NOTE: The Transaxle Drive Cycle Test must be in diagnosing transaxle electrical concerns. Make
followed exactly. Transaxle failure must occur four sure that the vehicle wiring harness and the PCM
times consecutively for shift error DTC code to be are diagnosed as well. The PCED will aid in
set, and five times consecutively for continuous diagnosing non-transaxle electronic components.
torque converter clutch code to set.
NOTE: When carrying out the Transaxle Drive Before Pinpoint Tests
Cycle Test, refer to the Solenoid Application Chart
for correct solenoid operation. NOTE: Before entering pinpoint tests, check the
powertrain control module wiring harness for
After carrying out the Quick Test, use the Transaxle correct connections, bent or broken pins, corrosion,
Drive Cycle Test for checking continuous codes. loose wires, correct routing, correct seals and their
1. Record and then erase Quick Test codes. condition. Check the PCM, sensors and actuators
2. Warm engine to normal operating temperature. for damage. Refer to the PCED.
3. Make sure transaxle fluid level is correct. NOTE: If a concern still exists after electrical
4. With transaxle in O/D position, moderately diagnosis.
accelerate from stop to 80 km/h (50 mph). This REFER to Diagnosis by Symptom in this section.
allows the transaxle to shift into fourth gear.
If DTCs appear while carrying out the on-board
Hold speed and throttle open steady for a
diagnostics, refer to the Diagnostic Trouble Code
minimum of 15 seconds.
Chart for the appropriate repair procedure. Prior
5. NOTE: PCA, EPC and VFS all refer to the to entering pinpoint tests, refer to any TSBs and
solenoids. PCA is preffered for this OASIS messages for transaxle concerns.
transmission because the scan tool displays
PCA.
With transaxle in fourth gear and maintaining
steady speed and throttle opening, lightly apply
and release brake to operate stop lamps. Then
hold speed and throttle steady for a minimum
of five seconds.
6. Brake to a stop and remain stopped for a
minimum of 20 seconds.
7. Repeat steps 4 through 6 at least five times.
8. Carry out Quick Test and record continuous
DTCs.
After On-Board Diagnostics

NOTE: The vehicle wiring harness, powertrain
control module and non-transaxle sensors may
affect transaxle operations. Repair these concerns
first.
After the on-board diagnostic procedures are
completed, repair all DTCs.
Begin with non-transaxle related DTCs, then repair
any transaxle related DTCs. Refer to the Diagnostic
Trouble Code Chart for information on condition
and symptoms. This chart will be helpful in referring
2007.50 Focus 3/2007 G17972en

307-01-44 Transmission (4F27E) 307-01-44
Diagnostic Trouble Code Charts

General Equipment 3. If an obvious cause for an observed or reported
Inspection and Verification 4. If the cause is not visually evident, connect the
diagnostic tool to the data link connector (DLC)
1. Verify the customer concern. and select the vehicle to be tested from the
2. Visually inspect for obvious signs of mechanical diagnostic tool menu.
or electrical damage. 5. Retrieve the diagnostic trouble codes (DTCs)
and refer to the DTC Charts.
DTC Charts
• P0602: Module configuration • Powertrain control module • Run module configuration
failure (PCM) programming error. option from the toolbox menu.
• Module configuration failure. REFER to WDS.
• P0705: TR sensor circuit in • Transmission range (TR) • REFER to WDS.
range fault sensor.
• Transmission control module
(TCM).
• Circuit(s).
• P0710: TFT circuit • Transmission fluid temperature • REFER to WDS.
range/performance problem (TFT) sensor.
(TCM).
• Circuit(s).
• P0711: TFT sensor out of self • Transmission fluid temperature • GO to Pinpoint Test A.
test range (TFT) sensor.
(TCM).
• Circuit(s).
• P0712: TFT sensor circuit low • Transmission fluid temperature • REFER to WDS.
voltage input (TFT) sensor.
(TCM).
• Circuit(s).
• P0713: TFT sensor circuit high • Transmission fluid temperature • REFER to WDS.
voltage input (TFT) sensor.
(TCM).
• Circuit(s).
• P0715: Turbine speed sensor • Turbine shaft speed (TSS) • REFER to WDS.
circuit malfunction sensor.
(TCM).
• Circuit(s).
2007.50 Focus 3/2007 G526638en

307-01-45 Transmission (4F27E) 307-01-45

circuit no signal sensor.
(TCM).
• Circuit(s).
circuit intermittent sensor.
(TCM).
• Circuit(s).
• P0720: Output shaft speed • Output shaft speed (OSS) • REFER to WDS.
sensor circuit fault sensor.
(TCM).
• Circuit(s).
sensor circuit performance fault sensor.
(TCM).
• Circuit(s).
sensor no signal sensor.
(TCM).
• Circuit(s).
• P0731: Transmission gear #1 • Transmission fluid level low. • Check the transmission fluid
incorrect ratio • Transmission fluid condition. level and condition.
REFER to: Preliminary Inspec-
tion (307-01 Automatic
Transmission/Transaxle -
Vehicles With: 4-Speed
Automatic Transmission
(4F27E), Diagnosis and
Testing).
• Transmission line pressure low. • Check the transmission line
• Pump assembly. pressure.
REFER to: Special Testing
Procedures (307-01 Auto-
matic Transmis-
sion/Transaxle - Vehicles
With: 4-Speed Automatic
Transmission (4F27E),
2007.50 Focus 3/2007 G526638en

307-01-46 Transmission (4F27E) 307-01-46

• Clutch slipping. • REFER to: Diagnosis By
Symptom (307-01 Automatic
Testing).
• Shift solenoids. • GO to Pinpoint Test B.
Testing).
matic Transmis-
Testing).
• Shift solenoids. • GO to Pinpoint Test C.
Testing).
2007.50 Focus 3/2007 G526638en

307-01-47 Transmission (4F27E) 307-01-47

matic Transmis-
Testing).
• Shift solenoids. • GO to Pinpoint Test D.
Testing).
matic Transmis-
Testing).
• Shift solenoids. • GO to Pinpoint Test E.
2007.50 Focus 3/2007 G526638en

307-01-48 Transmission (4F27E) 307-01-48

• P0741: TCC system perform- • Transmission fluid level low. • Check the transmission fluid
ance. Torque converter slip is • Transmission fluid condition. level and condition.
greater than expected REFER to: Preliminary Inspec-
Testing).
matic Transmis-
• Torque converter clutch (TCC). • GO to Pinpoint Test F.
• P0748: EPC A electrical (VPS) • Electronic pressure control • GO to Pinpoint Test G.
(EPC) solenoid A.
• P0750: SSA or SSPCA shift • Shift solenoid A (SSA). • REFER to WDS.
solenoid electrical circuit open • Transmission control module
failure (TCM).
• Circuit(s).
• P0751: SSA or SSPCA • Transmission fluid level low. • Check the transmission fluid
performance or stuck OFF • Transmission fluid condition. level and condition.
Testing).
matic Transmis-
• Shift solenoid A (SSA). • GO to Pinpoint Test H.
2007.50 Focus 3/2007 G526638en

307-01-49 Transmission (4F27E) 307-01-49

• P0752: SSA or SSPCA stuck • Transmission fluid level low. • Check the transmission fluid
ON • Transmission fluid condition. level and condition.
Testing).
matic Transmis-
• Shift solenoid A (SSA). • GO to Pinpoint Test I.
• P0753: SSA or SSPCA shift • Shift solenoid A (SSA). • GO to Pinpoint Test J.
solenoid electrical circuit failure • Transmission control module
(TCM).
• Circuit(s).
• P0755: SSB or SSPCB shift • Shift solenoid B (SSB). • REFER to WDS.
failure (TCM).
• Circuit(s).
• P0756: SSB or SSPCB • Transmission fluid level low. • Check the transmission fluid
Testing).
matic Transmis-
• Shift solenoid B (SSB). • GO to Pinpoint Test K.
2007.50 Focus 3/2007 G526638en

307-01-50 Transmission (4F27E) 307-01-50

• P0757: SSB or SSPCB • Transmission fluid level low. • Check the transmission fluid
performance or stuck ON • Transmission fluid condition. level and condition.
Testing).
matic Transmis-
• Shift solenoid B (SSB). • GO to Pinpoint Test L.
• P0758: SSB or SSPCB shift • Shift solenoid B (SSB). • GO to Pinpoint Test M.
(TCM).
• Circuit(s).
• P0760: SSC or SSPCC shift • Shift solenoid C (SSC). • REFER to WDS.
failure (TCM).
• Circuit(s).
• P0761: SSC or SSPCC • Transmission fluid level low. • Check the transmission fluid
Testing).
matic Transmis-
• Shift solenoid C (SSC). • GO to Pinpoint Test N.
2007.50 Focus 3/2007 G526638en

307-01-51 Transmission (4F27E) 307-01-51

• P0762: SSC or SSPCC • Transmission fluid level low. • Check the transmission fluid
Testing).
matic Transmis-
• Shift solenoid C (SSC). • GO to Pinpoint Test O.
• P0763: SSC or SSPCC shift • Shift solenoid C (SSC). • GO to Pinpoint Test P.
(TCM).
• Circuit(s).
• P0765: SSD or SSPCD shift • Shift solenoid D (SSD). • REFER to WDS.
failure (TCM).
• Circuit(s).
• P0766: SSD or SSPCD • Transmission fluid level low. • Check the transmission fluid
Testing).
matic Transmis-
• Shift solenoid D (SSD). • GO to Pinpoint Test Q.
2007.50 Focus 3/2007 G526638en

307-01-52 Transmission (4F27E) 307-01-52

• P0767: SSD or SSPCD • Transmission fluid level low. • Check the transmission fluid
Testing).
matic Transmis-
• Shift solenoid D (SSD). • GO to Pinpoint Test R.
• P0768: SSD or SSPCD shift • Shift solenoid D (SSD). • GO to Pinpoint Test S.
(TCM).
• Circuit(s).
• P0770: SSE or SSPCE shift • Shift solenoid E (SSE). • REFER to WDS.
failure (TCM).
• Circuit(s).
• P0771: SSE or SSPCE • Transmission fluid level low. • Check the transmission fluid
Testing).
matic Transmis-
• Shift solenoid E (SSE). • GO to Pinpoint Test T.
2007.50 Focus 3/2007 G526638en

307-01-53 Transmission (4F27E) 307-01-53

• P0772: SSE or SSPCE • Transmission fluid level low. • Check the transmission fluid
Testing).
matic Transmis-
• Shift solenoid E (SSE). • GO to Pinpoint Test U.
• P0773: SSE or SSPCE shift • Shift solenoid E (SSE). • GO to Pinpoint Test V.
(TCM).
• Circuit(s).
• P0815: Upshift switch circuit • Gear selector lever. • REFER to WDS.
(TCM).
• Circuit(s).
• P0816: Downshift switch circuit • Gear selector lever. • REFER to WDS.
(TCM).
• Circuit(s).
• P0882: Supply voltage too low • Battery. • REFER to WDS.
• Charging system.
• Circuit(s).
• P0883: TCM power input signal • Charging system. • REFER to WDS.
high
• P0960: PCA or LPC solenoid • Electronic pressure control • REFER to WDS.
open circuit failure (EPC) solenoid A.
• Circuit(s).
short to ground circuit failure (EPC) solenoid A.
• Circuit(s).
control circuit high (EPC) solenoid A.
• P0972: Shift solenoid A • Shift solenoid A (SSA). • GO to Pinpoint Test W.
performance or stuck OFF
2007.50 Focus 3/2007 G526638en

307-01-54 Transmission (4F27E) 307-01-54

• P0973: SSA control circuit low • Shift solenoid A (SSA). • REFER to WDS.
(TCM).
• Circuit(s).
• P0974: SSA control circuit high • Shift solenoid A (SSA). • REFER to WDS.
(TCM).
• Circuit(s).
• P0975: Shift solenoid B • Shift solenoid B (SSB). • GO to Pinpoint Test X.
performance or stuck OFF
• P0976: SSB control circuit low • Shift solenoid B (SSB). • REFER to WDS.
(TCM).
• Circuit(s).
• P0977: SSB control circuit high • Shift solenoid B (SSB). • REFER to WDS.
(TCM).
• Circuit(s).
• P0978: SSC or SSPCC • Shift solenoid C (SSC). • GO to Pinpoint Test Y.
performance
• P0979: SSC control circuit low • Shift solenoid C (SSC). • REFER to WDS.
(TCM).
• Circuit(s).
• P0980: SSC control circuit high • Shift solenoid C (SSC). • REFER to WDS.
(TCM).
• Circuit(s).
• P0981: SSD or SSPCD • Shift solenoid D (SSD). • GO to Pinpoint Test Z.
performance
• P0982: SSD or SSPCD shift • Shift solenoid D (SSD). • REFER to WDS.
solenoid electrical circuit short • Transmission control module
to ground failure (TCM).
• Circuit(s).
• P0983: SSD control circuit high • Shift solenoid D (SSD). • REFER to WDS.
(TCM).
• Circuit(s).
• P0984: SSE or SSPCE • Shift solenoid E (SSE). • GO to Pinpoint Test AA.
performance
to ground failure (TCM).
• Circuit(s).
2007.50 Focus 3/2007 G526638en

307-01-55 Transmission (4F27E) 307-01-55

to power failure (TCM).
• Circuit(s).
• P1397: System voltage out of • Transmission control module • GO to Pinpoint Test AB.
self test range (TCM).
• Battery.
• Charging system.
• Circuit(s).
• P1635: Tire/Axle out of accept- • Transmission control module • Reprogram the TCM. REFER
able range (TCM). to WDS.
• P1639: Vehicle ID block • Transmission control module • Reprogram the TCM. REFER
corrupted, not programmed (TCM). to WDS.
• P1700: Transmission failed to • Shift solenoid C (SSC). • GO to Pinpoint Test AC.
engage NEUTRAL • Transmission control module
(TCM).
• Circuit(s).
• P1702: TR sensor circuit inter- • Transmission range (TR) • REFER to WDS.
mittent sensor.
(TCM).
• Circuit(s).
• P1705: TR sensor out of self • Transmission range (TR) • REFER to WDS.
test range sensor.
(TCM).
• Circuit(s).
• P1711: TFT sensor out of self • Transmission fluid temperature • GO to Pinpoint Test AD.
test range (TFT) sensor.
(TCM).
• Circuit(s).
• P1744: Torque converter clutch • Torque converter clutch (TCC) • GO to Pinpoint Test AE.
system performance or mech- solenoid.
anically stuck OFF
• P1783: Transmission overtem- • Low transmission fluid level. • Check the transmission fluid
perature condition level.
Testing).
• Transmission control module • GO to Pinpoint Test AF.
(TCM).
2007.50 Focus 3/2007 G526638en

307-01-56 Transmission (4F27E) 307-01-56

• P1910: Reverse lamp control • Circuit(s). • REFER to WDS.
circuit open
• U0073: CAN communication • Transmission control module • GO to Pinpoint Test AG.
bus fault (TCM).
• Circuit(s).
• U0100: Lost communication • Powertrain control module • GO to Pinpoint Test AH.
with the PCM (PCM).
(TCM).
• Circuit(s).
PINPOINT TEST A : P0711: TFT SENSOR OUT OF SELF TEST RANGE

A1: CHECK THE TFT SENSOR RESISTANCE
NOTE: Make sure that DTCs P0712 or P0713 are not present. Repair these DTCs before starting this
pinpoint test.
1 Disconnect TFT Sensor C439.

2 Measure the resistance between the main
control valve C439 pin 4, circuit 9-TA36
(BK/GN), component side and the main control
valve C439 pin 5, circuit 8-TA36 (WH/GN),
component side.
• Is the resistance between 1,000 ohms and
6,000 ohms?
→ Yes
GO to A2.
E62371 → No
INSTALL a new TFT sensor.
REFER to: Main Controls (307-01 Automatic
Transmission/Transaxle - Vehicles With: 4-
Speed Automatic Transmission (4F27E), In-
vehicle Repair).
CLEAR the DTCs. TEST the system for
normal operation.
A2: CHECK THE TCM TRANSMISSION TABLES
1 Connect TFT Sensor C439.
2 Clear the DTCs.
3 RESET the transmission tables. REFER to
WDS.
2007.50 Focus 3/2007 G526638en

307-01-57 Transmission (4F27E) 307-01-57

4 Drive the vehicle for approximately 5 minutes.
• Is the DTC present?
→ Yes
INSTALL a new TCM. CLEAR the DTCs.
→ No
PINPOINT TEST B : P0731: TRANSMISSION GEAR #1 INCORRECT RATIO

B1: CHECK THE OPERATION OF EACH SOLENOID AND RETURN SPRING
1 Remove the main control valve body.
vehicle Repair).
2 Disassemble the main control valve body.
REFER to: Transaxle (307-01 Automatic
Speed Automatic Transmission (4F27E),
Disassembly).
• Are the solenoids and return springs
damaged?
→ Yes
INSTALL new main control valve components
as necessary.
REFER to: Main Control Valve Body (307-01
Vehicles With: 4-Speed Automatic Transmis-
sion (4F27E), ).
normal operation.
→ No
DISASSEMBLE the transmission and
Disassembly).
normal operation.
2007.50 Focus 3/2007 G526638en

307-01-58 Transmission (4F27E) 307-01-58
PINPOINT TEST C : P0732 : TRANSMISSION GEAR #2 INCORRECT RATIO
C1: CHECK THE OPERATION OF EACH SOLENOID AND RETURN SPRING
vehicle Repair).
Disassembly).
damaged?
→ Yes
as necessary.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST D : P0733: TRANSMISSION GEAR #3 INCORRECT RATIO

D1: CHECK THE OPERATION OF EACH SOLENOID AND RETURN SPRING
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-59 Transmission (4F27E) 307-01-59

Disassembly).
damaged?
→ Yes
as necessary.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST E : P0734: TRANSMISSION GEAR #4 INCORRECT RATIO

E1: CHECK THE OPERATION OF EACH SOLENOID AND RETURN SPRING
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-60 Transmission (4F27E) 307-01-60

Disassembly).
damaged?
→ Yes
as necessary.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST F : P0741: TCC SYSTEM PERFORMANCE. TORQUE CONVERTER SLIP IS GREATER
THAN EXPECTED
F1: CHECK THE OPERATION OF EACH SOLENOID AND RETURN SPRING
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-61 Transmission (4F27E) 307-01-61

Disassembly).
damaged?
→ Yes
as necessary.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST G : P0748: EPC A ELECTRICAL (VPS)

G1: CHECK EPC A HARNESS RESISTANCE
1 Disconnect Main Control Valve C439.
control valve C439 pin 2 and pin 7, component
side.
• Is the resistance between 2-7 ohms?
→ Yes
GO to G2.
→ No
GO to G4.
E62372
G2: CHECK FOR SUPPLY VOLTAGE TO EPC A

2007.50 Focus 3/2007 G526638en

307-01-62 Transmission (4F27E) 307-01-62

2 Measure the voltage between the main control
valve C439 pin 2, harness side and ground.
→ Yes
GO to G3.
→ No
GO to G5.
E62373
G3: CHECK THE MAIN CONTROL VALVE CONNECTOR CIRCUIT FOR A SHORT TO POWER
SUPPLY
2 Disconnect Transmission Control Module (TCM)
C414.
valve C439 pin 2, circuit 15S-TA17 (GN/OG),
→ Yes
REPAIR circuit 15S-TA17 (GN/OG). CLEAR
the DTCs. TEST the system for normal opera-
tion.
→ No
E62373
GO to G6.
G4: CHECK EPC A RESISTANCE

1 Remove the main control valve body cover.
(4F27E), ).
2 Disconnect EPC A.
2007.50 Focus 3/2007 G526638en

307-01-63 Transmission (4F27E) 307-01-63

3 Measure the resistance between EPC A pin A
and pin B component side.
→ Yes
INSTALL a new EPC A wiring harness.
Disassembly).
E52263 CLEAR the DTCs. TEST the system for
normal operation.
→ No
INSTALL a new EPC A.
sion (4F27E), ).
normal operation.
G5: CHECK FOR CONTINUITY BETWEEN THE TCM AND EPC A
2 Disconnect TCM C414.
3 Measure the resistance between the TCM C414
pin 6, circuit 15S-TA17 (GN/OG), harness side
and the main control valve C439 pin 2, circuit
15S-TA17 (GN/OG), harness side.
→ Yes
Install a new TCM. CLEAR the DTCs. TEST
→ No
E62374 REPAIR circuit 15S-TA17 (GN/OG). CLEAR
tion.
G6: CHECK THE MAIN CONTROL VALVE CONNECTOR CIRCUIT FOR A SHORT TO GROUND
2007.50 Focus 3/2007 G526638en

307-01-64 Transmission (4F27E) 307-01-64

control valve C439 pin 7, circuit 91S-TA17
(BK/RD), harness side and ground.
→ Yes
GO to G7.
→ No
REPAIR circuit 91S-TA27 (BK/RD). CLEAR
E62375 the DTCs. TEST the system for normal opera-
tion.
G7: CHECK FOR CONTINUITY BETWEEN THE TCM AND EPC A GROUND
pin 92, circuit 91S-TA17 (BK/RD), harness side
91S-TA17 (BK/RD), harness side.
→ Yes
Clear the DTCs. Test the system for normal
operation. If the DTC remains, INSTALL a new
TCM.
E62376 → No
REPAIR circuit 91S-TA27 (BK/RD). CLEAR
tion.
PINPOINT TEST H : P0751: SSA OR SSPCA PERFORMANCE OR STUCK OFF

H1: CHECK THE OPERATION OF SSA
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-65 Transmission (4F27E) 307-01-65

Disassembly).
• Is the solenoid or return spring damaged?
→ Yes
INSTALL a new SSA.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST I : P0752: SSA OR SSPCA STUCK ON

I1: CHECK THE OPERATION OF SSA
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-66 Transmission (4F27E) 307-01-66

Disassembly).
→ Yes
INSTALL a new SSA.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST J : P0753: SSA OR SSPCA SHIFT SOLENOID ELECTRICAL CIRCUIT FAILURE
J1: CHECK SSA CIRCUIT FOR A SHORT TO BATTERY
valve C439 pin 6, circuit 15S-TA23 (GN/YE),
→ Yes
REPAIR circuit 15S-TA23 (GN/YE). CLEAR
tion.
E62377 → No
GO to J2.
2007.50 Focus 3/2007 G526638en

307-01-67 Transmission (4F27E) 307-01-67

J2: CHECK SSA CIRCUIT FOR A SHORT TO GROUND
(GN/YE), harness side and ground.
→ Yes
GO to J3.
→ No
tion.
J3: CHECK FOR CONTINUITY BETWEEN THE TCM AND SSA

pin 12, circuit 15S-TA23 (GN/YE), harness side
15S-TA23 (GN/YE), harness side.
→ Yes
GO to J4.
→ No
tion.
J4: CHECK SSA RESISTANCE

1 Disconnect SSA connector.
(4F27E), ).
2007.50 Focus 3/2007 G526638en

307-01-68 Transmission (4F27E) 307-01-68

2 Measure the resistance between SSA pin A and
pin B, component side.
→ Yes
INSTALL a new SSA wiring harness.
vehicle Repair).
normal operation.
→ No
INSTALL a new SSA.
sion (4F27E), ).
normal operation.
PINPOINT TEST K : P0756: SSB OR SSPCB PERFORMANCE OR STUCK OFF

K1: CHECK THE OPERATION OF SSB
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-69 Transmission (4F27E) 307-01-69

Disassembly).
→ Yes
INSTALL a new SSB.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST L : P0757: SSB OR SSPCB PERFORMANCE OR STUCK ON

L1: CHECK THE OPERATION OF SSB
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-70 Transmission (4F27E) 307-01-70

Disassembly).
→ Yes
INSTALL a new SSB.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST M : P0758: SSB OR SSPCB SHIFT SOLENOID ELECTRICAL CIRCUIT FAILURE
M1: CHECK SSB CIRCUIT FOR A SHORT TO BATTERY
valve C439 pin 8, circuit 15S-TA24 (GN/BU),
→ Yes
REPAIR circuit 15S-TA24 (GN/BU). CLEAR
tion.
E62380
→ No
GO to M2.
2007.50 Focus 3/2007 G526638en

307-01-71 Transmission (4F27E) 307-01-71

M2: CHECK SSB CIRCUIT FOR A SHORT TO GROUND
(GN/BU), harness side and ground.
→ Yes
GO to M3.
→ No
tion.
M3: CHECK FOR CONTINUITY BETWEEN THE TCM AND SSB

pin 13, circuit 15S-TA24 (GN/BU), harness side
15S-TA24 (GN/BU), harness side.
→ Yes
GO to M4.
→ No
tion.
M4: CHECK SSB RESISTANCE

1 Disconnect SSB connector.
(4F27E), ).
2007.50 Focus 3/2007 G526638en

307-01-72 Transmission (4F27E) 307-01-72

2 Measure the resistance between SSB pin A and
→ Yes
INSTALL a new SSB wiring harness.
vehicle Repair).
normal operation.
→ No
INSTALL a new SSB.
sion (4F27E), ).
normal operation.
PINPOINT TEST N : P0761: SSC OR SSPCC PERFORMANCE OR STUCK OFF

N1: CHECK THE OPERATION OF SSC
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-73 Transmission (4F27E) 307-01-73

Disassembly).
→ Yes
INSTALL a new SSC.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST O : P0762: SSC OR SSPCC PERFORMANCE OR STUCK ON

O1: CHECK THE OPERATION OF SSC
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-74 Transmission (4F27E) 307-01-74

Disassembly).
→ Yes
INSTALL a new SSC.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST P : P0763: SSC OR SSPCC SHIFT SOLENOID ELECTRICAL CIRCUIT FAILURE
P1: CHECK SSC CIRCUIT FOR A SHORT TO BATTERY
valve C439 pin 3, circuit 15S-TA63 (GN/BK),
→ Yes
REPAIR circuit 15S-TA63 (GN/BK). CLEAR
tion.
→ No
E62383
GO to P2.
2007.50 Focus 3/2007 G526638en

307-01-75 Transmission (4F27E) 307-01-75

P2: CHECK SSC CIRCUIT FOR A SHORT TO GROUND
(GN/BK), harness side and ground.
→ Yes
GO to P3.
→ No
E62384
tion.
P3: CHECK FOR CONTINUITY BETWEEN THE TCM AND SSC

pin 51, circuit 15S-TA63 (GN/BK), harness side
15S-TA63 (GN/BK), harness side.
→ Yes
GO to P4.
→ No
tion.
P4: CHECK SSC RESISTANCE

1 Disconnect SSC connector.
(4F27E), ).
2007.50 Focus 3/2007 G526638en

307-01-76 Transmission (4F27E) 307-01-76

2 Measure the resistance between SSC pin A and
→ Yes
INSTALL a new SSC wiring harness.
vehicle Repair).
normal operation.
→ No
INSTALL a new SSC.
sion (4F27E), ).
normal operation.
PINPOINT TEST Q : P0766: SSD OR SSPCD PERFORMANCE OR STUCK OFF

Q1: CHECK THE OPERATION OF SSD
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-77 Transmission (4F27E) 307-01-77

Disassembly).
→ Yes
INSTALL a new SSD.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST R : P0767: SSD OR SSPCD PERFORMANCE OR STUCK ON

R1: CHECK THE OPERATION OF SSD
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-78 Transmission (4F27E) 307-01-78

Disassembly).
→ Yes
INSTALL a new SSD.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST S : P0768: SSD OR SSPCD SHIFT SOLENOID ELECTRICAL CIRCUIT FAILURE
S1: CHECK SSD CIRCUIT FOR A SHORT TO BATTERY
valve C439 pin 9, circuit 15S-TA64 (GN/OG),
→ Yes
tion.
E62386
→ No
GO to S2.
2007.50 Focus 3/2007 G526638en

307-01-79 Transmission (4F27E) 307-01-79

S2: CHECK SSD CIRCUIT FOR A SHORT TO GROUND
(GN/OG), harness side and ground.
→ Yes
GO to S3.
→ No
tion.
S3: CHECK FOR CONTINUITY BETWEEN THE TCM AND SSD

pin 7, circuit 15S-TA64 (GN/OG), harness side
15S-TA64 (GN/OG), harness side.
→ Yes
GO to S4.
→ No
tion.
S4: CHECK SSD RESISTANCE

1 Disconnect SSD connector.
(4F27E), ).
2007.50 Focus 3/2007 G526638en

307-01-80 Transmission (4F27E) 307-01-80

2 Measure the resistance between SSD pin A and
→ Yes
INSTALL a new SSD wiring harness.
vehicle Repair).
normal operation.
→ No
INSTALL a new SSD.
sion (4F27E), ).
normal operation.
PINPOINT TEST T : P0771: SSE OR SSPCE PERFORMANCE OR STUCK OFF

T1: CHECK THE OPERATION OF SSE
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-81 Transmission (4F27E) 307-01-81

Disassembly).
→ Yes
INSTALL a new SSE.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST U : P0772: SSE OR SSPCE PERFORMANCE OR STUCK ON

U1: CHECK THE OPERATION OF SSE
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-82 Transmission (4F27E) 307-01-82

Disassembly).
→ Yes
INSTALL a new SSE.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST V : P0773: SSE OR SSPCE SHIFT SOLENOID ELECTRICAL CIRCUIT FAILURE
V1: CHECK SSE CIRCUIT FOR A SHORT TO BATTERY
valve C439 pin 1, circuit 15S-TA65 (GN/WH),
→ Yes
REPAIR circuit 15S-TA65 (GN/WH). CLEAR
tion.
E62389 → No
GO to V2.
2007.50 Focus 3/2007 G526638en

307-01-83 Transmission (4F27E) 307-01-83

V2: CHECK SSE CIRCUIT FOR A SHORT TO GROUND
(GN/WH), harness side and ground.
→ Yes
GO to V3.
→ No
tion.
V3: CHECK FOR CONTINUITY BETWEEN THE TCM AND SSE

pin 29, circuit 15S-TA65 (GN/WH), harness side
15S-TA65 (GN/WH), harness side.
→ Yes
GO to V4.
→ No
tion.
V4: CHECK SSE RESISTANCE

1 Disconnect SSE connector.
(4F27E), ).
2007.50 Focus 3/2007 G526638en

307-01-84 Transmission (4F27E) 307-01-84

2 Measure the resistance between SSE pin A and
•
→ Yes
INSTALL a new SSE wiring harness.
vehicle Repair).
normal operation.
→ No
INSTALL a new SSE.
sion (4F27E), ).
normal operation.
PINPOINT TEST W : P0972: SHIFT SOLENOID A PERFORMANCE OR STUCK OFF

W1: CHECK THE OPERATION OF SSA
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-85 Transmission (4F27E) 307-01-85

Disassembly).
→ Yes
INSTALL a new SSA.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST X : P0975: SHIFT SOLENOID B PERFORMANCE OR STUCK OFF

X1: CHECK THE OPERATION OF SSB
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-86 Transmission (4F27E) 307-01-86

Disassembly).
→ Yes
INSTALL a new SSB.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST Y : P0978: SSC OR SSPCC PERFORMANCE

Y1: CHECK THE OPERATION OF SSC
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-87 Transmission (4F27E) 307-01-87

Disassembly).
→ Yes
INSTALL a new SSC.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST Z : P0981: SSD OR SSPCD PERFORMANCE

Z1: CHECK THE OPERATION OF SSD
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-88 Transmission (4F27E) 307-01-88

Disassembly).
→ Yes
INSTALL a new SSD.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST AA : P0984: SSE OR SSPCE PERFORMANCE

AA1: CHECK THE OPERATION OF SSE
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-89 Transmission (4F27E) 307-01-89

Disassembly).
→ Yes
INSTALL a new SSE.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
PINPOINT TEST AB : P1397: SYSTEM VOLTAGE OUT OF SELF TEST RANGE

AB1: CHECK THE TCM GROUND CIRCUITS
2 Measure the resistance between the:
• TCM C414 pin 3, circuit 91-TA55A (BK/GN),
• TCM C414 pin 4, circuit 91-TA55B (BK/GN),
• Are the resistances less than 5 ohms?
→ Yes
GO to AB2.
→ No
E62392 REPAIR circuit 91-TA55A (BK/GN) or circuit
91-TA55B (BK/GN). CLEAR the DTCs. TEST
AB2: CHECK FOR VOLTAGE TO THE TCM
2007.50 Focus 3/2007 G526638en

307-01-90 Transmission (4F27E) 307-01-90

2 Measure the voltage between the:
• TCM C414 pin 1, circuit 15-TA55A (GN/BK),
• TCM C414 pin 2, circuit 15-TA55B (GN/BK),
→ Yes
GO to AB3.
→ No
E62393 GO to AB4.
AB3: CHECK FOR OVER VOLTAGE TO THE TCM

• TCM C414 pin 1, circuit 15-TA55A (GN/BK),
• TCM C414 pin 2, circuit 15-TA55B (GN/BK),
→ Yes
Check the charging system.
E62393 ging System - General Information,
normal operation.
→ No
normal operation. If the DTC remains
INSTALL a new TCM.
AB4: CHECK FOR CONTINUITY BETWEEN THE BATTERY JUNCTION BOX AND THE TCM
2 Disconnect Fuse 32.
2007.50 Focus 3/2007 G526638en

307-01-91 Transmission (4F27E) 307-01-91

• Fuse 32, circuit 91-TA55A (BK/GN), harness
side and TCM C414 pin 3, circuit 91-TA55A
(BK/GN), harness side.
• Fuse 32, circuit 91-TA55A (BK/GN), harness
side and TCM C414 pin 4, circuit 91-TA55B
→ Yes
E62394 Check the charging system.
normal operation.
→ No
REPAIR circuit 15-TA55A (GN/BK) or circuit
15-TA55B (GN/BK). CLEAR the DTCs. TEST
PINPOINT TEST AC : P1700: TRANSMISSION FAILED TO ENGAGE NEUTRAL

AC1: CHECK SSC RESISTANCE
NOTE: If any of the following DTCs P0760, P0761, P0762, P0763, P0978, P0979, P0980 are present,
clear these DTCs before commencing this pinpoint test.

(GN/BK), component side and ground.
→ Yes
GO to AC2.
→ No
GO to AC4.
E62384
AC2: CHECK FOR CONTINUITY BETWEEN THE TCM AND SSC

2007.50 Focus 3/2007 G526638en

307-01-92 Transmission (4F27E) 307-01-92

2 Measure the resistance between main control
valve C349 pin 3, circuit 15S-TA63 (GN/BK),
harness side and the TCM C414 pin 51, circuit
15S-TA63 (GN/BK), harness side.
•
→ Yes
GO to AC3.
→ No
tion.
AC3: CHECK THE TCM

1 Connect Main Control Valve C349.
2 Connect TCM C414.
3 Clear the DTCs, Carry out road test.
• Is DTC P1700 still present?
→ Yes
→ No
AC4: CHECK FOR CONTINUITY BETWEEN SSC AND GROUND
1 Disconnect SSC.
vehicle Repair).
2007.50 Focus 3/2007 G526638en

307-01-93 Transmission (4F27E) 307-01-93

(GN/BK), component side and SSC.
→ Yes
INSTALL a new SSC.
sion (4F27E), ).
normal operation.
→ No
INSTALL new main control valve wiring
harness.
vehicle Repair).
normal operation.
PINPOINT TEST AD : P1711: TFT SENSOR OUT OF SELF TEST RANGE

AD1: CHECK THE TFT SENSOR RESISTANCE
NOTE: If any of the following DTCs P0710, P0712 or P0713 are present, clear these DTCs before
commencing this pinpoint test.

(BN/GN), component side and the main control
valve C439 pin 5, circuit 8-TA36 (WH/GN),
component side.
• Is the resistance between 1,000 ohms and
6,000 ohms?
→ Yes
GO to AD2.
E62371 → No
GO to AD4.
2007.50 Focus 3/2007 G526638en

307-01-94 Transmission (4F27E) 307-01-94

AD2: CHECK THE TFT SENSOR CIRCUIT FOR A SHORT TO GROUND
(WH/GN), harness side and ground.
→ Yes
GO to AD3.
→ No
REPAIR circuit 8-TA36 (WH/GN). CLEAR the
E62395 DTCs. TEST the system for normal operation.
AD3: CHECK THE TFT SENSOR CIRCUIT FOR A SHORT TO BATTERY

valve C439 pin 4, circuit 9-TA36 (BN/GN),
→ Yes
REPAIR circuit 9-TA36 (BN/GN). CLEAR the
DTCs. TEST the system for normal operation.
→ No
E62396 GO to AD5.
AD4: CHECK THE TFT SENSOR RESISTANCE

1 Remove the main control valve body cover.
(4F27E), ).
2 Disconnect TFT Sensor.
2007.50 Focus 3/2007 G526638en

307-01-95 Transmission (4F27E) 307-01-95

3 Measure the resistance between the TFT sensor
pin A and pin B component side.
• Is the resistance between 1,000 and 6,000
ohms?
→ Yes
INSTALL a new solenoid wiring harness.
E52263 sion (4F27E), ).
normal operation.
→ No
INSTALL a new TFT sensor.
sion (4F27E), ).
normal operation.
AD5: CHECK FOR CONTINUITY BETWEEN THE MAIN CONTROL VALVE AND THE TCM
• TCM C414 pin 14, circuit 9-TA36 (BN/GN),
harness side and the main control valve C439
pin 4, circuit 9-TA36 (BN/GN), harness side.
• TCM C414 pin 38, circuit 8-TA36 (WH/GN),
harness side and the main control valve C439
pin 5, circuit 8-TA36 (WH/GN), harness side.
→ Yes
E62397 GO to AD6.
→ No
REPAIR circuit 8-TA36 (WH/GN) or circuit 9-
TA36 (BN /GN). CLEAR the DTCs. TEST the
AD6: CHECK THE TCM TRANSMISSION TABLES
1 Connect TCM C414.
2 Connect Main Control Valve C439.
3 Clear the DTCs.
2007.50 Focus 3/2007 G526638en

307-01-96 Transmission (4F27E) 307-01-96

WDS.
→ Yes
→ No
PINPOINT TEST AE : P1744: TORQUE CONVERTER CLUTCH SYSTEM PERFORMANCE OR

MECHANICALLY STUCK OFF
AE1: CHECK THE OPERATION OF SSB
1 Remove the main control valve.
vehicle Repair).
(4F27E), ).
→ Yes
INSTALL a new SSB.
sion (4F27E), ).
normal operation.
→ No
Disassembly).
normal operation.
2007.50 Focus 3/2007 G526638en

307-01-97 Transmission (4F27E) 307-01-97
PINPOINT TEST AF : P1783: TRANSMISSION OVERTEMPERATURE CONDITION
AF1: CHECK THE TCM TRANSMISSION TABLES
2 Wait for 2 minutes.
3 Connect TCM C414.
4 Clear the DTCs.
WDS.
→ Yes
→ No
PINPOINT TEST AG : U0073: CAN COMMUNICATION BUS FAULT

AG1: CHECK THE TCM COMMUNICATION BUS CIRCUIT FOR A SHORT CIRCUIT
pin 8, circuit 5-EC7E (BU/RD), harness side and
the TCM C414 pin 9, circuit 4-EC7E (GY/RD),
harness side.
→ Yes
GO to AG2.
→ No
REPAIR circuit 4-EC7E (GY/RD) and circuit
E62398 5-EC7E (BU/RD). CLEAR the DTCs. TEST
2007.50 Focus 3/2007 G526638en

307-01-98 Transmission (4F27E) 307-01-98

AG2: CHECK THE TCM COMMUNICATION BUS CIRCUIT FOR A SHORT TO GROUND
pin 9, circuit 4-EC7E (GY/RD), harness side and
ground.
→ Yes
GO to AG3.
→ No
REPAIR circuit 4-EC7E (GY/RD). CLEAR the
E62399
AG3: CHECK THE TCM COMMUNICATION BUS CIRCUIT FOR A SHORT CIRCUIT TO BATTERY
OR IGNITION
2 Measure the voltage between the TCM C414
ground.
→ Yes
REPAIR circuit 5-EC7E (BU/RD). CLEAR the
→ No
PINPOINT TEST AH : U0100: LOST COMMUNICATION WITH THE PCM

AH1: CHECK THE TCM COMMUNICATION BUS CIRCUIT FOR A SHORT CIRCUIT
2007.50 Focus 3/2007 G526638en

307-01-99 Transmission (4F27E) 307-01-99

the TCM C414 pin 9, circuit 4-EC7E (GY/RD),
harness side.
→ Yes
GO to AH2.
→ No
REPAIR circuit 4-EC7E (GY/RD) and circuit
E62398 5-EC7E (BU/RD). CLEAR the DTCs. TEST
AH2: CHECK THE TCM COMMUNICATION BUS CIRCUIT FOR A SHORT TO GROUND
pin 9, circuit 4-EC7E (GY/RD), harness side and
ground.
→ Yes
GO to AH3.
→ No
REPAIR circuit 4-EC7E (GY/RD). CLEAR the
E62399
AH3: CHECK THE TCM COMMUNICATION BUS CIRCUIT FOR A SHORT CIRCUIT TO BATTERY
OR IGNITION
2 Measure the voltage between the TCM C414
ground.
→ Yes
REPAIR circuit 5-EC7E (BU/RD). CLEAR the
→ No
2007.50 Focus 3/2007 G526638en

307-01-100 Transmission (4F27E) 307-01-100
Transmission/Transaxle Connector Layouts

Item Description
Transaxle Solenoid Location
2 SSB
2 1 6 3 SSC
4 SSD
5 SSE
6 PCA
4 5 3
TIA0006159
Item Description
1 SSA
2007.50 Focus 3/2007 G17974en

307-01-101 Transmission (4F27E) 307-01-101
Transaxle Internal Harness Connectors
5 2
1 3
4 6
7 8 9 10 1
2 7
11 3
4 5
12 9
ELE0010468
Pin Circuit Func- Connector Pin Circuit Func- Connector

tion Color tion Color
1 SSE GREEN 7 PCA BLACK
2 PCA BLACK 8 SSB BLACK
3 SSC WHITE 9 SSD BLUE
4 TFT SIGRTN BLACK 10 SSE GROUND GREEN
5 TFT BLACK 11 SSC GROUND WHITE
6 SSA WHITE 12 SSD GROUND BLUE
2007.50 Focus 3/2007 G17974en

307-01-102 Transmission (4F27E) 307-01-102
Transaxle Vehicle Harness Connector Pin Number EEC Pin Circuit Func-
Number tion
2 1 4 4 Reverse posi-
3 tion
5 64 Park position
6 - Starting system
6 4
7 8 2nd position
7 8 64 Park position
9 8 5 9 - Starting system
ELE0010469
Output Shaft Speed Sensor (OSS) Vehicle Harness

Pin Number EEC Pin Circuit Func- Connector
Number tion
1 102 SSE
2
2 44 PCA
3 82 SSC
4 91 TFT signal
return
5 37 TFT 1
6 73 SSA
ELE0010471
7 81 PCA
8 1 SSB Pin Number Circuit Function
9 99 SSD 1 Output shaft speed
sensor (OSS)
Transmission Range (TR) Sensor Vehicle Harness
Connector 2 Signal return
Turbine Shaft Speed (TSS) Sensor Vehicle Harness

5 4 3 2 1 Connector
9 8 7 6
ELE0010470
1
Pin Number EEC Pin Circuit Func-
ELE0010471
Number tion
1 - VPWR Pin Number Circuit Function
2 11 Drive position 1 Turbine shaft speed
3 7 1st position sensor (TSS)
2 Signal return
2007.50 Focus 3/2007 G17974en

307-01-103 Transmission (4F27E) 307-01-103
Transmission Range (TR) Sensor Diagnosis
Chart
Selector Posi- TR Sensor Expected
tion PinsCom- Value
ponent Side
PARK 1 and 2, 3 and Less than 5
4 ohms
REVERSE 3 and 5 Less than 5
ohms
NEUTRAL 1 and 2, 3 and Less than 5
6 ohms
DRIVE 3 and 7 Less than 5
ohms
2 3 and 8 Less than 5
ohms
1 3 and 9 Less than 5
ohms
2007.50 Focus 3/2007 G17974en

307-01-104 Transmission (4F27E) 307-01-104
Special Testing Procedures

Special Tool(s) completed before carrying out the line
pressure test or test results may be
Hydraulic Pressure Gauge
incorrect.
(0–60 bar)
307-201 Carry out the transmission preliminary
inspection.
REFER to: Preliminary Inspection (307-01
17033 Automatic Transmission/Transaxle - Vehicles
Adaptor for 301-201
307-201-01
E48050
Transmission Air Test Plate

307-412
E52581
307412 2.
WARNING: When removing the line
pressure test point plug, take care to prevent
General Equipment scalding. Failure to follow this instruction
Remove and discard the line pressure test point
The following tests are designed to aid the plug.
technician in diagnosing the hydraulic and
mechanical portion of the transmission.
Engine Idle Speed Check 307-201
Refer to WDS to check the engine idle speed.
Line Pressure Test

CAUTIONS: 307-201-01
Carry out the line pressure test before E52582
carrying out the stall speed test. If the line
pressure is low at stall, do not carry out
the stall speed test or further transmission 4. Start the engine and check the line pressures.
damage may occur. Refer to the line pressure chart below to
determine if the line pressures are within
Do not maintain wide open throttle (WOT) specification.
in any gear range for more than 5 seconds.
5. If the line pressure is not within specification,
1. NOTE: Certain sensor concerns may cause refer to the line pressure diagnosis chart below
high powertrain control failure mode effect for possible line pressure concern sources.
management actions. Make sure that all
necessary electrical repairs have been
2007.50 Focus 3/2007 G528302en

307-01-105 Transmission (4F27E) 307-01-105
307-201
307-201-01 7 Nm
E52582 E52583
6. Remove the special tools. 7. Install a new line pressure test point plug.
Line Pressure Chart

Range Idle Stall
kPa psi kPa psi
"P" (PARK) and "N" 345-450 50-65 1240-1450 180-210
(NEUTRAL)
"R" (REVERSE) 500-750 72-109 1600-2000 232-290
"D" (DRIVE) 345-450 50-65 1240-1450 180-210
Line Pressure Diagnosis Chart

Test Results Possible Source
Low pressure in all ranges Worn transmission fluid pump.
Fluid leaking from the transmission fluid pump, main
control valve body or transmission fluid pan.
Pressure control solenoid inoperative.
Solenoid regulating valve sticking.
Low pressure in "D" only Fluid leaking from the forward clutch hydraulic line.
Low pressure in "D" and "R" only Fluid leaking from the low/reverse clutch hydraulic
line.
Low pressure in "R" only Fluid leaking from the reverse clutch hydraulic line.
High pressure in all ranges Pressure control solenoid inoperative or open circuit
wiring harness.
Pressure regulator valve sticking.
Powertrain control module (PCM) inoperative.
Stall Speed Test Carry out the line pressure test before
carrying out the stall speed test. If the line
CAUTIONS: pressure is low at stall, do not carry out
Make sure that the parking brake is fully the stall speed test or further transmission
applied while carrying out each stall speed damage may occur.
test.
2007.50 Focus 3/2007 G528302en

307-01-106 Transmission (4F27E) 307-01-106
NOTE: The stall speed test should be carried out NOTE: This procedure may set diagnostic trouble
with the engine and transmission at normal codes (DTCs) P0712 and P1783. After carrying
operating temperatures. out the stall speed test, using WDS, carry out the
The stall speed test will confirm correct operation on-board diagnostics (OBD) test and clear the
of the following items: DTCs from the memory.
• torque converter clutch Press the accelerator pedal to the floor, WOT
in each gear range. Record the rpm reached in
• forward clutch each gear range. Stall speeds should be as
• low one-way clutch assembly follows:
• engine performance
Stall Speed Chart
1. Using WDS, measure the engine rpm. Engine RPM
2. CAUTIONS:
1.6L Duratec-16v 2200-2800
After testing each of the following ranges (Sigma)
"D" and "R", move the selector lever to the
"N" position and run the engine at 1000 rpm 1.8L/2.0L Duratec-HE 2200-2800
for approximately 15 seconds to allow the (MI4)
torque converter to cool before testing the
3. If the stall speeds are too high, refer to the stall
next range.
speed diagnosis chart below. If the stall speeds
Do not maintain wide open throttle (WOT) are too low, first check the engine idle speed.
in any gear range for more than 5 seconds. If the engine idle speed is OK, remove the
torque converter and check the torque converter
If the recorded engine rpm exceeds the one-way clutch for slippage.
maximum specified rpm, release the
accelerator pedal immediately. Torque
converter clutch or transmission brake band
slippage is indicated.
Stall Speed Diagnosis Chart
Gear Selector Lever Position Possible Cause
Above specification in "D" Forward clutch slipping.
Above specification in "D" and "R" Low/reverse clutch slipping.
Above specification in "R" Reverse clutch slipping.
Carry out a road test to determine whether the
concern is in the low/reverse clutch.
Low/reverse clutch is slipping.
2007.50 Focus 3/2007 G528302en

307-01-107 Transmission (4F27E) 307-01-107
Air Pressure Tests
307-412 1 2
Transmission Air Test Plate
307-412 1 2 3 4
10
6
3 4
7
10 5
6 8
9
7
5 A0005636
8
9
2. NOTE: Use the fluid pan retaining bolts to
A0005636
hold the transmission air test plate in
position.
Item Description Install the special tool.
1 Servo release • Tighten the transmission fluid pan retaining
bolts to 10 Nm.
2 Servo apply
3. NOTE: A dull thud should be felt, heard or
3 Direct clutch apply movement may be observed when the
4 Reverse clutch apply component applies. There should be no
hissing sound when the component is fully
5 Torque converter bypass applied. If the clutch seals or check valves
are leaking a hissing sound may be heard.
6 Low/reverse clutch
Apply air pressure to the appropriate clutch port,
7 Torque converter charge refer to the transmission air test plate diagram
8 Forward clutch apply in this procedure.
4. If the test results indicate that the intermediate
9 Servo accumulator apply
and overdrive brake band servo does not
10 Forward servo accumulator apply operate, clean and check the intermediate and
overdrive brake band servo to locate the
NOTE: A no-drive condition can exist even with concern.
correct transmission fluid pressure due to
inoperative clutches or bands. An erratic shift can REFER to: Transaxle (307-01 Automatic
be located by a series of checks substituting air Transmission/Transaxle - Vehicles With:
pressure for fluid pressure to determine the location 4-Speed Automatic Transmission (4F27E),
of the concern. Disassembly).
5. If the air pressure applied to the clutch passages
NOTE: Use only dry, regulated (40 psi maximum), fails to operate a clutch, or operates another
air pressure. clutch simultaneously, disassemble the
1. Remove the main control valve body. transmission and use air pressure to check the
fluid passages in the center support and
clutches to detect obstructions.
4-Speed Automatic Transmission (4F27E), REFER to: Transaxle (307-01 Automatic
In-vehicle Repair). Transmission/Transaxle - Vehicles With:
Disassembly).
2007.50 Focus 3/2007 G528302en

307-01-108 Transmission (4F27E) 307-01-108
Leakage Inspection
General Equipment The cooler can be further checked for leaks.
UV fluid leak detection euipment
[Transmission/Transaxle Cooling -- Vehicles With:
CAUTION: Do not try to stop the fluid leak 4-Speed Automatic Transmission (4F27E)] /
by increasing the torque beyond 307-02B [Transmission/Transaxle Cooling --
specifications. This may cause damage to Vehicles With: Automatic Transmission (CFT23)]
the transaxle case threads. / 307-02C [Transmission/Transaxle Cooling --
Check the fluid filler tube at the transaxle case. If (FN4A-EL)].
any leakage is found, install a new plug.
If leakage is found at the transaxle range selector
Check the fluid tubes and fittings between the lever, install a new seal.
transaxle and the cooler for looseness, wear or
damage. If leakage cannot be stopped by If leakage is found at the transaxle wiring harness
tightening a fluid tube nut, install new components. connector, install a new O-ring.
If the leak continues, install a new cooler line fitting The transaxle is equipped with the following
and tighten to specification. The same procedure components to prevent external fluid leakage:
should be followed for fluid leaks between the • sealer
cooler and the cooler line fittings in this section. • lip-type seals
[Transmission/Transaxle Cooling -- Vehicles With: • O-ring seals
4-Speed Automatic Transmission (4F27E)] / • seal rings
307-02B [Transmission/Transaxle Cooling -- • seal grommets
Vehicles With: Automatic Transmission (CFT23)] • thread sealant
/ 307-02C [Transmission/Transaxle Cooling --
• panfluid
(FN4A-EL)].
2007.50 Focus 3/2007 G17977en

307-01-109 Transmission (4F27E) 307-01-109
External Sealing
5 6 7
1 2
3
4 8
10 9
11
7 12
TIA0005562
Item Description
1 O-ring - Output speed sensor Fluid Leakage in Torque Converter Area
2 Converter housing (sealant to case) In diagnosing and correcting fluid leaks in the pump
support and gear and torque converter area, use
3 Seal - Fluid pump
the following procedures to locate the exact cause
4 Seal - Pump fluid of the leakage. Leakage between the transaxle
and engine, as evidenced by fluid around the
5 Case (sealant to converter housing) torque converter housing, may have several
6 O-ring - Turbine speed sensor sources. By careful observation it is possible, in
many instances, to pinpoint the source of leak
7 Seal assy - Differential before removing the transaxle from the vehicle.
8 O-ring - Bulkhead wiring harness The paths which the fluid may take to reach the
connector bottom of the torque converter housing are shown
in the illustration. The five steps following
9 Cover assy - End (sealant to case) correspond to the numbers in the illustration.
10 Seal - Case cover (end cover to case) (2)
11 Seal - Manual shaft - Fluid (2)
12 Pan - Fluid (sealant to case)
2007.50 Focus 3/2007 G17977en

307-01-110 Transmission (4F27E) 307-01-110
housing and cylinder block causing oil to be
present in or at the bottom of the torque
1 2
5 converter housing.
b. Oil gallery plug leaks will allow oil to flow down
the rear face of the cylinder block to the bottom
4 of the torque converter housing.
c. Leakage at the crankshaft rear oil seal will work
back to the flexplate, and then into the torque
3 converter housing.
4
TIE0037864 Leak Check Test
1. Fluid leaking past the pump seal lip will tend to 1. Original factory fill fluid is dyed red to aid in
move along the impeller hub and onto the rear determining if leakage is from the engine or
of the impeller housing. Except in the case of a transaxle. The red color should assist in
total seal failure, fluid leakage past the lip of the pinpointing the leak.
seal will be deposited on the inside of the torque 2. Clean off any fluid from the top and bottom of
converter housing only, near the outside the torque converter housing, of the case, and
diameter of the housing. Fluid from the vent the rear face of the engine and oil pan. Clean
assembly may move along the impeller hub and the torque converter area by washing with a
onto the rear of the impeller housing. Fluid from suitable nonflammable solvent and blow dry
a converter hub weld leak will move along a using compressed air.
path on the inside of the converter housing.
3. Wash out the torque converter housing, and the
2. Fluid leakage past the outside diameter of the front of the flexplate. The torque converter
pump seal and pump body will follow the same housing may be washed out using cleaning
path that leaks past the inside diameter of the solvent and a squirt-type oil can. Blow dry all
pump seal follow. Fluid from a converter hub washed areas using compressed air.
weld leak will move along a path on the inside
of the converter housing. 4. Start and run the engine until the transaxle
reaches its normal operating temperature.
3. Fluid that leaks past a pump-to-case screw or Observe the rear of the cylinder block and the
pump gasket will be deposited on the inside of top of the torque converter housing for evidence
the torque converter housing only. Fluid will not of fluid leakage. Raise and support the vehicle
be deposited on the rear of the torque converter. REFER to Section 100-02 [Jacking and Lifting].
4. Fluid leakage from the converter drain plug, Run the engine at fast idle, then at engine idle,
(model-dependent) converter seal weld or occasionally shifting to the D and R positions to
converter-to-flexplate stud weld will appear at increase pressure within the transaxle. Observe
the outside diameter of the torque converter on the front of the flexplate, rear of the cylinder
the rear face of the flexplate, and in the block (in as far as possible), and inside the
converter housing only near the flexplate. Fluid torque converter housing and front of the
leaks from the torque converter will leave a ring transaxle case. Run the engine until fluid
of fluid around the inside of the torque converter leakage is evident and the probable source of
housing. leakage can be determined.
5. NOTE: White facial tissue paper may aid in
determining the color (red is transaxle fluid) Leak Check Test With Black Light
and source of the leaking fluid.
Engine oil leaks are sometimes incorrectly Fluid soluble aniline or fluorescent dyes premixed
diagnosed as transaxle pump gasket leaks. The at the rate of 2.5ml (1/2 teaspoon) of dye powder
following areas of possible leakage should also to 0.24L (1/2 pint) of automatic transaxle fluid have
be checked to determine if engine oil leakage proven helpful in locating the source of fluid
is causing the concern. leakage. Such dyes may be used to determine
a. Leakage at the valve cover gasket may allow whether an engine fluid or transaxle fluid leak is
oil to flow over the torque converter housing or present. An ultraviolet light must be used to detect
seep down between the torque converter the fluorescent dye solution.
2007.50 Focus 3/2007 G17977en

307-01-111 Transmission (4F27E) 307-01-111
Diagnosis By Symptom
Special Tool(s) 2. Refer to the routine indicated in the diagnosis
by symptom index.
Hydraulic Pressure Gauge
(0–60 bar) 3. Always begin the diagnosis of a symptom with:
307-201 a. Preliminary inspections.
17033 With: 4-Speed Automatic Transmission
b. Verifications of condition.
Adaptor for 301-201
307-201-01 REFER to: Preliminary Inspection (307-01
c. Checking the transmission fluid levels.
E48050
General Equipment
Worldwide Diagnostic System (WDS) (4F27E), Diagnosis and Testing).
Ultraviolet fluid leak detection equipment 4. NOTE: Not all concerns and conditions with
electrical components will set a diagnostic
The diagnosis by symptom index gives the trouble code (DTC). Be aware that the
technician diagnostic information, direction, and components listed may still be the cause.
suggests possible components, using a symptom Verify the correct function of these
as a starting point. components prior to proceeding to the
The diagnosis by symptom index is divided into hydraulic or mechanical routine listed.
two categories: Begin with the electrical routine, if indicated.
• Electrical routines are indicated by 200 series Follow the reference or action statements.
numbers. The electrical routines list the possible Always carry out the on-board diagnostic tests
electrical components that could cause or as necessary. Never skip steps. If the concern
contribute to the symptom described. is still present after electrical diagnosis, then
• Hydraulic or mechanical routines are indicated proceed to the hydraulic or mechanical routine
by 300 series numbers. The hydraulic or listed.
mechanical routines list the possible hydraulic 5. The hydraulic or mechanical routines list
or mechanical components that could cause or possible hydraulic or mechanical components
contribute to the symptom described. that may cause the concern. These components
are listed in the removal sequence and by the
most probable cause. All components listed
Diagnosis by Symptom Directions must be inspected to make sure of correct
repair.
1. Using the diagnosis by symptom index, select
the concern or symptom that best describes the
condition.
2007.50 Focus 3/2007 G526641en

307-01-112 Transmission (4F27E) 307-01-112
Diagnosis by Symptom Index
Engagement Concerns: Routines

Electrical Hydraulic or Mechanical
No forward movement in "D" 201A 301A
DRIVE only
No forward movement only (all 201B 301B
positions)
No reverse movement only 202 302
Harsh reverse movement only 203 303
Harsh forward movement only 204A 304A
Harsh manual 1st gear only 204B 304B
Delayed or soft reverse movement 205 305
only
Delayed or soft forward movement 206 306
only
No forward movement and no 207 307
reverse movement
Harsh forward movement and 208 308
harsh reverse movement
Delayed or soft forward movement 209 309
and delayed reverse movement
Gearshift Concerns: Routines

Some or all shifts missing in "D" 210 310
(DRIVE) only
Gearshift timing concern - early 211 311
or late
Gearshift timing concern - erratic 212 312
or hunting
Gearshift feel - soft or slipping 213 313
Gearshift feel - harsh 214 314
No 1st gear in "D" (DRIVE), 215 315
engages in a higher gear
No manual 1st gear 216 316
No manual 2nd gear 217 317
No 1-2 upshift 220 220
No 4-3 downshift 223 323
2007.50 Focus 3/2007 G526641en

307-01-113 Transmission (4F27E) 307-01-113
Gearshift Concerns: Routines

Soft or slipping 1-2 upshift 226 326
Soft or slipping 4-3 downshift 229 329
Harsh 1-2 upshift 232 332
Harsh 4-3 downshift 235 335
Torque Converter Clutch Oper- Routines

ation Concerns:
Torque converter clutch does not 240 340
apply
Torque converter clutch always 241 341
applied or stalls vehicle
Torque converter clutch cycling, 242 342
shudder or chatter
Other Concerns: Routines

Selector lever efforts high 251 351
External leaks from the transmis- 252 352
sion case
Poor vehicle performance 253 353
Noise or vibration - forward or 254 354
reverse movement
Engine will not crank 255 355
No "P" (PARK) range 256 356
Transmission overheating 257 357
2007.50 Focus 3/2007 G526641en

307-01-114 Transmission (4F27E) 307-01-114
Other Concerns: Routines

No engine braking in manual 1st 259 359
gear
Transmission fluid venting or 261 361
foaming
Transmission slips or chatters in 263 363
manual 1st gear
manual 2nd gear
manual 3rd gear
No engine braking in all gears 283 383
Diagnostic Routines
Possible Component Reference or Action

NO FORWARD MOVEMENT in "D" DRIVE ONLY: 201A - ELECTRICAL ROUTINE
Transmission Control System
TCM, vehicle wiring harness, shift solenoid C (SSC) Carry out the WDS quick test. REFER to WDS.
(off = low). REPAIR or INSTALL new components as neces-
sary. Clear the DTCs. Carry out a road test and
NO FORWARD MOVEMENT in "D" DRIVE ONLY: 301A - HYDRAULIC or MECHANICAL ROUTINE
Transmission fluid
Incorrect transmission fluid level. Adjust the transmission fluid to the correct level.
REFER to: Preliminary Inspection (307-01 Auto-
matic Transmission/Transaxle - Vehicles With: 4-
Transmission fluid condition. Carry out the Transmission Fluid Condition Check.
Forward Clutch
Forward clutch balance piston or seals damaged. Disassemble the forward clutch.
Forward clutch friction elements damaged or worn. REFER to: Forward Clutch (307-01 Automatic
Forward clutch return springs damaged. Automatic Transmission (4F27E), ).
INSPECT for visible signs of damage. REPAIR or
Intermediate and Overdrive Brake Band Servo
2007.50 Focus 3/2007 G526641en

307-01-115 Transmission (4F27E) 307-01-115

Intermediate and overdrive brake band servo seal(s) Disassemble the main control valve body.
damaged. REFER to: Main Controls (307-01 Automatic
Intermediate and overdrive brake band servo piston Transmission/Transaxle - Vehicles With: 4-Speed
damaged. Automatic Transmission (4F27E), In-vehicle
Repair).
Intermediate and overdrive brake band servo piston
spring damaged.
Intermediate and Overdrive Brake Band
Intermediate and overdrive brake band damaged. Disassemble the transmission.
REFER to: Transaxle (307-01 Automatic Transmis-
sion/Transaxle - Vehicles With: 4-Speed Auto-
matic Transmission (4F27E), Disassembly).
Inspect for damage. REPAIR or INSTALL new
Intermediate and overdrive brake band anchor bolt INSPECT for visible signs of damage. REPAIR or
damaged or worn. INSTALL new component as necessary.
Transmission Case
Transmission case damaged. INSPECT for visible signs of damage. REPAIR or
INSTALL a new component as necessary.

NO FORWARD MOVEMENT ONLY (ALL POSITIONS): 201B - ELECTRICAL ROUTINE
TCM, vehicle wiring harness, shift solenoids (SSC, Carry out the WDS quick test. REFER to WDS.
SSD, and SSE). REPAIR or INSTALL new components as neces-
NO FORWARD MOVEMENT ONLY (ALL POSITIONS): 301B - HYDRAULIC or MECHANICAL
ROUTINE
Main Control Valve Body
Main control valve body retaining bolts not tightened Tighten to specification.
to specification. REFER to: Main Controls (307-01 Automatic
Automatic Transmission (4F27E), In-vehicle
Repair).
Main control valve body separator plate damaged. Disassemble the main control valve body.
REFER to: Main Control Valve Body (307-01 Auto-
Speed Automatic Transmission (4F27E), ).
2007.50 Focus 3/2007 G526641en

307-01-116 Transmission (4F27E) 307-01-116

Main control valve body contaminated. Disassemble the main control valve body.
INSPECT for visible signs of contamination.
REPAIR or INSTALL new components as neces-
sary.
Main control valve body valves or springs damaged, Disassemble the main control valve body.
incorrectly assembled, missing or stuck. REFER to: Main Control Valve Body (307-01 Auto-
INSTALL new components as necessary. DO NOT
stone, file or sand the valves. This will remove the
anodized finish and may result in further main
control valve body or transmission damage.
Forward Clutch
Forward clutch return springs damaged.
Automatic Transmission (4F27E), ).
Forward Planetary Assembly
Forward planetary assembly damaged. Disassemble the forward planetary assembly.
REFER to: Planetary Assembly (307-01 Automatic
One-Way Clutch
One-way clutch assembly worn, damaged or incor- Disassemble the transmission.
rectly assembled. REFER to: Transaxle (307-01 Automatic Transmis-
Low/Reverse Clutch
2007.50 Focus 3/2007 G526641en

307-01-117 Transmission (4F27E) 307-01-117

Low/reverse clutch balance piston or seals Disassemble the transmission.
damaged. REFER to: Transaxle (307-01 Automatic Transmis-
Low/reverse clutch friction elements damaged or sion/Transaxle - Vehicles With: 4-Speed Auto-
worn. matic Transmission (4F27E), Disassembly).
Low/reverse clutch return springs damaged. components as necessary.

NO REVERSE MOVEMENT ONLY: 202 - ELECTRICAL ROUTINE
TCM, vehicle wiring harness, shift solenoids (SSC, Carry out the WDS quick test. REFER to WDS.
SSD and SSE). REPAIR or INSTALL new components as neces-
NO REVERSE MOVEMENT ONLY: 302 - HYDRAULIC or MECHANICAL ROUTINE
Repair).
sary.
Reverse Clutch
2007.50 Focus 3/2007 G526641en

307-01-118 Transmission (4F27E) 307-01-118

Reverse clutch balance piston or seals damaged. Disassemble the reverse clutch.
Reverse clutch friction elements damaged or worn. REFER to: Reverse Clutch (307-01 Automatic
Reverse clutch return springs damaged. Automatic Transmission (4F27E), ).
Low/Reverse Clutch

HARSH REVERSE MOVEMENT ONLY: 203 - ELECTRICAL ROUTINE
TCM, vehicle wiring harness or SSD. Carry out the WDS quick test. REFER to WDS.
HARSH REVERSE MOVEMENT ONLY: 303 - HYDRAULIC or MECHANICAL ROUTINE
Incorrect Automatic Transmission Fluid Pres-
sure
High transmission fluid pressure. Carry out the Line Pressure Test.
REFER to: Special Testing Procedures (307-01
With: 4-Speed Automatic Transmission (4F27E),
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-119 Transmission (4F27E) 307-01-119

sary.
Reverse Clutch
Reverse clutch return springs damaged. Automatic Transmission (4F27E), ).
Low/Reverse Clutch

HARSH FORWARD MOVEMENT ONLY: 204A - ELECTRICAL ROUTINE
TCM, vehicle wiring harness and SSC. Carry out the WDS quick test. REFER to WDS.
HARSH FORWARD MOVEMENT ONLY: 304A - HYDRAULIC or MECHANICAL ROUTINE
Incorrect Transmission Fluid Pressure
2007.50 Focus 3/2007 G526641en

307-01-120 Transmission (4F27E) 307-01-120

sary.
Repair).
sary.
Forward Clutch

HARSH MANUAL 1st GEAR ONLY: 204B - ELECTRICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-121 Transmission (4F27E) 307-01-121

TCM, vehicle wiring harness and turbine shaft speed Carry out the WDS quick test. REFER to WDS.
(TSS) sensor. REPAIR or INSTALL new components as neces-
HARSH MANUAL 1st GEAR ONLY: 304B - HYDRAULIC or MECHANICAL ROUTINE
No Hydraulic or Mechanical Concerns.

DELAYED or SOFT REVERSE MOVEMENT ONLY: 205 - ELECTRICAL ROUTINE
TCM, vehicle wiring harness, SSD or EPC A. Carry out the WDS quick test. REFER to WDS.
DELAYED or SOFT REVERSE MOVEMENT ONLY: 305 - HYDRAULIC or MECHANICAL ROUTINE
Low transmission fluid pressure. Carry out the Line Pressure Test.
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-122 Transmission (4F27E) 307-01-122

Low/Reverse Clutch

DELAYED or SOFT FORWARD MOVEMENT ONLY: 206 - ELECTRICAL ROUTINE
TCM, vehicle wiring harness, SSC or PCA. Carry out the WDS quick test. REFER to WDS.
DELAYED or SOFT FORWARD MOVEMENT ONLY: 306 - HYDRAULIC or MECHANICAL ROUTINE
High or low transmission fluid pressure. Carry out the Line Pressure Test.
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-123 Transmission (4F27E) 307-01-123

sary.
Forward Clutch

NO FORWARD MOVEMENT and NO REVERSE MOVEMENT: 207 - ELECTRICAL ROUTINE
TCM or vehicle wiring harnesses (no electrical Carry out the WDS quick test. REFER to WDS.
activity equals 3rd gear default). REPAIR or INSTALL new components as neces-
NO FORWARD MOVEMENT and NO REVERSE MOVEMENT: 307 - HYDRAULIC or MECHANICAL
ROUTINE
Transmission Fluid
Selector Lever Cable
2007.50 Focus 3/2007 G526641en

307-01-124 Transmission (4F27E) 307-01-124

Selector lever cable adjustment. Adjust the selector lever cable.
REFER to: Selector Lever Cable Adjustment (307-
05 Automatic Transmission/Transaxle External
Controls - Vehicles With: 4-Speed Automatic
Transmission (4F27E), General Procedures).
Selector lever cable damaged. INSPECT the selector lever cable for visible signs
of damage. REPAIR or INSTALL a new selector
lever cable as necessary.
REFER to: Selector Lever Cable (307-05 Automatic
Transmission/Transaxle External Controls -
(4F27E), Removal and Installation).
Transmission Range (TR) Sensor
TR sensor incorrectly aligned. CHECK the TR sensor alignment and ADJUST if
necessary.
REFER to: Transmission Range (TR) Sensor (307-
In-vehicle Repair).
TR sensor damaged. INSPECT the TR sensor for visible signs of damage.
INSTALL a new TR sensor as necessary.
In-vehicle Repair).
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-125 Transmission (4F27E) 307-01-125

Turbine Shaft
Turbine shaft damaged. Inspect for damage.
sary.
Transmission Fluid Pump Assembly
Transmission fluid pump assembly retaining bolts Tighten to specification.
not tightened to specification. REFER to: Specifications (307-01 Automatic
Transmission fluid pump assembly seals damaged. Disassemble the transmission fluid pump assembly.
Transmission fluid pump assembly channel(s) cross REFER to: Pump Assembly (307-01 Automatic
leaking or blocked. Transmission/Transaxle - Vehicles With: 4-Speed
Rear Planetary Assembly
Rear planetary assembly damaged. Disassemble the planetary assembly.
Forward Clutch
Forward Planetary Assembly
2007.50 Focus 3/2007 G526641en

307-01-126 Transmission (4F27E) 307-01-126

Forward planetary assembly damaged. Disassemble the planetary assembly.
Final Drive Carrier and Differential Assembly
Final drive carrier and differential assembly Disassemble the final drive carrier and differential
damaged. assembly .
REFER to: Final Drive Carrier and Differential
Assembly (307-01 Automatic Transmis-
matic Transmission (4F27E), ).
Torque Converter
Damaged torque converter flexplate or torque CHECK the torque converter for damage.
converter adapter plate. REFER to: Torque Converter Diagnosis (307-01
Damaged torque converter impeller. Automatic Transmission/Transaxle - Vehicles
Damaged torque converter turbine. Diagnosis and Testing).
sary.
One-Way Clutch
One-way clutch worn, damaged or incorrectly Disassemble the transmission.
assembled. REFER to: Transaxle (307-01 Automatic Transmis-
Low/Reverse Clutch

HARSH FORWARD MOVEMENT and HARSH REVERSE MOVEMENT: 208 - ELECTRICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-127 Transmission (4F27E) 307-01-127

TCM, vehicle wiring harnesses, TR sensor, trans- Carry out the WDS quick test. REFER to WDS.
mission fluid temperature (TFT) sensor, SSC and REPAIR or INSTALL new components as neces-
SSD. sary. Clear the DTCs. Carry out a road test and
HARSH FORWARD MOVEMENT and HARSH REVERSE MOVEMENT: 308 - HYDRAULIC or
MECHANICAL ROUTINE
Transmission Fluid
Transmission fluid condition Carry out the Transmission Fluid Condition Check.
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-128 Transmission (4F27E) 307-01-128

Forward Clutch
Reverse Clutch
Reverse clutch return springs damaged.
Direct Clutch
Direct clutch balance piston or seals damaged. Disassemble the direct clutch.
Direct clutch friction elements damaged or worn. REFER to: Direct Clutch (307-01 Automatic Trans-
mission/Transaxle - Vehicles With: 4-Speed
Direct clutch return springs damaged. Automatic Transmission (4F27E), ).
One-way Clutch
One-way clutch assembly worn, damaged or incor- Disassemble the transmission.
rectly assembled. REFER to: Transaxle (307-01 Automatic Transmis-
Low/Reverse Clutch
2007.50 Focus 3/2007 G526641en

307-01-129 Transmission (4F27E) 307-01-129

Low/reverse clutch seals, piston damaged. Disassemble the transmission.
Low/reverse clutch friction elements damaged or REFER to: Transaxle (307-01 Automatic Transmis-
worn. sion/Transaxle - Vehicles With: 4-Speed Auto-
Low/reverse clutch return springs damaged. Inspect for damage. REPAIR or INSTALL new

DELAYED or SOFT FORWARD MOVEMENT and DELAYED REVERSE MOVEMENT: 209 - ELEC-
TRICAL ROUTINE
TCM, vehicle wiring harnesses, TR sensor, TFT Carry out the WDS quick test. REFER to WDS.
sensor, SSC and SSD. REPAIR or INSTALL new components as neces-
DELAYED or SOFT FORWARD MOVEMENT and DELAYED REVERSE MOVEMENT: 309 -
HYDRAULIC or MECHANICAL ROUTINE
Transmission Fluid
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-130 Transmission (4F27E) 307-01-130

sary.

SOME or ALL SHIFTS MISSING in "D" (DRIVE) ONLY: 210 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, TR sensor, intake Carry out the WDS quick test. REFER to WDS.
manifold air temperature (IAT) sensor, vehicle speed REPAIR or INSTALL new components as neces-
sensor (VSS) input, SSA, SSB, SSC, SSD SSE and sary. Clear the DTCs. Carry out a road test and
pressure control solenoid (PCA). TEST the system for normal operation.
SOME or ALL SHIFTS MISSING in "D" (DRIVE) ONLY: 310 - HYDRAULIC or MECHANICAL ROUTINE
Some Shifts Missing ONLY
If only some of the shifts are missing, determine
which shift(s) is missing. Refer to the following
routine(s) for further No Gearshift Concerns:
2007.50 Focus 3/2007 G526641en

307-01-131 Transmission (4F27E) 307-01-131

No 1-2 Upshift - Routine 220 or 320.
No 4-3 Downshift - Routine 223 or 323.
Transmission Fluid
TR sensor incorrectly aligned. CHECK the TR sensor alignment and ADJUST as
necessary.
In-vehicle Repair).
In-vehicle Repair).
2007.50 Focus 3/2007 G526641en

307-01-132 Transmission (4F27E) 307-01-132

sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-133 Transmission (4F27E) 307-01-133

Direct Clutch
REFER to: Direct Clutch (307-01 Automatic Trans-
Direct clutch friction elements damaged or worn.
Forward Clutch
One-way Clutch
Intermediate and overdrive brake band servo seal(s) Disassemble the transmission.
Intermediate and overdrive brake band servo piston sion/Transaxle - Vehicles With: 4-Speed Auto-
damaged. matic Transmission (4F27E), Disassembly).
Intermediate and overdrive brake band servo piston components as necessary.
spring damaged.

GEARSHIFT TIMING CONCERN - EARLY or LATE: 211 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, VSS, TSS sensor Carry out the WDS quick test. REFER to WDS.
SSA, SSB, SSC, SSD, SSE and VFS. REPAIR or INSTALL new components as neces-
GEARSHIFT TIMING CONCERN - EARLY or LATE: 311 - HYDRAULIC or MECHANICAL ROUTINE
Some Shifts Early or Late
2007.50 Focus 3/2007 G526641en

307-01-134 Transmission (4F27E) 307-01-134

If only some of the shifts are early or late, determine
which shift(s) are early or late. Refer to the following
routine(s) for further Early or Late Gearshift
Concerns:
Soft or Slipping 1-2 upshift - Routine 226 or 326.
Soft or Slipping 4-3 downhift - Routine 229 or 329.
Soft or Slipping 3-2 downshift - Routine 230 or 330.
Soft or Slipping 2-1 downshift - Routine 231 or 331.
Transmission Fluid
Transmission fluid condition.. Carry out the Transmission Fluid Condition Check.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-135 Transmission (4F27E) 307-01-135

spring damaged.
damaged or worn. INSTALL a new component as necessary.

GEARSHIFT TIMING CONCERN - ERRATIC or HUNTING: 212 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, VSS, IAT sensor. Carry out the WDS quick test. REFER to WDS.
GEARSHIFT TIMING CONCERN - ERRATIC or HUNTING: 312 - HYDRAULIC or MECHANICAL
ROUTINE
Transmission Fluid
2007.50 Focus 3/2007 G526641en

307-01-136 Transmission (4F27E) 307-01-136

Repair).
sary.
Further Diagnosis
Refer to the following routine(s) for further Timing
Concerns:
No 1-2 upshift - Routine 220 or 330
No 4-3 downshift - Routine 223 or 323
Soft or slipping 1-2 upshift - Routine 226 or 326
2007.50 Focus 3/2007 G526641en

307-01-137 Transmission (4F27E) 307-01-137

Soft or slipping 4-3 downshift - Routine 229 or 329
Harsh 1-2 upshift - Routine 232 or 332
Harsh 4-3 downshift - Routine 235 or 335

GEARSHIFT FEEL - SOFT or SLIPPING: 213 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, TFT sensor, IAT Carry out the WDS quick test. REFER to WDS.
sensor, VSS input SSA, SSB, SSC, SSD, SSE, VFS REPAIR or INSTALL new components as neces-
and PCA. sary. Clear the DTCs. Carry out a road test and
GEARSHIFT FEEL - SOFT or SLIPPING: 313 - HYDRAULIC or MECHANICAL ROUTINE
Some Shifts Soft or Slipping
If only some of the shifts are soft or slipping,
determine which shift(s) are soft or slipping. Refer
to the following routine(s) for further Soft or Slipping
Gearshift Concerns:
Transmission Fluid
2007.50 Focus 3/2007 G526641en

307-01-138 Transmission (4F27E) 307-01-138

sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-139 Transmission (4F27E) 307-01-139

Inspect for damage. REPAIR or INSTALL a new
spring damaged.
Direct Clutch
Forward Clutch
Transmission Case

GEARSHIFT FEEL - HARSH: 214 - ELECTRICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-140 Transmission (4F27E) 307-01-140

sensor, IAT sensor, VSS input, SSA, SSB, SSC, REPAIR or INSTALL new components as neces-
SSD, SSE and PCA. sary. Clear the DTCs. Carry out a road test and
GEARSHIFT FEEL - HARSH: 314 - HYDRAULIC or MECHANICAL ROUTINE
Some Shifts Harsh
If only some of the shifts are harsh, determine which
shift(s) are harsh. Refer to the following routine(s)
for further Harsh Gearshift Concerns:
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-141 Transmission (4F27E) 307-01-141

Turbine Shaft
Turbine shaft damaged. Inspect for damage.
sary.
spring damaged.
Forward Clutch
2007.50 Focus 3/2007 G526641en

307-01-142 Transmission (4F27E) 307-01-142

Final drive carrier and differential assembly Disassemble the final drive carrier and differential
damaged. assembly .
REFER to: Final Drive Carrier and Differential
Assembly (307-01 Automatic Transmis-
matic Transmission (4F27E), ).
Transmission Case

NO 1st GEAR in "D" (DRIVE), ENGAGES in HIGHER GEAR: 215 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, TR sensor and Carry out the WDS quick test. REFER to WDS.
SSC. REPAIR or INSTALL new components as neces-
NO 1st GEAR in "D" (DRIVE), ENGAGES in HIGHER GEAR: 315 - HYDRAULIC or MECHANICAL
ROUTINE
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-143 Transmission (4F27E) 307-01-143

sary.
One-Way Clutch
Low/Reverse Clutch

NO MANUAL 1st GEAR: 216 - ELECTRICAL ROUTINE
TCM and vehicle wiring harnesses. Carry out the WDS quick test. REFER to WDS.
NO MANUAL 1st GEAR: 316 - HYDRAULIC or MECHANICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-144 Transmission (4F27E) 307-01-144

sary.
Repair).
sary.
Low/Reverse Clutch
Low/reverse clutch return spring damaged. components as necessary.
Planetary Assembly
2007.50 Focus 3/2007 G526641en

307-01-145 Transmission (4F27E) 307-01-145

Planetary assembly damaged. Disassemble the planetary assembly.

NO MANUAL 2nd GEAR: 217 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses and SSD. Carry out the WDS quick test. REFER to WDS.
NO MANUAL 2nd GEAR: 317 - HYDRAULIC or MECHANICAL ROUTINE
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-146 Transmission (4F27E) 307-01-146

spring damaged.
Direct Clutch
One-way Clutch Assembly
Low/Reverse Clutch
2007.50 Focus 3/2007 G526641en

307-01-147 Transmission (4F27E) 307-01-147

Low/reverse clutch return spring damaged. components as necessary.

NO 1-2 UPSHIFT: 220 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, VSS, TR sensor, Carry out the WDS quick test. REFER to WDS.
TSS sensor and SSD. REPAIR or INSTALL new components as neces-
NO 1-2 UPSHIFT: 320 - HYDRAULIC or MECHANICAL ROUTINE
Transmission Fluid
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-148 Transmission (4F27E) 307-01-148

sary.
spring damaged.
Planetary Assembly
Forward Clutch
2007.50 Focus 3/2007 G526641en

307-01-149 Transmission (4F27E) 307-01-149


TCM, vehicle wiring harnesses, TR sensor, VSS, Carry out the WDS quick test. REFER to WDS.
SSD and SSE. REPAIR or INSTALL new components as neces-
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-150 Transmission (4F27E) 307-01-150

spring damaged.
Forward Clutch

SSC and SSA. REPAIR or INSTALL new components as necessary.
Clear the DTCs. Carry out a road test and TEST the
Automatic Transmission/Transaxle - Vehicles With:
REPAIR or INSTALL new components as necessary.
Main control valve body retaining bolts not Tighten to specification.
tightened to specification. REFER to: Main Controls (307-01 Automatic
Repair).
2007.50 Focus 3/2007 G526641en

307-01-151 Transmission (4F27E) 307-01-151

INSPECT for visible signs of contamination. REPAIR
or INSTALL new components as necessary.
anodized finish and may result in further main control
valve body or transmission damage.
Forward Clutch
Intermediate and overdrive brake band servo Disassemble the transmission.
seal(s) damaged. REFER to: Transaxle (307-01 Automatic Transmis-
Intermediate and overdrive brake band servo piston sion/Transaxle - Vehicles With: 4-Speed Automatic
damaged. Transmission (4F27E), Disassembly).
spring damaged.

NO 4-3 DOWNSHIFT: 223 - ELECTRICAL ROUTINE
SSA and SSC. REPAIR or INSTALL new components as neces-
NO 4-3 DOWNSHIFT: 323 - HYDRAULIC or MECHANICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-152 Transmission (4F27E) 307-01-152

sary.
Repair).
sary.
Forward Clutch
2007.50 Focus 3/2007 G526641en

307-01-153 Transmission (4F27E) 307-01-153

spring damaged.

TCM, vehicle wiring harnesses, TR sensor, VSS Carry out the WDS quick test. REFER to WDS.
and SSE. REPAIR or INSTALL new components as neces-
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-154 Transmission (4F27E) 307-01-154

spring damaged.
Direct Clutch
Direct clutch return springs damaged.

TCM, vehicle wiring harnesses, TR sensor, VSS Carry out the WDS quick test. REFER to WDS.
and SSD. REPAIR or INSTALL new components as neces-
2007.50 Focus 3/2007 G526641en

307-01-155 Transmission (4F27E) 307-01-155

sary.
Repair).
sary.
One-way Clutch
2007.50 Focus 3/2007 G526641en

307-01-156 Transmission (4F27E) 307-01-156


SOFT or SLIPPING 1-2 UPSHIFT: 226 - ELECTRICAL ROUTINE
Incorrect Pressures
TCM, vehicle wiring harnesses, TSS sensor, VSS, Carry out the WDS quick test. REFER to WDS.
TFT sensor and SSD. REPAIR or INSTALL new components as neces-
SOFT or SLIPPING 1-2 UPSHIFT: 326 - HYDRAULIC or MECHANICAL ROUTINE
Transmission Fluid
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-157 Transmission (4F27E) 307-01-157

sary.
spring damaged.

2007.50 Focus 3/2007 G526641en

307-01-158 Transmission (4F27E) 307-01-158

TCM, vehicle wiring harnesses, TSS sensor, TFT Carry out the WDS quick test. REFER to WDS.
sensor and SSE. REPAIR or INSTALL new components as neces-
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-159 Transmission (4F27E) 307-01-159

spring damaged.
Direct Clutch

TCM, SSA, SSC, vehicle wiring harnesses and TFT Carry out the WDS quick test. REFER to WDS.
sensor. REPAIR or INSTALL new components as neces-
sary.
2007.50 Focus 3/2007 G526641en

307-01-160 Transmission (4F27E) 307-01-160

Repair).
sary.
Forward Clutch
spring damaged.
2007.50 Focus 3/2007 G526641en

307-01-161 Transmission (4F27E) 307-01-161


SOFT or SLIPPING 4-3 DOWNSHIFT: 229 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, TFT sensor, SSA Carry out the WDS quick test. REFER to WDS.
and SSC. REPAIR or INSTALL new components as neces-
SOFT or SLIPPING 4-3 DOWNSHIFT: 329 - HYDRAULIC or MECHANICAL ROUTINE
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-162 Transmission (4F27E) 307-01-162

Forward Clutch
spring damaged.

TCM, vehicle wiring harnesses, TFT sensor and Carry out the WDS quick test. REFER to WDS.
SSE. REPAIR or INSTALL new components as neces-
sary.
2007.50 Focus 3/2007 G526641en

307-01-163 Transmission (4F27E) 307-01-163

Repair).
sary.
spring damaged.

2007.50 Focus 3/2007 G526641en

307-01-164 Transmission (4F27E) 307-01-164

TCM, SSD, VSS, TSS, TR sensor, vehicle wiring Carry out the WDS quick test. REFER to WDS.
harnesses and TFT sensor. REPAIR or INSTALL new components as neces-
sary.
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-165 Transmission (4F27E) 307-01-165

spring damaged.

HARSH 1-2 UPSHIFT: 232 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, TSS sensor, TR Carry out the WDS quick test. REFER to WDS.
sensor, TFT sensor and SSD. REPAIR or INSTALL new components as neces-
HARSH 1-2 UPSHIFT: 332 - HYDRAULIC or MECHANICAL ROUTINE
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-166 Transmission (4F27E) 307-01-166

sary.
spring damaged.

sensor, TFT sensor and SSE. REPAIR or INSTALL new components as neces-
2007.50 Focus 3/2007 G526641en

307-01-167 Transmission (4F27E) 307-01-167

sary.
Repair).
sary.
Direct Clutch
2007.50 Focus 3/2007 G526641en

307-01-168 Transmission (4F27E) 307-01-168

spring damaged.

sensor, SSA and SSC. REPAIR or INSTALL new components as neces-
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-169 Transmission (4F27E) 307-01-169

sary.
Direct Clutch
Forward Clutch

HARSH 4-3 DOWNSHIFT: 235 - ELECTRICAL ROUTINE
sensor, SSA and SSC. REPAIR or INSTALL new components as neces-
HARSH 4-3 DOWNSHIFT: 335 - HYDRAULIC or MECHANICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-170 Transmission (4F27E) 307-01-170

sary.
Repair).
sary.
Forward Clutch
2007.50 Focus 3/2007 G526641en

307-01-171 Transmission (4F27E) 307-01-171

spring damaged.

sensor, TFT sensor and SSE. REPAIR or INSTALL new components as neces-
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-172 Transmission (4F27E) 307-01-172

sary.
spring damaged.
Direct Clutch
Direct clutch return springs damaged.

2007.50 Focus 3/2007 G526641en

307-01-173 Transmission (4F27E) 307-01-173

sensor, TFT sensor, VFS and SSD. REPAIR or INSTALL new components as neces-
sary.
Repair).
sary.
One-Way Clutch
2007.50 Focus 3/2007 G526641en

307-01-174 Transmission (4F27E) 307-01-174

spring damaged.

TORQUE CONVERTER CLUTCH DOES NOT APPLY: 240 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, TFT sensor, SSB Carry out the WDS quick test. REFER to WDS.
and SSC. REPAIR or INSTALL new components as neces-
TORQUE CONVERTER CLUTCH DOES NOT APPLY: 340 - HYDRAULIC or MECHANICAL ROUTINE
sary.
2007.50 Focus 3/2007 G526641en

307-01-175 Transmission (4F27E) 307-01-175

Repair).
sary.
Torque Converter Assembly
2007.50 Focus 3/2007 G526641en

307-01-176 Transmission (4F27E) 307-01-176

sary.

TORQUE CONVERTER CLUTCH ALWAYS APPLIED or STALLS VEHICLE: 241 - ELECTRICAL
ROUTINE
TCM, vehicle wiring harnesses, SSC and SSB. Carry out the WDS quick test. REFER to WDS.
TORQUE CONVERTER CLUTCH ALWAYS APPLIED or STALLS VEHICLE: 341 - HYDRAULIC or
MECHANICAL ROUTINE
Repair).
sary.
2007.50 Focus 3/2007 G526641en

307-01-177 Transmission (4F27E) 307-01-177

One-Way Clutch
Low/Reverse Clutch
Low/reverse clutch return springs damaged.
Torque Converter
sary.

TORQUE CONVERTER CLUTCH CYCLING, SHUDDER or CHATTER: 242 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, SSB and SSC. Carry out the WDS quick test. REFER to WDS.
TORQUE CONVERTER CLUTCH CYCLING, SHUDDER or CHATTER: 342 - HYDRAULIC or
MECHANICAL ROUTINE
Transmission Fluid
Repair).
2007.50 Focus 3/2007 G526641en

307-01-178 Transmission (4F27E) 307-01-178

sary.
Torque Converter Assembly
sary.

SELECTOR LEVER EFFORTS HIGH: 251 - ELECTRICAL ROUTINE
TR sensor. Carry out the WDS quick test. REFER to WDS.
SELECTOR LEVER EFFORTS HIGH: 351 - HYDRAULIC or MECHANICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-179 Transmission (4F27E) 307-01-179

necessary.
In-vehicle Repair).
In-vehicle Repair).
Repair).
Transmission Case
Selector lever damaged. INSPECT the selector lever for visible signs of
damage. INSTALL a new selector lever as neces-
sary.
REFER to: Selector Lever Assembly (307-05 Auto-
matic Transmission/Transaxle External Controls
- Vehicles With: 4-Speed Automatic Transmission
Selector lever shaft damaged. Disassemble the transmission.
Selector lever shaft retaining pin damaged. REFER to: Transaxle (307-01 Automatic Transmis-

EXTERNAL LEAKS FROM the TRANSMISSION CASE: 252 - ELECTRICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-180 Transmission (4F27E) 307-01-180

VSS, TSS and TR sensors. Inspect for leakage. If areas around VSS or TSS
sensors show signs of leakage, install a new sensor
O-ring seal. If area behind TR sensor shows signs
of leakage, install a new selector lever shaft seal.
EXTERNAL LEAKS FROM the TRANSMISSION CASE: 352 - HYDRAULIC or MECHANICAL ROUTINE
Transmission Fluid
Transmission Case
Transmission case vent tube damaged. INSPECT the transmission case vent tube for visible
signs of damage. REPAIR or INSTALL new
Transmission Case Seals and Gaskets
Fluid leakage at transmission case seals and Inspect for fluid leakage.
gaskets. REFER to: Leakage Inspection (307-01 Automatic
Automatic Transmission (4F27E), Diagnosis and
Testing).
sary.

POOR VEHICLE PERFORMANCE: 253 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, VSS, TSS sensor, Carry out the WDS quick test. REFER to WDS.
TFT sensor, TR sensor, SSA, SSB, SSC, SSD, SSE REPAIR or INSTALL new components as neces-
and PCA. sary. Clear the DTCs. Carry out a road test and
POOR VEHICLE PERFORMANCE: 353 - HYDRAULIC or MECHANICAL ROUTINE
Transmission Fluid
Turbine Shaft
2007.50 Focus 3/2007 G526641en

307-01-181 Transmission (4F27E) 307-01-181

Turbine shaft damaged. INSPECT the turbine shaft for visible signs of
damage.
sary.
Forward Clutch
Torque Converter
sary.
One-Way Clutch

NOISE or VIBRATION - FORWARD or REVERSE MOVEMENT: 254 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, SSA, SSB, SSC, Carry out the WDS quick test. REFER to WDS.
SSD, SSE and PCA. REPAIR or INSTALL new components as neces-
NOISE or VIBRATION - FORWARD or REVERSE MOVEMENT: 354 - HYDRAULIC or MECHANICAL
ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-182 Transmission (4F27E) 307-01-182

Flexplate
Flexplate damaged. INSPECT the flexplate for visible signs of damage.
sary.

ENGINE WILL NOT CRANK: 255 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses and TR sensor. Carry out the WDS quick test. REFER to WDS.
ENGINE WILL NOT CRANK: 355 - HYDRAULIC or MECHANICAL ROUTINE
necessary.
In-vehicle Repair).
In-vehicle Repair).
2007.50 Focus 3/2007 G526641en

307-01-183 Transmission (4F27E) 307-01-183

Flexplate
Flexplate damaged. INSPECT the flexplate for visible signs of damage.
sary.

NO "P" (PARK) RANGE: 256 - ELECTRICAL ROUTINE
No electrical concerns.
NO "P" (PARK) RANGE: 356 - HYDRAULIC or MECHANICAL ROUTINE
necessary.
In-vehicle Repair).
In-vehicle Repair).
Transmission Case
Selector lever damaged. INSPECT the selector lever for visible signs of
damage. INSTALL a new selector lever as neces-
sary.
REFER to: Selector Lever Assembly (307-05 Auto-
matic Transmission/Transaxle External Controls
- Vehicles With: 4-Speed Automatic Transmission
2007.50 Focus 3/2007 G526641en

307-01-184 Transmission (4F27E) 307-01-184

Selector lever shaft damaged. Disassemble the transmission.
Selector lever shaft retaining pin damaged. REFER to: Transaxle (307-01 Automatic Transmis-
Transmission Park Assembly
Transmission park assembly damaged or incorrectly Disassemble the transmission.

TRANSMISSION OVERHEATING: 257 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses, TFT sensor and Carry out the WDS quick test. REFER to WDS.
SSB. REPAIR or INSTALL new components as neces-
TRANSMISSION OVERHEATING: 357 - HYDRAULIC or MECHANICAL ROUTINE
Transmission Fluid
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-185 Transmission (4F27E) 307-01-185

sary.
Transmission Case
Torque Converter
Damaged torque converter turbine.
sary.
Other
2007.50 Focus 3/2007 G526641en

307-01-186 Transmission (4F27E) 307-01-186

Restriction in the transmission cooling system. CHECK the transmission cooling system for
damage.
REFER to: Transaxle Cooling (307-02 Transmis-
sion/Transaxle Cooling - Vehicles With: 4-Speed
Automatic Transmission (4F27E), Diagnosis and
Testing).
sary.
Excessive trailer tow load. REFER to the relevant section of the owner liter-
ature for specifications on trailer towing.
Poor engine performance. Check the engine performance.
REFER to: Engine (303-00 Engine System -
General Information, Diagnosis and Testing).

NO ENGINE BRAKING IN MANUAL 1st GEAR: 259 - ELECTRICAL ROUTINE
NO ENGINE BRAKING IN MANUAL 1st GEAR: 359 - HYDRAULIC or MECHANICAL ROUTINE
Transmission Fluid
sary.
2007.50 Focus 3/2007 G526641en

307-01-187 Transmission (4F27E) 307-01-187

Low/Reverse Clutch
Low/reverse clutch return springs damaged.

TRANSMISSION FLUID VENTING or FOAMING: 261 - ELECTRICAL ROUTINE
TRANSMISSION FLUID VENTING or FOAMING: 361 - HYDRAULIC or MECHANICAL ROUTINE
Transmission Fluid
Transmission Case
2007.50 Focus 3/2007 G526641en

307-01-188 Transmission (4F27E) 307-01-188

Other
Refer to the following routine(s) for further Other
Concerns:
Transmission overheating - Routine 257 or 357

TRANSMISSION SLIPS or CHATTERS IN MANUAL 1st GEAR: 263 - ELECTRICAL ROUTINE
TCM, vehicle wiring harnesses and SSC. Carry out the WDS quick test. REFER to WDS.
TRANSMISSION SLIPS or CHATTERS IN MANUAL 1st GEAR: 363 - HYDRAULIC or MECHANICAL
ROUTINE
Transmission Fluid
sary.
Repair).
2007.50 Focus 3/2007 G526641en

307-01-189 Transmission (4F27E) 307-01-189

sary.
Forward Clutch
One-Way Clutch
2007.50 Focus 3/2007 G526641en

307-01-190 Transmission (4F27E) 307-01-190

Low/Reverse Clutch

TRANSMISSION SLIPS or CHATTERS IN MANUAL 2nd GEAR: 264 - ELECTRICAL ROUTINE
TRANSMISSION SLIPS or CHATTERS IN MANUAL 2nd GEAR: 364 - HYDRAULIC or MECHANICAL
ROUTINE
Transmission Fluid
sary.
2007.50 Focus 3/2007 G526641en

307-01-191 Transmission (4F27E) 307-01-191

spring damaged.
Planetary Assembly
Forward Clutch

TRANSMISSION SLIPS or CHATTERS IN MANUAL 3rd GEAR: 282 - ELECTRICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-192 Transmission (4F27E) 307-01-192

TRANSMISSION SLIPS or CHATTERS IN MANUAL 3rd GEAR: 382 - HYDRAULIC or MECHANICAL
ROUTINE
Transmission Fluid
sary.
Forward Clutch
Reference or Action
NO ENGINE BRAKING IN ALL GEARS: 283 - ELECTRICAL ROUTINE
2007.50 Focus 3/2007 G526641en

307-01-193 Transmission (4F27E) 307-01-193
Reference or Action
NO ENGINE BRAKING IN ALL GEARS: 383 - HYDRAULIC or MECHANICAL ROUTINE
No Hydraulic or Mechanical concerns.
2007.50 Focus 3/2007 G526641en

307-01-194 Transmission (4F27E) 307-01-194
GENERAL PROCEDURES

Materials
container.
Name Specification For additional information, refer to: Health
Automatic Transmission WSS-M2C202-B and Safety Precautions (100-00 General
Fluid Information, Description and Operation).
See - Transmission Fluids.
and Operation)
/ Jacking (100-02 Jacking and Lifting,
1 2
E50955
4. Attach a length of suitable drain hose to the

transmission fluid cooler return hose.
6. Insert the drain hose into a calibrated 10 liter
E50539 container.
7.
3. transaxle do not run the engine above idle.
WARNING: When releasing the
transmission fluid, take care to prevent NOTE: If the fluid return rate is less than 0.95 liters
scalding. Failure to follow this instruction in 30 seconds or if the return hose pulsates,
may result in personal injury. CHECK for restrictions at the pump, cooler or
cooler lines.
CAUTION: Plug the transmission fluid
cooler lines to prevent fluid loss or dirt Run the engine at idle and pump out 3 liters
ingress. of automatic transmission fluid.
For additional information, refer to: Health 8. Switch OFF the engine.
and Safety Precautions (100-00 General 9. Remove the fluid level indicator.
Detach the transmission return line from the
transmission fluid cooler.
1. Push the transmission fluid cooler line quick
release connector toward the transmission
fluid cooler.
2. Press together the retaining tabs and detach
the transmission fluid line from the
E53008
2007.50 Focus 3/2007 G420725en

307-01-195 Transmission (4F27E) 307-01-195
GENERAL PROCEDURES
10. Add 3 liters of automatic transmission fluid 16. Raise and support the vehicle.
to the transaxle. For additional information, refer to: Lifting
and Operation)
/ Jacking (100-02 Jacking and Lifting,
17. Detach the drain hose from the
transmission fluid return hose.
18. NOTE: Remove the plug from the
transmission fluid cooler return port.
Attach the transmission return line to the
E53007
11.
transaxle do not run the engine above idle.
NOTE: If the fluid return rate is less than 0.95 liters
in 30 seconds or if the return hose pulsates,
CHECK for restrictions at the pump, cooler or
cooler lines.
Run the engine at idle and pump out 3 liters
of automatic transmission fluid.
E50956
13. Add 3 liters of automatic transmission fluid
to the transaxle.
E50539
E53007

14.
Run the engine at idle and pump out 3 liters
of automatic transmission fluid.
2007.50 Focus 3/2007 G420725en

307-01-196 Transmission (4F27E) 307-01-196
GENERAL PROCEDURES
21. Add 3 liters of automatic transmission fluid
to the transaxle.
E53007
22. Install the fluid level indicator.
E53008
23.
Run the engine and check the automatic
transmission fluid level and top up if
necessary.
2007.50 Focus 3/2007 G420725en

307-01-197 Transmission (4F27E) 307-01-197
IN-VEHICLE REPAIR
Transmission Fluid Pan, Gasket and Filter

Special Tool(s) 3. Clean the sealer from the fluid pan and
transaxle case surfaces thoroughly with
Separator, Oil Pan
Metal Surface Cleaner or equivalent.
303-428 (21-179)
Installation
21179 1. Apply a bead of Loctite 5699 one and a half
millimeters thick to the fluid pan.
Materials
Name Specification
Metal Surface Cleaner WSE-M5B-392-A
Loctite 5699 WSS-M4G-320-A3
Automatic Transmission WSS-M2C202-B
Fluid
Removal ELE0009780

information, refer to: (100-02 Jacking and 2. Install the fluid pan.
Lifting)
2. NOTE: Position a suitable container under 10 Nm
the fluid pan.
NOTE: The fluid pan is filled with automatic
transmission fluid and can not be drained before
removing.
Remove the fluid pan.
• Remove the bolts. E0010230
• Using the special tool, separate the bead of
sealer. 3. Lower the vehicle.
4. Check the transmission fluid level.
Transmission Fluid Drain and Refill (307-01
Transmission (4F27E), General
Procedures).
ELE0010229
2007.50 Focus 3/2007 G17981en

307-01-198 Transmission (4F27E) 307-01-198
IN-VEHICLE REPAIR
Main Controls
Removal
6. Solenoid SSB; Color B (Black).
1. Remove the fluid pan.
For additional information, refer to Fluid Pan
in this section. 2 3
2. Disconnect the transmission fluid 1
temperature (TFT) sensor electrical
connector.
4
5 6
TIA0002950
5. NOTE: Note the locations of the two long

bolts.
Remove the main control valve body and
accumulators.
TIA0002948
3. Remove the fluid filter.
TIE0029517
6. NOTE: Each accumulator is equipped with

TIA0002949 two springs. All four springs are different
sizes.
4. NOTE: It is necessary to note the location of NOTE: Note the size and location of the
the main control wire harness connectors accumulator springs to aid assembly.
so they can be connected in the same
positions. Connector color letters are cast
into the solenoid body.
Remove the ground wire bolt. Disconnect
the electrical connectors and remove the
main control wiring harness.
1. Solenoid SSC; Color N (Neutral/White).
2. Solenoid SSE; Color G (Green).
3. Solenoid SSD; Color L (Blue).
4. Solenoid EPC; Color B (Black).
5. Solenoid SSA; Color N (Neutral).
2007.50 Focus 3/2007 G17983en

307-01-199 Transmission (4F27E) 307-01-199
IN-VEHICLE REPAIR
Remove the accumulator pistons and Install the main control valve body.
springs.
TIE0029518
TIE0018391
3. Tighten the main control valve body retaining

Installation bolts.
1. NOTE: The thin longer springs are for the
neutral and drive accumulator.
12 11 10 9 8 7
Install the accumulator pistons and springs. 6
13
1. Accumulator 1 and 2.
2. Accumulator N and D.
5
9 Nm 4
1 1 3
2 2
TIE0026121
4. NOTE: It is necessary to connect the

electrical connectors in the same positions
as noted in disassembly. Connector color
TIE0027873 letters are cast into the solenoid body.
Install the main control valve wiring harness,
2. connect the electrical connectors and install
CAUTION: Make sure that the manual the ground wire bolt.
valve is in the manual control valve shift
lever. 1. Solenoid SSC; Color N (Neutral/White).
2. Solenoid SSE; Color G (Green).
NOTE: Do not fully tighten the main control valve
3. Solenoid SSD; Color L (Blue).
4. Solenoid EPC; Color B (Black).
5. Solenoid SSA; Color N (Neutral).
2007.50 Focus 3/2007 G17983en

307-01-200 Transmission (4F27E) 307-01-200
IN-VEHICLE REPAIR
6. Solenoid SSB; Color B (Black).
2 3
1
10 Nm
4
5 6
TIA0002951
5. Install the fluid filter.
TIA0002949
6. Connect the TFT sensor electrical connector.
TIA0002948
7. Install the fluid pan.

For additional information, refer to Fluid Pan
in this section.
2007.50 Focus 3/2007 G17983en

307-01-201 Transmission (4F27E) 307-01-201
IN-VEHICLE REPAIR
Turbine Shaft Speed (TSS) Sensor

Materials
Name Specification
Sealant - Loctite 270 SD-M4G9107-A
Removal
1. Disconnect the turbine shaft speed (TSS)
ELE0008689
2. Remove the TSS sensor (transaxle shown

• Check the TSS sensor bore.
• Check the O-ring seal for nicks or cuts.
10 Nm
TIE0018397
Installation
1. NOTE: Install a new TSS sensor O-ring if
necessary.
NOTE: Apply a light coat of petroleum jelly to the
O-ring seal before installation.
• Apply sealant to the TSS sensor retaining
bolt thread.
2007.50 Focus 3/2007 G401949en

307-01-202 Transmission (4F27E) 307-01-202
IN-VEHICLE REPAIR
Output Shaft Speed (OSS) Sensor

Materials Installation
Name Specification 1. NOTE: Apply a light coat of petroleum jelly
to the O-ring before installation.
Automatic transmission WSS-M2C202-B
fluid NOTE: Apply thread sealer to the bolt.
Thread sealer SD-M4G9107-A Install the OSS sensor.
• Connect the electrical connector.
Removal
and Lifting].
2. Place a drain pan beneath the output shaft 10 Nm
speed (OSS) sensor.
3. Remove the OSS sensor.
• Disconnect the electrical connector.
• Remove the bolt.
TIE0018396
• Inspect the OSS bore.
2. Lower vehicle.
3. Check the transmission fluid level, add
automatic transmission fluid as necessary.
ELE0008691
4. Inspect the O-ring seal for nicks or cuts;

install a new as necessary.
ELE0008136
4. Start the engine and move the transaxle

range selector lever through all gear
positions.
V9010124
2007.50 Focus 3/2007 G17986en

307-01-203 Transmission (4F27E) 307-01-203
IN-VEHICLE REPAIR
Halfshaft Seal LH
Special Tool(s) 1. Remove the left-hand front drive halfshaft.
Installer, Transmission For additional information, refer to: Front
Extension Housing Seal Halfshaft LH (205-04 Front Drive Halfshafts,
307-028 Removal and Installation).
17002
table(s).
Remover, Halfshaft Seal

308-208
16074
E50551

1 Halfshaft seal
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G388139en

307-01-204 Transmission (4F27E) 307-01-204
IN-VEHICLE REPAIR
Item 1 Halfshaft seal
1. Remove the halfshaft seal using the special
308-208
tool.
TIE0027877
1. NOTE: Install a new halfshaft seal.
Install the halfshaft seal using the special
tool.
307-028
TIE0027878
2007.50 Focus 3/2007 G388139en

307-01-205 Transmission (4F27E) 307-01-205
IN-VEHICLE REPAIR
Halfshaft Seal RH
Special Tool(s) 1. Remove the right-hand front drive halfshaft.
Installer, Transmission For additional information, refer to: Front
Extension Housing Seal Halfshaft RH - 3-Door (205-04 Front Drive
307-028 Halfshafts, Removal and Installation).
17002
table(s).

308-208
16074
E50550

1 Halfshaft seal
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G388140en

307-01-206 Transmission (4F27E) 307-01-206
IN-VEHICLE REPAIR
1. Remove the halfshaft seal using the special
308-208
tool.
TIE0027875
1. NOTE: Install a new halfshaft seal.
Install the halfshaft seal using the special
tool.
307-028
TIE0027876
2007.50 Focus 3/2007 G388140en

307-01-207 Transmission (4F27E) 307-01-207
IN-VEHICLE REPAIR
Transmission Range (TR) Sensor(17 705 0)

Special Tool(s) 2. Lift the locking tab, press the locking pins
together and detach the selector lever cable
Alignment Gauge, TR Sensor
from the selector lever cable bracket.
307-415
307415
Removal
1
1. Shift the transmission selector lever to the
"D" (DRIVE) position.
E47354
For additional information, refer to: Lifting 5. NOTE: Failure to hold the shift lever while
(100-02 Jacking and Lifting, Description loosening or tightening the manual shift lever
and Operation). will transmit rotational torque to the TR
3. Disconnect the transmission range (TR) switch and shift mechanism.
sensor electrical connector. Remove the TR sensor (automatic transaxle
1. Remove the manual control lever.
2. Remove the bolts.
E50546
4. 1
CAUTION: Do not bend the selector lever.
ELE0008657
Detach the selector lever cable from the
manual shift lever.
Installation
1. Detach the selector lever cable from the
manual shift lever. 1. NOTE: Failure to hold the shift lever while
loosening or tightening the manual shift lever
will transmit rotational torque to the
transmission range (TR) switch and shift
mechanism.
NOTE: Do not tighten the TR sensor retaining bolts
at this stage.
2007.50 Focus 3/2007 G401950en

307-01-208 Transmission (4F27E) 307-01-208
IN-VEHICLE REPAIR
Install the TR sensor (automatic transaxle Move the transaxle selector lever to the "D"
shown removed for clarity). (DRIVE) position (TR sensor shown removed
for clarity).
E0011806
ELE0008134
2. Using the special tool, align the TR sensor

and tighten the TR sensor retaining bolts. 5.
Attach the selector lever cable to the manual
307-415 shift lever.
1. Attach the selector lever cable to the selector
lever cable bracket, close the locking tab.
2. Attach the selector lever cable to the lever.
10 Nm
TIA0006339
3.
CAUTION: Do not use air tools on this
bolt. Hold the manual control lever while 2
tightening the manual control lever bolt,
failure to the manual control lever shaft could E47355
occur.
Install the manual control lever. 6. Connect the TR sensor electrical connector.
22 Nm
E0011807
E50546
4. NOTE: The transmission range (TR) sensor 7. Lower the vehicle.

mark must be inline with the transaxle
selector lever.
2007.50 Focus 3/2007 G401950en

307-01-209 Transmission (4F27E) 307-01-209
IN-VEHICLE REPAIR
8. Check the selector lever cable adjustment
by moving the transmission selector lever
through all gear ranges.
2007.50 Focus 3/2007 G401950en

307-01-210 Transmission (4F27E) 307-01-210
REMOVAL
Transaxle — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE

(MI4)(17 214 0)
Special Tool(s)
Support Bar, Engine Removal
303-290A
303290A

303-290-03A
2114003
TIE44765
Adapter for 303-290A 2. Remove the air cleaner.

303-290-13
30329013 Distribution and Filtering, Removal and
Installation).
303-290A-15
E42950 and Installation).
4. Remove the headlamp assembly on both
General Equipment sides.
Transmission jack For additional information, refer to:
Securing straps
Cable ties
2007.50 Focus 3/2007 G420946en

307-01-211 Transmission (4F27E) 307-01-211
REMOVAL
5. Install the special tools on both sides 8. Detach the ground cable from the transaxle.
303-290-13
E55378
TIE0036685

6. Detach the engine and transaxle assembly
central electrical connector from the fluid
level indicator tube retaining bracket.
E52745
10.
E50540 WARNING: When releasing the
transmission fluid, take care to prevent
scalding. Failure to follow this instruction
7. Detach the engine and transaxle assembly
wiring harness from the fluid level indicator
tube retaining bracket. CAUTION: Plug the transmission fluid
cooler feed and return lines to prevent fluid
loss or dirt ingress.
NOTE: The transmission fluid cooler lines are
coloured red (feed line) and black (return line) to
aid installation.
Detach the transmission fluid cooler lines
from the transaxle.
release connector onto the transaxle.
E50541
the transmission fluid cooler line from the
transaxle.
2007.50 Focus 3/2007 G420946en

307-01-212 Transmission (4F27E) 307-01-212
REMOVAL
• Allow the fluid to drain into a suitable 14. Remove the engine undershield.
container.
1 2
E40677
E50542

11. Disconnect the transaxle central electrical
connector.
E50539
E50543
16. Loosen the radiator left-hand retaining
bracket.
12. Disconnect the turbine shaft speed (TSS)
sensor electrical connector. • Loosen the front retaining bolt three turns.
• Remove the rear retaining bolt.
ELE0008689
E50553

2007.50 Focus 3/2007 G420946en

307-01-213 Transmission (4F27E) 307-01-213
REMOVAL
17. Disconnect the transmission range (TR) 20. Remove the floor panel brace.
E47678
E50546
21.
18.
CAUTION: Do not bend or kink the flexible pipe may cause damage resulting
selector lever cable. in failure.
Detach the selector lever cable from the Support the exhaust flexible pipe with a
transaxle. suitable support wrap or suitable splint.
selector mechanism.
2. Lift the locking tab, press the locking pins
from the bracket.
TIE0014991
22.
1 CAUTION: Twisting the exhaust flexible
pipe more than two degrees may cause
E47354
damage resulting in failure.
NOTE: Use a pry-bar to prevent the exhaust
19. Remove the crashbox (if equipped). flexible pipe from twisting when removing the
exhaust flexible pipe to catalytic converter retaining
nuts.
Detach the exhaust flexible pipe from the
muffler and tailpipe assembly.
E47211
2007.50 Focus 3/2007 G420946en

307-01-214 Transmission (4F27E) 307-01-214
REMOVAL
• Discard the gasket and retaining nuts. 26. Remove the halfshafts. For additional
information, refer to: (205-04 Front Drive
Halfshafts)
Front Halfshaft LH (Removal and
Installation),
Front Halfshaft RH (Removal and
Installation).
27. Disconnect the output shaft speed (OSS)
E57917

exhaust hanger insulators.
ELE0007584
TIE39009
24. Remove the engine support insulator.
E44534

30. Remove the engine rear mount retaining
bolt.
TIE0036808

For additional information, refer to: Starter
Motor - 2.0L Duratec-HE (MI4)/1.8L
2007.50 Focus 3/2007 G420946en

307-01-215 Transmission (4F27E) 307-01-215
REMOVAL
• Discard the bolt. • Turn the crankshaft to gain access to the four
retaining nuts.
• Discard the torque converter retaining nuts.
TIE0037845
ELE0022082
31. Remove the engine rear mount bracket
(engine rear mount shown removed for
clarity). 35. Remove the transaxle lower retaining bolts.
E60964 E52747
32. Raise and support the vehicle. For 36. Remove the transaxle right-hand retaining
additional information, refer to: (100-02 bolts.
33. Using the special tools, lower the engine
and transaxle assembly slightly.
E52746
E44534
34. Remove the torque converter retaining

nuts.
2007.50 Focus 3/2007 G420946en

307-01-216 Transmission (4F27E) 307-01-216
REMOVAL
37. Using suitable securing straps and wooden
blocks, secure the transaxle to the
transmission jack.
ELE0001540

bolt.
E52748
39.
CAUTION: Make sure that the torque
converter remains in the transaxle housing.
Support the transaxle using the transmission
jack and remove the transaxle.
2007.50 Focus 3/2007 G420946en

307-01-217 Transmission (4F27E) 307-01-217
DISASSEMBLY
Transaxle(17 214 8)
Remover, O - Ring Mounting Bracket for 303-435
100-010 (17-063) 303-435-06 (21-031B)
17063 21031B
Adapter Holding Tool, Final Drive

205-071-02 (15-026-51) Input Gear
307-413 (17-079)
307413
1502651
Mounting Bracket, Engine Socket, Final Drive Input Nut

Differential 307-414 (17-080)
205-329 (15-105A)
15105A 307414
Compressor, Valve Spring Plate wrenching

303-364 (21-158) 307-420 (17-085)
21158 307420
Separator, Oil Pan Remover, Mainshaft Needle

303-428 (21-179) Bearing Sleeve
308-191 (16-056)
21179 16056
Mounting Stand Materials

303-435 (21-187)
Name Specification
Automatic Transmission WSS–M2C202–B
Fluid
21187 Metal Surface Cleaner WSE–M5B392–A
Screw M10 x 1.25
2007.50 Focus 3/2007 G17996en

307-01-218 Transmission (4F27E) 307-01-218
DISASSEMBLY
Disassembly While holding the lever remove the manual
control lever.
1.
CAUTION: If, during repair work, abrasive
particles are found in the transaxle fluid
(particles from the clutch, metal chips or
foreign material), the transaxle must be
disassembled completely and cleaned. Also,
clean the fluid pipes, fluid cooler and torque
converter carefully. In the case of extreme
soiling of the fluid pipes, install a new fluid
cooler and torque converter.
NOTE: In case of clutch abrasion, rinse the torque
converter with clean Automatic Transmission Fluid
or equivalent meeting Ford specification. E0011840
Inspect the transaxle during disassembly.

5. Remove the transmission range (TR) sensor.
2. Remove the output shaft speed (OSS)
sensor.
TIE0018847
TIA0005641
3. Remove the turbine shaft speed (TSS)
sensor.
303-364
ELE0015296
TIA0002969 7.
CAUTION: Do not tilt the torque converter
when removing it, to avoid damaging the
4. torque converter hub.
CAUTION: Do not use air tools.
NOTE: The torque converter is filled with fluid.
Drain into a suitable container.
Remove the torque converter.
2007.50 Focus 3/2007 G17996en

307-01-219 Transmission (4F27E) 307-01-219
DISASSEMBLY
8. Using the special tool, mount the transaxle. 11. Remove the fluid pump seals.
303-435-06
205-329
303-435
ELE0011716 TIA0003701
9. Remove the fluid pump bolts. 12. Remove the forward clutch thrust washer.
TIA0002939 A0007054
10. Remove the fluid pump. 13. Remove the forward clutch assembly.
• Install two M10 x 1.25 bolts into the fluid
pump and remove the fluid pump.
1 1
A0002943
ELE0022488
14. NOTE: Small levers will aid in the removal
of the forward clutch hub.
2007.50 Focus 3/2007 G17996en

307-01-220 Transmission (4F27E) 307-01-220
DISASSEMBLY
Remove the forward clutch hub. 19. Using the special tool, remove the end
cover seals.
TIA0003726 100-010
ELE0011720
15. Rotate the transaxle 180 degrees.

20. Remove the end cover to case seals.
16. Remove the end cover.
TIA0003694
TIA0003028
21. Using the special tool, remove the direct

17. Clean the silicone sealant from the end
clutch cylinder thrust bearing.
cover and transaxle case surfaces
thoroughly with Metal Surface Cleaner or
equivalent to Ford specification.
100-010
18. Remove the direct clutch hub bearing shim.
ELE0011717
E0011842
2007.50 Focus 3/2007 G17996en

307-01-221 Transmission (4F27E) 307-01-221
DISASSEMBLY
22. Remove the intermediate and overdrive 25. Remove the planet gear assembly.
brake band anchor bolt.
TIA0002942
TIA0003030
26. Remove the low and reverse clutch plate

23. Remove the intermediate and overdrive retaining ring.
brake band.
TIA0002944
TIA0003032
27. Remove the low and reverse clutch plates,

24. Remove the intermediate and overdrive pressure plate and bevel ring.
brake drum assembly.
TIA0002945
TIA0002938
2007.50 Focus 3/2007 G17996en

307-01-222 Transmission (4F27E) 307-01-222
DISASSEMBLY
28. Remove the low gear one-way clutch 31. Remove the low and reverse gear clutch
retaining ring. piston.
TIA0003727 TIA0003718
29. Remove the low gear one-way clutch inner 32. Remove the transaxle fluid pan and drain
race. transmission fluid, using a suitable tray.
2. Using the special tool, separate the transaxle
fluid pan from the transaxle.
303-428
TIA0003728 2
30. Remove the low and reverse gear clutch

return spring. ELA0002946
33. Clean the silicone sealant from the

transaxle fluid pan and transaxle case
surfaces thoroughly with Metal Surface
Cleaner or equivalent to Ford specification.
34. Remove the transmission fluid temperature
(TFT) sensor.
TIA0003729
TIA0002948
2007.50 Focus 3/2007 G17996en

307-01-223 Transmission (4F27E) 307-01-223
DISASSEMBLY
35. Remove the fluid filter. Remove the 13 main control valve body
retaining bolts.
TIA0002949
TIA0002952
36. NOTE: It is necessary to note the location

of the main control wire harness 38. NOTE: Squeeze the tabs on the side of the
connectors so they can be connected in electrical connector.
the same positions. Connector color letters
Remove the transaxle internal harness
are cast into the solenoid body.
Remove the ground wire bolt. Disconnect
the electrical connectors and remove the
wire harness.
1. Solenoid SSC; Color W (White)
2. Solenoid SSE; Color G (Green)
3. Solenoid SSD; Color L (Blue)
4. Solenoid EPC; Color B (Black)
5. Solenoid SSA; Color N (Neutral)
6. Solenoid SSB; Color B (Black)
2 3 TIA0002959
1
39. NOTE: Each of the two accumulators have
two springs. All four springs are different
sizes.
NOTE: Note the size and location of the
4 accumulator springs for assembly.
Remove the accumulator pistons and
5 6
TIA0002950 springs.
37. NOTE: Note the location of the longer bolts.
TIA0002954
2007.50 Focus 3/2007 G17996en

307-01-224 Transmission (4F27E) 307-01-224
DISASSEMBLY
40. Remove the manual lever shaft roll pin. 43. Remove the control lever assembly.
TIA0003686 TIE0022368
41. Remove the manual lever shaft. 44.

CAUTION: The intermediate and
overdrive brake band servo cover plate is
spring loaded. The bolts should be removed
evenly until the plate is unloaded, then
remove the bolts.
Remove the intermediate and overdrive
piston servo cover.
• Remove the bolts.
• Remove the intermediate and overdrive
piston servo cover.
TIA0002957
42. Remove the O-ring seals from the manual

lever shaft.
TIA0005614
45. Remove the O-ring seal.
TIA0003685
TIA0002962
2007.50 Focus 3/2007 G17996en

307-01-225 Transmission (4F27E) 307-01-225
DISASSEMBLY
46. Remove the intermediate and overdrive 50. Remove the differential assembly.
servo piston.
TIA0002965
TIA0002961
51. Remove the parking pawl assembly cover.

47. Remove the intermediate and overdrive
servo piston return spring.
TIA0007068
TIA0003683
52. Remove the parking pawl abutment.
1. Unclip the spring.
2. Remove the pin.
49. Remove the bolts and separate the 3. Remove the lever.
converter housing from the transaxle case. 4. Remove the parking pawl abutment.
TIA0002963 TIA0002967
2007.50 Focus 3/2007 G17996en

307-01-226 Transmission (4F27E) 307-01-226
DISASSEMBLY
53. Remove the spring. Using the special tool, remove the final drive
input gear bearing retaining nut.
450 Nm
307-414
307-420
TIA0003697
ELE0015298
54. Remove the transfer shaft gear.

307-413
TIA0003721
55. Using the special tool, lock the final drive TIA0006348
input gear.
60.
CAUTION: Hold the final drive input gear
while removing the bearing to prevent it
307-413 from falling out of the transaxle case.
Rotate the transaxle 180 degrees.
61. Remove the final drive input gear bearing
by lightly tapping on the end of the final
drive input gear. Remove the final drive
input gear.
TIA0006348

57. NOTE: Release the locking sleeve away
from the final drive input gear bearing
retaining nut.
TIA0002972
2007.50 Focus 3/2007 G17996en

307-01-227 Transmission (4F27E) 307-01-227
DISASSEMBLY
62. Remove and discard the collapsible spacer.
TIA0005617
63. Using the special tool, remove the final

drive input gear bearing.
308-191
205-071-02
ELE0011719
64. Clean the converter housing and transaxle

case surfaces thoroughly with Metal
Surface Cleaner or equivalent meeting Ford
specification.
2007.50 Focus 3/2007 G17996en

307-01-228 Transmission (4F27E) 307-01-228

Special Tool(s) Using the special tools, remove the
differential case bearings.
Installer Differential Bearing
205-062 (15-025A)
205-295
205-071-01
15025A
308-197
Remover, Bearing (Main

Tool)
205-295 (15-050A)
ELE0011721
15050A
2. NOTE: The roll pin can be driven through the

housing.
Collet for 205-295
308-197 (16-062) Remove the differential pinion shaft.
• Remove and discard the pin.
• Remove the differential pinion shaft.
16062
Adapter
205-071-01 (15-026A-01)
15026A01
TIA0005619
Materials
Name Specification 3. Remove the differential side gears.
Automatic Transmission WSS–M2C202–B 1. Turn the differential pinion gears 90 degrees
Fluid and remove the differential pinion gears with
the thrust washers.
Disassembly
1.
CAUTION: Do not damage the speed
sensor wheel.
NOTE: Left-hand side shown, right-hand side
similar.
2007.50 Focus 3/2007 G17998en

307-01-229 Transmission (4F27E) 307-01-229
2. Remove the differential side gears with the 2. Install the differential pinion gears and thrust
thrust washers. washers by rotating 90 degrees.
1 2 2 1
TIA0005622 TIA0005623
4. Clean all parts thoroughly in suitable solvent 3. Install the differential pinion shaft.
and blow dry with moisture-free regulated
1. Push the pinion shaft in place.
compressed air.
2. Install a new pin.
5. Inspect the differential parts for damage and
wear.
• Pinion gear teeth and bores 2
• Side gear teeth and five plines
• Thrust washers
1
• Differential pinion shaft
• Differential case bearing and surfaces
Assembly
1. Lubricate the gears and thrust washers with TIA0005624
clean Automatic Transmission Fluid.
4. Using the special tool, install the differential
case bearings.
205-062
TIA0005625
2. Install the different pinion gears and thrust TIA0005784

washers.
1. Install the differential side gears and thrust
washers.
2007.50 Focus 3/2007 G17998en

307-01-230 Transmission (4F27E) 307-01-230
Pump Assembly
Special Tool(s) 3. Remove the pump seal.
Installer, Drive Pinion Oil Seal
205-115 (15-058)
15058
Materials
Name Specification
E0011841
Automatic transmission WSS–M2C202–B
fluid
4. Inspect the upper portion of the pump for
nicks, scratches or gouges.
Disassembly
1. Remove the top portion of the pump.
TIA0002981
TIA0002978 5. Inspect the pump gears for nicks, scratches

or gouges.
2. Inspect the lower portion of the pump and
gear pocket for nicks, scratches, gouges or
wear.
TIA0002982
Assembly
TIA0002980
1. NOTE: The smaller gear has a recess on both
sides.
NOTE: The smaller recess must face away from
the torque converter seal.
2007.50 Focus 3/2007 G17999en

307-01-231 Transmission (4F27E) 307-01-231
NOTE: The larger recess, with the beveled edge,
must face toward the torque converter.
Lubricate the gears and thrust washers with
clean automatic transmission fluid.
TIA0002982
2. Using the special tool, install the pump seal.

• Lubricate the gears and thrust washers with
automatic transmission fluid.
205-1 15
ELE0012424
3. Install the top portion of the pump.
13 Nm
TIA0002979
2007.50 Focus 3/2007 G17999en

307-01-232 Transmission (4F27E) 307-01-232
Transfer Shaft
Special Tool(s)
Collet for 205-295 Disassembly
308-197 (16-062)
1. Using the special tools, remove the
right-hand side transfer shaft gear bearing.
16062
205-295
Remover, Bearing (Main 204-158-01

Tool)
205-295 (15-050A) 308-197
15050A
ELE0011723
Adapter
205-071-01 (15-026A-01) 2. Using the special tool and a press, remove
the left-hand side transfer shaft gear bearing
while separating the gears.
15026A01
Installer, Drive Pinion Bearing

205-068 (15-042) 204-158-01
15042
ELE0015299
Adapter
204-158-01 (14-038-01)
Assembly
1. Using the special tool, install the right-hand
1403801 side transfer shaft gear and park assembly.
205-068
ELE0011761
2007.50 Focus 3/2007 G18000en

307-01-233 Transmission (4F27E) 307-01-233
2. Using the special tool, assemble the gears
and install the left-hand side transfer shaft
gear bearing.
205-068
ELE0011762
2007.50 Focus 3/2007 G18000en

307-01-234 Transmission (4F27E) 307-01-234
Forward Clutch
Compressor, Spring Washer Feeler gauge
307-209 (17-040)
Materials
Name Specification
Automatic Transmission WSS–M2C202–B
17040
Fluid
10
9
8
6
6
4 5
3
2
1
7
7
ELE0007780
1 Shaft assembly - turbine 9 Retaining ring
2 Piston assembly - forward clutch 10 Hub - forward clutch cylinder
3 Spring assembly - forward piston return

Disassembly
4 Piston - forward clutch balance
5 Ring - forward clutch balance piston snap 1. Remove the forward clutch plates.
thrust bearing 1. Remove the snap ring.
6 Steel plates - forward clutch separator
7 Friction plate assembly - forward clutch
8 Plate - forward clutch pressure
2007.50 Focus 3/2007 G18001en

307-01-235 Transmission (4F27E) 307-01-235
2. Remove the pressure plate, the friction plates Remove and inspect the forward clutch
and the steel plates. balance piston.
TIA0002983
TIA0002987
2. Using the special tool, place the forward 5. Remove the return spring assembly.
clutch assembly in a press.
307-209
TIA0002998
TIA0005905
6.
3. Using the special tool, remove the forward CAUTION: If damage is found to the
clutch balance piston snap ring. forward clutch piston seals, install a new
forward clutch piston assembly.
Remove the forward clutch piston assembly.
307-209
TIA0005906
4. TIA0003732
CAUTION: If damage is found to the
balance piston seals, install a new forward
clutch balance piston. Assembly
1. Soak the internal spline clutch plates in clean
Automatic Transmission Fluid for 15 minutes
before assembly.
2007.50 Focus 3/2007 G18001en

307-01-236 Transmission (4F27E) 307-01-236
2. Inspect the forward clutch piston bore 6. Using the special tool, install the forward
surfaces for nicks or scratches. Install a new clutch assembly using a press.
forward clutch balance piston if necessary.
3. Lubricate and install the forward clutch
piston assembly.
307-209
TIA0005905
7. Using the special tool, install the forward

TIA0003732 clutch balance piston snap ring.
4. Install the return spring assembly.

307-209
TIA0005906
TIA0002998 8. Install the forward clutch plates.

1. Install the steel plates, the friction plates and
5. Lubricate and install the forward clutch the pressure plate.
balance piston. 2. Install the snap ring.
• Using a feeler gauge, check clearance.
Specifications in this section.
TIA0002987
TIA0002984
2007.50 Focus 3/2007 G18001en

307-01-237 Transmission (4F27E) 307-01-237
Direct and Reverse Clutch Assembly
2 4
1 3
ELE0022382
2007.50 Focus 3/2007 G18002en

307-01-238 Transmission (4F27E) 307-01-238
Item Description 3. Remove the bearing.
1 Snap ring
2 Rear sun gear assembly
3 Thrust bearing assembly
4 Direct clutch hub assembly
5 Direct clutch thrust bearing
6 Direct Clutch cylinder assembly
7 Intermediate and overdrive band assembly
TIA0002991
Disassembly
4. Remove the direct clutch hub.
1. Remove the snap ring from the reverse drum.
TIA0002992
TIA0002989
5. Remove the direct clutch thrust bearing.

2. Remove the sun gear.
TIA0002993
TIA0002990
2007.50 Focus 3/2007 G18002en

307-01-239 Transmission (4F27E) 307-01-239
6. Remove the direct clutch cylinder assembly.
TIA0003733
Assembly
1. To assemble, reverse the disassembly
procedure.
2007.50 Focus 3/2007 G18002en

307-01-240 Transmission (4F27E) 307-01-240
Direct Clutch
Compressor, Spring Washer Name Specification
307-209 (17-040)
Automatic transmission WSS–M2C202–B
fluid
17040
3 4
1 2
10
9
8
7
6
5
4
4 3
3
ELE0011725
2. Remove the direct clutch pressure plate and

Item Description
plates.
1 Retaining ring
2 Direct clutch pressure plate
3 Friction plates 1
4 Steelplates - forward clutch separator 2

5 Selective snap ring
6 Direct clutch balance piston
7 Direct clutch return spring
8 Direct clutch piston TIA0002994
9 Bearing - direct clutch thrust

10 Cylinder assembly - direct clutch
Disassembly
1. Remove the direct clutch pressure plate and
plates.
1. Remove the selective direct clutch pressure
plate retaining ring.
2007.50 Focus 3/2007 G18003en

307-01-241 Transmission (4F27E) 307-01-241
2. Using the special tool, remove the snap ring. Remove and inspect the direct clutch piston.
307-209
A0007053 TIA0002997
3. Remove the direct clutch balance piston. Assembly

automatic transmission fluid for 15 minutes
before assembly.
2. Inspect the direct clutch piston bore surfaces
for nicks or scratches. Install a new direct
clutch piston if necessary.
3. Lubricate and install the direct clutch piston.
TIA0002995
4. Remove the direct clutch return spring.
TIA0002997
4. Install the direct clutch return spring.
TIA0002996
5.
CAUTION: If damage is found on the
direct clutch piston seals, install a new direct
clutch piston.
TIA0002996
2007.50 Focus 3/2007 G18003en

307-01-242 Transmission (4F27E) 307-01-242
5. Install the direct clutch balance piston.
TIA0002995
6. Using the special tool, install the snap ring.
307-209
A0007053
7. Install the direct clutch pressure plate

retaining ring.
1. Install the direct clutch plates and pressure
plate.
2. Install the selective direct clutch pressure
plate retaining ring.
2
1
TIA0003716
2007.50 Focus 3/2007 G18003en

307-01-243 Transmission (4F27E) 307-01-243
Reverse Clutch
Clutch Spring Compressor Name Specification
307-015 (17-058)
Automatic Transmission WSS-M2C202-B
Fluid
17058
9
8
7
3
6
5
2
1
4
ELE0022381
2. Remove the pressure plate and clutch plates.

Item Description
1 Retaining ring
1
2 Pressure plate 2
3 Steel plate
4 Friction plate assembly
5 Spring retainer ring
6 Spring retainer
7 Piston return spring
ELE0011763
8 Piston assembly
9 Intermediate and overdrive drum assembly
Disassembly
1. Remove the reverse clutch pressure plate
and clutch plates.
1. Remove the reverse clutch pressure plate
retaining snap ring.
2007.50 Focus 3/2007 G18004en

307-01-244 Transmission (4F27E) 307-01-244
2. Using the special tool, remove the reverse Inspect the seal bore, inner and outer seals.
clutch snap ring and retainer.
307-015
TIA0003002
TIA0005908
Assembly
3. Remove the reverse clutch return spring.
Automatic Transmission Fluid for 15 minutes
before assembly.
2. Lubricate and install the reverse clutch
piston assembly.
TIA0003000
4. Remove the reverse clutch piston assembly.
TIA0003001
3. Install the reverse clutch return spring.
TIA0003001
5.
CAUTION: If damage is found to the
reverse clutch piston seals, install a new
reverse clutch piston.
TIA0003000
2007.50 Focus 3/2007 G18004en

307-01-245 Transmission (4F27E) 307-01-245
4. Using the special tool, install the reverse
clutch retainer and snap ring.
307-015
TIA0005908
5. Install the reverse clutch pressure plate

1. Install the reverse clutch plates and pressure
plate.
2. Install the reverse clutch pressure plate
1
2
ELE0011763
2007.50 Focus 3/2007 G18004en

307-01-246 Transmission (4F27E) 307-01-246
Planetary Assembly
Disassembly
4. Remove the thrust bearing.
1. Inspect the planetary assembly internal
bearing for damage.
TIA0003005
A0007710
5. Remove the forward planet sun gear.
2. Remove the snap ring.
TIA0003006
TIA0003003
6. Remove the thrust bearing.
3. Remove the rear planet assembly.
TIA0003007
TIA0003004
2007.50 Focus 3/2007 G18005en

307-01-247 Transmission (4F27E) 307-01-247
7. Remove the forward planet assembly. 10. Remove the one-way clutch upper ring.
TIA0003008 A0003011
8. Inspect the low and reverse ring gear. 11. Remove the low one-way clutch assembly.
TIA0003009 TIA0003012
9. Remove the one-way clutch upper retainer. 12. Remove the one-way clutch lower ring.
TIA0003010 TIA0003679
2007.50 Focus 3/2007 G18005en

307-01-248 Transmission (4F27E) 307-01-248
Assembly 4. Install the low one-way clutch assembly.
1. Install the one-way clutch lower ring.
TIA0003012
TIA0003679
5. Install the one-way clutch upper ring.
2. Inspect the rollers and the springs of the

one-way clutch assembly.
A0003011
6. Install the one-way clutch upper retainer.

TIA0003681
3. Make sure the one-way clutch assembly is

installed with the tab pointing in the direction
as shown.
TIA0003010
TIA0006157
2007.50 Focus 3/2007 G18005en

307-01-249 Transmission (4F27E) 307-01-249
7. Install the forward planet assembly. 10. Install the forward planet sun gear.
TIA0003008 TIA0003006
8. NOTE: Make sure the locking tabs face 11. NOTE: Make sure the tab faces downwards.
downwards.
Install the thrust bearing.
Install the thrust bearing.
TIA0003005
TIA0003007
12. Install the rear planet assembly.

9. Inspect the forward planet sun gear retaining
ring.
TIA0003004
TIA0003734
2007.50 Focus 3/2007 G18005en

307-01-250 Transmission (4F27E) 307-01-250
13. Install the snap ring.
TIA0003003
2007.50 Focus 3/2007 G18005en

307-01-251 Transmission (4F27E) 307-01-251

Disassembly
9 7
8 1
7
9
10
4
3
11 21
6 22
2 5 2
23
6
12
2
13 3
24
14
2
16 17 18 3
4
15
25 2
20 3
19 24
2 32
7 31
26
28
30
28
27
29
TIE0018307
2007.50 Focus 3/2007 G18006en

307-01-252 Transmission (4F27E) 307-01-252
Item Part Description Item Part Description

Number Number
1 Manual control valve 30 Solenoid bracket screws
2 Spring retainer plate 31 Solenoid body bolt
3 Bypass clutch control plate 32 Solenoid body
spring
33 Shift control solenoids
4 Bypass clutch control valve
34 Shift solenoids hold down
5 Modulator valve spring bracket
6 Line pressure modulator valve 1. Remove the solenoid body.
7 Main control valve body bolt
9 Main control valve body seal
11 Main control upper valve body
12 Main control valve body gasket
13 Main control valve body
separator plate (bonded gasket)
TIA0003708
14 Main control valve lower body
15 Main regulator valve stop 2. Remove and discard the solenoid body
16 Throttle valve plunger sleeve gaskets.
clip
17 Main fluid pressure regulator
valve spring
18 Main fluid pressure regulator
valve
19 Solenoid regulator valve spring
20 Shift solenoid valve
21 Intermediate servo accumulator
spring
TIA0003710
22 Intermediate servo accumulator
valve
23 Converter regulator valve spring
24 Lock up control valve
25 Solenoid body gasket
26 Solenoid plate
27 Regulator body gasket
28 Shift control solenoid
29 Electrical pressure control
solenoid
2007.50 Focus 3/2007 G18006en

307-01-253 Transmission (4F27E) 307-01-253
3. Remove and discard the valve body seals. Inspect and clean the main control valve
body and install a new separator plate
assembly and gasket.
A0003711
TIA0003713
4. Disassemble the main control valve body.
2. Assemble the upper and lower main control

valve bodies and loosely install the bolts.
TIA0003712
5. Remove and discard the separator plate and

TIA0003712
gasket.
3. Install the new solenoid body gaskets.
TIA0003713
TIA0003710
Assembly
1. NOTE: The top side of the separator plate
has a bonded gasket. Separate gasket goes
on the bottom side.
2007.50 Focus 3/2007 G18006en

307-01-254 Transmission (4F27E) 307-01-254
4. Install the solenoid body and install the two 6. Install new valve body seals.
bolts as shown.
9 Nm
A0003711
TIE0022585
5. Install the remaining bolts and tighten in the

sequence shown.
12 1 5 6 13
4 9 Nm
2 14
11
15
10
17 3 8 16
9 7
TIE0022532
2007.50 Focus 3/2007 G18006en

307-01-255 Transmission (4F27E) 307-01-255
Transaxle Case
Installer, Rear Wheel Hub Installer, Rear Wheel Hub
Seal Seal
205-075 (15-036) 205-075 (15-036)
15036 15036
Installer, Differential Double

Lip Seal Disassembly
308-203 (16-066)
1. Remove the halfshaft seals (left-hand side
shown).
16066
Remover, Differential Bearing

Cone
205-176 (15-074)
15074
Installer, Transmission A0006164

Extension Housing Seal
307-028 (17-002)
2. Using the special tool, remove the differential
bearing cups (left-hand side shown).
307418
Remover, Drive Pinion Seal

205-078 (15-048) 205-176
15048
Adapter for 206-066 ELE0022489

205-066-03 (15-033-3)
20506603
2007.50 Focus 3/2007 G18007en

307-01-256 Transmission (4F27E) 307-01-256
3. Using the special tool, remove the final drive 7. Using the special tool, remove the final drive
input gear bearing cup. input gear bearing cup.
205-176
205- 176
ELE0022490 ELE0015303
4. Using the special tool, remove the transfer Assembly

shaft gear bearing cups (left-hand side
shown). 1. NOTE: The converter housing side bearing
cups for the transfer shaft bearing and
differential case bearing will be installed
205-078 during the assembly of the transaxle.
Using the special tool, install the final drive
input gear bearing cup.
308- 203
TIE0022491
5. NOTE: Note the location of the bleed hole in

the funnel in relation to the bottom of the
case.
ELE0015304
NOTE: Inspect the bleed hole for foreign material.
Remove the funnel.
3. NOTE: Note the location of the bleed hole.
NOTE: Inspect the bleed hole for foreign material.
ELE0012501
2007.50 Focus 3/2007 G18007en

307-01-257 Transmission (4F27E) 307-01-257
Install the funnel. 6. Using the special tool, install the differential
case bearing cups (left-hand side shown).
205-075
TIE0018507
TIE0015307
4. Using the special tool, install the transfer

shaft gear bearing cups (left-hand side 7. Using the special tool, install the halfshaft
shown). seals (left-hand side shown).
205-066-03
307-028
TIE0015305 ELE0015308
5. Using the special tool, install the final drive

input gear bearing cup (left-hand side
shown).
308-203
ELE0015306
2007.50 Focus 3/2007 G18007en

307-01-258 Transmission (4F27E) 307-01-258
Torque Converter
1. A new torque converter must be installed if
one or more of the following statements are
true:
• A torque converter malfunction has been
detected based on completed diagnostic
procedures.
• Impeller hub or bushing is damaged.
• If there is a discoloration of the torque
converter (due to overheating).
• The torque converter is found to be out of
specification, when carrying out the following
checks:
• torque converter pump insert check
• torque converter end play check
• torque converter turbine torque check
• torque converter leakage check
• If there is evidence of transaxle assembly
damage or fluid contamination due to the
following transaxle or converter failure
modes:
• major metallic failure
• multiple clutches or clutch plate failures
• sufficient component wear which results in
metallic contamination
2007.50 Focus 3/2007 G18008en

307-01-259 Transmission (4F27E) 307-01-259
Torque Converter Leak Check

Special Tool(s) Connect the airline to the special tool and
apply air pressure.
Torque Converter Leak
Check Tool and Gasket
307-421
5.6
307-421
307421
1. Clean the outside surface of the torque

converter.
2. Install the special tool onto the converter
hub. TIA0007050
5. With air pressure applied to the valve,

307-421 inspect for leaks at the converter hub, the
seams and the studs. A soap bubble solution
can be applied around these areas to aid in
the diagnosis. If any leaks are present, install
a new converter.
307-421
TIA0002587
3.
WARNING: Always follow correct safety
procedures while using a press. Failure to
personal injury.
Install the torque converter with the special
TIA0007051
tool installed onto the arbor press.
• Apply only enough force from the press to 6. Remove the air hose. Release the pressure,
seal the special tool into the torque converter. and then slowly release the press. Remove
the converter. Remove the special tool.
307-421
307-421
TIA0007049
TIA0002591
4.
CAUTION: Use only clean, dry shop air.
2007.50 Focus 3/2007 G18009en

307-01-260 Transmission (4F27E) 307-01-260
Torque Converter End Play Check

Special Tool(s)
Gauge, Torque Converter
Clutch
307-409 (17-078)
307409
1. Using the special tool, measure the torque

converter clutch end play.
0.05-0.50 mm
307-409
TIA0006347
2007.50 Focus 3/2007 G18010en

307-01-261 Transmission (4F27E) 307-01-261
ASSEMBLY
Transaxle(17 214 8)
Preload Gauge Depth Gauge, Shim Selection
205-067 (15-041) 307-300-02 (17-055-02)
1705502
15041
Installer, Differential Bearing Holding Tool, Final Drive

Cone Input Gear
205-073 (15-034) 307-413 (17-079)
15034 307413
Installer, Rear Wheel Hub Socket, Final Drive Input Nut

Seal 307-414 (17-080)
205-075 (15-036)
15036 307414
Installer, Timing Cover Seal Alignment Gauge, TR Sensor

303-255 (21-136) 307-415 (17-081)
21136 307415
Compressor, Valve Spring Adjustment Bolt,

303-364 (21-158) Transmission Band
307-416 (17-082)
21158
307416
Installer, Extension Housing Gauge, Differential/Transfer

Seal Gear Bearing Shim
307-028 (17-002) 307-417 (17-083)
17002
307417
2007.50 Focus 3/2007 G18024en

307-01-262 Transmission (4F27E) 307-01-262
ASSEMBLY
Special Tool(s) Assembly
Holding Fixture, Final Drive
307-420 (17-085) 1. Using an arbor press and the special tools,
seat the final drive input gear bearing.
307420
308-203
Gauge, Transmission End 303-255

Play
307-430 (17-084)
307430
ELE0011766
Remover, Input Shaft Fifth 2. Install a new collapsible spacer.

Gear
308-082 (16-035)
16035
Installer, Differential Double

Lip Seal
308-203 (16-066)
16066 TIA0005617
3. Using the special tool, position the final drive

Materials input gear.
Name Specification
Thread sealer TN-YS5J-M4G9107-AA
205-073
Loctite 5699 WSS-M4G-320-A3
ELE0015309
4.
CAUTION: Hold the final drive input gear
while installing the final drive input gear
bearing to prevent it from falling out of the
transaxle case.
Rotate the transaxle 180 degrees.
2007.50 Focus 3/2007 G18024en

307-01-263 Transmission (4F27E) 307-01-263
ASSEMBLY
5. Using the special tools, install the final drive Using the special tools, tighten the nut to
input gear bearing. achieve the preload specification.
205-073
450 Nm
307-414
308-082 307-420
ELE0015310 ELE0015311
6. Rotate the transaxle 180 degrees. 10. Rotate the transaxle 180 degrees.
7. Using the special tool, lock the final drive 11. NOTE: Make sure that the final drive
input gear. rotates.
Unlock the special tool.
307-413
TIA0006348
TIE0029137
9. NOTE: A high tightening torque specification 12. Rotate the transaxle 180 degrees.
(between 400-450 Nm) is necessary to crush
13.
the collapsible spacer for correct bearing CAUTION: Make sure that the bearing
preload. preload is within specification.
NOTE: If the preload is too high a new collapsible NOTE: Rotate the gear ten times to make sure that
spacer must be installed. the bearings are correctly seated.
2007.50 Focus 3/2007 G18024en

307-01-264 Transmission (4F27E) 307-01-264
ASSEMBLY
Using the special tools, measure the rotating 17. Install the parking pawl return spring.
torque.
0.6-0.9 Nm
205-067
307-414
307-420 ELE0011767
TIE0022370
18. Connect the parking pawl return spring.

14. After achieving the correct torque, remove
1. Install the parking pawl abutment.
the special tools and stake the nut to
prevent movement. 2. Install the lever.
3. Install the pin.
4. Reconnect the pawl spring.
4
2
TIE0018521 3
TIA0002968
16. Position the transfer shaft gears in the 19. Install the parking pawl cover.
transaxle case.
13 Nm
A0007709
TIA0003736
2007.50 Focus 3/2007 G18024en

307-01-265 Transmission (4F27E) 307-01-265
ASSEMBLY
20. Install the differential case assembly. 3. Install the short bolts.
5 Nm
3 2
A0007713
TIA0002965
21. Install the bearing cups. 24. Remove the converter housing.
2. Remove the converter housing.
TIA0006150
A0007714
25. NOTE: Do not move the special tool

307-430 307-417 plunger, settings are made.
Remove the special tools.
307-430
307-417
307-430
E56511
23. NOTE: The converter housing cover must

be installed evenly or an incorrect reading 307-430
will result. E56512
Assemble the transaxle for end play

measurement.
1. Install the converter housing.
2. Install the long bolts and seat the converter
housing.
2007.50 Focus 3/2007 G18024en

307-01-266 Transmission (4F27E) 307-01-266
ASSEMBLY
26. Remove the bearing cups. To determine the correct differential shaft
shim, measure the depth of the plunger on
the special tool and select the correct
differential shaft shim.
Specifications (307-01 Automatic
Specifications).
307-417
TIA0006150
27. NOTE: If the plunger is above the contact

surface, the reading will be incorrect.
To determine the correct transfer shaft shim,
measure the depth of the plunger on the
special tool and select the correct transfer
shaft shim.
TIA0006470
29. Using the special tool, install the correct
transfer shaft shim and differential case
bearing cup into the converter housing.
Specifications).
307-028
307-417
ELE0015314
TIA0006470
28. NOTE: If the plunger is above the contact

surface, the reading will be incorrect.
2007.50 Focus 3/2007 G18024en

307-01-267 Transmission (4F27E) 307-01-267
ASSEMBLY
30. Using the special tool, install the correct 33. Install the servo piston return spring.
differential shaft shim and differential case
bearing cup in to the converter housing.
205-075
TIA0003683
ELE0015315
34. Install the servo piston.
31. NOTE: The components must be assembled

within 15 minutes.
Apply a one millimeter thick bead of Loctite
5699.
TIA0002961
35. Install the O-ring seal.
TIA0003740
32. Install the converter housing.
22 Nm
TIA0002962
36. NOTE: The three bolts need to be loosely

installed, then tightened in sequence to
compress the servo piston return spring
TIA0002964 evenly.
2007.50 Focus 3/2007 G18024en

307-01-268 Transmission (4F27E) 307-01-268
ASSEMBLY
Install the servo piston cover. 39. Install the manual lever shaft.
13 Nm
TIA0003719 TIA0002957
37. Install the shifter assembly and bolt. 40. NOTE: The roll pin does not need to sit
flush with the shifter assembly.
Install the manual lever shaft roll pin.
13 Nm
ELA0003720
38. NOTE: Lubricate the O-ring prior to TIA0003686

assembly.
Install the new O-rings on the manual lever 41. Loosely install the transmission range (TR)
shaft. sensor.
TIA0003685 TIA0002955
42. NOTE: The neutral drive accumulator

springs are thinner than the 1-2
accumulator springs.
2007.50 Focus 3/2007 G18024en

307-01-269 Transmission (4F27E) 307-01-269
ASSEMBLY
Install the neutral drive accumulator springs. 45. Install the 1-2 accumulator piston.
TIA0003703 TIA0003706
43. Install the neutral drive accumulator piston. 46. NOTE: Inspect the seals.
Lubricate and install the transaxle internal
harness electrical connector.
TIA0003704
44. Install the 1-2 accumulator springs. TIA0002959
47. NOTE: Make sure that the manual valve is

in the manual control valve shift lever.
NOTE: Do not fully tighten the bolts at this stage.
Install the main control valve body.
TIA0003705
TIE0029518
48. Tighten the main control valve body bolts.
2007.50 Focus 3/2007 G18024en

307-01-270 Transmission (4F27E) 307-01-270
ASSEMBLY
• Tighten the bolts in the sequence shown. 50. Install the fluid filter.
12 11 10 9 8 7
6
13
5
9 Nm 4
1 3
2
TIE0026121
TIA0002949
49. NOTE: It is necessary to connect the 51. Connect the transmission fluid temperature
connectors in the same positions as noted (TFT) sensor.
in disassembly. Connector color letters are
cast into the solenoid body.
Install the main control wire harness,
connect the electrical connectors and install
the ground wire bolt.
1. Solenoid SSC; Color W (/Neutral/White)
2. Solenoid SSE; Color G (Green)
3. Solenoid SSD; Color L (Blue)
4. Solenoid EPC; Color B (Black)
5. Solenoid SSA; Color N (Neutral)
6. Solenoid SSB; Color B (Black)
TIA0002948
2 3 52. Apply a one and a half millimeter thick bead

1 of Loctite 5699 to the transaxle fluid pan.
10 Nm
4
5 6
TIA0002951
ELE0009780
2007.50 Focus 3/2007 G18024en

307-01-271 Transmission (4F27E) 307-01-271
ASSEMBLY
53. Install the transaxle fluid pan. 57. Install the bevel ring with the outer edge
uppermost.
10 Nm
A0002947
TIA0003687

58. Inspect the position of the bevel ring.
55. Install the low and reverse clutch piston.
1. Make sure the low and reverse clutch piston
is seated.
2. Make sure the bevel ring is installed with the
inside edge facing down.
TIA0003718 1
56. NOTE: Make sure that the clutch return

spring is inserted with the tabs facing TIE0018538
upwards
Install the low and reverse clutch return 59. Install the low one-way clutch inner race.
spring.
TIA0003728
ELE0022367
60. NOTE: The opening of the retaining ring

must be at the ten o'clock position.
2007.50 Focus 3/2007 G18024en

307-01-272 Transmission (4F27E) 307-01-272
ASSEMBLY
Install the low one-way clutch retaining ring. 63. NOTE: Make sure that the snap ring is
installed before installing the planet
assembly.
Install the planet assembly.
TIE0033660
61. Install the low and reverse gear plate and

pressure plate. TIA0003688
64.
CAUTION: The edge of the planet
assembly must fit flush with the transaxle
case.
Inspect the planet assembly installation.
TIA0002945
62. Install the low reverse gear clutch plate

selective retaining ring.
• Check the clutch clearance.
For additional information, refer to: TIA0003689
65.
4-Speed Automatic Transmission (4F27E), CAUTION: The planet assembly must
Specifications). only rotate counterclockwise.
Check that the one way clutch is installed
correctly.
TIA0002944
2007.50 Focus 3/2007 G18024en

307-01-273 Transmission (4F27E) 307-01-273
ASSEMBLY
• Rotate the planet assembly clockwise and 68. Install the direct clutch cylinder thrust
counterclockwise. bearing with the rollers facing up.
A0007715
TIA0003693
66. Install the intermediate and overdrive drum 69. Install new end cover to case seals.
assembly.
TIA0003694
TIA0003690
70. Install new end cover seals.

67. Install the intermediate and overdrive brake
band.
TIA0003695
TIA0003032
2007.50 Focus 3/2007 G18024en

307-01-274 Transmission (4F27E) 307-01-274
ASSEMBLY
71. Install the direct clutch hub bearing shim 73. Remove the transaxle end cover.
and an additional shim to increase the total
shim thickness to the specification shown
or greater.
TIA0005621
74. NOTE: The clearance for the direct clutch

E62313 shim is 0.25 - 0.50 mm.
NOTE: The correct shim thickness is between the
72. NOTE: Make sure the cover is seated down
minimum and maximum value.
on both shims.
Select and install the correct direct clutch
NOTE: Take measurements from several positions
hub bearing shim.
and calculate the average gap.
• Line 1: total amount of shim thickness used
Measure the gap between the transaxle end
during transaxle end cover mock up.
cover and the transaxle assembly.
• Line 2: measure the gap between transaxle
1. Install the transaxle end cover on the end cover and transaxle case.
transaxle assembly. • Line 3: subtract Line 2 from Line 1 to obtain
2. Measure the gap between the transaxle end the actual clearance.
cover and the transaxle assembly. • Line 4: subtract 0.25 mm from Line 3 for
maximium shim thickness.
• Subtract 0.50 mm from Line 3 for the
1 minimum shim thickness.
2
TIA0005620
E0011842
75.
CAUTION: Make sure that the sealant
does not enter the fluid return holes.
2007.50 Focus 3/2007 G18024en

307-01-275 Transmission (4F27E) 307-01-275
ASSEMBLY
Apply a one millimeter thick bead of Loctite 78. Holding the special tool, lightly seat the nut
5699 to the transaxle end cover. against the transaxle case, then remove the
special tool without changing the
relationship of the nut on the bolt.
307-416
ELE0009799
TIA0005570
76. Install the transaxle end cover.
79. Using the special tool, select a band bolt

that measures from the end of the bolt to
the face of the nut as shown.
307-416
22 Nm
TIA0003029
77. Using the special tool, collapse the band

to specification then slacken three and a
TIA0006343
half turns.
80. NOTE: Apply thread sealer to the bolt.

307-416 Install the band anchor bolt.
45 Nm
5 Nm
TIA0006165
TIA0006340
2007.50 Focus 3/2007 G18024en

307-01-276 Transmission (4F27E) 307-01-276
ASSEMBLY
82. Install the forward clutch hub. 85. Lubricate and install new fluid pump seals.
TIA0003726 TIA0003701
83. Install the forward clutch assembly. 86. NOTE: Do not force the pump down at this
time.
Install the fluid pump.
A0002943
84. Install the forward clutch thrust washer. TIA0003702
87. Install the fluid pump.

• Use the bolts to seat the fluid pump.
• Tighten the retaining bolts in an alternating
sequence.
22 Nm
A0007054
ELA0002940
2007.50 Focus 3/2007 G18024en

307-01-277 Transmission (4F27E) 307-01-277
ASSEMBLY
88. Install the output shaft speed (OSS) sensor. Install the manual control lever.
10 Nm
22 Nm
TIA0005642 TIE0018536
89. NOTE: Apply thread sealer to the bolt. 92. Install the torque converter.
Install the turbine shaft speed (TSS) sensor.
10 Nm
ELE0015318
TIA0002970
93. Using the special tool, secure the torque
converter.
90. Using the special tool, align the TR sensor
and tighten the retaining bolts.
307-415
303-364
ELE0015296
10 Nm
TIA0006339
91.
CAUTION: Do not use air tools on this
bolt. Hold the manual control lever while
tightening the manual control lever
retaining bolt.
2007.50 Focus 3/2007 G18024en

307-01-278 Transmission (4F27E) 307-01-278
INSTALLATION
Transaxle — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE

(MI4)(17 214 0)
Special Tool(s) 1. Raise and support the vehicle. For additional
Support Bar, Engine information, refer to: (100-02 Jacking and
303-290A Lifting)
2.
303290A CAUTION: The torque converter hub must
engage fully with the oil pump drive gear.
Check the installation depth of the torque
Adapter for 303-290A converter.
303-290-03A
1. Position a steel straightedge on the transaxle
flange.
2. Measure the installation depth between the
2114003
automatic transaxle flange and the torque
converter guide collar.

303-290-13 1
30329013

303-290A-15
15 mm 2
E42950
General Equipment
Transmission jack
Securing straps
Materials
Name Specification TIE0008159
Grease SA-M1C9107-A
3.
CAUTION: The torque converter must
Installation remain at the correct installation depth
during the entire installation.
All vehicles NOTE: Using suitable securing straps and wooden
CAUTION: Make sure that the two dowel blocks, secure the transaxle to the transmission
pins are installed. jack.
2007.50 Focus 3/2007 G420948en

307-01-279 Transmission (4F27E) 307-01-279
INSTALLATION
Using a transmission jack, install the 8. Install the transaxle lower retaining bolts.
transaxle.
48 Nm
E52753
ELE0001540
9.
CAUTION: Make sure that the torque
4. Install the transaxle left-hand retaining bolt.
converter retaining nuts do not fall into the
torque converter housing.
NOTE: Install new torque converter retaining nuts.
Install the torque converter retaining nuts.
48 Nm • Turn the crankshaft to gain access to the
torque converter studs.
36 Nm
E52754
5. Remove the securing straps.

6. Remove the transmission jack.
bolts. ELE0022083
10. Using the special tools, raise the engine

and transaxle assembly.
48 Nm
E52752
E44534
2007.50 Focus 3/2007 G420948en

307-01-280 Transmission (4F27E) 307-01-280
INSTALLATION
12. Install the engine rear mount bracket 16. Connect the output shaft speed (OSS)
(engine rear mount shown removed for sensor electrical connector.
clarity).
80 Nm
ELE0007584
E60965
17. Install the halfshafts. For additional

13. NOTE: Install a new rear engine mount information, refer to: (205-04 Front Drive
retaining bolt. Halfshafts)
Install the engine rear mount retaining bolt. Front Halfshaft LH (Removal and
Installation),
Front Halfshaft RH (Removal and
Installation).
148 Nm
Motor - 2.0L Duratec-HE (MI4)/1.8L
E0037846
80 Nm
80 Nm
TIE0036809
E44534
2007.50 Focus 3/2007 G420948en

307-01-281 Transmission (4F27E) 307-01-281
INSTALLATION
20. Attach the exhaust flexible pipe to the 22. Remove the support wrap or splint.
exhaust hanger insulators.
TIE0014991
TIE39009
23. Install the floor panel brace.

21.
CAUTION: Twisting the exhaust flexible
pipe more than two degrees may cause
damage resulting in failure.
NOTE: Use a pry-bar to prevent the exhaust
flexible pipe from twisting when installing the
catalytic converter to muffler and tailpipe assembly
retaining nuts.
NOTE: Install a new gasket and new retaining nuts. 30 Nm
Attach the exhaust flexible pipe to the muffler
and tailpipe assembly.
E47580
• Coat the catalytic converter studs with
grease.
24. Install the crashbox (if equipped).
1. Install one retaining bolt M10 x 16.
51 Nm 2. Install two retaining bolts M10 x 25.
E60282
2 40 Nm 2
40 Nm
40 Nm 1
E49015
25.
CAUTION: Do not bend or kink the
selector lever cable.
Attach the selector lever cable to the
transaxle.
1. Press the locking pins together and attach
the selector lever cable to the bracket, press
down the locking tab.
2007.50 Focus 3/2007 G420948en

307-01-282 Transmission (4F27E) 307-01-282
INSTALLATION
2. Attach the selector lever cable to the selector 29. Connect the turbine shaft speed (TSS)
mechanism. sensor electrical connector.
E47355 ELE0007583
26. Connect the transmission range (TR) 30.

sensor electrical connector. CAUTION: The automatic transaxle
contains components and assemblies
which are sensitive to electrostatic
charging.
Connect the transaxle central electrical
connector.
E50546
27. Tighten the radiator left-hand retaining

bracket.
• Install the rear retaining bolt.
E50543
31. NOTE: The transmission fluid cooler lines

25 Nm are coloured red (feed line) and black
(return line) to aid installation.
Attach the transmission fluid cooler feed and
return lines to the transaxle.
E50544
E50552
2007.50 Focus 3/2007 G420948en

307-01-283 Transmission (4F27E) 307-01-283
INSTALLATION
32. Install the transaxle upper retaining bolts. 35. Attach the engine and transaxle assembly
central electrical connector to the fluid level
indicator tube retaining bracket.
48 Nm
E52751
E50540
33. Attach the ground cable to the transaxle.
36. Remove the special tools on both sides

25 Nm (right-hand side shown).
E55379
303-290-13
34. Attach the engine and transaxle assembly

TIE0036685
wiring harness to the fluid level indicator
tube retaining bracket.
37. Install the headlamp assembly on both
sides.
38. Adjust the selector lever cable.
For additional information, refer to: Selector
Lever Cable Adjustment (307-05
Automatic Transmission/Transaxle
External Controls - Vehicles With:
E50541
and Installation).
2007.50 Focus 3/2007 G420948en

307-01-284 Transmission (4F27E) 307-01-284
INSTALLATION
40. Install the air cleaner. 45. Install the engine undershield.
Installation).
E40677

47. Reset the transmission tables with
worldwide diagnostic system (WDS).
TIE39686 Vehicles with global closing

42. Fill the transaxle with automatic
transmission fluid. For additional information, refer to: Door
For additional information, refer to: Frames and Mechanisms, General
Transmission Fluid Drain and Refill Procedures).
(307-01 Automatic
E50539
2007.50 Focus 3/2007 G420948en

Transmission/Transaxle Cooling — Vehicles
307-02-1 (4F27E) 307-02-1
.
SECTION 307-02 Transmission/Transaxle Cooling —

(4F27E)
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 307-02-2

Transaxle Cooling............................................................................................................... 307-02-3

Symptom Chart................................................................................................................... 307-02-5

Transmission Fluid Cooler.............................................................................. (17 834 0) 307-02-6
Transmission Fluid Cooler Tubes................................................................... (17 857 0) 307-02-8
307-02-2 (4F27E) 307-02-2
SPECIFICATIONS
Item Specification
Automatic Transmission Fluid WSS-M2C202-B
2007.50 Focus 3/2007 G388141en

307-02-3 (4F27E) 307-02-3
Transaxle Cooling
Transaxle Cooling
3
E61537
Vehicles with 1.6L Item Description

Item Description
3 Transmission fluid cooler outlet tube
1 Transmission fluid cooler
2 Transmission fluid cooler inlet tube
2007.50 Focus 3/2007 G526642en

307-02-4 (4F27E) 307-02-4
E61538
Vehicles with 2.0L

Item Description
1 Transmission fluid cooler
2 Transmission fluid cooler inlet tube
3 Transmission fluid cooler outlet tube
NOTE: The quick release couplings on the

transmission fluid cooler tubes are colored to aid
installation. The transmission fluid cooler inlet tube
quick release couplings are marked red on the
transmission end and yellow on the transmission
fluid cooler end. The transmission fluid cooler outlet
tube quick release couplings are marked black on
the transmission end and blue on the transmission
fluid cooler end.
The transmission fluid cooler is positioned in front
of the engine cooling radiator.
The transmission fluid cooler is connected to the
transmission by means of 2 hose lines with quick
release couplings.
The Transmission fluid cooler cooling circuit does
not have a bypass valve.
2007.50 Focus 3/2007 G526642en

307-02-5 (4F27E) 307-02-5
Transaxle Cooling
Inspection and Verification Do not repair a leak through tightening
more as the required torque in the
1. Verify the customer concern by operating the specification.
transaxle.
2. Visually inspect for obvious signs of mechanical Overview
damage.
Mechanical
1 2
– Feed and return tubes
– Connections to the automatic transaxle and
the automatic transmission fluid cooler
– Automatic transmission fluid level
3
3. If an obvious cause for an observed or reported ELE0008653
Item Part Description
4. If the concern is not visually evident, verify the Number
1 Return tube
CAUTIONS:
2 Feed tube
Do not overtighten cooler line fittings. Case
of fitting damage may result. 3 Transmission Fluid Cooler
Symptom Chart
Symptom Chart
• Loss of automatic transmission • Connections to the automatic • Check the torque of the tubes,
fluid transmission and the automatic if correct, check the condition
transmission fluid cooler. of the tubes and connections.
2007.50 Focus 3/2007 G18033en

307-02-6 (4F27E) 307-02-6
Transmission Fluid Cooler(17 834 0)

Removal CAUTION: Plug the transmission fluid
cooler lines to prevent fluid loss or dirt
All vehicles ingress.
1. Raise and support the vehicle. For additional For additional information, refer to: Health
information, refer to: (100-02 Jacking and and Safety Precautions (100-00 General
Lifting) Information, Description and Operation).
Lifting (Description and Operation). NOTE: The position of the feed line (yellow) and
return line (blue) to the transmission fluid cooler is
2. Remove the engine undershield (if equipped). marked on the connectors.
3. Remove the radiator lower splash shield. Detach the transmission fluid cooler lines
from the transmission fluid cooler.
fluid cooler.
container.
E50539 For additional information, refer to: Health
4. Remove the right-hand and left-hand air
deflector.
1 2
E51251
E49166
6.
Vehicles with 1.6L engine WARNING: When releasing the
5. transmission fluid, take care to prevent
WARNING: When releasing the scalding. Failure to follow this instruction
transmission fluid, take care to prevent may result in personal injury.
may result in personal injury. CAUTION: Plug the transmission fluid
ingress.
2007.50 Focus 3/2007 G402215en

307-02-7 (4F27E) 307-02-7
See - Transmission Fluids. 8. Unclip the transmission fluid cooler on the
right-hand side (headlamp shown removed
NOTE: The position of the feed line (yellow) and
for clarity).
marked on the connectors. • Pull the clip forwards and hold, then pull the
transmission fluid cooler upwards out of the
Detach the transmission fluid cooler lines
bracket.
fluid cooler.
container.
Information, Description and Operation). TIE45231
9. Remove the transmission fluid cooler.
Installation
2. Check the automatic transmission fluid level
and fill if necessary.
1 2 Transmission Fluid Drain and Refill (307-01
E60949 Vehicles With: 4-Speed Automatic
All vehicles Procedures).
7. Unclip the transmission fluid cooler on the

left-hand side (headlamp shown removed for
clarity).
• Pull the clip forwards and hold, then pull the
bracket.
TIE45230
2007.50 Focus 3/2007 G402215en

307-02-8 (4F27E) 307-02-8
Transmission Fluid Cooler Tubes(17 857 0)

Removal CAUTION: Plug the transmission fluid
All vehicles ingress.
1. Raise and support the vehicle. For additional For additional information, refer to: Health
information, refer to: (100-02 Jacking and and Safety Precautions (100-00 General
Lifting) Information, Description and Operation).
Lifting (Description and Operation). NOTE: The position of the feed line (yellow) and
2. Remove the engine undershield (if equipped). marked on the connectors.
3. Remove the radiator lower splash shield. Detach the transmission fluid cooler lines
fluid cooler.
container.
E50539 For additional information, refer to: Health
4. Remove the left-hand air deflector.
1 2
E51251
E51436

6.
5. WARNING: When releasing the
WARNING: When releasing the transmission fluid, take care to prevent
transmission fluid, take care to prevent scalding. Failure to follow this instruction
scalding. Failure to follow this instruction may result in personal injury.
ingress.
2007.50 Focus 3/2007 G402212en

307-02-9 (4F27E) 307-02-9
See - Transmission Fluids. 1. Push the transmission fluid cooler line quick
release connector toward the transmission.
NOTE: The position of the feed line (yellow) and
return line (blue) to the transmission fluid cooler is 2. Press together the retaining tabs and detach
marked on the connectors. the transmission fluid cooler line from the
transmission.
Detach the transmission fluid cooler lines • Allow the fluid to drain into a suitable
from the transmission fluid cooler. container.
1. Push the transmission fluid cooler line quick For additional information, refer to: Health
release connector toward the transmission and Safety Precautions (100-00 General
fluid cooler. Information, Description and Operation).
2. Press together the retaining tabs and detach See - Transmission Fluids.
container.
For additional information, refer to: Health 1 2
E50542
Installation
2. Check the automatic transmission fluid level
1 2 and fill if necessary.
E60949 For additional information, refer to:
Transmission Fluid Drain and Refill (307-01
All vehicles Automatic Transmission/Transaxle -
7. Transmission (4F27E), General
WARNING: When releasing the
transmission fluid, take care to prevent Procedures).
ingress.
NOTE: The position of the feed line (black) and
return line (red) to the transmission is marked on
the connectors.
Remove the transmission fluid cooler lines
from the transmission (fluid cooler lines
shown from above for clarity).
2007.50 Focus 3/2007 G402212en

Automatic Transmission/Transaxle External
Controls — Vehicles With: 4-Speed Automatic
307-05-1 Transmission (4F27E) 307-05-1
.
SECTION 307-05 Automatic Transmission/Transaxle

External Controls — Vehicles With: 4-Speed Automatic
Transmission (4F27E)
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 307-05-2

External Controls................................................................................................................ 307-05-3
Selector lever cable............................................................................................................ 307-05-4
Selector Lever.................................................................................................................... 307-05-4
Function.............................................................................................................................. 307-05-4
Selector lever spring loaded button.................................................................................... 307-05-4

External Controls................................................................................................................ 307-05-5
Symptom Chart................................................................................................................... 307-05-5
Pinpoint Tests..................................................................................................................... 307-05-6
GENERAL PROCEDURES
Selector Lever Cable Adjustment....................................................................................... 307-05-11

Selector Lever Cable.......................................................................................................... 307-05-12
Selector Lever Assembly.................................................................................................... 307-05-15

Selector Lever Assembly.................................................................................................... 307-05-16
307-05-2 Transmission (4F27E) 307-05-2
SPECIFICATIONS
Tightening Torques
Item Nm lb-ft lb-in
Selector lever cable nuts 9 - 80
Bolts - centre console reinforcing elements 25 18 -
Bolts - selector mechanism assembly 9 - 80
Selector lever knob bolt 1,5 - 13
2007.50 Focus 3/2007 G388291en

307-05-3 Transmission (4F27E) 307-05-3
External Controls
Overview
E55728

Number
1 Selector lever cable - transaxle
end
2 Gearshift cable bushing
retaining nuts
3 Selector lever cable - selector
lever end
2007.50 Focus 3/2007 G428581en

307-05-4 Transmission (4F27E) 307-05-4
Selector lever cable When the ignition is switched on, the selector lever
shift lock solenoid is actuated by depressing the
– The selector lever adjustment mechanism is brake pedal (signal from the stoplamp switch). This
connected to the transaxle selector lever pin, retracts the locking pin so that the selector lever
which is located above the transmission range can be moved out of position "P" (PARK).
(TR) sensor.
– The cable abutments are secured firstly to the Function
transaxle housing and secondly to the selector
lever bracket. – NOTE: If "P" (PARK) is selected again the
– The selector lever cable adjustment mechanism selector lever is locked.
is Locked at the transaxle end of the selector
lever cable. If the brake signal should fail due to a
malfunction, the selector lever can be manually
– At the selector lever end the cable is clipped unlocked as follows:
onto a pin.
– The cover of the release mechanism must be
– Adjustment is required if the transaxle or the opened and a suitable object (ignition key)
selector lever has been removed, if the engine pressed into the opening until the selector lever
does not start in "P" (PARK) or "N" (NEUTRAL), can be moved out of position "P" (PARK).
in cases of shift quality concerns, or if the switch
catches are incorrect.
Selector lever spring loaded button
– To move the selector lever from the "P" (PARK)
position, the ignition lock must be set to "II", the
brake pedal must be depressed and shift
release button pressed in.
– The spring loaded button must also be pressed.
ELE0008134
To adjust the selector lever cable, the selector lever

must be in position "D" (DRIVE).
– The selector lever cable must not be stressed.
The selector lever cable must be free from
binding.
The selector lever cable adjustment mechanism is
locked by pressing the selector lever mechanism
locking clip fully, after making sure that the shift
mechanism is in "D" (DRIVE).
For additional information, refer to: Selector Lever
Cable Adjustment (307-05 Automatic
(4F27E), General Procedures).
Selector Lever
Location
The selector lever shift lock solenoid is located in
the selector lever bracket.
2007.50 Focus 3/2007 G428581en

307-05-5 Transmission (4F27E) 307-05-5
External Controls
WARNING: Danger of accident. Apply the before proceeding to the next step.
parking brake. Shift the transaxle to "P". 4. If the concern is not visually evident, verify the
Failure to follow these instructions may symptom and refer to the Symptom Chart.
Because fault diagnosis starts as soon as the
vehicle is taken in for repair we recommend the Mechanical Electrical
following procedure: – Visibly damaged or – Fuse.
1. Verify the customer concern by operating the worn parts. – Wiring harness.
system. – Loose or missing – Loose or corroded
2. Visually inspect for obvious signs of mechanical nuts or bolts. connector(s).
Symptom Chart
Symptom Chart
• The shift interlock system does • Damaged brake shift interlock • GO to Pinpoint Test A.
not release/lock properly/is actuator.
blocked • Circuitry open/shorted.
• Damaged brake pedal position
(BPP) switch.
• Damaged selector lever.
• The shift interlock system is • Circuitry shorted. • GO to Pinpoint Test A.
blocked or not operating • Park interlock solenoid
sticking/defect.
• Selector lever damaged. • REPAIR selector lever.
• The shift control is out of proper • Shift linkage out of adjustment. • ADJUST linkage/selector lever
gear relationship cable.
• It is impossible to get gearshift • Linkage/selector lever cable out • ADJUST linkage/selector lever
lever into position "P" or "1". of adjustment. cable.
• Selector lever defect (mechan- • REPAIR selector lever.
ical).
2007.50 Focus 3/2007 G18039en

307-05-6 Transmission (4F27E) 307-05-6
Pinpoint Tests
PINPOINT TEST A : THE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK PROPERLY/IS
BLOCKED
A1: CHECK IF STOPLAMPS LIGHT
1 Switch ON ignition. Depress brake pedal.
• Are the stoplamps ON?
→ Yes
GO to A3.
→ No
GO to A2.
A2: CHECK FUSE 54 IN CJB
2 CHECK F54 (15 A).
• Is fuse F54 OK?
→ Yes
REFER to Section 417-01 [Exterior Lighting].
→ No
INSTALL a new fuse. RECHECK system, if
fuse fails again. REFER to Section 417-01
[Exterior Lighting].
A3: CHECK KEY REMOVAL INHIBIT CIRCUIT
1 Turn ignition ON, gear selection in "P" (PARK)
position.
• Can ignition switch be turned into position "0"
and can key be removed only when gear
selector in "P"?
→ Yes
GO to A4.
→ No
GO to A8.
A4: CHECK VOLTAGE TO PARK INTERLOCK SOLENOID
1 Disconnect Gearshift lever unit (C931).
2007.50 Focus 3/2007 G18039en

307-05-7 Transmission (4F27E) 307-05-7

2 Measure the voltage between C931 pin 3
(GN/WH) and ground.
• Is the voltage 0 V when brake pedal is not
1 4 V depressed, and is battery voltage indicated
when brake pedal is depressed?
+ -
→ Yes
GO to A5.
36
→ No
REPAIR circuit 15S-TA33 between C444
ELE0009741
(stoplamp switch), Pin 1 and C931, pin 3 for
open.
A5: CHECK GROUND TO PARK INTERLOCK SOLENOID

1 Measure resistance between C931, pin 1 (BK)
and ground.
• Is resistance less than 5 ohms?
1 4
→ Yes
GO to A6.
- +
→ No
36 REPAIR circuit 31-TA34 between C931, pin
1 and ground for open.
ELE0009742
A6: CHECK SELECTOR LEVER CIRCUIT

1 Measure resistance at the connector of the
gearshift lever unit (C931), between pins 3 and
1. Gearshift lever in position "P".
• Is resistance between 20 ohms and 35 ohms?
→ Yes
GO to A7.
→ No
REPLACE park interlock solenoid.
2007.50 Focus 3/2007 G18039en

307-05-8 Transmission (4F27E) 307-05-8

A7: CHECK FUNCTION OF PARK INTERLOCK SOLENOID
1 Position gearshift lever into positions "R", "N",
"D", "1" and "2".
– If necessary, release mechanically as
described in this section.
• Is resistance greater than 10 ohms in all
mentioned positions?
→ Yes
Park interlock solenoid is electrically OK,
CHECK for mechanical fault.
→ No
REPLACE park interlock solenoid.
A8: CHECK FUSE F8 IN CJB
1 CHECK F8 (30 A).
• Is the fuse F8 OK?
→ Yes
GO to A9.
→ No
INSTALL a new fuse. RECHECK the system.
A9: CHECK PARK INTERLOCK SWITCH
1 Disconnect Gearshift lever unit (C931).
2 Connect a jumper wire between C931, pin 2
(BK/YE) and ground.
– Be sure that only pin 2 and not another pin is
grounded.
• Can ignition key be removed when jumper wire
is connected?
→ Yes
GO to A10.
→ No
GO to A11.
2007.50 Focus 3/2007 G18039en

307-05-9 Transmission (4F27E) 307-05-9

A10: CHECK GROUND TO SELECTOR LEVER UNIT
1 Measure resistance between C931, pin 1 (BK)
and ground.
• Is resistance less than 5 ohms?
1 4
→ Yes
REPLACE the gearshift lever unit.
- +
→ No
36 REPAIR circuit 31-TA34 between C931, pin
1 and ground for open.
ELE0009742
A11: CHECK VOLTAGE AT FUSE F8

1 Measure voltage at fuse F8 (30A).
• Is battery voltage indicated?
→ Yes
GO to A12.
→ No
REPAIR supply circuit to F8 for open.
A12: CHECK VOLTAGE AT IGNITION SWITCH
1 Disconnect Ignition switch (C456).
2 Measure the voltage between C456, pin 4 (RD)
and ground.
7 • Is battery voltage indicated?

V → Yes
+ - GO to A13.
→ No
REPAIR circuit between fuse F8 (30 A) and
1 C456, pin 4 for open.
ELE0009743
2007.50 Focus 3/2007 G18039en

307-05-10 Transmission (4F27E) 307-05-10

A13: CHECK CIRCUIT 31S-TA34
1 Measure resistance between C456, pin 3
(BK/WH) and C931, pin 2 (BK/YE).
7 • Is resistance less than 1 ohm?

1 4
→ Yes
Key removal inhibit solenoid within the ignition
switch is damaged. REPLACE the ignition
switch. REFER to Section 211-05 [Steering
36 Column Switches].
1
- +
→ No
ELE0009036 REPAIR circuit 31S-TA34 between C456, pin
3 and C931, pin 2 for open.
2007.50 Focus 3/2007 G18039en

307-05-11 Transmission (4F27E) 307-05-11
GENERAL PROCEDURES
Selector Lever Cable Adjustment

Adjustment Press in the selector lever cable adjustment
mechanism locking clip fully.
1. Shift the selector lever to the "D" (DRIVE)
position.
and Operation).
4. Release the selector lever cable adjustment
mechanism locking clip.
E47698
7. Install the engine undershield (if equipped).

9. Start the engine and move the selector lever
through all the gear positions. Wait until each
gear engages when moving through the gear
positions.
10. Check that the selector lever position
E47697
indicator corresponds to the position of the
selector lever, repeat the adjustment
5. NOTE: The transmission range (TR) sensor procedure if necessary.
mark must be inline with the transaxle
selector lever. 11. Move the selector lever into the "P" (PARK)
position and switch off the engine.
Move the transaxle selector lever to the "D"
(DRIVE) position (TR sensor shown removed
for clarity).
ELE0008134
6. NOTE: Ensure that the selector lever cable

adjustment mechanism is locked.
2007.50 Focus 3/2007 G402252en

307-05-12 Transmission (4F27E) 307-05-12

3. Remove the center console reinforcing
1. Remove the center console.
element right-hand bracket.
• Detach the wiring harness bracket from the
Floor Console (501-12 Instrument Panel
center console reinforcing element bracket.
and Console, Removal and Installation).

element left-hand bracket.
25 Nm
TIE44891
25 Nm
TIE44890 table(s).
2
3 9 Nm
E51418
2007.50 Focus 3/2007 G402253en

307-05-13 Transmission (4F27E) 307-05-13
1 Transmission-side selector lever cable 6. Adjust the selector lever cable.

See Removal Detail For additional information, refer to:
Selector Lever Cable Adjustment (307-05A
2 Selector lever-side selector lever cable
See Removal Detail
Controls - Vehicles With: 4-Speed
3 Selector lever cable nuts Automatic Transmission (4F27E), General
See Removal Detail Procedures).
Removal Details
Item 1 Transmission-side selector lever cable 2. Lift the locking tab, press the locking pins
from the abutment.
2. Remove the engine undershield (if fitted).
2 1
3.
CAUTION: Do not kink the selector lever
cable.
Detach the selector lever cable from the
transmission.
selector mechanism. E51419
together and detach the selector lever cable Item 3 Selector lever cable nuts
from the abutment.
2 For additional information, refer to:
2. Remove the front heat shield.
Item 2 Selector lever-side selector lever cable

2.
CAUTION: Do not kink the selector lever TIE44826
cable.
Detach the selector lever cable from the 3.
selector lever. CAUTION: Do not kink the selector lever
cable.
selector lever.
2007.50 Focus 3/2007 G402253en

307-05-14 Transmission (4F27E) 307-05-14
Detach the selector lever cable from the clip.
TIE44897
4.
cable.
Remove the selector lever cable from the
bracket.
E51417

6.
cable.
Remove the selector lever cable.
• Discard the selector lever cable nuts.
TIE44898
2007.50 Focus 3/2007 G402253en

307-05-15 Transmission (4F27E) 307-05-15
Selector Lever Assembly

Removal
4. Remove the selector lever assembly.
1. Remove the floor console.
For additional information, refer to: Floor
Console - 3-Door (501-12 Instrument Panel
2.
Detach the selector lever cable from the 9 Nm
selector lever and cable bracket.
selector lever.
together and detach the selector lever cable E51564
from the cable bracket.
Installation
1 2. Adjust the selector lever cable.
2
For additional information, refer to: Selector
Lever Cable Adjustment (307-05 Automatic
Transmission/Transaxle External Controls
- Vehicles With: 4-Speed Automatic
Procedures).
E51419
3. Disconnect the selector lever assembly

E51563
2007.50 Focus 3/2007 G402298en

307-05-16 Transmission (4F27E) 307-05-16
Selector Lever Assembly

Disassembly
1. Disconnect the connector for the selector
1. Remove the selector lever knob.
lever lock solenoid.
• Remove the bolt. 2. Detach the ignition key interlock switch from
the gear selector housing.
3. Detach the selector lever central connector
from the gear selector housing.
1.5 Nm • Unhook the selector lever unit cable from the
cable guide.
1
E51742
3
2. Pull out the plunger and spring of the
selector lever lock.
E53658
5. Remove the cover for the manual selector

lever lock.
• Press down the retaining clip of the manual
selector lever lock cover until the cover of
the manual selector lever lock can be pulled
out.
E51743
3. Unclip the selector lever unit bezel from the

selector lever unit (six clips).
E53551
6. NOTE: Solenoid - gear selector cover plate

faces upwards.
E53550
4. Remove the selector lever unit bezel.
2007.50 Focus 3/2007 G402256en

307-05-17 Transmission (4F27E) 307-05-17
Remove the selector lever bezel.
E51748
Assembly
1.
CAUTION: Check that the cable of the
selector lever unit is in the correct
installation position.
NOTE: Apply thread locking compound to the bolt
of the selector lever knob.
To assemble, reverse the disassembly
procedure.
2007.50 Focus 3/2007 G402256en

Manual Transmission/Transaxle and Clutch -
.
SECTION 308-00 Manual Transmission/Transaxle and

Clutch - General Information
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 308-00-2
Clutch ............................................................................................................................. 308-00-2

Manual Transaxle and Clutch............................................................................................. 308-00-3
Principles of Operation....................................................................................................... 308-00-3
Inspection and Checking.................................................................................................... 308-00-3
Inspection and Verification - Manual Transmission............................................................ 308-00-3
Gear Shifting Concerns...................................................................................................... 308-00-3
Transmission Noise Concerns............................................................................................ 308-00-3
Fluid Leakage Concerns..................................................................................................... 308-00-3
Symptom Chart - General Concerns.................................................................................. 308-00-4
Symptom Chart - Transmission Noises.............................................................................. 308-00-7
Symptom Chart - Fluid Leakage......................................................................................... 308-00-11
Symptom Chart - Clutch..................................................................................................... 308-00-12
System Check.................................................................................................................... 308-00-12
GENERAL PROCEDURES
Clutch System Bleeding................................................................................. (16 843 0) 308-00-25
Gearshift Cable Adjustment — Vehicles With: 5-Speed Manual Transmission
(iB5).............................................................................................................. (16 513 0) 308-00-27
(MTX-75)....................................................................................................... (16 513 0) 308-00-29
(F35M-R)...................................................................................................... (16 513 0) 308-00-31
SPECIFICATIONS
Lubricants, Sealers and Adhesives
Item Specification
Transmission fluid WSD-M2C200-C
High-temperature grease ESD-M1C220-A
Super DOT4 brake fluid ESD-M6C57-A
Filling Capacities
Liters
iB5 manual transmission (5 - 10 mm below lower edge of check hole) 2.3
MTX -75 manual transmission (0 - 5 mm below lower edge of check hole) 1.9
MMT6 manual transmission (0 - 5 mm below lower edge of check hole) 1.75
Clutch
Description mm
Clutch pedal travel - MTX-75 manual transmission 135 ± 3
Clutch pedal travel - MMT6 manual transmission 140 ± 3
Tightening Torques
Clutch bleed nipple - iB5 manual transmission 5 - 44
Clutch bleed nipple - MTX-75 manual transmission 5 - 44
Clutch bleed nipple - MMT6 manual transmission 5 - 44
2007.50 Focus 5/2007 G402257en

Manual Transaxle and Clutch

Principles of Operation
Gear Shifting Concerns
Inspection and Checking
• Clutch does not operate correctly
1. Verify the customer concern. • External shift mechanism.
2. Visually check for any obvious mechanical or REFER to: External Controls (308-06 Manual
electrical damage. Transmission/Transaxle External Controls -
3. If an obvious cause for an observed or reported Vehicles With: 5-Speed Manual Transmission
concern is found, correct the cause (if possible) (iB5), Diagnosis and Testing)
before proceeding to the next step. / External Controls (308-06 Manual
4. If the concern persists, check the symptoms
Vehicles With: 5-Speed Manual Transmission
and proceed according to WDS instructions.
(MTX-75), Diagnosis and Testing)
/ External Controls - Vehicles With: 6-Speed
Inspection and Verification - Manual Manual Transmission (MMT6) (308-06 Manual
Transmission Transmission/Transaxle External Controls -
The following checks should be carried out before (MMT6), Diagnosis and Testing)
repairing or installing a new transmission. / External Controls (308-06D Manual
Inspection and checking for vehicles with manual
transmission can be divided into three main areas.
(F35M-R), Diagnosis and Testing).
Transmission Noise Concerns

• Check the engine and transmission mountings
for sufficient clearance to the transmission and
the body.
• Any other noise excluding shift noises.
Fluid Leakage Concerns

• Check that the leaking fluid is actually
transmission fluid and not hydraulic fluid (from
the hydraulically-operated clutch) or engine oil.
• Check the transmission fluid level. If necessary,
drain off any excess fluid.
• Locate the fluid leak with the aid of a fluorescent
tracer dye and an ultraviolet inspection lamp.
• Clean the transmission and the adjacent areas
thoroughly before road testing.
2007.50 Focus 5/2007 G426304en

Symptom Chart - General Concerns

• High-effort gear shifting in one • Synchronizer ring or synchron- • RENEW the synchronizer hub
or more gears ization damaged with synchronizer ring set and,
if necessary, the relevant gear
wheel.
Because of various modifications
and the difficulty in estimating the
degree of wear, replacement of
the complete unit (as described
above) is recommended.
• Clutch does not operate • CHECK the clutch function and
correctly the brake fluid level.
• Internal gearshift mechanism. • Remove the internal gearshift
mechanism and check the
components. If necessary,
RENEW.
• Rattling or scratching noise • Synchronizer hub or synchron- • RENEW the synchronizer hub
during gear shifting izer ring damaged with synchronizer ring set and,
if necessary, the relevant gear
wheel.
Because of various modifications
and the difficulty in estimating the
degree of wear, replacement of
the complete unit (as described
above) is recommended.
• Clutch does not operate • CHECK the clutch function and
correctly. the brake fluid level.
2007.50 Focus 5/2007 G426304en


• Gear engagement not func- • External gearshift mechanism • CHECK the external gearshift
tioning correctly damaged mechanism for damage. If no
concern is determined,
REMOVE the transmission.
REFER to: Transaxle - 1.4L
Duratec-16V (Sigma) (308-
03A, Removal)
/ Transaxle - 1.8L Duratec-HE
(MI4) (308-03A Manual
Manual Transaxle (iB5),
Removal)
(MI4) (308-03B Manual
Manual Transaxle (MTX-75),
Removal)
/ Transaxle - 1.6L Duratorq-
TDCi (DV) Diesel (308-03B
Manual Transmis-
With: 5-Speed Manual
Transaxle (MTX-75),
Removal)
TDCi (DW) Diesel (308-03C
Manual Transmis-
Transaxle (MMT6), Removal)
/ Transaxle (308-03D Manual
Manual Transaxle (F35M-R),
Removal).
• Gear jumps out of engagement • Missing snap rings; synchroniz- • RENEW gear wheels,
while driving ation components damaged or synchronizer and selector fork
worn clutch splines as necessary. CHECK the
transmission for damage,
particularly to the sliding
sleeve.
• Incorrect sliding sleeve; worn • RENEW gear wheels,
clutch splines synchronizer and selector fork
as necessary. CHECK the
transmission for damage,
particularly to the sliding
sleeve.
2007.50 Focus 5/2007 G426304en


• Selector forks • RENEW gear wheels, sliding
sleeves and selector forks as
necessary. CHECK the trans-
mission for damage, particu-
larly to the sliding sleeve.
• Gear lever feels loose • Gear lever mounting • Check the external gearshift
mechanism; replace if neces-
sary. Check gear lever
mounting, external gearshift
mechanism and shift cables;
tighten if necessary.
REFER to: External Controls
(308-06 Manual Transmis-
sion/Transaxle External
Controls - Vehicles With: 5-
Speed Manual Transmission
(iB5), Diagnosis and Testing)
/ External Controls (308-06
Manual Transmis-
(MTX-75), Diagnosis and
Testing)
/ External Controls - Vehicles
Transmission (MMT6) (308-
06 Manual Transmis-
(MMT6), Diagnosis and
Testing)
/ External Controls (308-06D
Manual Transmis-
Speed Manual Transaxle
(F35M-R), Diagnosis and
Testing).
• Internal shift mechanism • Check the internal shift mech-
anism for play at the transmis-
sion.
2007.50 Focus 5/2007 G426304en

Symptom Chart - Transmission Noises

• Gear wheels grating when • Clutch worn • Check clutch
shifting • REFER to: Clutch Disc and
Pressure Plate (308-01A
Clutch - Vehicles With: 5-
(iB5), Removal and Installa-
tion)
/ Clutch Disc and Pressure
Plate (308-01B Clutch -
Plate (308-01C Clutch -
Manual Transaxle (MMT6),
Plate (308-01D Clutch -
• Air in the clutch system; fluid • Check clutch system for leaks;
loss bleed the clutch system.
REFER to: Clutch System
Bleeding (308-00 Manual
Transmission/Transaxle and
Clutch - General Information,
• Slight buzzing, rattling or • Rotational vibration from the • These noises do not affect the
metallic scraping noise from the engine not sufficiently damped operation and service life of the
transmission at 2500 to 3500 by the clutch. transmission.
rpm when on overrun or driving
without load (particularly in 2nd
and 3rd gear)
2007.50 Focus 5/2007 G426304en


• Engine speed-dependent • CHECK transmission input
transmission noise shaft bearings. REMOVE the
transmission.
03A, Removal)
Removal)
Removal)
Manual Transmis-
Transaxle (MTX-75),
Removal)
Manual Transmis-
Removal).
• Vehicle speed-dependent • CHECK driveshaft tripode
transmission noise joints.
• Steering angle-dependent • CHECK differential splines for
transmission noise damage. Turn the differential
bevel gears against one
another. For this purpose,
REMOVE the halfshafts.
REFER to: Halfshaft LH (205-
04 Front Drive Halfshafts,
/ Intermediate Shaft (205-04
Front Drive Halfshafts,
2007.50 Focus 5/2007 G426304en


• The engine/transmission • Visually inspect for evidence of
assembly is in contact with the contact and REPAIR as
body necessary.
• Engine/transmission washer- • TIGHTEN the transmission
head bolts retaining bolts.
03A, Installation)
Installation)
Installation)
Manual Transmis-
Transaxle (MTX-75), Installa-
tion)
Manual Transmis-
Transaxle (MMT6), Installa-
tion)
Installation).
• Transmission fluid level too • Check the transmission fluid
low. level.
00 Manual Transmis-
Specifications).
2007.50 Focus 5/2007 G426304en


• Transmission bearings and • REMOVE the transmission.
gear wheels (usually on high- CHECK the transmission bear-
mileage vehicles) ings and gear wheels and
RENEW as necessary.
03A, Removal)
Removal)
Removal)
Manual Transmis-
Transaxle (MTX-75),
Removal)
Manual Transmis-
Removal).
2007.50 Focus 5/2007 G426304en


• Rattling noises or vibration • External gearshift mechanism • CHECK the external gearshift
mechanism.
REFER to: External Controls
(308-06 Manual Transmis-
(iB5), Diagnosis and Testing)
/ External Controls (308-06
Manual Transmis-
(MTX-75), Diagnosis and
Testing)
/ External Controls - Vehicles
Transmission (MMT6) (308-
06 Manual Transmis-
(MMT6), Diagnosis and
Testing)
/ External Controls (308-06D
Manual Transmis-
(F35M-R), Diagnosis and
Testing).
• Engine front and rear mounting • CHECK engine front and rear
defective mounting; RENEW if neces-
sary.
Symptom Chart - Fluid Leakage

• Fluid leakage • Oil seals or O-rings • CHECK the mating surfaces
and INSTALL a new gasket.
• Fluid leak between the clutch- • DISMANTLE the transmission
side and transmission-side and clean the mating surfaces.
housing halves. CHECK the mating surfaces for
damage. Seal the transmission
using WSK-M2G348-A5 sealer.
• Fluid leak at transmission • Tighten transmission housing
housing bolt bolts to specified tightening
torque.
2007.50 Focus 5/2007 G426304en

Symptom Chart - Clutch

• Clutch slips • No clutch pedal free play • GO to Pinpoint Test A.
• Clutch Belleville springs broken
• Clutch disc facing broken
• Hardened or oil-contaminated
clutch disc facing
• Clutch juddering • Engine mounting defective • GO to Pinpoint Test B.
• Tilted clutch disc
• Clutch disengages too late or • Insufficient brake fluid • GO to Pinpoint Test C.
not at all; high-effort gear • Air in hydraulic system
shifting • Excessive clutch pedal free
play
• Clutch Belleville springs broken
• Clutch disc deformed or broken
• Clutch disc splines corroded
• Clutch pedal pulsating • Non-uniform Belleville spring • GO to Pinpoint Test D.
fingers
• Frequency modulator defective
(if present)
• Excessive noise • Release bearing defective • GO to Pinpoint Test E.
• Input shaft pilot bearing
• Excessive crankshaft end float
• Fluid leakage • Clutch master cylinder • GO to Pinpoint Test F.
• Clutch slave cylinder
• Hydraulic lines in area of
engine and transmission
System Check
PINPOINT TEST A : CLUTCH SLIPS
A1: CHECK THE CLUTCH FOR SLIPPAGE
1 Chock the wheels and apply the parking brake.
3 Start the engine, depress the clutch pedal and
engage 4th gear.
4 Run the engine at approx. 2000 rpm.
2007.50 Focus 5/2007 G426304en


5 Release the clutch pedal slowly.
• Does the engine stall when the clutch pedal is
fully released?
→ Yes
Clutch OK.
→ No
GO to A2.
A2: CHECK THE CLUTCH PEDAL FREE PLAY
1 Measure the clutch pedal free play.
2 Depress the clutch pedal manually to the point
of resistance and release, record clutch pedal
travel.
• Is the travel within 10 mm?
→ Yes
Clutch pedal free play OK.
→ No
GO to A3.
2007.50 Focus 5/2007 G426304en


A3: CHECK THE CLUTCH BELLEVILLE SPRINGS
1 REMOVE the transmission. CHECK the clutch
Belleville springs.
REFER to: Transaxle - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma) (308-03A,
Removal)
/ Transaxle - 1.8L Duratec-HE (MI4) (308-03A
Manual Transmission/Transaxle - Vehicles
With: 5-Speed Manual Transaxle (iB5),
Removal)
/ Transaxle - 2.0L Duratec-HE (MI4) (308-03B
With: 5-Speed Manual Transaxle (MTX-75),
Removal)
/ Transaxle - 1.6L Duratorq-TDCi (DV) Diesel
(308-03B Manual Transmission/Transaxle -
(MTX-75), Removal)
/ Transaxle - 2.0L Duratorq-TDCi (DW) Diesel
(308-03C Manual Transmission/Transaxle -
(MMT6), Removal)
/ Transaxle (308-03D Manual Transmis-
sion/Transaxle - Vehicles With: 5-Speed
Manual Transaxle (F35M-R), Removal).
• Are clutch Belleville springs broken?
→ Yes
REPLACE the clutch pressure plate.
→ No
GO to A4.
2007.50 Focus 5/2007 G426304en


A4: CHECK THE CLUTCH DISC
1 Remove the clutch disc and clutch pressure
plate.
REFER to: Clutch Disc and Pressure Plate (308-
01A Clutch - Vehicles With: 5-Speed Manual
Transaxle (iB5), Removal and Installation)
/ Clutch Disc and Pressure Plate (308-01B
Transaxle (MTX-75), Removal and Installation)
/ Clutch Disc and Pressure Plate (308-01C
Transaxle (MMT6), Removal and Installation)
/ Clutch Disc and Pressure Plate (308-01D
Transaxle (F35M-R), Removal and Installa-
tion).
• Is the clutch disc or the clutch pressure plate
broken, contaminated with oil or hardened?
→ Yes
CHECK the engine and transmission for leaks.
REFER to: Engine (303-00 Engine System -
General Information, Diagnosis and Testing).
RENEW the clutch pressure plate and the
clutch disc.
→ No
CHECK the operation of the system.
PINPOINT TEST B : CLUTCH JUDDERING

B1: CHECK FOR CLUTCH JUDDER
2 Start the engine, depress the clutch pedal and
engage 1st gear.
3 Run the engine at between 1200 and 1500 rpm.
4 Release the clutch pedal slowly.
• Does the vehicle judder when it starts off?
→ Yes
GO to B2.
→ No
Clutch OK.
2007.50 Focus 5/2007 G426304en


B2: CHECK ENGINE/TRANSMISSION MOUNTINGS AND ROLL RESISTOR
1 Check the engine/transmission mountings and
roll resistor for damage or loose bolted connec-
tions.
• Are the engine/transmission mountings or roll
restrictor loose or damaged?
→ Yes
TIGHTEN the bolts or REPLACE as neces-
sary. CHECK the operation of the system.
→ No
GO to B3.
B3: CHECK THE CLUTCH PRESSURE PLATE
1 Remove the clutch pressure plate.
tion).
• Does the clutch pressure plate show signs of
wear or damage?
→ Yes
→ No
GO to B4.
B4: CHECK THE CLUTCH DISC
1 CHECK the clutch disc.
• Does the clutch disc show evidence of damage
due to tilting?
→ Yes
REPLACE the clutch disc.
→ No
CHECK the flywheel.
REFER to: Flywheel Inspection (303-00
Engine System - General Information,
2007.50 Focus 5/2007 G426304en

PINPOINT TEST C : CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
C1: CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
1 Bleed the clutch system.
REFER to: Clutch System Bleeding (308-00
• Does the clutch show improved disengaging
characteristics following bleeding of the
system?
→ Yes
Clutch OK.
→ No
GO to C2.
C2: CHECK THE BRAKE FLUID LEVEL
1 Check the brake fluid level.
• Is the brake fluid level in the reservoir between
the MAX and MIN marks?
→ Yes
GO to C3.
→ No
Top up the brake fluid, CHECK the brake and
clutch systems for leaks.
C3: CHECK THE CLUTCH PEDAL FREE PLAY
1 Measure the clutch pedal free play.
2007.50 Focus 5/2007 G426304en


2 Depress the clutch pedal until resistance is felt,
then release it again.
• Is the travel within 10 mm?
→ Yes
GO to C4.
→ No
CHECK that the clutch pedal moves freely;
remove if necessary.
REFER to: Clutch Master Cylinder (308-02A
Clutch Controls - Vehicles With: 5-Speed
Manual Transaxle (iB5), Removal and
Installation)
/ Clutch Master Cylinder (308-02 Clutch
Controls - Vehicles With: 5-Speed Manual
Installation)
/ Clutch Master Cylinder (308-02D Clutch
tion).
2007.50 Focus 5/2007 G426304en


C4: CHECK THE CLUTCH BELLEVILLE SPRINGS
1 Remove the transmission; CHECK clutch
Belleville springs.
Removal)
Removal)
Removal)
(MTX-75), Removal)
(MMT6), Removal)
• Are clutch Belleville springs broken?
→ Yes
REFER to: Clutch Disc and Pressure Plate
(308-01A Clutch - Vehicles With: 5-Speed
Installation)
Transaxle (MTX-75), Removal and Installa-
tion)
Transaxle (MMT6), Removal and Installa-
tion)
tion).
→ No
GO to C5.
2007.50 Focus 5/2007 G426304en


C5: CHECK THE CLUTCH DISC
1 Remove the clutch disc.
tion).
• Is the clutch disc deformed or broken?
→ Yes
RENEW the clutch disc.
→ No
GO to C6.
C6: CHECK THE CLUTCH DISC SPLINES
1 CHECK clutch disc splines for corrosion.
• Are the clutch disc splines corroded?
→ Yes
RENEW the clutch disc.
→ No
Check the transmission input shaft for damage
or corrosion.
2007.50 Focus 5/2007 G426304en

PINPOINT TEST D : CLUTCH PEDAL PULSATING
D1: CHECK THE BELLEVILLE SPRING FINGERS FOR UNIFORMITY
1 REMOVE the transmission.
Removal)
Removal)
Removal)
(MTX-75), Removal)
(MMT6), Removal)
CHECK the Belleville spring fingers for
uniformity.
• Are the Belleville spring fingers uniform?
→ Yes
Check the frequency modulator and RENEW
if necessary (if present)
→ No
REFER to: Clutch Disc and Pressure Plate
(308-01A Clutch - Vehicles With: 5-Speed
Installation)
tion)
tion)
tion).
2007.50 Focus 5/2007 G426304en

PINPOINT TEST E : EXCESSIVE NOISE
E1: CHECK THE TRANSMISSION IN NEUTRAL
2 Start the engine.
3 Depress the clutch pedal fully.
• Is noise audible when the clutch is operated?
→ Yes
GO to E2.
→ No
The transmission is the cause of the concern.
REFER to Symptom Chart(s).
E2: CHECK THE CLUTCH RELEASE BEARING
1 Remove the clutch slave cylinder/release
bearing assembly.
REFER to: Clutch Slave Cylinder (308-02A
Manual Transaxle (iB5), Removal and Install-
ation)
/ Clutch Slave Cylinder (308-02B Clutch
/ Clutch Slave Cylinder (308-02C Clutch
/ Clutch Slave Cylinder (308-02D Clutch
tion).
2 Check the release bearing for wear and corro-
sion.
• Are there signs of wear or corrosion?
→ Yes
REPLACE the release bearing.
→ No
CHECK the crankshaft for excessive end float.
REFER to: Crankshaft End Play (303-00
Engine System - General Information,
2007.50 Focus 5/2007 G426304en

PINPOINT TEST F : FLUID LEAKAGE
F1: CHECK THE CLUTCH SLAVE CYLINDER
1 Check the clutch master cylinder for leaks.
• Is the clutch master cylinder OK?
→ Yes
GO to F2.
→ No
RENEW the clutch master cylinder.
REFER to: Clutch Master Cylinder (308-02A
Installation)
/ Clutch Master Cylinder (308-02 Clutch
Installation)
/ Clutch Master Cylinder (308-02D Clutch
tion).
F2: CHECK THE CLUTCH SLAVE CYLINDER
1 Check the clutch slave cylinder for leaks.
• Is the clutch slave cylinder OK?
→ Yes
GO to F3.
→ No
REPLACE the clutch slave cylinder.
REFER to: Clutch Slave Cylinder (308-02A
Installation)
/ Clutch Slave Cylinder (308-02B Clutch
tion)
/ Clutch Slave Cylinder (308-02C Clutch
tion)
/ Clutch Slave Cylinder (308-02D Clutch
tion).
2007.50 Focus 5/2007 G426304en


F3: CHECK THE HYDRAULIC PIPES
1 Check the hydraulic lines in area of engine and
transmission for loose or damaged unions.
• Are the hydraulic lines OK?
→ Yes
PERFORM a road test to verify the customer
concern.
→ No
REPAIR or REPLACE components as
necessary. PERFORM road test.
2007.50 Focus 5/2007 G426304en

GENERAL PROCEDURES
Clutch System Bleeding(16 843 0)

Special Tool(s) 5. Raise and support the vehicle, if necessary.
Hand Vacuum
Section 100-02 [Jacking and Lifting].
Pump/Pressure Pump
416-D001 (23-036A) 6. Fill the reservoir of the special tool with
approximately 100 ml of new brake fluid.
7. NOTE: Make sure that the special tool
23036A
reservoir is positioned lower than the bleed
nipple.
Materials
Name Specification
Super DOT 4 Brake ESD-M6C57-A
Fluid
WARNING: Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with 416-D001
the eyes. Wash hands thoroughly after
flush the eyes for 15 minutes with cold
running water. Get medical attention if
irritation persists. If taken internally, drink TIE0005266
water and induce vomiting. Get medical
attention immediately. Failure to follow
these instructions may result in personal 8. Using the special tool, bleed the clutch
injury. system.
CAUTION: If brake fluid is spilt on the • Pump approximately 80 ml of brake fluid into
paintwork, the affected area must be the clutch system.
immediately washed down with cold water. 9. Close the bleed nipple.
NOTE: If proprietary brake bleeding equipment is 10. Remove the special tool.
available, this can be used to bleed the clutch
system, following the method below. The maximum 11. Lower the vehicle, if necessary.
pressure must not exceed 1.5 bar. 12. In order to remove any small amounts of
NOTE: The clutch control system is self-venting. trapped air remaining in the system,
The components are arranged in such a way that operate the clutch pedal several times
small amounts of air trapped in the system are (maximum five times), using the full clutch
removed automatically during clutch operation. pedal travel.
1. Remove the air cleaner, if necessary.For 13. Check the fluid level in the brake fluid
additional information, refer to reservoir and top up to the MAX mark with
Section 303-12A [Intake Air Distribution and brake fluid if necessary.
Filtering] / 303-12B [Intake Air Distribution 14. Install the battery tray, if necessary.
and Filtering -- 2.5L Duratec-ST (VI5)].
15. Install the battery, if necessary. For
2. Remove the battery, if necessary. For additional information, refer to
additional information, refer to Section 414-01 [Battery, Mounting and
Section 414-01 [Battery, Mounting and Cables].
Cables].
16. Install the air cleaner, if necessary. For
3. Remove the battery tray, if necessary. additional information, refer to
4. Drain the brake fluid reservoir. Section 303-12A [Intake Air Distribution
2007.50 Focus 5/2007 G183752en

GENERAL PROCEDURES
and Filtering] / 303-12B [Intake Air
Distribution and Filtering -- 2.5L Duratec-ST
(VI5)].
17. Test the clutch control system for normal
operation.
• Start the engine, depress the clutch pedal,
wait two seconds, then carefully engage
reverse gear. If there are any abnormal
noises, or reverse gear is difficult to engage,
repeat the clutch system bleeding procedure.
18. Initialize the door window motors, if
to Section 501-11 [Glass, Frames and
Mechanisms].
2007.50 Focus 5/2007 G183752en

GENERAL PROCEDURES
Gearshift Cable Adjustment — Vehicles With: 5-Speed Manual

Transmission (iB5)(16 513 0)
General Equipment 5. Remove the gearshift cable cover.
3 mm drill
1. Detach the gearshift lever gaiter and trim
panel from the centre console and pull
upwards.
TIE0026646
6. NOTE: Only adjust the selector cable.

Unlock the selector cable adjusting
mechanism.
E49966
2.
CAUTION: Wrap the flutes of the drill bit
with a suitable tape.
Lock the gear lever in 3rd/4th gear using the
3 mm drill.
E53426
7. NOTE: Ensure that the gearshift lever is in

the 4th gear position and ensure that 4th
gear is engaged in the transmission.
The selector cable is automatically adjusted
E60280 to the correct length.
3. 4. Engage gear.
4. Raise the vehicle. For additional information,
refer to: (100-02 Jacking and Lifting)
2007.50 Focus 5/2007 G528303en

GENERAL PROCEDURES
8. Lock the selector cable adjusting 12. Install the gearshift lever gaiter and trim
mechanism. panel in the centre console.
E53425 E49966
9. Install the gearshift cable cover.
TIE0026646

11. Remove the 3 mm drill.
E60280
2007.50 Focus 5/2007 G528303en

GENERAL PROCEDURES

Transmission (MTX-75)(16 513 0)
General Equipment Release the selector cable adjuster (air
cleaner shown removed for clarity).
3 mm drill
1. Detach the gearshift lever gaiter and trim
panel from the centre console and pull
upwards.
TIE0038226
5. NOTE: Ensure that the gearshift lever is in

the 4th gear position and ensure that 4th
E49966 gear is engaged in the transmission.
The selector cable is automatically adjusted
2. to the correct length.
CAUTION: Wrap the flutes of the drill bit
with a suitable tape. 6. Lock the selector cable adjuster (air cleaner
Lock the gear lever in 3rd/4th gear using the shown removed for clarity).
3 mm drill.
TIE0038227
E60280
7. Remove the 3 mm drill.
3. 4th gear - engage.
4. NOTE: Only adjust the selector cable.
E60280
2007.50 Focus 5/2007 G402258en

GENERAL PROCEDURES
8. Install the gearshift lever gaiter and trim
panel in the centre console.
E49966
2007.50 Focus 5/2007 G402258en

GENERAL PROCEDURES

Transmission (F35M-R)(16 513 0)
Installation).
2. NOTE: Only adjust the selector cable. The
gearshift cable is automatically adjusted to
the correct length.
Release the selector cable adjuster.
E53257
3. Make sure that the gearshift lever and the

transaxle are in the neutral position.
4. Lock the selector cable adjuster.
E53256

Installation).
2007.50 Focus 5/2007 G420952en

Clutch — Vehicles With: 5-Speed Manual
308-01A-1 Transmission (iB5) 308-01A-1
.
SECTION 308-01A Clutch — Vehicles With: 5-Speed

Manual Transmission (iB5)
CONTENTS PAGE
SPECIFICATIONS
Clutch.............................................................................................................................. 308-01A-2

Clutch.................................................................................................................................. 308-01A-3

Clutch Disc and Pressure Plate...................................................................... (16 724 4) 308-01A-4
SPECIFICATIONS
Clutch
Type Single plate dry clutch
Actuation hydraulic
Item Nm lb-ft lb-in
Clutch pressure plate retaining bolts 29 21 -
2007.50 Focus 3/2007 G307456en

Clutch
REFER to: Manual Transaxle and Clutch - 3-Door
(308-00 Manual Transmission/Transaxle and
Clutch - General Information, Diagnosis and
Testing).
2007.50 Focus 3/2007 G18068en

Clutch Disc and Pressure Plate(16 724 4)

Special Tool(s) • Remove the bolts and lift the clutch pressure
plate and disc from the guide pegs.
Aligner, clutch plate
308204 (16-067)
303-393
16067
Locking tool, crankshaft

303393 (21-168)
ELE0001412
21168
Installation
1. Center the clutch disk on the pressure plate.
Removal
1. Remove the transmission. For additional
[Manual Transmission/Transaxle -- Vehicles
With: 5-Speed Manual Transmission (iB5)] /
308-03B [Manual Transmission/Transaxle --
(iB5)] / 308-03C [Manual
Transmission/Transaxle -- Vehicles With:
308-204
5-Speed Manual Transmission (MTX-75)] /
308-03D [Manual Transmission/Transaxle --
Vehicles With: 6-Speed Manual Transmission ELE0001411
(MMT6)] / 308-03E [Manual

Transmission/Transaxle -- Vehicles With: 2.
5-Speed Manual Transmission (F35M-R)] / CAUTION: Tighten the bolts evenly,
308-03F [Manual Transmission/Transaxle -- working diagonally, until the pressure plate
Vehicles With: 6-Speed Manual Transmission is fully in contact with the flywheel.
(M66)]. Install the clutch friction disc with the clutch
2. pressure plate.
CAUTION: If the clutch pressure plate is
to be re-used, undo the bolts evenly in 1. Locate the clutch pressure plate on the guide
stages working diagonally until the pins of the flywheel with the aligner and the
diaphragm spring is no longer under centered clutch friction disc.
pressure (about two turns). 2. Tighten the clutch pressure plate bolts
evenly, working diagonally (six bolts).
Detach the clutch from the flywheel.
2007.50 Focus 3/2007 G21492en

• Remove the aligner.
29 Nm 2
308-204
V9610314
3. Install the transmission. For additional

[Manual Transmission/Transaxle -- Vehicles
With: 5-Speed Manual Transmission (iB5)] /
308-03B [Manual Transmission/Transaxle --
(iB5)] / 308-03C [Manual
5-Speed Manual Transmission (MTX-75)] /
308-03D [Manual Transmission/Transaxle --
(MMT6)] / 308-03E [Manual
5-Speed Manual Transmission (F35M-R)] /
308-03F [Manual Transmission/Transaxle --
(M66)].
2007.50 Focus 3/2007 G21492en

308-01B-1 Transmission (MTX-75) 308-01B-1
.
SECTION 308-01B Clutch — Vehicles With: 5-Speed

Manual Transmission (MTX-75)
CONTENTS PAGE
SPECIFICATIONS
Clutch.............................................................................................................................. 308-01B-2

Clutch.................................................................................................................................. 308-01B-3

Clutch Disc and Pressure Plate...................................................................... (16 724 4) 308-01B-4
SPECIFICATIONS
Clutch
Type Single-plate dry clutch
Actuation Hydraulic
External diameter 228 mm
Tightening Torques
Clutch pressure plate to flywheel 29 21 -
2007.50 Focus 3/2007 G296635en

Clutch
Testing).
2007.50 Focus 3/2007 G18068en

Clutch Disc and Pressure Plate(16 724 4)

Special Tool(s) Check that the stop pin is movable during
the removal of the clutch pressure plate
Aligner, Clutch Disc
retaining bolts.
308-204
16067
Removal
All vehicles
1. Remove the transaxle. For additional E61514
information, refer to: (308-03 Manual
5-Speed Manual Transmission (MTX-75)) All vehicles
Transaxle - 2.0L Duratec-HE (MI4) (Removal), 4. Loosen the clutch pressure plate retaining
Transaxle - 1.6L Duratorq-TDCi (DV) Diesel bolts by two turns at a time in the sequence
(Removal), shown.
Transaxle - 1.8L Duratorq-TDCi (Lynx) Diesel
(Removal).
4 6
2. Identify the type of clutch pressure plate 1
installed.
• A self adjusting clutch pressure plate is
identified by a stop pin. 2
5 3
ELE0010462

E61513
3. NOTE: This step is only required if the

vehicle is equipped with a self adjusting
clutch pressure plate.
NOTE: A new self adjusting clutch pressure plate
must be installed if a new clutch friction disc is
being installed.
2007.50 Focus 3/2007 G325408en

Installation Tighten the clutch pressure plate retaining
bolts finger tight and then by two turns at a
1. Using the special tool, centralize the clutch time in the sequence shown to the specified
disc on the pressure plate. torque.
3 29 Nm 1
5 6
308-204
308-204
4
2
ELE0001411 TIE0021848
2. Using the special tool, install the clutch disc 4. Remove the special tool.
and pressure plate.
5. Install the transaxle. For additional
information, refer to: (308-03 Manual
5-Speed Manual Transmission (MTX-75))
Transaxle - 2.0L Duratec-HE (MI4)
(Installation),
Transaxle - 1.6L Duratorq-TDCi (DV) Diesel
308-204 (Installation),
Transaxle - 1.8L Duratorq-TDCi (Lynx) Diesel
(Installation).
TIE0036856
3.
CAUTION: At self adjusting clutches,
check if the stop is movable during the
installation of the bolts.
NOTE: Install new clutch pressure plate retaining
bolts.
2007.50 Focus 3/2007 G325408en

308-01C-1 Transmission (F35M-R) 308-01C-1
.
SECTION 308-01C Clutch — Vehicles With: 5-Speed

Manual Transmission (F35M-R)
CONTENTS PAGE
SPECIFICATIONS

Clutch.................................................................................................................................. 308-01C-3

Clutch Disc and Pressure Plate.......................................................................................... 308-01C-4
SPECIFICATIONS
Clutch
Type Single plate dry clutch
Actuation Hydraulic
General specifications
Item mm inches
Clutch disc diameter 200 7.874
Maximum clutch disc runout * 0.7 0.028
Minimum depth between clutch disc surface and 0.3 0.012
rivet head *
* When the minimum depth or maximum runout has been reached, install a new clutch disc.
Item Nm lb-ft lb-in
Clutch pressure plate retaining bolts 29 21 -
2007.50 Focus 4/2007 G385289en

Clutch
Testing).
2007.50 Focus 4/2007 G18068en

Clutch Disc and Pressure Plate

Special Tool(s) 1. Remove the transaxle.
Aligner, Clutch Disk For additional information, refer to: Transaxle
308-204 (308-03 Manual Transmission/Transaxle -
Transmission (F35M-R), Removal).
16067 indicated in the following illustration(s) and
table(s).
Materials
Name Specification
High-Temperature ESD-M1C220-A
Grease
5
1 29 Nm
E52971
1 Clutch pressure plate retaining bolts 3 Clutch disc

See Installation Detail 4 Clutch release lever and release bearing
2 Clutch pressure plate See Installation Detail
See Installation Detail 5 Pilot bearing
2007.50 Focus 4/2007 G385292en

Removal Details
Item 1 Clutch pressure plate retaining bolts
CAUTION: Loosen the clutch pressure
plate retaining bolts evenly by two turns
at a time.
Item 4 Clutch release lever and release bearing 2. Using the special tool, centralize the clutch
disc on the clutch pressure plate.
1. Apply a thin film of grease to the clutch
release bearing, the clutch release lever and
to the transaxle input shaft.
308-204
ELE0001411
E52973 Item 2 Clutch pressure plate

1.
CAUTION: Tighten the clutch pressure
Item 3 Clutch disc plate retaining bolts finger tight and then
1. Clutch installation position. evenly by two turns at a time to the specified
torque.
• X = Transaxle side
• Y = Engine side Using the special tool, install the clutch disc
and pressure plate.
• Working in stages, tighten the bolts in the
sequence shown.
3 29 Nm 1
5 6
308-204
E52972
4
2
E52974
Item 1 Clutch pressure plate retaining bolts
2007.50 Focus 4/2007 G385292en

Clutch Controls — Vehicles With: 5-Speed
308-02A-1 Manual Transmission (iB5) 308-02A-1
.
SECTION 308-02A Clutch Controls — Vehicles With:

5-Speed Manual Transmission (iB5)
CONTENTS PAGE
SPECIFICATIONS

Clutch Controls................................................................................................................... 308-02A-3

Clutch Master Cylinder................................................................................... (16 856 0) 308-02A-4
Clutch Slave Cylinder..................................................................................... (16 862 4) 308-02A-9
SPECIFICATIONS
Specificat
ions
High-temperature grease ESDM-1C2
20-A
Item Nm lb-ft lb-in
Clutch slave cylinder retaining bolts 10 - 89
Clutch master cylinder retaining bolts 8 - 71
Pedal pivot shaft retaining nut 25 18 -
2007.50 Focus 3/2007 G113286en

Clutch Controls
Testing).
2007.50 Focus 3/2007 G18080en

Clutch Master Cylinder(16 856 0)

Special Tool(s)
RHD vehicles
Remover/Installer, Clutch
Master Cylinder 3. Disconnect the battery.
308-554 For additional information, refer to: Battery
E42935
All vehicles
4. Extract brake fluid from the brake fluid
Materials reservoir until the level reaches the MIN
Name Specification mark.
Grease WSD-M1C230-A 5. Remove the lower footwell trim.
CAUTION: If brake fluid comes into contact

with the paintwork, rinse off the affected
areas with cold water without delay.
All vehicles
1. Remove the air cleaner. For additional
information, refer to: (303-12 Intake Air
Distribution and Filtering)
Air Cleaner - 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma) (Removal and
E49958
Installation),
Air Cleaner - 1.6L Duratec-16V Ti-VCT
(Sigma) (Removal and Installation), 6. Detach the data link connector (DLC) from
Air Cleaner - 2.0L Duratec-HE (MI4)/1.8L the footwell lower trim.
Duratec-HE (MI4) (Removal and • Detach the data link connector clips.
Installation),
Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel
Air Cleaner - 2.0L Duratorq-TDCi (DW) Diesel
Air Cleaner - 1.6L (Z6) (Removal and
Installation).

2. Remove the battery carrier. For additional
information, refer to: (414-01 Battery,
Mounting and Cables) TIE44539
Battery Tray - 2.0L Duratec-HE (MI4)/1.4L

Duratec-16V (Sigma)/1.6L Duratec-16V 7. Detach the steering column shaft joint from
(Sigma)/1.8L Duratec-HE (MI4) (Removal the steering.
and Installation),
Battery Tray - 1.6L Duratorq-TDCi (DV)
2007.50 Focus 3/2007 G402261en

• Remove the steering column shaft joint bolt. 8. Remove the components in the order
table(s).
TIE0027063
6 2
25 Nm 3
1
5
4
E40867
1 Clutch master cylinder pipes. 5 Catch for clutch master cylinder actuating
See Removal Detail rod
See Removal Detail
2 Clutch pedal return spring(vehicles with
1.4L, 1.6L, 1.8L, 2.0L engines shown) 6 Clutch master cylinder
3 Nuts, clutch pedal bracket
4 Clutch pedal bracket
See Removal Detail
All vehicles
10. Attach the steering column shaft joint to
the steering.
2007.50 Focus 3/2007 G402261en

• Tighten the steering column shaft joint bolt. Left-hand drive vehicles
14. Install the battery carrier. For additional
Mounting and Cables)
(Sigma)/1.8L Duratec-HE (MI4) (Removal
and Installation),
28 Nm
TIE0027064
RHD vehicles
11. Attach the data link connector (DLC) at the
footwell lower trim. 15. Connect the battery.
• Install the data link connector clips. For additional information, refer to: Battery
Procedures).
All vehicles
16. Install the air cleaner. For additional
Installation),
TIE44539
(Sigma) (Removal and Installation),
12. Install the lower footwell trim. Air Cleaner - 2.0L Duratec-HE (MI4)/1.8L
Duratec-HE (MI4) (Removal and
Installation),
Installation).

17. Initialize the window regulator motors.
E49958
13. Bleed the clutch system. Frames and Mechanisms, General
For additional information, refer to: Clutch Procedures).
2007.50 Focus 3/2007 G402261en

Removal Details
Item 1 Clutch master cylinder pipes. • Discard the nuts.
1. NOTE: The next step should only be
performed on RHD vehicles.
Raise the vehicle for access For additional
Lifting)
Lifting (Description and Operation),
Jacking (Description and Operation).
2.
CAUTION: Close off the clutch master
cylinder line to prevent fluid loss or dirt
ingress. TIE40762
Detach the clutch master cylinder pipes from

the clutch master cylinder. Item 4 Clutch pedal bracket
1. Press the clutch master cylinder supply line 1. Detach the clutch pedal position (CPP)
lock button. switch from the clutch pedal bracket.
2. Remove the clutch slave cylinder pressure • Detach the cable from the wiring harness
line securing clip. bracket.
TIE40757
TIE40760
3. NOTE: The next step should only be 2. Detach the clutch master cylinder from the
performed on RHD vehicles. bulkhead using the special tool.
Lower the vehicle. • Turn the clutch master cylinder 60 degrees
counter-clockwise.
Item 3 Nuts, clutch pedal bracket
1. Remove the clutch pedal bracket nuts.
TIE44480
2007.50 Focus 3/2007 G402261en

3. Remove the clutch master cylinder together Item 5 Catch for clutch master cylinder
with the clutch pedal bracket. actuating rod
• Turn the clutch pedal bracket to the position 1. Detach the clutch master cylinder from the
shown. clutch pedal bracket.
• Press together the catch for the clutch master
cylinder actuating rod.
TIE40763
TIE44540
Item 6 Clutch master cylinder
1. NOTE: Coat the clutch master cylinder gaiter
with grease before installing.
Install the clutch master cylinder.
TIE44541
2007.50 Focus 3/2007 G402261en

Clutch Slave Cylinder(16 862 4)

Materials If brake fluid is spilt on the paintwork,
Name Specification washed down with cold water.
High-temperature ESDM-1C220-A
grease Do not apply grease on any area of the
Install the clutch slave cylinder.
Removal
1. Remove the transaxle. For additional
information, refer to: (308-03 )
Transaxle - 1.25L Duratec-16V (Sigma)/1.4L
(Sigma) (Removal),
Transaxle - 1.3L Duratec-8V (Rocam)
(Removal),
Transaxle - 2.0L Duratec-HE (MI4) (Removal),
Transaxle - 1.4L Duratorq-TDCi (DV) 10 Nm
Diesel/1.6L Duratorq-TDCi (DV) Diesel
(Removal). TIE0029733
2. Clean any grease and foreign material from

the input shaft. 2. Remove the adhesive tape from the input
shaft splines.
3. CAUTIONS:
3. Coat the input shaft splines with a thin layer
If brake fluid is spilt on the paintwork, of high-temperature grease.
washed down with cold water. 4. Install the transaxle. For additional
information, refer to: (308-03 )
Using suitable adhesive tape, cover the Transaxle - 1.25L Duratec-16V (Sigma)/1.4L
input shaft splines to prevent damage to the Duratec-16V (Sigma)/1.6L Duratec-16V
input shaft oil seal. (Sigma) (Installation),
Remove the clutch slave cylinder. Transaxle - 1.3L Duratec-8V (Rocam)
(Installation),
Transaxle - 2.0L Duratec-HE (MI4)
(Installation),
Transaxle - 1.4L Duratorq-TDCi (DV)
Diesel/1.6L Duratorq-TDCi (DV) Diesel
(Installation).
TIE0029777
Installation
1. CAUTIONS:
2007.50 Focus 3/2007 G113288en

308-02B-1 Manual Transmission (MTX-75) 308-02B-1
.
SECTION 308-02B Clutch Controls — Vehicles With:

5-Speed Manual Transmission (MTX-75)
CONTENTS PAGE
SPECIFICATIONS

Clutch Controls................................................................................................................... 308-02B-3

Clutch Master Cylinder................................................................................... (16 856 0) 308-02B-4
Clutch Slave Cylinder..................................................................................... (16 862 4) 308-02B-9
SPECIFICATIONS
Item Specification
Sealer, clutch slave cylinder ESK-M4G269-A
Clutch Control
Actuation Hydraulic
Adjustment Automatic
Pedal travel (not adjustable) 135 ± 3 mm
Tightening Torques
Bolts, clutch slave cylinder 11 8 -
Nuts, clutch pedal bracket 25 18 -
2007.50 Focus 3/2007 G402260en

Clutch Controls
Testing).
2007.50 Focus 3/2007 G18080en


Special Tool(s)
RHD vehicles
E42935
All vehicles

All vehicles
E49958
Installation),
Installation),
Installation).


and Installation),
2007.50 Focus 3/2007 G402261en

table(s).
TIE0027063
6 2
25 Nm 3
1
5
4
E40867
See Removal Detail
See Removal Detail
All vehicles
the steering.
2007.50 Focus 3/2007 G402261en

and Installation),
28 Nm
TIE0027064
RHD vehicles
Procedures).
All vehicles
Installation),
TIE44539
Installation),
Installation).

E49958
2007.50 Focus 3/2007 G402261en

Removal Details
Lifting)
2.
ingress. TIE40762

TIE40757
TIE40760
counter-clockwise.
TIE44480
2007.50 Focus 3/2007 G402261en

TIE40763
TIE44540
TIE44541
2007.50 Focus 3/2007 G402261en


2.
Materials CAUTION: If brake fluid is spilt on the
Name Specification immediately washed down with cold water.
Sealer ESK-M4G269-A NOTE: Install a new clutch slave cylinder/release
bearing assembly.
Removal Install the clutch slave cylinder/release
bearing assembly.
1. Remove the transmission.
• Attach the boot.
For additional information, refer to: Transaxle
- 1.8L Duratec-HE (MI4) (308-03 Manual
5-Speed Manual Transmission (MTX-75),
Removal)
/ Transaxle - 1.6L Duratorq-TDCi (DV) Diesel 11 Nm
- Vehicles With: 5-Speed Manual
Transmission (MTX-75), Removal).
2. Clean the input shaft splines.
3. CAUTIONS:
TIE44676
If brake fluid is spilt on the paintwork,
3. Remove the adhesive tape from the input
washed down with cold water.
shaft splines.
Wrap the input shaft splines with 4. Install the transmission.
adhesive tape to protect the input shaft oil
For additional information, refer to: Transaxle
seal.
- 1.8L Duratec-HE (MI4) (308-03 Manual
Remove the clutch slave cylinder/release Transmission/Transaxle - Vehicles With:
bearing assembly. 5-Speed Manual Transmission (MTX-75),
• Detach the boot. Installation)
• Discard the clutch slave cylinder/release
bearing assembly.
- Vehicles With: 5-Speed Manual
Transmission (MTX-75), Installation).
5. Bleed the clutch system.
ELE0022099
Installation
1. Apply sealer to the clutch slave
cylinder/release bearing assembly.
2007.50 Focus 3/2007 G325459en

308-02C-1 Manual Transmission (F35M-R) 308-02C-1
.
SECTION 308-02C Clutch Controls — Vehicles With:

5-Speed Manual Transmission (F35M-R)
CONTENTS PAGE
SPECIFICATIONS

Clutch Controls................................................................................................................... 308-02C-3

Clutch Master Cylinder................................................................................... (16 856 0) 308-02C-4
Clutch Slave Cylinder..................................................................................... (16 862 4) 308-02C-9
SPECIFICATIONS
Item Nm lb-ft lb-in
Clutch slave cylinder retaining bolts 22 16 -
2007.50 Focus 4/2007 G385303en

Clutch Controls
Testing).
2007.50 Focus 4/2007 G18080en


Special Tool(s)
RHD vehicles
E42935
All vehicles

All vehicles
E49958
Installation),
Installation),
Installation).


and Installation),
2007.50 Focus 4/2007 G402261en

table(s).
TIE0027063
6 2
25 Nm 3
1
5
4
E40867
See Removal Detail
See Removal Detail
All vehicles
the steering.
2007.50 Focus 4/2007 G402261en

and Installation),
28 Nm
TIE0027064
RHD vehicles
Procedures).
All vehicles
Installation),
TIE44539
Installation),
Installation).

E49958
2007.50 Focus 4/2007 G402261en

Removal Details
Lifting)
2.
ingress. TIE40762

TIE40757
TIE40760
counter-clockwise.
TIE44480
2007.50 Focus 4/2007 G402261en

TIE40763
TIE44540
TIE44541
2007.50 Focus 4/2007 G402261en


and Operation).
E40677

table(s).
2 22 Nm
3
E52978

1 Clutch slave cylinder supply line 5. Bleed the clutch system.
See Removal Detail For additional information, refer to: Clutch
See Installation Detail System Bleeding (308-00 Manual
2 Clutch slave cylinder retaining bolts Transmission/Transaxle and Clutch -
3 Clutch slave cylinder
Removal Details
2007.50 Focus 4/2007 G385307en

Item 1 Clutch slave cylinder supply line 2. Pull the clutch slave cylinder supply line out
of the clutch slave cylinder.
1.
CAUTION: Cap the clutch slave cylinder
supply line to prevent fluid loss or dirt 1
ingress.
Disconnect the clutch slave cylinder supply 2
line.
1. Pull the clip to the position shown.
E52979
Item 1 Clutch slave cylinder supply line
1. NOTE: Make sure that the clutch slave
cylinder supply line O-ring is not damaged.
line.
1. Check the O-ring seal and install a new
O-ring seal if necessary.
2. Insert the clutch slave cylinder supply line
into the clutch slave cylinder.
3. Push in the clip.
3
2
E52980
2007.50 Focus 4/2007 G385307en

Manual Transmission/Transaxle — Vehicles
308-03A-1 With: 5-Speed Manual Transmission (iB5) 308-03A-1
.
SECTION 308-03A Manual Transmission/Transaxle —

Vehicles With: 5-Speed Manual Transmission (iB5)
CONTENTS PAGE
SPECIFICATIONS
Transaxle ratios.............................................................................................................. 308-03A-3
Shim thickness................................................................................................................ 308-03A-3
Fifth gear snap ring thickness......................................................................................... 308-03A-3

Manual Transaxle............................................................................................................... 308-03A-5
General............................................................................................................................... 308-03A-5
Transmission construction.................................................................................................. 308-03A-6
Internal shift mechanism..................................................................................................... 308-03A-11
Power transmission in the individual gears........................................................................ 308-03A-15

Manual Transaxle............................................................................................................... 308-03A-17
GENERAL PROCEDURES
Bearing Check.................................................................................................................... 308-03A-18
IN-VEHICLE REPAIR
Halfshaft Seal LH............................................................................................ (14 303 0) 308-03A-20
Halfshaft Seal RH........................................................................................... (14 304 0) 308-03A-21
Vehicle Speed Sensor (VSS).......................................................................... (33 654 0) 308-03A-22
REMOVAL
Transaxle — 1.8L Duratec-HE (MI4).............................................................. (16 114 0) 308-03A-23
DISASSEMBLY
Transaxle........................................................................................................ (16 118 8) 308-03A-28

Output Shaft........................................................................................................................ 308-03A-34
Input Shaft.......................................................................................................................... 308-03A-39
Differential...................................................................................................... (16 118 6) 308-03A-41
Selector Plate................................................................................................. (16 284 8) 308-03A-43
ASSEMBLY
Transaxle........................................................................................................ (16 118 8) 308-03A-45
.
INSTALLATION
Transaxle — 1.8L Duratec-HE (MI4).............................................................. (16 114 0) 308-03A-55
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives Description Specificat
Description Specificat ions
ions
Sealant, fifth gear end cap WSE-M4G
High-temperature grease ESDM-1C2 323-A4
20-A
Manual transmission fluid WSD-M2C Capacities
200-C
Description Litres
Super DOT 4 brake fluid ESD-M6C5
7-A Manual transmission fluid (just below 2.3
the level of the fluid filler plug)
Sealant, transaxle housing to clutch WSK-M2G
housing 348-A5
Transaxle ratios
1.6L/1.8L
First gear 3.58
Second gear 2.04
Third gear 1.41
Fourth gear 1.11
Fifth gear 0.88
Reverse gear 3.62
Final drive 4.06
Shim thickness
Description mm
Measuring shim 3.8
Shim availability (in increments of 0.1 mm) 0.1 - 0.7
Fifth gear snap ring thickness

Description mm
Snap ring fifth gear 1.48
Item Nm lb-ft lb-in
Clutch slave cylinder retaining bolts 10 - 89
Selector gate retaining bolts 22 16 -
Crashbox retaining bolts 40 30 -
Transaxle housing retaining bolts 25 18 -
Fifth gear housing to transaxle housing retaining 17 13 -
bolts
Selector mechanism to transaxle retaining bolts 22 16 -
Reversing lamp switch 12 9 -
Transaxle housing final drive cover retaining bolts 12 9 -
2007.50 Focus 3/2007 G357622en

SPECIFICATIONS
Item Nm lb-ft lb-in

Transaxle to engine retaining bolts - Vehicles with 47 35 -
1.6L engine
Transaxle to engine retaining bolts - Vehicles with 48 35 -
1.8L engine
Engine support insulator to engine retaining bolt 80 59 -
Engine support insulator to subframe retaining bolts 80 59 -
Engine and transaxle rear mount outer retaining 48 35 -
nuts
Engine and transaxle rear mount center retaining 80 59 -
nut
Exhaust flexible pipe retaining nuts 51 38 -
Engine and transaxle rear mount retaining bracket 148 109 -
retaining bolts
Transmission fluid filler plug 35 26 -
2007.50 Focus 3/2007 G357622en

Manual Transaxle
General
E38500
The iB5 manual transmission is a two shaft 1st and 2nd gears are double synchronised.
transmission. There is no need to change the oil.
All gear wheels are helical toothed, synchronised
(except reverse gear) and run in plain bearings.
2007.50 Focus 3/2007 G281365en

Transmission construction
2 6
1 8
E38501
1 5th gear housing 6 Slave cylinder with integral release

bearing
2 Transmission side housing halves
7 Input shaft
3 Breather
8 Output shaft
4 Hydraulic clutch connection
9 Differential assembly
5 Clutch side housing halves
2007.50 Focus 3/2007 G281365en

Input shaft
1 3
2
4
5
6
7
8
1
9
10
11
W1601033
1 Ball bearing 6 2nd gear wheel
2 Input shaft 7 3rd gear wheel
3 Reverse gear idler 8 4th gear wheel
4 1st gear wheel 9 Snap ring
5 Reverse gear wheel 10 5th gear wheel

11 Snap ring
2007.50 Focus 3/2007 G281365en

Output shaft
3
1
4 2
8
6
9 7
10
11
14
12
15
13
16
17
18
19
E38502
1 Open cylinder roller bearing 7 2nd gear wheel
2 Output shaft with differential drive wheel 8 3rd gear wheel
3 1st gear wheel 9 3rd gear simple synchronisation
4 1st gear double synchronisation 10 Synchroniser assembly - 3rd/4th gear
5 Synchroniser - 1st/2nd gear with reverse 11 4th gear simple synchronisation

gear wheel 12 4th gear wheel
6 2nd gear double synchronisation 13 Ball bearing (closed both sides)
2007.50 Focus 3/2007 G281365en


14 Snap ring 17 5th gear synchroniser assembly
15 5th gear wheel 18 Retaining plate
16 5th gear simple synchronisation 19 Snap ring
Double synchronisation
1
2
3
4
5
W1601039
Item Description 1st and 2nd gears are double synchronised.

1 Gearwheel The effective synchronisation surface for double
synchronisation is almost twice that of simple
2 Inner synchroniser ring synchronisation. Because of this, the speeds of
3 Conical ring the gearwheels are equalised much faster, which
considerably improves gearshifting comfort.
4 Outer synchroniser ring
5 Synchroniser hub
2007.50 Focus 3/2007 G281365en

Differential assembly
1
4
2
1
E38503
The differential assembly contains differential

Item Description
pinion gears mounted on a spindle and the axle
1 Bearing halfshaft pinion gears which connect to the front
wheel axle halfshafts through helical gearing.
2 Crown wheel
The axle halfshaft pinion gears can revolve around
3 Differential assembly the differential pinion gears when the road wheel
4 Sender wheel - Vehicle Speed Sensor speeds are different (e.g when cornering).
(VSS) On vehicles without Anti-lock Brake System (ABS)
5 Crown wheel bolts a VSS detects the speed of the differential
assembly at the VSS sender wheel.
The differential assembly is built into the On vehicles with ABS the VSS sender wheel is
transmission housing. also installed. The VSS is however not installed in
The drive torque is transmitted to the differential this case. A plug with an O-ring closes the
by the crown wheel which is bolted to it. corresponding bore instead.
2007.50 Focus 3/2007 G281365en

Internal shift mechanism
Layout
2
4
1
5
7
6
E38504
1 Selector gate 8 Selector shaft
2 Shift locking bush 9 Guide sleeve
3 Return spring from reverse gear position The shift locking bush prevents two gears from
being engaged at the same time.
4 Reverse gear selector shaft
The selector interlock maintains engagement of
5 Snap ring the selected gear.
6 Shift rod - 5th gear/reverse gear Both the shift and the select process is performed
7 Selector interlock through the selector shaft.
2007.50 Focus 3/2007 G281365en

Select movement
E38505
If the gearshift lever is moved to the left or right,

Item Description
the selector shaft and the selector boss both turn
1 Shift locking bush together in the corresponding direction.
2 Selector shaft As this happens, the selector shaft is guided by a
pin in the selector gate.
3 Selector boss
The selector boss selects the required selector
4 Selector gate fork.
The axial movement of the selector cable is At the same time the shift locking bush prevents
transferred at the transmission to the selector shaft access to other gear combinations.
which can turn in its bearing.
2007.50 Focus 3/2007 G281365en

Shift movement
E38506
Here the axial movement of the shift cable at the

Item Description
transmission produces an axial movement of the
1 Shift locking bush selector shaft.
2 Selector shaft If the gearshift lever is moved forwards or
backwards, the selector shaft and the selector boss
3 Selector boss both move vertically together.
4 Selector gate As this happens, the selector shaft is guided by a
pin in the selector gate.
After the gear pair to be shifted has been selected,
the shift movement takes place. The selector boss shifts the required selector fork.
At the same time the shift locking bush prevents
access to other gear combinations.
2007.50 Focus 3/2007 G281365en

Engage reverse gear
1
2
3
5
6
E38507
When shifting into reverse gear, the gearshift lever

Item Description
is moved backwards. The selector boss engages
1 Shift locking bush in the 5th gear/reverse gear shift rod, which in turn
engages through a pin in the reverse gear selector
2 Reverse gear selector shaft shaft.
3 Shift rod - 5th gear/reverse gear During the select and shift process the selector
4 Selector shaft shaft is guided through the selector gate by a pin.
5 Selector boss The reverse gear idler is slid by the reverse gear
selector shaft and reverse gear is engaged.
6 Selector gate
At the same time the shift locking bush prevents
In order to select reverse gear, the gearshift lever access to other gear combinations.
must be moved to the right over and past the
reverse gear inhibit device. As this occurs the axial
movement of the selector cable is transferred to
the selector shaft which can turn in its bearing.
2007.50 Focus 3/2007 G281365en

Power transmission in the individual gears
E38508
2007.50 Focus 3/2007 G281365en

E38509
2007.50 Focus 3/2007 G281365en

Manual Transaxle
Testing).
2007.50 Focus 3/2007 G18097en

GENERAL PROCEDURES
Bearing Check
• Check the bearing is correctly lubricated.
1. NOTE: Establish the cause of the damage
and resolve it.
Check whether the bearing cage is damaged
at the top, side or at the openings is
damaged because of the unprofessional use
of a special tool or of the wrong tool.
• Install a new bearing if necessary.
ELV1601173
4. Check whether the bearing surfaces are grey

or grey/black with deposits between the
rollers.
• Install a new bearing and new seals if
ELV1601171
necessary.
2. Check whether the ends of the taper rollers

are discoloured as a result of inadequate
lubrication or overheating, possibly through
excessive pre-load.
necessary.
ELV1601174
5. Check whether the bearing ring surfaces are

grooved caused by static impact.
• Install a new bearing if its surface is rough,
or if it is noisy.
ELV1601172

are worn away due to incorrect installation,
excessive pre-load or faulty bearing seating.
necessary.
ELV1601175
2007.50 Focus 3/2007 G21559en

GENERAL PROCEDURES
6. NOTE: Overheating can cause loss of surface
hardness.
Check for a dark blue colour caused by
overheating (yellow or brown is normal) due
to excessive pre-load or inadequate
lubrication.
• Install a new bearing, new seals and check
other components as necessary.
ELV1601174
7. Check the surfaces for abrasion due to metal

fatigue.
• Install a new bearing and clean all other
affected components as necessary.
ELV1601175
2007.50 Focus 3/2007 G21559en

IN-VEHICLE REPAIR
Halfshaft Seal LH(14 303 0)

Special Tool(s) Installation
Installer, Drive Pinion Seal
205-115 (15-058) 1. Using the special tool, install the halfshaft
seal.
15058
205-1 15

308-208 (16-074)
16074
ELE0001756
Materials 2. Install the left-hand halfshaft.

Name Specification For additional information, refer to: Front
3. With the vehicle on a level surface, fill the
Removal transaxle with transmission fluid until the
fluid level is just below the bottom of the
1. Remove the left-hand halfshaft. filler hole.
2. Using the special tool, remove the halfshaft
seal.
308-208
ELV9810271
2007.50 Focus 3/2007 G357623en

IN-VEHICLE REPAIR
Halfshaft Seal RH(14 304 0)

seal.
15048 308-039
Installer, Halfshaft Seal

308-039 (16-018)
16018
ELE0001541
Materials 2. Install the right-hand halfshaft.

Name Specification For additional information, refer to: Front
Manual transmission WSD-M2C200-C
fluid
transaxle with transmission fluid until the
Removal fluid level is just below the bottom of the
filler hole.
seal.
205-078
ELE0001550
2007.50 Focus 3/2007 G357624en

IN-VEHICLE REPAIR
Vehicle Speed Sensor (VSS)(33 654 0)

Removal 2. Insert the retaining pin.

Lifting)
1
2. Disconnect the vehicle speed sensor (VSS) 2
ELE0001542
2. Install VSS connector.
ELE0001689
3. Remove the VSS.

1. Remove the retaining pin.
2. Remove the VSS.
ELE0001689

2
ELE0001413
Installation
1. Install VSS.
1. Insert the VSS.
2007.50 Focus 3/2007 G18104en

REMOVAL
Transaxle — 1.8L Duratec-HE (MI4)(16 114 0)

Special Tool(s)
Support Bar, Engine Removal
303-290A
303290A

303-290-03A
2114003
TIE39686
Adapter for 303-290A 2. Remove the air cleaner.

303-290-13
30329013 Distribution and Filtering, Removal and
Installation).
303-290-15
General Equipment sides.
Transmission jack For additional information, refer to:
Retaining straps
5. Secure the radiator to the lock panel with
cable ties.
2007.50 Focus 3/2007 G400662en

REMOVAL
6. Detach the reversing lamp switch connector. 10. Remove the engine undershield.
TIE0026645 E40677
7. Remove the starter motor. 11. Remove the radiator support bracket.
• Secure the starter motor to one side. • Remove the radiator support bracket
left-hand retaining bolts.
TIE0026643
TIE0037847
8. Remove the transmission upper bolts.

12. Remove the radiator support bracket.
• Remove the radiator support bracket
right-hand retaining bolts.
TIE0036566

TIE0037849
Description and Operation). 13.
CAUTION: Excessive bending of the
flexible pipe can cause damage that may
lead to component failure.
2007.50 Focus 3/2007 G400662en

REMOVAL
Protect the flexible pipe with a support 16. Remove the engine roll restrictors.
sleeve or suitable splints.
TIE0036808
TIE0014991
17. Remove the crashbox.

14. Detach the flexible pipe from the
crossmember rubber insulators.
E47211
TIE39009
15. Detach the flexible pipe from the catalytic
converter.
• Discard the gasket and retaining nuts. 19. Remove the right-hand halfshaft.
51 Nm Halfshafts, Removal and Installation).
20. Remove the gearshift cable cover.
TIE40628
TIE0026646
21. Remove the gearshift cables.
2007.50 Focus 3/2007 G400662en

REMOVAL
1. Detach the gearshift and selector cables from 24. Install the special tools.
2. Turn the catch clockwise and detach from
the abutment.
E0037888
1
TIE0026442 25. Install the special tools.
22. Attach the special tool on both sides

E0037886
303-290-13
26. CAUTIONS:
TIE0036685 If brake fluid comes into contact with
the paintwork, rinse off the affected areas
23. Install the special tools. with cold water without delay.
Close off the clutch slave cylinder pipe

Detach the clutch slave cylinder pipe from
the clutch slave cylinder.
E0037887
TIE0026654
2007.50 Focus 3/2007 G400662en

REMOVAL
28. Remove the rear engine mount. 32. Remove the right-hand transmission bolts.
TIE45137
TIE40728
33. Secure the transmission on the
29. Raise and support the vehicle. transmission jack using suitable retaining
straps.
30. Lower the engine / transmission assembly

using the special tools.
ELE0001101
34. Remove the left-hand transmission bolt.
E0037886
31. Remove the transmission lower bolts.
TIE0038272
35. Support the transmission using the

transmission jack and remove.
TIE0036565
2007.50 Focus 3/2007 G400662en

DISASSEMBLY
Transaxle(16 118 8)
Remover, Drive Pinion Seal Installer, Extension Housing
205-078 (15-048) Bushing/Seal
308-045 (16-015)
16015
15048
Remover, Differential Bearing Remover, Input Shaft Fifth

Cone Gear
205-176 (15-074) 308-082 (16-035)
15074 16035
Mounting Bracket, General Equipment

Engine/Differential Blanking plugs
205-329 (15-105A)
Drift
CAUTIONS:
15105A
Use vise protectors.
Separator, Oil Pan Use a copper or plastic mallet to prevent

303-428 (21-179) damage.
1. Using the special tools, mount the transaxle
on the mounting stand.
21179
303-435-06
Mounting Stand
303-435 (21-187)
205-329
21187
Mounting Bracket for 303-435 ELE0001414
303-435-06 (21-031B)
2. Clean any grease and foreign material from
the input shaft.
21031B
2007.50 Focus 3/2007 G23118en

DISASSEMBLY
3. Remove the clutch slave cylinder. 2. Remove and discard the snap ring.
1 2
TIE0023944
TIE0029777
4. Remove the vehicle speed sensor (VSS) (if 7. Remove the gearshift cable bracket.
equipped).
1. Remove the retaining pin.
2. Pull out the VSS.
1
TIE0024058
8. Remove the selector lever.

ELE0001413
• Remove the bellows.
5. Remove the selector mechanism cover.
TIE0023945
V9410261
6. Remove the gearshift lever.

1. Remove the protective cap (if equipped).
2007.50 Focus 3/2007 G23118en

DISASSEMBLY
9. Remove the selector interlock mechanism. 2. Remove and discard the retaining pin.
2
TIE0021707
TIE0023946
10. Remove the fifth gear housing cover 13. NOTE: To aid assembly mark the position
retaining bolts. of the fifth gear synchroniser assembly.
Disassemble the fifth gear and synchroniser
assembly.
1. Snap ring.
2. Retaining plate.
3. Synchroniser assembly.
4. Synchroniser ring.
5. Fifth gear.
TIE0023948
1
11. Using the special tool, remove the fifth gear
housing cover. 2
303-428
TIE0023950 5
12. Remove the fifth gear synchroniser

assembly, the selector fork and the fifth
gear.
TIC1601235
1. Remove and discard the snap ring.
14. Remove the fifth gear snap ring.
2007.50 Focus 3/2007 G23118en

DISASSEMBLY
• Discard the snap ring. 4. Pull out the blanking plug.
3 1
2
4
TIE0021708 TIE0037749
15. Using the special tool, remove the fifth 18. Using the special tool, remove both
gear. halfshaft oil seals (left-hand side shown).
• Only remove the reversing lamp switch if
there is evidence of leakage.
308-082
205-078
TIE0021709
V9910261
16. Remove the fifth gear housing.
19. Separate the two halves of the transaxle
housing (14 bolts).
• Carefully separate the transaxle housing.
TIE0021710
17. Remove the fifth gear housing gasket, the

TIE0031398
snap rings and the blanking plug.
1. Remove and discard the gasket.
20. Remove the selector shaft guide sleeve
2. Remove the output shaft snap ring.
upper snap ring.
3. Remove the input shaft snap ring.
1. Remove and discard the upper snap ring.
2007.50 Focus 3/2007 G23118en

DISASSEMBLY
2. Slide the selector shaft guide sleeve 23. Using a suitable drift remove and discard
downwards. the input shaft oil seal.
TIE0024055
TIE0021718
21. Remove the selector shaft guide sleeve. 24. Remove the differential assembly and the
1. Remove and discard the selector shaft guide permanent magnet.
sleeve lower snap ring.
2. Remove the selector shaft guide sleeve.
TIE0023951
TIE0024056
25. Remove the reverse gear idler.
22. NOTE: Install a rubber band to the second

selector shaft to aid disassembly.
Remove the input shaft, the output shaft and
the selector forks as an assembly.
TIE0023952
26. Remove the selector shaft and the shift

lock.
TIE0024059
1. Remove the shift lock.
2007.50 Focus 3/2007 G23118en

DISASSEMBLY
2. Remove the fifth and reverse gear selector 29. Using the special tool, remove the
shaft. differential bearing cup.
308-045
2
1
TIE0023953
ELE0001416
27. Remove the output shaft roller bearing. 30. NOTE: Install the special tool in the
• Remove the rollers and the roller cage from transaxle housing grooves.
the output shaft roller bearing. Using the special tool, remove the differential
bearing cup.
205-176
TIE0023955
V9810262
28.
CAUTION: Only use the special tool as
shown, failure to do so may result in the
blanking plug being pressed out of the
housing.
Using the special tool, remove the output
shaft roller bearing outer race.
• Remove the oil funnel.
205-078
TIE0024057
2007.50 Focus 3/2007 G23118en

Output Shaft
Special Tool(s) 4. Remove the fourth gear and the synchronizer
ring.
Tool)
205-295 (15-050A)
15050A
3
Bushing Oil Seal
308-045 (16-015)
2
16015
Collet for 205-295

307-217 (17-048)
4 1
17048
General Equipment
Two-leg puller C1601188
Press
2. Remove the third and fourth gear
Materials synchronizer assembly.
Name Specification 1. Remove and discard the snap ring.
Transmission Oil WSD-M2C200-C 2. Remove the gear synchronizer, third and
fourth gear synchronizer assembly and the
third gear as an assembly.
Disassembly
1. Remove the ball bearing and the fourth gear. 1
1. Remove and discard the small snap ring.
2. Install the output shaft snap ring .
3. Using a suitable two-leg puller, remove the
ball bearing.
• Discard the output shaft snap ring and the
ball bearing.
2
ELC1601226
3. Third gear synchronizer assembly.

1. Outer synchronizer ring.
2. Synchronizer cone.
2007.50 Focus 3/2007 G21539en

3. Third gear. 1. Remove and discard the snap ring.
2. Remove the first and second gear
synchronizer clutch and the reverse gear .
1 3. Outer synchronizer ring.
2 5. Inner synchronizer ring.
6. First gear.
3 1
TIE0031362
2
4. Remove the second gear synchronizer
assembly
1. Retaining ring.
2. Snap rings. 3
3. Second gear.
4. Inner synchronizer ring.
6. Outer synchronizer ring. 4
1 5
2
6
3 ELC1601200
6.
CAUTION: To aid assembly mark the
position of the selector ring in relation to the
4 synchronizer hub.
Disassemble the synchronizer clutch.
1. Selector ring.
5 2. Synchronizer spring.
3. Synchronizer lock.
C1601191
5. NOTE: Remove the synchronizer assembly

and the first gear as an assembly.
Remove the first and reverse gear , the gear
synchronizer and synchronizer assembly.
2007.50 Focus 3/2007 G21539en

4. Synchronizer hub. 2. Carefully clean and check all running
surfaces and coat them with clean
transmission oil before assembly.
2 1 3. NOTE: Install a new output shaft bearing
3 cone snap ring.
NOTE: Install a new output shaft bearing cone.
Install the output shaft bearing cone.
2 • Evenly heat the bearing cone to
approximately 80°C and install it onto the
4 output shaft.
C1601193
• Install the snap ring.
7. Using the special tools, remove the output

shaft bearing cone.
1. Remove and discard the output shaft bearing
cone snap ring.
2. Install the special tools underneath the
bearing cone.
• Discard the output shaft bearing cone.
ELC1601694
4. NOTE: Assemble the synchronizer clutch to

the marks.
205-295 Assemble the synchronizer clutch.
1. Synchronizer hub.
2. Selector ring.
4. Synchronizer spring.
2
1 3 4 2
307-217
1
ELC1601693
ELE0001709
5. NOTE: Use a new first and reverse gear snap
ring.
Assembly
Install the first and reverse gear, the gear
1. Coat the synchronizer assembly with clean synchronizer and synchronizer assembly.
transmission oil before assembly. 1. First gear.
2007.50 Focus 3/2007 G21539en

3. Synchronizer cone. 6. Retaining ring.
5. Install the first and second gear synchronizer
clutch and the reverse gear.
6
5
6
4
5
3
4
2
3
2 1
ELC1601691
1 7. Third gear synchronizer assembly.

ELC1601700 1. Third gear.
6. NOTE: Assemble the synchronizer assembly
before installation on the output shaft.
Install the second gear synchronizer 3
assembly.
1. Outer synchronizer ring. 2
4. Second gear. 1
5. Snap rings.
TIE0031363
8. NOTE: Install a new third and fourth gear

synchronizer assembly snap ring.
NOTE: Install the selector ring with the annular
groove facing downwards and the small hub collar
facing upwards.
Install the third and fourth gear synchronizer
assembly.
2007.50 Focus 3/2007 G21539en

1. Install the gear synchronizer, third and fourth • Install the snap ring.
gear synchronizer assembly and the third
gear.
2
308-045 2
1
ELC1601726

NOTE: Install a new ball bearing.
NOTE: Install the ball bearing with the annular
groove facing outwards.
1
Using the special tool and a suitable press,
install the fourth gear and the ball bearing.
1. Install the synchronizer ring and the fourth
ELE0001710
gear.
2. Using a suitable press , install the ball
bearing.
2007.50 Focus 3/2007 G21539en

Input Shaft
Special Tool(s) • Discard the ball bearing.
Bushing/Oil Seal
308-045 (16-015)
16015
General Equipment
Two-leg puller
Press C1601186
Materials
Assembly
Name Specification
1. Coat all components with clean transmission
Transmission Oil WSD-M2C200-C
oil before assembly.
2. NOTE: Install a new ball bearing.
Disassembly
Using the special tool and a suitable press ,
1. Using a suitable two-leg puller, remove the install the ball bearing.
ball bearing.
1. Install the input shaft snap ring.
2. Remove the ball bearing.
• Discard the input shaft snap ring and the 308-045
ball bearing.
2
ELE0001711
3. NOTE: Install a new ball bearing.

1 NOTE: The ball bearing groove must face
outwards.
C1601185
2. Using a suitable two-leg puller remove the

ball bearing.
2007.50 Focus 3/2007 G21537en

Using the special tool and a suitable press ,
install the ball bearing.
308-045
ELE0001712
2007.50 Focus 3/2007 G21537en

Differential(16 118 6)
Special Tool(s) 3. Remove the vehicle speed sensor (VSS)
sensor ring.
Adapter for 204-158 (Thrust
Pad)
204-158-01 (14-038-01)
1403801
205-295
Installer, Differential Bearing
205-062 (15-025A)
308-197 2
15025A
1 204-158-01
Tool)
205-295 (15-050A) 3
15050A
Collet for 205-295

308-197 (16-062) ELE0001713
2. Remove the differential pinions and the ring

gear.
16062
1. Rotate the differential pinions approximately
90 degrees in the differential case and
General Equipment remove them.
Press 2. Remove and discard the snap ring and using
a suitable drift, drive out the pin.
Drift
• Remove the two differential pinions and
Materials plastic thrust elements.
3. Remove the ring gear retaining bolts.
Name Specification
2
1
Disassembly
1. Using the special tools, remove the
differential taper roller bearings.
2. Remove the differential taper roller bearings.
3
ELW1601037
2007.50 Focus 3/2007 G21541en

Assembly 3. Using the special tool, install the differential
taper roller bearings.
1. NOTE: Do not lubricate the differential
bearings.
Carefully clean and check all components 205-062 3
and coat them with clean transmission oil
before assembly.
2. NOTE: Install a new differential pinion snap 2
ring. 1 90 Nm
Install the ring gear and the differential
pinions.
1. Using the old bolts, carefully attach the ring TIE0001714
gear to the differential case.
• Discard the ring gear bolts.
2. Install the two differential pinions, plastic
thrust elements and using a suitable drift,
install the pin and snap ring.
3. Install the differential pinions and rotate them
90 degrees in the differential case.
2
3
1
ELE0002347
3. NOTE: Install new ring gear retaining bolts.

NOTE: Do not rest the differential on the lower
differential taper roller bearing.
Using the special tool, install the differential
taper roller bearings and tighten the ring gear
retaining bolts.
1. Install new ring gear retaining bolts and
tighten the bolts working diagonally.
2. Install the vehicle speed sensor (VSS) sensor
ring.
2007.50 Focus 3/2007 G21541en

Selector Plate(16 284 8)

Overview, selector mechanism
3 7
6
8
2
9
5
ELE0001562
4. Selector plate.
Item Description
5. Fifth and reverse gear selector shaft guide
1 Fifth and reverse gear selector shaft guide sleeve.
sleeve
2 Selector plate 1
3 Shift lock 2 3
4 Selector shaft interlock mechanism

5 Selector shaft
6 Reverse gear selector lever return spring
7 Reverse gear selector lever 4
5
8 Snap-ring V9710262
9 Fifth and reverse gear selector shaft
Assembly
Disassembly
1. Install the selector mechanism.
1. Remove the selector mechanism. 1. Selector shaft.
1. Fifth and reverse gear selector shaft. 2. Reverse gear selector lever.
2. Selector shaft. 3. Fifth and reverse gear selector shaft guide
3. Reverse gear selector lever . sleeve.
2007.50 Focus 3/2007 G18111en

4. Selector plate.
1 2
4 22 Nm
3
TIE0001719
2007.50 Focus 3/2007 G18111en

ASSEMBLY
Transaxle(16 118 8)
Installer, Wheel Hub Bearing Installer, Input Shaft Bearing
Cone/Seal Cone
205-296 (15-085) 308-041 (16-020)
16020
15085
Compressor, Valve Spring Installer, Extension Housing

303-060 (21-024) Bushing/Seal
308-045 (16-015)
16015
21024
Adapter for 303-060 Installer, Input Shaft Snap

303-060-02 (21-024-02) Ring
308-076 (16-031)
2102402 16031

303-060-07 (21-024-07) Press
Dial indicator gauge
Magnetic stand for dial indicator gauge
2102407
Blanking plugs
M8 x 50 mm bolt
Mounting Stand
303-435 (21-187) Thread die
Materials
Name Specification
21187 Sealant ESEE-M4G1008-A
308-039 (16-018) Oil Pan Sealer WSK-M2G348-A5
Silicon Sealer WSE-M4G323-A4
High Temperature ESDM-1C220-A
16018
Grease
1. Clean and check all parts carefully before
reassembly.
• Apply clean transmission oil to all running
surfaces.
2007.50 Focus 3/2007 G23119en

ASSEMBLY
2. 2. Install the fifth and reverse gear selector
CAUTION: Make sure the output shaft
shaft.
roller bearing is installed with the scribed
text uppermost.
Using the special tool, install the output shaft
roller bearing and the output shaft bearing 2
cup. 1
1. Install the oil funnel.
2. Install the output shaft roller bearing.
308-041
TIE0023953
5. Install the reverse gear idler.

2
1
TIE0024018

bearing cup.
205-296 TIE0023952
6. Install the differential assembly and the

permanent magnet.
ELE0002206
4. Install the fifth and reverse gear selector

shaft, and the shift lock.
1. Install the shift lock.
TIE0023951
7. Prepare the input and output shaft for

installation.
1. Engage the input shaft and output shaft.
2. Move the first and second gear shift forks to
the installation position.
2007.50 Focus 3/2007 G23119en

ASSEMBLY
3. Move the third and fourth gear shift forks to 2. Install the snap ring.
the installation position.
2
1
2 3 TIE0024020
ELC1601702

8. NOTE: Install a rubber band to the second
Install the selector shaft guide sleeve upper
selector shaft to aid assembly.
snap ring.
Install the input shaft, the output shaft and
1. Lift the guide sleeve.
the selector forks.
• Insert the input shaft to a depth of
approximately 50 mm and move it slightly to
one side. 1
• Insert the output shaft to the level of the input
shaft and engage the gear wheels.
• Install the input shaft and the output shaft.
2
TIE0024021
11. Move the inner gearshift linkage to the fifth

gear.
• Before pressing it downwards, turn the
TIE0024019 selector shaft clockwise until it reaches the
reverse and fifth gear passage.
Install the selector shaft guide sleeve lower
snap ring.
1. Install the guide sleeve.
TIE0037750
12. Install the 3.8 mm thick measuring shim

and secure it with a punch mark.
2007.50 Focus 3/2007 G23119en

ASSEMBLY
1. Transaxle housing. 15. Prepare the differential for measuring.
2. Measuring shim. • Turn the differential assembly approximately
3. Bearing cup. ten times to settle the bearings.
• Position the dial indicator gauge and
magnetic stand and set the dial indicator
1 gauge to zero.
2
3 • Pre-tension the dial indicator gauge by a
minimum of 1 mm.
ELC1601703
13. NOTE: Make sure that the transaxle housing

mating surfaces are clean.
Assemble the transaxle housing.
ELE0002342
• Using a M8 x 50 mm bolt install the special
tool.
16. NOTE: Carry out the measuring procedure
• Install the blanking plugs. three times and calculate the average value.
• Install the bolts.
• Turn the transaxle 180 degrees. NOTE: The adjusting shims are available from 0.1
mm to 1.1 mm in steps of 0.1 mm.
Measure the differential end float.
1. Using the special tool, lift the differential
assembly.
2. Note the resulting measurement.
• Example: 0.73 mm + 0.74 mm + 0.72 mm
divided by three = 0.73 mm.
• The value of the thickness of the shim
28 Nm
should be rounded down to the nearest
303-060-07 tenth of a millimeter below if the value ends
ELE0002242

• Remove the blanking plugs.
303-060-07
303-060
303-060-02
ELE0002241
2007.50 Focus 3/2007 G23119en

ASSEMBLY
in 0.05 mm and below, and rounded up to • Remove the dial indicator gauge, the
the nearest tenth of a millimeter if the value magnetic stand and the special tools.
ends in 0.06 mm and above.
V9810261
19. Using the special tool, remove the

differential bearing cup and the measuring
shim.
308-045
1
ELE0002341
ELE0001416
17. Calculate the required adjusting shim
thickness.
• Thickness of adjusting shim = measuring 20.
CAUTION: The Belleville washers must
shim (3.80 mm) + average value (0.73 mm) be installed with the inner diameter of both
+ bearing pre-load (0.14 mm) – thickness of washers touching.
the Belleville washers (4.42 mm)
Install the measured adjusting shim.
• Example: Adjusting shim = 3.80 mm + 0.73
mm + 0.14 mm – 4.42 mm = 0.25 mm. 1. Install the Belleville washers.
• The thickness of the adjusting shim becomes 2. Install the measured adjusting shim.
0.2 mm (rounded down from 0.25 mm). 3. Install the bearing cone.
18. Separate the transaxle housing. • Using a suitable center punch, secure the
bearing cone.
• Install the blanking plugs.
• Turn the transmission approximately 180
degrees.
1
2
3
ELC1601669
2007.50 Focus 3/2007 G23119en

ASSEMBLY
21. Apply sealer on the inside edge of the Install the fifth gear housing gasket.
transaxle housing mating face.
ELE0021724
TIE0024022
26.
CAUTION: Make sure the snap rings are
22. Assemble the transaxle housing and tighten
in the correct position. Failure to follow this
the bolts.
instruction may cause damage to the fifth
gear housing.
Turn the snap rings to the position shown.
22 Nm
ELE0002245
23. NOTE: Install new input and output shaft TIE0037723

snap rings.
Raise the input and output shafts slightly
27. NOTE: Install new fifth gear housing
and install the snap rings.
retaining bolts.
Install the fifth gear housing.
17 Nm
ELE0021723
TIE0021725
24. Using a suitable thread die, clean all the
hole threads in the fifth gear housing.
28. Remove the transaxle from the mounting
25. NOTE: Install a new fifth gear housing
stand.
gasket.
2007.50 Focus 3/2007 G23119en

ASSEMBLY
29. NOTE: The transaxle housing must not • Correct installation position for the selector
contact the press table. Support the input shaft interlock mechanism.
shaft splines.
Using the special tool and a suitable press,
install the fifth gear.
308-045
ELE0002248
33. Install the selector shaft interlock

TIE0021726
mechanism.
• Apply sealant to the thread.
30. Mount the transaxle on the mounting stand.
31. NOTE: Install a new fifth gear snap ring.
25 Nm
Install the fifth gear snap ring.
1. Install the snap ring onto the special tool.
2. Install the special tool and push on the snap
ring.
308-076
TIE0023947
2
34. NOTE: Align the gear synchronizer to the
1 marks.
Assemble the fifth gear synchronizer.
1. Fifth gear.
ELE0002247
2. Synchronizer ring.
3. Synchronizer assembly.
4. Retaining plate.
32. Make sure that the selector shaft is in the
neutral position.
4
1
TIC1601741
2007.50 Focus 3/2007 G23119en

ASSEMBLY
35. NOTE: Install a new fifth gear synchronizer • Install the bellows.
assembly snap ring.
NOTE: Use a new selector fork retaining pin.
25 Nm
Install the fifth gear synchronizer assembly
and the selector fork.
• Install the retaining pin.
• Install the snap ring.
TIE0024061
39. Engage the fifth gear.

• Turn the selector shaft clockwise as far as
possible and push the shaft in.
TIE0021728
36. Apply sealer evenly to the inside edge of

the fifth gear housing mating face.
TIE0023956
40. NOTE: Install new halfshaft oil seals.

Using the special tools, install both halfshaft
oil seals (left-hand side shown).
TIE0021730
308-039
37. Install the fifth gear housing cover.
12 Nm
TIE0023957
TIE0023949
38. Install the selector lever.
2007.50 Focus 3/2007 G23119en

ASSEMBLY
41. Install the gearshift cable bracket. 2. Install the retaining pin.
20 Nm 1
ELE0001542
TIE0024065
42. NOTE: Install a new snap ring. 45.

CAUTION: Using suitable adhesive tape,
Install the gearshift lever. cover the input shaft splines to prevent
damage to the input shaft oil seal.
2. Install the protective cap (if equipped). Position the input shaft oil seal.
2 1
TIE0024060 TIE0029451
43. Install the selector mechanism cover. 46.

CAUTION: Do not apply grease on any
parts of the clutch slave cylinder.
Install the clutch slave cylinder.
• Tighten the bolts evenly. In doing so, press
the input shaft oil seal into the transmission
housing.
5 Nm
ELE0002490
44. Install the vehicle speed sensor (VSS) (if

equipped).
10 Nm
1. Push in the VSS.
TIE0029733
2007.50 Focus 3/2007 G23119en

ASSEMBLY
shaft splines.
of grease.
2007.50 Focus 3/2007 G23119en

INSTALLATION

Special Tool(s) 2.
Support Bar, Engine sleeves are installed.
303-290A Move the transmission into position using
the transmission jack and install.
303290A

303-290-03A
2114003
ELE0001101

303-290-13 3. NOTE: Perform this and the following
operation simultaneously.
Install the right-hand transmission bolt.
30329013
48 Nm
303-290-15
E42950
General Equipment TIE45138

Transmission jack
Retaining straps 4. Install the left-hand transmission bolt.
Materials
Name Specification
High-temperature ESD-M1C220-A
grease 48 Nm
Installation
All vehicles TIE45141
1. Secure the transmission on the transmission

jack using suitable retaining straps. 5. Remove the retaining straps.
2007.50 Focus 3/2007 G400663en

INSTALLATION
6. Remove the transmission jack. Install the rear engine mount.
7. Install the right-hand transmission bolts.
48 Nm
TIE40728
TIE45139
12.
CAUTION: If brake fluid comes into
8. Install the transmission lower bolts. contact with the paintwork, rinse off the
affected areas with cold water without
delay.
NOTE: Make sure the spring clip is seated
correctly.
48 Nm Connect the clutch slave cylinder line to the
48 Nm
TIE45142
9. Raise the engine / transmission assembly

slightly using the special tools.
TIE0026655

E44534

11. NOTE: Install new rear engine mount
retaining nuts.
NOTE: Do not tighten the rear engine mounting
retaining nuts for the moment.
2007.50 Focus 3/2007 G400663en

INSTALLATION
14. Remove the special tools. 17. Remove the special tools on both sides
303-290-13
E0037886
TIE0036685

18. Attach the gearshift cables to the bracket
and lock by turning the catch
counter-clockwise.
E0037888

TIE0026568
19. Attach the gearshift and selector cables to

E0037887
TIE0028774
2007.50 Focus 3/2007 G400663en

INSTALLATION
20. Install the gearshift cable cover. 25. NOTE: Install new flexible pipe gaskets and
nuts.
Attach the flexible pipe to the catalytic
converter.
51 Nm
TIE0026646

TIE40628
Halfshafts, Removal and Installation). 26. Attach the flexible pipe in the crossmember
rubber insulators.
23. Install the crashbox.
1. Install the M10 x 16 bolt.
2. Install the M10 x 25 bolt.
TIE39009
27. Remove the support sleeve or suitable

splints from the flexible pipe.
2 40 Nm 2
40 Nm
40 Nm 1
E49015
24. Install the engine roll restrictors.
80 Nm
TIE0014991
28. Install the radiator support bracket.

80 Nm
TIE0036809
2007.50 Focus 3/2007 G400663en

INSTALLATION
• Install the radiator support bracket left-hand 32. Install the transmission upper bolts.
retaining bolts.
25 Nm 48 Nm
TIE45136
TIE0037848

• Connect the starter motor connector.
• Install the radiator support bracket right-hand
retaining bolts.
25 Nm
47 Nm
TIE0026644
TIE0037850
34. Tighten the rear engine mount nuts.
148 Nm
48 Nm
E40729
E40677
2007.50 Focus 3/2007 G400663en

INSTALLATION
35. Attach the reversing lamp switch distributed in the transmission and the fluid
connector. level has dropped, and then add more
transmission fluid to the transmission until
the level is exactly at the bottom edge of
the filler hole.
TIE0026645
36. Remove the cable ties from the radiator.

TIE39686
sides.
Headlamp Assembly (417-01 Exterior Vehicles with global closing
Lighting, Removal and Installation). 44. Initialize the window winder motors.
38. Install the battery tray. For additional information, refer to: Door
Procedures).
and Installation).
Installation).
With: 5-Speed Manual Transmission (iB5)
Procedures).
transmission with transmission fluid until
the fluid level is just below the filler hole.
Wait a few minutes until the fluid has
2007.50 Focus 3/2007 G400663en

308-03B-1 With: 5-Speed Manual Transmission (MTX-75) 308-03B-1
.
SECTION 308-03B Manual Transmission/Transaxle —

Vehicles With: 5-Speed Manual Transmission (MTX-75)
CONTENTS PAGE
SPECIFICATIONS
Transmission Ratios....................................................................................................... 308-03B-2
Required Shim Thickness............................................................................................... 308-03B-2

Manual Transaxle............................................................................................................... 308-03B-5
Manual Transmission.......................................................................................................... 308-03B-5
Input and Output Shaft....................................................................................................... 308-03B-6
Power Flow......................................................................................................................... 308-03B-7
General Illustrations............................................................................................................ 308-03B-9

Manual Transaxle — Vehicles With: Manual Transaxle..................................................... 308-03B-12
GENERAL PROCEDURES
Bearing Check.................................................................................................................... 308-03B-13
IN-VEHICLE REPAIR
Halfshaft Seal LH............................................................................................ (14 303 0) 308-03B-15
Halfshaft Seal RH........................................................................................... (14 304 0) 308-03B-16
REMOVAL
Transaxle — 2.0L Duratec-HE (MI4).............................................................. (16 114 0) 308-03B-17
DISASSEMBLY
Transaxle........................................................................................................ (16 118 8) 308-03B-23

Input Shaft.......................................................................................................................... 308-03B-28
Output Shaft........................................................................................................................ 308-03B-33
Differential...................................................................................................... (16 118 6) 308-03B-38
ASSEMBLY
Transaxle........................................................................................................ (16 118 8) 308-03B-42
INSTALLATION
Transaxle — 2.0L Duratec-HE (MI4).............................................................. (16 114 0) 308-03B-53
SPECIFICATIONS
Lubricants, Sealants and Adhesives
Item Specification
High-temperature grease ESD-M1C220-A
Grease SA-M1C9107-A
Sealant WSK-M2G348-A5
Manual transmission fluid WSD-M2C200-C
Capacities
Litres
Manual transmission oil (0- 5 mm below the lower edge of the filler hole) 1.9
Transmission Ratios
1.6L diesel engine 1.8L diesel engine 2.0L engine
First gear 3.667 3.800 3.417
Second gear 2.048 2.048 2.136
Third gear 1.345 1.345 1.448
Fourth gear 0.921 0.921 1.028
Fifth gear 0.705 0.705 0.805
Reverse gear 3.727 3.727 3.727
Final drive 3.412 3.410 4.067
Required Shim Thickness

Description Input shaft Output shaft Differential
assembly
Measuring shims (mm) 1.00 1.00 1.10
Determined end float (mm) + 0.22 + 0.33 + 0.36
Pre-load figure (mm) - + 0.13 + 0.33
End float (mm) - 0.07 - -
Required shim thickness (mm) = 1.15 = 1.46 = 1.79
Available shims (mm) 1.15 - 1.71 (in 0.01 1.31 - 1.91 (in 0.02 1.40 - 2.20 (in 0.05
mm steps) mm steps) mm steps)
Tightening Torques
Nut - lower suspension arm to steering knuckle 70 52 -
Nut and bolt - lower suspension arm to rear 130 96 -
subframe
Bolt - suspension strut upper mounting 30 22 -
Nuts - intermediate shaft centre bearing 25 18 -
Transmission bolts 48 35 -
2007.50 Focus 3/2007 G413428en

SPECIFICATIONS

Rear engine mounting bracket bolts 80 59 -
Engine roll restrictor to subframe 80 59 -
Engine roll restrictor to transmission 80 59 -
Rear engine mounting bolt 148 109 -
Rear engine mounting nuts 48 35 -
Ground cable bolt to transmission 18 13 -
Reverse gear idler shaft bolts 24 18 -
Transmission housing bolts 32 24 -
Clutch slave cylinder bolts 11 8 -
Transmission filler pipe blanking plug 35 26 -
Selector mechanism bolts 26 19 -
Gearshift cable bracket nuts 40 30 -
Subframe bolts 142 105 -
Subframe bracket bolts 10 - 89
Nuts - stabiliser bar connecting rod 25 18 -
Starter motor to transmission housing 35 26 -
Wiring harness bracket to starter motor 20 15 -
Catalytic converter - exhaust pipe 51 38 -
Catalytic converter - exhaust manifold 51 38 -
Bolt - catalytic converter bracket (vehicles built from 25 18 -
03/2004)
Intercooler 10 - 89
Bolt - intercooler air guide 20 15 -
Nut - intercooler air guide 10 - 89
Catalytic converter bracket (vehicles with 1.6L 48 35 -
diesel engine)
Reverse gear idler shaft mounting 34 25 -
Differential spur gear bolts 83 61 -
Subframe crashbox bolts 40 30 -
Bracket - turbocharger/intercooler connecting pipe 24 18 -
Coolant pipe bracket to transmission 24 18 -
Coolant pipe bracket to engine 25 18 -
Catalytic converter bracket (vehicles with 1.8L 25 18 -
diesel engine)
Exhaust manifold nuts. 25 18 -
Strengthening bar 30 22 -
2007.50 Focus 3/2007 G413428en

SPECIFICATIONS

Radiator support bracket bolts 25 18 -
2007.50 Focus 3/2007 G413428en

Manual Transaxle
Manual Transmission • Transmission with different axes (input and
output shafts)
MTX-75 means: • The final drive is integrated into the transmission
• M: Manual housing.
• T: Transmission • 5-speed manual transmission for FWD
• X: Transaxle (front wheel drive) • 1st/2nd gear double synchroniser
• 75: Distance between input and output shaft in • 3rd/4th gear and 5th/reverse gear single
mm. synchroniser
Overview
7 1
E55351
2007.50 Focus 3/2007 G428671en


Number Number
1 Transaxle housing - clutch side 5 Reverse gear idler
2 Input shaft 6 Transaxle housing - transaxle
side
3 Differential assembly
7 Selector mechanism
4 Output shaft
Input and Output Shaft
1 2 3 4 5 6 7 8
10
11
19 18 17 16 15 14 13 12
E56211

Number Number
1 Reverse gear idler 9 Input shaft
2 Reverse gear teeth 10 Output shaft
3 Gear wheel - 5th gear 11 Teeth - output shaft
4 Gear wheel - 4th gear 12 Gear wheel - 1st gear
5 3rd/4th gear synchroniser 13 1st/2nd gear synchroniser

assembly assembly
6 Gear wheel - 3rd gear 14 Gear wheel - 2nd gear
7 Teeth - 2nd gear 15 Gear wheel - 3rd gear
8 Teeth - 1st gear 16 Gear wheel - 4th gear
2007.50 Focus 3/2007 G428671en


Number Number
17 Gear wheel - 5th gear 4 Gear wheel - 1st gear
18 5th/reverse gear synchronizer 5 1st/2nd gear synchroniser
assembly assembly
19 Gear wheel - reverse gear 6 Teeth - 1st gear
All gear wheels are constantly engaged. 2nd gear
The output shaft teeth are part of the output shaft
and are constantly engaged with the differential
6 1
crown wheel.
In the neutral position, none of the gear wheels is
connected with the input or output shaft via the
corresponding synchroniser assembly. No torque
is transmitted to the differential. 2
The input and output shafts are respectively
mounted by means of tapered roller bearings in
the halves of the transaxle housing on the clutch 3
5 4
and transaxle sides. ELV1601165
This bearing arrangement requires the shafts to

be preloaded. Item Part Description
Number
The 3rd/4th gear synchroniser assembly is located
on the input shaft. 1 Input shaft
The 1st/2nd gear and 5th/reverse gear 2 Output shaft
synchroniser assemblies are located on the output
shaft. 3 Teeth - output shaft
4 1st/2nd gear synchroniser
assembly
Power Flow
5 Gear wheel - 2nd gear
1st gear
6 Teeth (2nd gear)
6 1 3rd gear
5 6 1
5 2
4 3
ELV1601164
Item Part Description 4 3

ELV1601166
Number
1 Input shaft Item Part Description
2 Output shaft Number
3 Teeth - output shaft 1 Input shaft

2 Output shaft
2007.50 Focus 3/2007 G428671en

Item Part Description 5th gear

Number
3 Teeth - output shaft 6 1
4 Gear wheel - 3rd gear

5 3rd/4th gear synchroniser
assembly
2
4th gear 5 4 3
ELV1601168
5 6
1
Number
1 Input shaft
2 Output shaft
2
3 Teeth - output shaft
3 4 Gear wheel - 5th gear

4
ELV1601167
5 5th/reverse gear synchronizer
assembly
Number 6 Gear wheel - 5th gear
1 Input shaft Reverse

2 Output shaft
3 Teeth - output shaft 6 1
7
4 Gear wheel - 4th gear
6 3rd/4th gear synchroniser 2
assembly
4 3
ELV1601169
5

Number
1 Input shaft
2 Output shaft
3 Teeth - output shaft
4 5th/reverse gear synchronizer
assembly
5 Gear wheel - reverse gear
6 Reverse gear idler
7 Teeth - reverse gear
2007.50 Focus 3/2007 G428671en

General Illustrations
Input shaft
3
2 5
6
1 7
8
9
10
11
12
13
14
15
E37322
1 Input shaft 8 3rd/4th gear synchroniser assembly
2 Teeth - 2nd gear 9 Snap ring
3 Teeth - 1st gear 10 Synchronizer ring - 4th gear
4 Tapered roller bearing (clutch side) 11 Needle roller bearing - 4th gear
5 Needle roller bearing - 3rd gear 12 Gear wheel - 4th gear
6 Gear wheel - 3rd gear 13 Gear wheel - 5th gear
7 Synchronizer ring - 3rd gear 14 Snap ring

15 Tapered roller bearing (transaxle side)
2007.50 Focus 3/2007 G428671en

Output shaft
1
2
3
5
6 4
7
8
9
16 10
17 11
18 12
13 14
19
15
20
21
22
23
24
25
26
27
ELE0018461
1 Tapered roller bearing (clutch side) 8 Outer synchroniser ring - 1st gear
2 Teeth - output shaft 9 1st/2nd gear synchroniser assembly
3 Output shaft 10 Snap ring
4 Needle roller bearing - 1st gear 11 Outer synchroniser ring - 2nd gear
5 Gear wheel - 1st gear 12 Synchroniser cone - 2nd gear
6 Inner synchroniser ring - 1st gear 13 Inner synchronizer ring - 2nd gear
7 Synchroniser cone - 1st gear 14 Gear wheel - 2nd gear
2007.50 Focus 3/2007 G428671en

Item Description Reverse gear idler
15 Needle roller bearing - 2nd gear

1
18 Snap ring
19 Needle roller bearing - 5th gear
2
21 Synchroniser ring - 5th gear
22 5th/reverse gear synchronizer assembly
23 Snap ring 3
24 Reverse gear synchroniser ring
25 Reverse gear needle roller bearing
26 Gear wheel - reverse gear 4
27 Tapered roller bearing (transaxle side)
The reverse gear idler runs on a needle roller
bearing on the reverse gear idler spindle. 5
The reverse gear idler is driven by the input shaft.
Its function is to reverse the direction of rotation of ELV1601162
the output shaft in reverse gear.
Number
1 Mounting
2 Thrust washer
4 Needle roller bearing
5 Thrust washer
2007.50 Focus 3/2007 G428671en

Manual Transaxle — Vehicles With: Manual Transaxle

Testing).
2007.50 Focus 3/2007 G18097en

GENERAL PROCEDURES
Bearing Check
and resolve it.
ELV1601173

rollers.
ELV1601171
necessary.

excessive pre-load.
necessary.
ELV1601174

or if it is noisy.
ELV1601172

necessary.
ELV1601175
2007.50 Focus 3/2007 G21559en

GENERAL PROCEDURES
hardness.
lubrication.
ELV1601174

fatigue.
ELV1601175
2007.50 Focus 3/2007 G21559en

IN-VEHICLE REPAIR

Special Tool(s) • Drive the oil seal fully home using the special
tool.
205-115
205-1 15
15058
Remover, Halfshaft Oil Seal

308-208
ELE0001756
16074

Removal Removal and Installation).
2. Remove the halfshaft oil seal using the
special tool.
308-208
ELV9810271
Installation
1. Install the halfshaft oil seal using the special
tool.
2007.50 Focus 3/2007 G325471en

IN-VEHICLE REPAIR

Special Tool(s) • Drive the oil seal fully home using the special
tool.
205-115
15058
Remover, Halfshaft Oil Seal

308-208 205-115
TIE45579
16074

Front Halfshaft RH (205-04
Removal Front Drive Halfshafts, Removal and
Installation).
Front Halfshaft RH (205-04
Front Drive Halfshafts, Removal and
Installation).
2. Remove the halfshaft oil seal using the
special tool.
308-208
Installation
1. Install the halfshaft oil seal using the special
tool.
2007.50 Focus 3/2007 G325472en

REMOVAL

Special Tool(s) 2. Remove the battery carrier.
Support Bar, Engine For additional information, refer to: Battery
303-290A Tray - 2.0L Duratec-HE (MI4)/1.4L
303290A and Installation).
sides.
303-290-03A For additional information, refer to:
4. Attach the special tool on both sides
2114003 (right-hand side shown).

303-290-13
30329013
303-290-13
303-290A-15
TIE0036685
5. Secure the radiator to the lock panel with

E42950
cable ties.
6. Detach the gearshift cables from the selector
mechanism.
General Equipment
1. Press the selector cable catch and detach
Transmission jack
the selector cable from the selector lever.
Retaining straps 2. Press the gearshift cable catch and detach
the gearshift cable from the gear lever.
Cable ties
1
Removal
2
Installation).
E44563
2007.50 Focus 3/2007 G402265en

REMOVAL
7. Detach the gearshift cables from the 9. Disconnect the reversing lamp switch
abutment. connector.
1. Release the selector cable by turning the
catch counter-clockwise and detach from the
abutment.
2. Release the gearshift cable by turning the
abutment.
1 TIE0024487
10. Detach the ground lead from the rear

engine mounting bracket.
2 • Detach the wiring harness bracket from the
TIE44564
rear engine mounting bracket.
8. CAUTIONS:
If brake fluid comes into contact with the
paintwork, rinse off the affected areas with
cold water without delay.
Close off the clutch slave cylinder pipe

Detach the clutch slave cylinder pipe from
the clutch slave cylinder.
E49980
• Detach the clutch slave cylinder pipe from
11. Remove the transmission upper bolts.
the bracket.
• Detach the ground cable from the
transmission.
TIE0036726
E49976
2007.50 Focus 3/2007 G402265en

REMOVAL
12. Raise the vehicle. • Remove the radiator support bracket.
Jacking (100-02 Jacking and Lifting,
13. Remove the lower radiator cover.
TIE0037849
17. Remove the crash box.
E50539
E47211
18. Remove the engine roll restrictor rubber

mountings.
E40677
15. Remove the radiator support bracket bolts

(left-hand side shown).
TIE0036808

TIE0037847
16. Remove the radiator support bracket bolts Halfshafts, Removal and Installation).
2007.50 Focus 3/2007 G402265en

REMOVAL
21. Remove the cross brace. • Discard the gasket and retaining nuts.
51 Nm
TIE40628
E47216
22. Install a support sleeve or reinforcement 25. Detach the wiring harness bracket from the
on the flexible exhaust pipe. engine.
ELE0015370
TIE0014991
23. Detach the flexible pipe from the 26. Detach the starter motor from the engine.
crossmember rubber insulators. • Secure the starter motor to one side.
ELE0015471
TIE39009
24. Detach the flexible pipe from the catalytic

converter.
2007.50 Focus 3/2007 G402265en

REMOVAL
27. Install the special tools. 31. Remove the rear engine mounting bracket
(rear engine mounting shown removed for
clarity).
E44535
TIE44967

33. Lower the engine / transmission assembly

using the special tools.
E44534

30. Remove the bolt from the rear engine
mounting.
E44534
34. Remove the transmission lower bolts.
TIE0037845
E49978
2007.50 Focus 3/2007 G402265en

REMOVAL
35. Remove the right-hand transmission bolts.
TIE45137
36. Secure the transmission on the

transmission jack using suitable retaining
straps.
ELE0001101
37. Remove the left-hand transmission bolt.
E49979
38. Support the transmission using the

transmission jack and remove.
2007.50 Focus 3/2007 G402265en

DISASSEMBLY
Transaxle(16 118 8)
Remover, Drive Pinion Oil Remover, Halfshaft Oil Seal
Seal 308-208
205-078
16074
15048

205-078-01 Two tire levers
Hardwood drift
1504801
Disassembly
1.
CAUTION: All bearings are paired and
Remover, Differential Bearing
must not be mixed.
Outer Race
205-176 Mount the transmission on the assembly
stand using the special tool.
15074
Mounting Bracket,
Engine/Differential 303-435-06
205-329
15105A
205-329
TIE0021790
Mounting Stand
303-435
2. Remove the gearshift cable abutment.
21187
Mounting Bracket for 303-435

303-435-06
21031B
TIE45077
3. NOTE: Ensure that the selector mechanism

is in the neutral position.
2007.50 Focus 3/2007 G296693en

DISASSEMBLY
Remove the selector mechanism. • Discard the clutch slave cylinder bolts.
R1601202
TIE0037824
4. Remove the input shaft oil seals on both 7. Remove the transmission housing bolts.
sides using the special tool and discard
(left-hand side shown). 205-329
308-208
303-435-06
TIE45074
ELV9810271 8.
CAUTION: Do not drive out the
transmission housing locating dowels.
5.
CAUTION: Wrap the input shaft splines Separate the clutch housing from the
with adhesive tape in order to protect the transmission housing using two tire levers.
input shaft oil seal.
Degrease the input shaft splines.
6.
CAUTION: Only remove the clutch slave
cylinder / release bearing assembly if it is
damaged or leaking.
Remove the clutch slave cylinder / release
bearing assembly.
• Detach the boot.
TIE0026087

shaft splines.
10. NOTE: Tilt the differential slightly.
Remove the differential assembly.
2007.50 Focus 3/2007 G296693en

DISASSEMBLY
• Remove the magnetic disc. 3. Remove the 5th/reverse gear selector fork.
2
1
ELV1601183 TIE0021794
11. Remove the bolts from the reverse gear 14. Remove the reverse gear idler shaft
idler shaft mounting. mounting.
• Turn the input shaft and output shaft to the
side in order to move the reverse gear idler
shaft mounting upwards.
• The reverse gear idler remains in the
transmission housing.
ELE0005831
12. Remove the selector rods.
TIE0026088
15. Remove the input shaft together with the

output shaft.
TIE0026201
13. Remove the selector forks.

1. Remove the 1st/2nd gear selector fork.
2. Remove the 3rd/4th gear selector fork.
ELV1601187
16. Remove the reverse gear idler.
2007.50 Focus 3/2007 G296693en

DISASSEMBLY
• Remove the needle roller bearing and thrust 19. Remove the input shaft bearing outer race
washers. and adjusting shim and the differential
bearing outer race and adjusting shim
205-176
TIE0021795
ELE0019829
17. Remove the differential bearing outer race
20. Remove the output shaft bearing outer race
and adjusting shim using the special tool.
205-176
205-078
205-078-01
ELE0019872
18. Remove the input shaft and output shaft V9210272

bearing outer races using the special tool.
21.
CAUTION: Only remove the reverse gear
idler shaft if it is damaged.
205-078 Remove and discard the reverse gear idler
shaft retaining bolts.
205-078-01
V9910271
ELV1601193
2007.50 Focus 3/2007 G296693en

DISASSEMBLY
22. Remove the reverse gear idler shaft using
a suitable hardwood drift.
ELV1601194
2007.50 Focus 3/2007 G296693en

Input Shaft
Special Tool(s)
Remover, Bearing (Main Disassembly
Tool)
205-295 (15-050A) All vehicles
1. NOTE: Use vise jaw protectors for all
operations in a vise.
15050A
Clamp the input shaft in a vise.
2. Using the special tools, remove the clutch
Collet for 205-295 housing roller bearing.
308-195 (16-060)
16060
Collet for 205-295

308-196 (16-061)
205-295
16061
308-196
Support Plate, Gear Removal
308-198 (16-063)
16063
Support Plate, Gear Removal

(Dia 81.2 mm)
308-230 (16-077) V9510272
ES16077
3. NOTE: When the roller bearing and the fifth
gear wheel are removed together, refer to
the following steps.
Materials
Name Specification
fluid
2007.50 Focus 3/2007 G37656en

Using the special tools, remove the transaxle • Discard the snap ring
housing roller bearing.
2
308-198
205-295
308-195
ELE0008645
V9610272

All except vehicles with diesel engine 5. NOTE: Using a suitable press, remove the
4. NOTE: Using a suitable press, remove the gear wheels.
gear wheels. Using the special tool, remove the fifth gear
Using the special tool, remove the fifth gear wheel and the transaxle housing roller
wheel and the transaxle housing roller bearing.
bearing. 1. Slide the snap ring up out of the annular
1. Slide the snap ring up out of the annular groove until it sits below the roller bearing.
groove until it sits below the roller bearing. 2. Using the special tool, remove the gear
2. Using the special tool, remove the gear wheel, snap ring and the roller bearing.
wheel, snap ring and the roller bearing.
2007.50 Focus 3/2007 G37656en

• Discard the snap ring. • Discard the snap ring.
2
308-230
TIE0023790
8. NOTE: Mark the position of the selector ring

in relation to the synchronizer hub to aid
installation. Components are paired.
NOTE: The detent balls are spring-loaded. Take
care when removing the selector ring from the
synchronizer hub.
Disassemble the third and fourth gear
synchronizer.
1. Remove the selector ring.
2. Remove the compression springs, blocker
ELE0021746 bars and detent balls.
All vehicles
6. Remove the fourth gear wheel.
1. Remove the gear wheel. 1
2. Remove the needle roller bearing.
3. Remove the synchronizer ring. 2
TIE0023793
2
1
9. Remove the third gear wheel.
1. Remove the synchronizer ring.
2. Remove the synchronizer cone.
3
3. Remove the gear wheel.
V1601200
7. Remove the third and fourth gear

synchronizer.
2007.50 Focus 3/2007 G37656en

4. Remove the needle roller bearing. 4. Install the synchronizer ring.
2 3
1 4
4 1
3 2
TIE0024438 TIE0024439
Assembly 4. NOTE: Observe the markings.

Assemble the third and fourth gear
1. NOTE: Use vise jaws protectors for all synchronizer.
1. Install the compression springs.
NOTE: Lubricate the synchronizer rings with 2. Install the blocker bars and detent balls.
manual transmission fluid before assembly.
3. Install the selector ring.
NOTE: If installing new roller bearings, do not
lubricate the bearings.
Carefully clean and check all sliding parts
and lubricate them with manual transmission 3
fluid before assembly.
2. Using a suitable length of tube, install the
clutch housing roller bearing.
1
2
V1601704
5. NOTE: Install the third and fourth gear

synchronizer with the large collar facing
outwards (towards to the fourth gear wheel).
Install the third and fourth gear synchronizer.
V1601702
1. Install the synchronizer.
3. Install the third gear wheel.

1. Install the needle roller bearing.
2. Install the gear wheel.
3. Install the synchronizer cone.
2007.50 Focus 3/2007 G37656en

2. Install the snap ring. 8. Using a length of suitable tube, install the
transaxle housing roller bearing.
1 2
TIE0023792
V1601208
6. Install the fourth gear wheel.
1. Install the synchronizer ring.
3. Install the gear wheel.
2
3
V1601700
7. NOTE: Install the fifth gear wheel with the

large collar facing outwards.
Using a length of suitable tube, install the
fifth gear wheel.
V1601207
2007.50 Focus 3/2007 G37656en

Output Shaft
Special Tool(s) 2. Remove the synchronizer ring.
Installer, Drive Pinion Bearing
205-068 (15-042)
15042
1
205-310 (15-091)
2
TIE0030886
TI15091 3. NOTE: If gear changes are difficult, carefully

remove the synchronizer hub assembly and
the fifth gear gearwheel
General Equipment Remove the fifth and reverse gear
Separating tool synchronizer hub assembly.
Materials 1. Remove the snap-ring.
2. Remove the synchronizer hub assembly.
Name Specification
2
Disassembly
1
1. Press off the transmission housing roller
bearing together with the reverse gear
gearwheel using the special tool.
205-310 V1601213
4. Remove the fifth gear gearwheel.

1. Remove the synchronizer ring.
2. Remove the fifth gear gearwheel.
TIE0021806 3
2
2. Remove the reverse gear synchronizer ring. 1
V1601214
2007.50 Focus 3/2007 G23120en

5. NOTE: Use the special tool with the flat side 4. Remove the outer synchronizer ring.
upwards.
Remove the fourth gear gearwheel using the
special tool. 2
• Remove the snap-ring. 3
4
1
205-310
TIE0030887
8. Remove the first and second gear

synchronizer hub assembly.
ELE0019910 1. Remove the snap-ring.
2. Remove the synchronizer hub assembly.
6. NOTE: Do not use Special Tool 205-310.
NOTE: Use the separating tool with the flat side 2
upwards.
Remove the second and third gear gearwheel
using a suitable separating tool. 1
ELE0019912
9.
CAUTION: Be careful when handling the
inner synchronizer ring and the synchronizer
cone.
E0019911 Remove the first gear gearwheel.
1. Remove the outer synchronizer ring.
7. 2. Remove the synchronizer cone.
3. Remove the inner synchronizer ring.
cone. 4. Remove the first gear gearwheel.
Remove the second gear synchronizer rings.

2. Remove the inner synchronizer ring.
3. Remove the synchronizer cone.
2007.50 Focus 3/2007 G23120en

5. Remove the needle roller bearing. 5. Remove the detent balls.
3
2 1
1
3
5
2
4
4
5
V1601220 V1601204
10. NOTE: Only remove the bearing if it is to Assembly

be renewed.
Remove the transmission housing roller 1.
bearing using the special tool. inner synchronizer ring and the synchronizer
cone. Lubricate the synchronizer rings with
transmission fluid prior to installation.
205-310 NOTE: Do not lubricate new roller bearings.
Carefully clean and check all parts and
lubricate sliding surfaces with transmission
fluid prior to assembly.
2.
cone.
TIE0021805 Install the first gear gearwheel.
11. 2. Install the first gear gearwheel.
CAUTION: Carefully remove the selector
ring from the synchronizer hub assembly. 3. Install the inner synchronizer ring.
The detent balls are spring-loaded. 4. Install the synchronizer cone.
5. Install the outer synchronizer ring.
NOTE: Mark the installed position of the selector
ring.
Disassemble the synchronizer hub assembly. 3
1. Remove the selector ring. 4
2. Remove the synchronizer body. 5
3. Remove the compression springs.
4. Remove the blocker bars. 1
V1601720
3. NOTE: Observe the markings.

Assemble the synchronizer hub assembly.
1. Install the compression springs.
2007.50 Focus 3/2007 G23120en

2. Install the blocker bar and the detent balls in 5. Install the second gear gearwheel.
the gear synchronizer hub against the force
of the spring.
3. Install the spring ring the correct way round
and push it on.
4
5
1
3
2
3
ELE0019915
1
6. Install the third gear gearwheel using the
2 special tool.
V1601704
4. NOTE: Install the synchronizer hub assembly

with the wider collar facing outwards
(towards the second gear gearwheel). 205-068
Install the first and second gear synchronizer

hub assembly.
1. Install the synchronizer hub assembly.
2. Install the snap-ring.
ELE0019916
1
7. NOTE: Install a new circlip.

2 Install the fourth gear gearwheel using the
special tool.
205-068
ELE0019914
5. Install the second gear gearwheel.

2. Install the outer synchronizer ring.
3. Install the synchronizer cone.
4. Install the inner synchronizer ring. ELE0019917
8. Install the fifth gear gearwheel.

2. Install the fifth gear gearwheel.
2007.50 Focus 3/2007 G23120en

3. Install the synchronizer ring. 11. Install the reverse gear gearwheel.
1. Install the synchronizer ring.
1
3. Install the reverse gear gearwheel.
2
3
2
3
V1601714
1
9. NOTE: Install the synchronizer hub assembly
with the narrower collar and the annular V1601712
groove facing outwards.
Installation position of fifth and reverse gear 12. Install the transmission housing roller
synchronizer hub assembly. bearing using a suitable tube.
V1601222
V1601711
10. NOTE: Install the synchronizer hub 13. Install the clutch housing roller bearing
assembly with the narrower collar and the using a suitable tube.
annular groove facing outwards.
Install the fifth and reverse gear synchronizer
hub assembly.
1. Install the synchronizer hub assembly.
2. Install a new snap ring.
2
V1601208
V1601713
2007.50 Focus 3/2007 G23120en

Differential(16 118 6)
Special Tool(s) 2. Using the special tools, remove the
differential roller bearing.
Adapter for 205-071 (Thrust
Pad)
205-071-01 (15-026A-01)
205-295
15026A01
Installer, Differential Bearing

205-081 (15-032)
308-197
15032
205-071-01
Tool)
205-295 (15-050A)
15050A
Collet for 205-295

308-197 (16-062)
TIE0025382
16062
Materials
Name Specification
fluid
Disassembly
All vehicles
NOTE: Use vise jaws protectors for all operations
in a vise.
1. Clamp the differential in a vise.
2007.50 Focus 3/2007 G37657en

3. Using the special tools, remove the Vehicles with diesel engine
differential roller bearing.
5. Remove the speedometer drive gear.
205-295
308-197
GC1444A
205-071-01
All vehicles
6. NOTE: Leave three ring gear retaining bolts
loosely installed. These should be evenly
distributed around the circumference of the
ring gear.
Remove the ring gear.
1. Loosen the bolts and remove seven retaining
bolts.
2. Using a soft faced hammer, lightly tap the
three remaining retaining bolts to release the
TIE0019950
ring gear from the differential case.
All except vehicles with diesel engine
4. Remove the vehicle speed sensor (VSS)
1
sensor ring. 2
2
TIE0024755
Assembly
ELE0019851
All vehicles
NOTE: If installing new roller bearings, do not
lubricate the bearings.
1. Carefully clean and check all parts and coat
with manual transmission fluid before
assembly.
2. NOTE: Use vise jaws protectors for all
2007.50 Focus 3/2007 G37657en

Clamp the differential in a vise. Install the VSS sensor ring.
3.
CAUTION: Tighten the ring gear retaining
bolts finger tight and then evenly by two
turns at a time to the specified torque.
NOTE: Install new ring gear retaining bolts.
Install the ring gear.
88 Nm ELE0019851
All vehicles
6. NOTE: Using a suitable press, install the
roller bearing.
V1601696
roller bearing.

4. NOTE: The speedometer drive gear must
snap into position. 205-081
Install the speedometer drive gear.
TIE0025741
7. NOTE: Using a suitable press, install the

roller bearing.
GC1444A

5. NOTE: The VSS sensor ring must snap into
position.
2007.50 Focus 3/2007 G37657en

roller bearing.
205-081
TIE0019949
2007.50 Focus 3/2007 G37657en

ASSEMBLY
Transaxle(16 118 8)
Remover/Installer, Front Mounting Bracket,
Wheel Hub Bearing Race Engine/Differential
204-017 205-329
14010 15105A
Installer, Front Wheel Hub Mounting Stand

Bearing Race/Oil Seal 303-435
204-050
14024
21187
Preload Gauge Mounting Bracket for 303-435

205-067 303-435-06
21031B
15041
Installer, Wheel Hub Oil Seal Mounting Plate for

205-075 303-435-06
303-435-14A
ES21212
15036
Installer, Drive Pinion Oil Seal Compressor, Valve Spring

205-115 303-060
15058 21024
Socket, Drive Pinion Nut Adapter for 303-060

205-175 303-060-02
2102402
15073
2007.50 Focus 3/2007 G296698en

ASSEMBLY
Special Tool(s) Install the reverse gear idler shaft.
Adapter for 303-060 1. Apply sealer to the housing in the area of the
303-060-07 of the reverse gear idler shaft mating surface.
2. Install the reverse gear idler shaft with a
locating bolt.
3. Remove the locating bolts and screw in new
2102407
bolts (three bolts).
2 24 Nm 3
Installer, Input Shaft Oil Seal
307-210
17041
1
Holding Fixture, Dial Indicator
Gauge (Output Shaft Bearing
V1601693
End Float)
308-194B
3.
CAUTION: The press force must not
exceed 15 kN.
16059A
NOTE: Install the bearing outer race using a
General Equipment suitable press.
Hot air gun Using the special tool, install the input shaft
bearing outer race into the transmission
Dial indicator gauge housing.
Magnetic base for dial indicator gauge • Heat up the transmission housing to
Temperature reduction spray approximately 80°C using a hot air gun.
• Cool the bearing outer races using
Materials temperature reduction spray and install.
Name Specification
307-210
Sealer WSK-M2G348-A5
Sealer ESKM-4G269-A
Assembly
1. NOTE: Check, thoroughly clean and if
necessary renew all components. TIE0021796
NOTE: Do not oil the taper roller bearing.
Coat all running surfaces with clean 4.
transmission fluid before assembly. exceed 15 kN.
2. NOTE: This operation is only necessary if NOTE: Install the bearing outer race using a
the reverse gear idler shaft has been suitable press.
removed.
NOTE: Install new reverse gear idler shaft retaining
bolts.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
Using the special tool, install the output shaft • Install a 1.00 mm measuring shim.
bearing outer race into the transmission • Heat up the clutch housing to approximately
housing. 80°C using a hot air gun.
• Heat up the transmission housing to • Cool the bearing outer races using
approximately 80°C using a hot air gun. temperature reduction spray and install.
temperature reduction spray and install.
204-017
205-075
TIE0021798
V9110273 7.
exceed 15 kN.
5.
CAUTION: The press force must not NOTE: Install the bearing outer race using a
exceed 15 kN. suitable press.
NOTE: Install the bearing outer race using a Install the output shaft outer bearing race in
suitable press. the clutch housing using the special tool.
Using the special tool, install the differential • Install a 1.00 mm measuring shim.
bearing outer race into the transmission • Heat up the clutch housing to approximately
housing. 80°C using a hot air gun.
• Heat up the transmission housing to • Cool the bearing outer races using
approximately 80°C using a hot air gun. temperature reduction spray and install.
205-075
204-050
TIE0021799
TIE0021797 8.
exceed 15 kN.
6.
CAUTION: The press force must not NOTE: Install the bearing outer race using a
exceed 15 kN. suitable press.
NOTE: Install the bearing outer race using a Install the differential bearing outer race in
suitable press. the clutch housing using the special tool.
Using the special tool, install the input shaft • Install a 1.10 mm measuring shim.
bearing outer race into the clutch housing.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
• Heat up the clutch housing to approximately Install the input and output shafts together.
80°C using a hot air gun.
204-050
GC1454A
TIE0021800
11. NOTE: Do not oil the taper roller bearing.
Install the differential.
4, gear engaged.
TIE45076
12. NOTE: Ensure that the transmission

housing mating surfaces are clean.
Attach the transmission housing to the
clutch housing.
• Attach the special tool.
V1601223
303-060-07
TIE45806
13. Tighten the transmission housing bolts.

1. Install the bolts.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
2. Install the studs. • Turn the input shaft approx. 20 times to settle
the bearings.
205-329 1 32 Nm 32 Nm 2
303-435-06
32 Nm 1
1 32 Nm
32 Nm 1
TIE45075

• Position the measuring rod on the 4th gear
wheel.
205-175
308-194B
TIE45242
TIE0021802
16. Attach the dial indicator gauge.
15. Align the input shaft for measuring using 2. Attach the magnetic base for dial indicator
the special tool. gauge.
3. Preload the dial indicator gauge to 1 mm and
zero.
3 2
303-435-14A 1
V1601228
17. NOTE: Perform the measurements three

times and calculate the average value from
the measurements. Zero the dial indicator
gauge after each measurement.
Measure the input shaft end float.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
1. Lift the input shaft using a suitable lever. Measure the output shaft end float.
2. Note the measurement result, e.g. 0.22 mm. • Lift the output shaft with a suitable lever and
• Example: 0.22 mm + 0.23 mm + 0.21 mm note the resulting measurement, e.g. 0.32
divided by three = 0.22 mm. mm.
• Example: 0.32 m + 0.34 mm + 0.33 mm
divided by three = 0.33 mm.
ELE0008644
20. Prepare the differential for measuring using

the special tool.
• Turn the input shaft 20 times while
simultaneously pressing down the differential.
• Preload the dial indicator gauge to 1 mm and
zero.
1
V1601229
18. Align the output shaft for measuring.

• Turn the output shaft approx. 20 times to
settle the bearings (via input shaft, refer to
previous steps).
• Attach the dial indicator gauge, preload to 1
mm and zero.
308-194B
205-175
TIE45674
TIE45241
19. NOTE: Carry out this and the following step

three times and calculate the average
measurement.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
21. NOTE: Carry out both this and the following 26. Remove the input shaft, output shaft and
step three times and calculate the average differential.
value.
27. Remove the bearing outer races, refer to
Measure the differential end float. previous steps.
• Lift the differential using the special tool and • Remove the input shaft bearing outer race.
note the measurement, e.g. 0.34 mm. • Remove the output shaft bearing outer race.
• Example: 0.34 mm + 0.36 mm + 0.38 mm • Remove the differential bearing outer race.
divided by three = 0.36 mm. • Remove the measurement shims.
28. Install the shims and bearing outer races,
refer to previous steps.
1. Install the required shims, refer to previous
steps.
2. Install the bearing outer races.
303-060 303-060-02
ELE0000595 1
22. Calculate the required input shaft shim

thickness.
• Installed measurement shim thickness: 1.00
mm. V1601692
• Measured input shaft end float: (e.g.) 0.22
mm.
• Preload figure: -0.07 mm. 29. Fabricate an installation hook for the
reverse gear idler.
• Shim required: 0.22 mm - 0.07 mm + 1.00
mm = 1.15 mm.
23. Calculate the required output shaft shim
thickness.
mm.
• Measured output shaft end float: (e.g.) 0.33
mm.
• Preload figure: 0.13 mm.
• Shim required: 1.00 mm + 0.33 mm + 0.13
mm = 1.46 mm.
24. Calculate the required differential shim
thickness.
mm.
• Measured differential end float: (e.g.) 0.36
mm.
• Preload figure: 0.33 mm.
• Shim required: 1.10 mm + 0.33 mm + 0.13
mm = 1.79 mm.
25. Detach the transmission housing from the
clutch housing.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
• Wire diameter: 3 mm 5. Install the reverse gear idler shaft mounting.
mm
V1601233 ELE0005836
30. Install the reverse gear idler. 31. NOTE: Install the reverse gear idler with the
narrow collar facing downwards.
1. Install the lower thrust washer.
2. Install the needle roller bearing. Insert the installation hook and install the
3. Install the reverse gear idler (narrow collar reverse gear idler shaft mounting.
facing downwards).
4. Install the upper thrust washer.
ELE0005837
32. NOTE: Lubricate the taper roller bearing

with transmission fluid.
Install the input shaft and the output shaft.
1. Insert the input and output shafts together
and move them to one side.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
2. Remove the installation hook. • Apply sealer to the bolts.
1
34 Nm
ELE0005921 ELE0005832
33. NOTE: The input shaft must be in the 35. NOTE: Ensure that the selector rods have
neutral position. the same installation height.
Install the selector forks. Install the selector rods.
1. Install the 5th/reverse gear selector fork.
2. Install the 3rd/4th gear selector fork.
3. Install the 1st/2nd gear selector fork.
3 TIE0026200
1
36. Install the differential.
TIE0021803
• Install the magnetic disc.
34. NOTE: If the holes for the bolts of the

reverse gear idler shaft mounting do not
line up exactly, check the installation
position of the reverse gear idler shaft
thrust washers.
Install the reverse gear mounting retaining
bolts.
ELV1601183
37. NOTE: Ensure that the threaded holes are

free of sealer.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
Apply sealer centrally to the indicated areas NOTE: Ensure that the threaded holes are free of
of the transmission mating surface and apply sealer.
inside the line of the threaded holes (bead NOTE: Observe the installation position of the long
diameter: 2 mm). bolt.
Apply sealer centrally to the transmission
mating surface and apply outside the line of
the threaded holes (bead diameter: 2 mm).
Install the selector mechanism.
1. Install the long bolt.
2. Install the short bolts.
2 26 Nm
TIE0036840
38. NOTE: The transmission housing must not

be turned before tightening the bolts.
Tighten the transmission housing bolts.
1 26 Nm
1. Install the bolts. 26 Nm 2
2. Install the studs. TIE44735
205-329 1 32 Nm 41.
32 Nm 2 CAUTION: If the torque is too high, all
the measurements (to establish the
required shim thickness) must be repeated.
Measure the torque using the special tools.
303-435-06 • 4, gear engaged.
32 Nm 1
1 32 Nm
32 Nm 1
TIE45075
39. Attach the gearshift cable abutment.

205-067 1 Nm
205-175
ELE0001504
42. NOTE: Install new input shaft oil seals.
40 Nm
TIE45078
40. NOTE: Ensure that no gear is engaged.

NOTE: Ensure that the selector mechanism is in
the neutral position.
2007.50 Focus 3/2007 G296698en

ASSEMBLY
Install the input shaft oil seals on both sides 45. Using the special tools, remove the
using the special tool (right-hand side transmission from the mounting stand.
shown).
303-435-06
205-1 15
205-329
TIE0021790
ELE0000593
43. CAUTIONS:
Wrap the input shaft splines with
adhesive tape in order to protect the input
shaft oil seal.
Do not lubricate the clutch slave cylinder.

NOTE: Install new clutch slave cylinder bolts.
Install the clutch slave cylinder/release
bearing.
• Apply sealer to the mating surfaces of the
clutch housing.
• Attach the boot.
11 Nm
TIE44676

shaft splines.
2007.50 Focus 3/2007 G296698en

INSTALLATION

Special Tool(s) 1. Raise the vehicle.
Support Bar, Engine For additional information, refer to:
303-290A Jacking (100-02 Jacking and Lifting,
303290A
2. Secure the transmission on the transmission
jack using suitable retaining straps.
Adapter for 303-290A 3. Thinly coat the input shaft splines with
303-290-03A grease.
4. Move the transmission into position using
the transmission jack and install.
2114003

303-290-13
30329013
ELE0001101
303-290A-15
5. NOTE: Perform this and the following
operation simultaneously.
Install the right-hand transmission bolt.
E42950
General Equipment 48 Nm
Transmission jack
Retaining straps
Materials
Name Specification
High-temperature ESD-M1C220-A
grease
Installation
All vehicles
sleeves are installed.
2007.50 Focus 3/2007 G402267en

INSTALLATION
6. Install the left-hand transmission bolt. 11. Raise the engine / transmission assembly
slightly using the special tools.
48 Nm
TIE45141
E44534
7. Remove the retaining straps.

8. Remove the transmission jack.
13. Install the rear engine mounting bracket
9. Install the transmission right-hand retaining
(rear engine mounting shown removed for
bolts.
clarity).
48 Nm
80 Nm
TIE45139
TIE44968
10. Install the transmission lower retaining

14. NOTE: Install new bolt on the rear engine
bolts.
mounting.
NOTE: Do not tighten the rear engine mounting
bolt for the moment.
Install bolt on the rear engine mounting.
48 Nm
48 Nm
TIE45142
TIE0037845
2007.50 Focus 3/2007 G402267en

INSTALLATION
15. Raise the vehicle. 19. Attach the starter motor to the engine.
16. Remove the special tools. 35 Nm
ELE0015472
20. Attach the wiring harness bracket to the

engine.
E44534

• Install the radiator support bracket bolts 20 Nm
ELE0015470
25 Nm
22. Remove the special tool on both sides
TIE0037848
18. Install the radiator support bracket bolts

303-290-13
TIE0036685
25 Nm
23. Remove the cable ties from the radiator.

sides.
TIE0037850 Headlamp Assembly (417-01 Exterior
2007.50 Focus 3/2007 G402267en

INSTALLATION
25. Raise the vehicle. 28. Hook the flexible pipe into the
crossmember rubber insulators.
26. NOTE: Install new flexible pipe gaskets and

nuts.
Attach the exhaust flexible pipe to the
catalytic converter.
TIE39009
51 Nm
29. Install the cross brace.
TIE40628
30 Nm
27. Remove the support sleeve or
reinforcement from the flexible exhaust
pipe. E47580

TIE0014991 32. Install the engine roll restrictors.
80 Nm
80 Nm
TIE0036809
2007.50 Focus 3/2007 G402267en

INSTALLATION
33. Install the crash box. 37.
1. Insert the M10 x 16 bolt. contact with the paintwork, rinse off the
2. Insert the M10 x 25 bolts. affected areas with cold water without
delay.
Connect the clutch slave cylinder line to the
• Attach the clutch slave cylinder pipe to the
bracket.
2 40 Nm 2
40 Nm
40 Nm 1
E49015

35. Install the transmission upper retaining
bolts.
• Attach the ground lead to the transmission.
TIE0036726

48 Nm General Information, General Procedures).
39. Attach the gearshift cables to the abutment.
1. Attach the gearshift cable to the abutment
and secure by turning the catches clockwise.
E49977 2. Attach the selector cable to the abutment
and secure by turning the catches clockwise.
36. Tighten the bolt on the rear engine
mounting.
148 Nm
TIE44565
E0037846 40. Install the gearshift cables on the shift

mechanism.
1. Press the gearshift cable catch and attach
the gearshift cable to the gear lever.
2007.50 Focus 3/2007 G402267en

INSTALLATION
2. Press the selector cable catch and attach the 43. Attach the reversing lamp switch
selector cable to the selector lever. connector.
E44566 TIE0024487
41. Adjust the selector cable. 44. Install the battery carrier.
For additional information, refer to: For additional information, refer to: Battery
Gearshift Cable Adjustment - Vehicles Tray - 2.0L Duratec-HE (MI4)/1.4L
With: 5-Speed Manual Transmission Duratec-16V (Sigma)/1.6L Duratec-16V
(MTX-75) (308-00 Manual (Sigma)/1.8L Duratec-HE (MI4) (414-01
Transmission/Transaxle and Clutch - Battery, Mounting and Cables, Removal
General Information, General Procedures). and Installation).
42. Attach the ground lead to the rear engine 45. Install the air cleaner.
mounting bracket.
• Attach the wiring harness bracket to the rear Cleaner - 2.0L Duratec-HE (MI4)/1.8L
engine mounting bracket. Duratec-HE (MI4) (303-12 Intake Air
Installation).
transmission with transmission fluid until
the fluid level is just below the filler hole.
18 Nm
E49981
35 Nm
E52022

2007.50 Focus 3/2007 G402267en

INSTALLATION
48. Install the lower engine cover.
E40677
49. Install the lower radiator cover.
E50539

51. Initialize window operating motors.
Procedures).
2007.50 Focus 3/2007 G402267en

308-03C-1 With: 5-Speed Manual Transmission (F35M-R) 308-03C-1
.
SECTION 308-03C Manual Transmission/Transaxle —

Vehicles With: 5-Speed Manual Transmission (F35M-R)
CONTENTS PAGE
SPECIFICATIONS

Manual Transaxle............................................................................................................... 308-03C-6
GENERAL PROCEDURES
Bearing Check.................................................................................................................... 308-03C-7
IN-VEHICLE REPAIR
Halfshaft Seal LH............................................................................................ (14 303 0) 308-03C-9
Halfshaft Seal RH........................................................................................... (14 304 0) 308-03C-10
REMOVAL
Transaxle........................................................................................................ (16 114 0) 308-03C-11
DISASSEMBLY
Transaxle............................................................................................................................ 308-03C-16

Input Shaft.......................................................................................................................... 308-03C-24
Output Shaft........................................................................................................................ 308-03C-30
Differential........................................................................................................................... 308-03C-38
ASSEMBLY
Transaxle............................................................................................................................ 308-03C-43
INSTALLATION
Transaxle........................................................................................................ (16 114 0) 308-03C-57
SPECIFICATIONS
Item Specification
High-Temperature Grease ESD-M1C220-A
Gear wheel clearance

Gear wheel Gear wheel inner Output shaft outer Clearance mm (in)
diameter mm diameter mm (in)
1st gear wheel 39.50 - 39.52 (1.555 - 39.45 - 39.47 (1.553 - 0.03 - 0.07 (0.002 - 0.003)
1.556) 1.554)
2nd gear wheel 35.20 - 35.22 (1.386 - 35.15 - 35.17 (1.384 - 0.03 - 0.07 (0.002 - 0.003)
1.387) 1.385)
Gear wheel Gear wheel inner Input shaft outer Clearance mm (in)
diameter mm (in) diameter mm (in)
3rd gear wheel 35.21 - 35.23 (1.386 - 35.15 - 35.17 (1.384 - 0.040 - 0.080 ( 0.0016 -
1.387) 1.385) 0.0031)
4th gear wheel 32.01 - 31.03 ( 1.260 - 31.95 - 31.97 (1.258 -
1.261) 1.259)
Gear wheel Gear wheel inner Fifth gear wheel sleeve Clearance mm (in)
diameter mm (in) outer diameter mm (in)
5th gear wheel 34.01 - 34.03 (1.3390 - 33.94 - 33.97 (1.3363 - 0.04 - 0.090 (0.0016 -
1.3397) 1.3374) 0.0035)
Thrust clearance
Gear Clearance mm (in) Maximum mm (in)
1st gear 0.05 - 0.28 (0.002 - 0.011) 0.33 (0.013)
2nd gear 0.18 - 0.51 (0.007 - 0.020) 0.56 (0.022)
3rd gear 0.06 - 0.21 (0.002 - 0.008) 0.26 (0.010)
4th gear 0.21 - 0.61 (0.008 - 0.024) 0.66 (0.026)
5th gear 0.06 - 0.26 (0.0024 - 0.0102) 0.31 (0.0122)
Shift fork and hub sleeve clearance

Clearance between Standard mm (in) Maximum mm (in)
1st/2nd shift fork and hub sleeve 0.10 - 0.36 (0.004 - 0.014) 0.86 (0.034)
3rd/4th shift fork and hub sleeve 0.20 - 0.50 (0.008 - 0.020) 1.00 (0.039)
5th shift fork and hub sleeve 0.40 - 0.75 (0.016 - 0.029) 1.25 (0.049)
Synchronizer ring clearance

Clearance between Standard mm (in) Minimum mm (in)
First gear wheel synchronizer cone 1.30 - 1.70 (0.052 - 0.066) 1.00 ( 0.039)
assembly and first gear wheel
2007.50 Focus 4/2007 G385333en

SPECIFICATIONS
Clearance between Standard mm (in) Minimum mm (in)

Third gear wheel synchronizer ring and 1.12 - 1.88 (0.044 - 0.074) 0.80 (0.031)
third gear wheel
5th/Reverse synchronizer ring and flank
surface of gear
Reverse gear idler and reverse lever clearance

Standard mm (in) Maximum mm (in)
0.10 - 0.32 (0.004 - 0.37 (0.015)
0.013)
Synchronizer lock size

Size at Length mm (in) Height mm (in) Thickness mm (in)
First, second and reverse gear 19.00 (0.748) 4.25 (0.167) 5.00 (0.197)
synchronizer hub
Third and fourth gear 17.00 (0.669)
synchronizer hub
Fifth gear wheel synchronizer 17.00 (0.669)
hub
Input shaft bearing race adjustment shims

Shim Thickness (mm) Shim Thickness (in)
0.10 0.004
0.20 0.008
0.30 0.012
0.40 0.016
0.50 0.020
0.60 0.024
Output shaft bearing race adjustment shims

0.15 0.006
0.20 0.008
0.25 0.010
0.30 0.012
0.35 0.014
0.40 0.016
0.45 0.018
0.50 0.020
0.55 0.022
0.60 0.024
2007.50 Focus 4/2007 G385333en

SPECIFICATIONS

0.65 0.026
0.70 0.028
Differential bearing race adjustment shims

0.10 0.004
0.15 0.006
0.20 0.008
0.25 0.010
0.30 0.012
0.35 0.014
0.40 0.016
0.45 0.018
0.50 0.020
0.55 0.022
0.60 0.024
0.65 0.026
0.70 0.028
0.75 0.030
0.80 0.031
0.85 0.033
0.90 0.035
Differential pinion gear backlash

Backlash mm (in) Thrust washer thickness mm (in)
0 - 0.1 (0 - 0.004) 2.0, 2.1, 2.2 (0.079, 0.083, 0.087)
Transaxle shaft runout

Shaft Runout mm (in) Thrust Clearance mm (in)
Input shaft runout at third gear wheel 0.050 (0.0020) 0.005 - 0.100 (0.0002 - 0.0039)
position
Output shaft runout at second gear -
wheel position
Engine and transaxle rear mount retaining bracket 80 59 -
retaining nuts
2007.50 Focus 4/2007 G385333en

SPECIFICATIONS
Engine rear mount retaining nuts 48 35 -
Engine rear mount retaining bolt 80 59 -
Crash-box retaining bolts 40 30 -
Engine support insulator 80 59 -
Exhaust flexible pipe to catalytic converter retaining 51 38 -
nuts
Transaxle wiring harness bracket retaining bolts 23 17 -
Transaxle ground cable retaining bolt 10 - 89
Transaxle housing retaining bolts 22 16 -
Input shaft retaining nut 150 111 -
Output shaft retaining nut 150 111 -
Fifth and reverse gear shift rod extension retaining 13 10 -
bolt
Fluid deflecting plate retaining bolt 10 - 89
Selector mechanism retaining bolts 22 16 -
Selector mechanism control end retaining bolt 30 22 -
Fluid drain plug 49 36 -
Differential guide plate right-hand retaining bolt 10 - 89
Differential guide plate left-hand retaining bolt 22 16 -
Shift lever assembly 22 16 -
Reversing lamp switch 25 18 -
Neutral switch 25 18 -
Differential preload 0.03 - 2.00 - 0.26 - 14.7
2007.50 Focus 4/2007 G385333en

Manual Transaxle
1. REFER to: Manual Transaxle and Clutch
Testing).
2007.50 Focus 4/2007 G385335en

GENERAL PROCEDURES
Bearing Check
and resolve it.
ELV1601173

rollers.
ELV1601171
necessary.

excessive pre-load.
necessary.
ELV1601174

or if it is noisy.
ELV1601172

necessary.
ELV1601175
2007.50 Focus 4/2007 G21559en

GENERAL PROCEDURES
hardness.
lubrication.
ELV1601174

fatigue.
ELV1601175
2007.50 Focus 4/2007 G21559en

IN-VEHICLE REPAIR

Installer, Drive Pinion Seal
seal.
15058
205-1 15

308-208 (16-074)
16074
ELE0001756
Materials 2. Install the left-hand halfshaft.

Name Specification For additional information, refer to: Halfshaft
LH (205-04 Front Drive Halfshafts, Removal
and Installation).
Removal transaxle with transmission fluid until the
fluid level is just below the bottom of the
1. Remove the left-hand halfshaft. filler hole.
For additional information, refer to: Halfshaft
LH (205-04 Front Drive Halfshafts, Removal
and Installation).
seal.
308-208
ELV9810271
2007.50 Focus 4/2007 G420773en

IN-VEHICLE REPAIR

seal.
15048 308-039

308-039 (16-018)
16018
ELE0001541
Materials 2. Install the right-hand halfshaft.

Name Specification For additional information, refer to: Halfshaft
RH (205-04 Front Drive Halfshafts, Removal
and Installation).
fluid
transaxle with transmission fluid until the
Removal fluid level is just below the bottom of the
filler hole.
For additional information, refer to: Halfshaft
RH (205-04 Front Drive Halfshafts, Removal
and Installation).
seal.
205-078
ELE0001550
2007.50 Focus 4/2007 G420774en

REMOVAL
Transaxle(16 114 0)
Special Tool(s) 5. Disconnect the reversing lamp and the
neutral switch electrical connectors.
Support Bar, Engine
303-290A
21140

303-290-13
E53286
30329013
6. Disconnect the vehicle speed sensor (VSS)

elecrical connector.
303-290-15
E42950
General Equipment
Retaining strap
Transmission jack
E53295
Removal
7. Remove the transaxle wiring harness.
Installation).
sides. E53334

4. Using suitable cable ties, secure the radiator
to the radiator grille opening panel.
2007.50 Focus 4/2007 G420738en

REMOVAL
8. Remove the transaxle wiring harness 12. Remove the right-hand side radiator
bracket. support bracket retaining bolts.
E53335 E53289
9. Remove the starter motor. 13.

For additional information, refer to: Starter flexible pipe may cause damage resulting
Motor - 1.6L (Z6) (303-06 Starting System, in failure.
10. Raise and support the vehicle. For suitable support wrap or suitable splint.
11. Remove the left-hand side radiator support
bracket retaining bolts.
TIE0014991

crossmember exhaust hanger insulators.
E53288
TIE39009

2007.50 Focus 4/2007 G420738en

REMOVAL
• Discard the gasket and nuts. 20. Install the special tools.
51 Nm
TIE40628 E0037887
16. Remove the engine support insulator. 21. Install the special tools.
TIE0036808
E0037888
17. Remove the left-hand halfshaft. 22. Install the special tools.
19. Install the special tools on both sides
E0037886
23.
Disconnect the clutch slave cylinder supply
line.
303-290-13
TIE0036685
2007.50 Focus 4/2007 G420738en

REMOVAL
• Remove the spring clip. 27. Remove the engine and transaxle rear
mount retaining bracket.
E53287
E53290
25. Detach the gearshift cables from the 28. Raise and support the vehicle. For
transaxle. additional information, refer to: (100-02
1. Detach the gearshift and selector cables from
the selector mechanism. Jacking (Description and Operation),
2. Press the locking pins together and detach Lifting (Description and Operation).
the gearshift and selector cables from the 29. Using the special tools, lower the engine
bracket. and transaxle assembly.
1
E52917
E0037886
26. Remove the engine and transaxle rear

mount.
TIE40728 E52870
2007.50 Focus 4/2007 G420738en

REMOVAL
33. NOTE: Secure the transaxle with a retaining
strap.
Using a suitable transmission jack, support
the transaxle.
TIE0028761
34. Remove the transaxle lower retaining bolts.
E52869
35. Using a suitable transmission jack, remove

the transaxle.
TIE0028761
2007.50 Focus 4/2007 G420738en

DISASSEMBLY
Transaxle
Socket, Drive Pinion Nut Calliper gauge
205-175 Dial indicator gauge
Drift
Feeler gauge
15073
CAUTIONS:
Mounting Bracket, Use vise jaw protectors.
Engine/Differential
205-329 Use a copper or plastic mallet to prevent
damage.
1. Using the special tools, mount the transaxle
15105A to the mounting stand.
Monting Stand 303-435

205-329
303-435 303-435-06
21187
Mounting Bracket for 303-435

303-435-06
TIE41234
2. Drain the transaxle fluid.

21031B • Allow the fluid to drain into a suitable
container.
Installer, Extension Housing 3. Disassemble the components in the order
Bushing/Seal indicated in the following illustration(s) and
308-045 table(s).
16015
2007.50 Focus 4/2007 G385341en

DISASSEMBLY
21
23 15
14 20
22 4
22
24 25
13 16
2
17
12 18
11 19
10
7
6 5
8 3
9 1
E53700
1 Fifth gear housing cover retaining bolts 13 Fifth gear wheel sleeve
2 Fifth gear housing cover 14 Fifth gear
3 Input shaft retaining nut 15 Retaining bolt

See Disassembly Detail 16 Washer
4 Output shaft retaining nut 17 Retaining bolt
18 Reversing lamp switch
5 Fifth gear wheel synchronizer sleeve
19 Reversing lamp switch washer
6 Fifth gear wheel synchronizer cone
20 Transaxle housing retaining bolts
7 Fifth gear wheel retaining plate
21 Transaxle housing
8 Fifth gear wheel selector fork
22 Fifth gear synchronizer spring
9 Fifth gear wheel selector fork retaining pin
23 Fifth gear synchronizer
10 Fifth gear wheel synchronizer hub See Disassembly Detail
11 Fifth gear wheel synchronizer ring 24 Fifth gear synchronizer lock
12 Fifth gear wheel 25 Fifth gear synchronizer hub
2007.50 Focus 4/2007 G385341en

DISASSEMBLY
45
26
44
21
27
39
40
43
28
52
30
53
29
31 51
38
32 50
33 48
36 47 46
34
35 37 49 41 42
E53341
26 Neutral switch 40 Push pin spring
27 Neutral switch washer 41 Selector fork assembly

28 Permanent magnet
42 Input shaft
29 Reverse gear idler lever
43 Output shaft
See Disassembly Detail 44 Differential
31 Fifth and reverse gear shift rod extension 45 Clutch housing

retaining bolt 46 Selector fork third/fourth gear
32 Fifth and reverse gear shift rod extension 47 Shift lock
33 Fifth and reverse gear shift rod 48 Control rod bushing
34 Fifth and reverse gear shift rod snap ring 49 Control rod bushing retaining pin
35 Selector lever retaining pin 50 Selector fork first/second gear
36 Selector lever 51 Control rod end
37 O-ring 52 Control rod end retaining pin
38 Selector lever fork 53 Control rod
39 Push pin
2007.50 Focus 4/2007 G385341en

DISASSEMBLY
67 68 60
69 65
66
70
59
58
72 57
73
61
71
56 77 62
54 75
55 76 63
74
64
E53347
54 Input shaft seal 66 Transaxle breather cover
55 Output shaft bearing race 67 Transaxle breather
56 Oil funnel 68 Vehicle speed sensor (VSS)
57 Differential guide plate retaining bolts 69 Differential seal
58 Differential guide plate 70 Differential bearing race

59 Differential guide plate bushing
71 Reverse lever spring
60 Sealing cap
See Disassembly Detail 72 Reverse lever spring retaining pin
61 Selector retaining pin 73 Reverse lever

See Disassembly Detail 74 Reverse lever shaft
62 Selector 75 Reverse lever shaft plug
63 Selector change arm retaining pin 76 Fluid drain plug
64 Selector change arm 77 Fluid drain plug washer
65 Control rod
2007.50 Focus 4/2007 G385341en

DISASSEMBLY
84 86
87 88
89
81 82 85
95 96 93
91
94
90 92
78
79
80
83
E53701
78 Transaxle bearing race 87 Selector mechanism control end retaining

See Disassembly Detail bolt
79 Transaxle bearing race adjustment shim 88 Selector mechanism control end washer
80 Transaxle bearing race adjustment shim 89 Selector mechanism control end lock
81 Differential bearing race 90 Selector mechanism control end

See Disassembly Detail 91 Selector mechanism control end spring
82 Differential bearing race adjustment shim 92 Selector mechanism control end spring
83 Differential seal washer
84 Selector mechanism retaining bolts 93 Selector shaft
85 Selector mechanism retaining pin 94 Seal
86 Selector mechanism 95 Fluid deflecting plate retaining bolt

96 Fluid deflecting plate
Disassembly Details
2007.50 Focus 4/2007 G385341en

DISASSEMBLY
Item 3 Input shaft retaining nut • Minimum clearance: 0.80 mm.
1. Using the special tool and a suitable wrench,
lock the input shaft and remove the input
shaft retaining nut.
205-175
E53091
2. Using a suitable dial indicator gauge and a

calliper gauge, measure the clearance
E53783
between the fifth gear wheel and the fifth
gear wheel sleeve.
Item 4 Output shaft retaining nut
• If the clearance is not within specification,
1. Using the special tool and a suitable wrench, install new components as necessary.
lock the input shaft and remove the output • Fifth gear wheel inner diameter: 34.01 mm -
shaft retaining nut. 34.03 mm.
• Fifth gear wheel sleeve outer diameter: 33.94
mm - 33.97 mm.
• Standard clearance: 0.04 mm - 0.09 mm
205-175
E53783
Item 12 Fifth gear wheel

E53346
1. Using a suitable feeler gauge, measure the
clearance between the fifth gear wheel and
the fifth gear wheel synchronizer ring. Item 23 Fifth gear synchronizer
• If the clearance is less than the minimum NOTE: Inspect the third and fifth gear synchronizer
specification, install a new fifth gear wheel for damage and wear and install new components
synchronizer ring. as necessary.
• Standard clearance: 1.12 mm - 1.88 mm. 1. Using a suitable feeler gauge, measure the
clearance between the fifth gear
synchronizer and the selector fork.
• If the clearance is greater than the maximum
specification, install a new first, second and
reverse gear synchronizer and a new selector
fork as a set.
• Standard clearance: 0.40 mm - 0.75 mm.
2007.50 Focus 4/2007 G385341en

DISASSEMBLY
• Maximum clearance: 1.25 mm. 2. Release the control rod end by shifting the
gears.
E53092
E53343
Item 30 Reverse gear idler
1. Using a suitable feeler gauge, measure the 3. Remove the selector fork assembly.
clearance between the reverse gear idler and • Raise the control rod end and the selector
the reverse gear idler lever. fork assembly.
specification, install a new reverse gear idler
and a new reverse gear idler lever as a set.
• Maximum clearance: 0.37 mm.
E53344
Item 60 Sealing cap

1. Move the control rod in the direction shown.
E53345
Item 41 Selector fork assembly

1. Align the shift lock and the control rod
bushing.
• Rotate the control rod counterclockwise.
E53351
E53342
2007.50 Focus 4/2007 G385341en

DISASSEMBLY
2. Using a suitable drift, remove the sealing Item 78 Transaxle bearing race
cap.
1. Using the special tool, remove the transaxle
bearing race.
308-045
E53353
E53358
Item 61 Selector retaining pin
1. Using a suitable drift, remove the selector Item 81 Differential bearing race
retaining pin.
• Align the selector with the clutch housing as bearing race.
shown.
308-045
E53355
E53350
Item 70 Differential bearing race

bearing race.
308-045
E53355
2007.50 Focus 4/2007 G385341en

Input Shaft
Remover, Bearing/Gear Installer, Extension Housing
205-310 Bushing/Seal
308-045
16015
TI15091
Remover, Bearing/Gear General Equipment

Feeler gauge
Two-leg puller
15092 Materials
Name Specification
table(s).
10 5
13
11
7
10
6
12
4
3
2
1
E53088
2007.50 Focus 4/2007 G385342en


1 Input shaft rear bearing 8 Input shaft front bearing
2 Fourth gear wheel 9 Input shaft
3 Fourth gear wheel synchronizer ring 10 Synchronizer spring
4 Snap ring 11 Selector ring
5 Third and fourth gear synchronizer hub 12 Synchronizer lock
assembly
See Disassembly Detail 13 Synchronizer hub
6 Third gear wheel synchronizer ring 2. Assemble the components in the order
7 Third gear wheel table(s).
NOTE: Coat all components with clean transmission oil before assembly.
9
4
7 3
4
8
10
11
12
13
E53096
1 Synchronizer hub 6 Input shaft front bearing

See Assembly Detail
2 Synchronizer lock
7 Third gear wheel
3 Selector ring See Assembly Detail
4 Synchronizer spring 8 Third gear wheel synchronizer ring
5 Input shaft 9 Third and fourth gear synchronizer hub
See Assembly Detail assembly
See Assembly Detail
2007.50 Focus 4/2007 G385342en

Item Description 4. Using a suitable feeler gauge, measure the

clearance between the fourth gear wheel and
10 Snap ring the input shaft rear bearing.
11 Forth gear wheel synchronizer ring • If the clearance is greater than the maximum
specification, disassemble the input shaft,
12 Fourth gear wheel
recheck all components for wear and damage
See Assembly Detail
and install new components as necessary.
13 Input shaft rear bearing • Standard clearance: 0.21 mm - 0.61 mm.
See Assembly Detail • Maximum clearance: 0.66 mm.
clearance between the second and third gear.
specification, disassemble the input shaft,
E53105
E53104
Disassembly Details
Item 1 Input shaft rear bearing Item 5 Third and fourth gear synchronizer hub
1. Using the special tools, remove the input assembly
shaft rear bearing. 1. Using the special tools, remove the third and
fourth gear synchronizer hub assembly.
205-311
205-311
205-310
205-310
E53089
E53089
2007.50 Focus 4/2007 G385342en

Item 8 Input shaft front bearing
1. Using a suitable two-leg puller, remove the
input shaft front bearing.
E53090
Assembly Details
Item 5 Input shaft 2. Third gear wheel location outer diameter:
35.15 mm - 35.17 mm.
NOTE: Inspect the input shaft for damage and wear
1 2
1. Using a suitable dial indicator gauge,
measure the input shaft runout at third gear
wheel position.
• If the value is greater than the maximum
runout, install a new input shaft.
• Maximum runout: 0.05 mm.
1 2
E53094

measure the inner diameter of the gear
wheels.
• If the diameter is not within specification,
install new components as necessary.
• Fourth gear wheel inner diameter: 32.01 mm
E53093
- 31.03 mm.
• Third gear wheel inner diameter: 35.21 mm
2. Measure the input shaft diameter where the - 35.23 mm.
third and fourth gear wheel is located.
1. Fourth gear wheel location outer diameter:
31.95 mm - 31.97 mm.
E53095
2007.50 Focus 4/2007 G385342en

Item 6 Input shaft front bearing Item 9 Third and fourth gear synchronizer hub
1. Using the special tool, install the input shaft assembly
front bearing. NOTE: Inspect the third and fourth gear
synchronizer hub assembly for damage and wear
and replace the components as necessary.
clearance between the selector ring and the
selector fork.
specification, install a new selector ring and
a new selector fork as a set.
• Maximum clearance: 1 mm.
E53092
308-045
2. Measure the synchronizer lock size.
E53101
• If the synchronizer lock measurements are
less than specification, install new
Item 7 Third gear wheel synchronizer locks.
1. Using a suitable feeler gauge, measure the • A: 17 mm.
clearance between the third gear wheel and • B: 4.25 mm.
the third gear wheel synchronizer ring. • C: 5 mm.
• If the clearance is less than the minimum
specification, install a new third gear wheel
synchronizer ring.
• Minimum clearance: 0.80 mm.
E53099
E53091
2007.50 Focus 4/2007 G385342en

3. Install the synchronizer spring, make sure Item 12 Fourth gear wheel
that the hooks on the synchronizer are
seated in the groove.
clearance between the fourth gear wheel and
the fourth gear wheel synchronizer ring.
specification, install a new fourth gear wheel
synchronizer ring.
• Minimum clearance: 0.80 mm.
E53098
4. Align the synchronizer ring grooves with the

synchronizer lock.
1. Synchronizer ring.
3. Selector ring. E53091
1 Item 13 Input shaft rear bearing

1. Using the special tool, install the input shaft
rear bearing.
• Make sure the bearing is fully seated.
3 2
E53100
5. Install the third and fourth gear synchronizer

hub assembly.
308-045
E53102
E53103
2007.50 Focus 4/2007 G385342en

Output Shaft
Adapter for 204-158 (Thrust Installer, Extension Housing
Pad) Bushing/Seal
204-158-01 308-045
16015
1403801
Installer, Differential Bearing Collet for 205-295

205-080 308-196
205080
16061
Remover, Bearing (Main General Equipment

Tool) Dial indicator gauge
205-295
Feeler gauge
Press
15050A
Two-leg puller
Materials
205-310 Name Specification
TI15091 indicated in the following illustration(s) and
table(s).
205-311
15092
2007.50 Focus 4/2007 G385343en

12
10
11
9
15
14
13
16 18 8
19
17
16
7
13
14
3
15
6
2
5
4 1
E53115
1 Output shaft front taper roller bearing 11 Output shaft rear taper roller bearing
2 Fourth gear 12 Output shaft
3 Snap ring 13 Outer synchronizer ring
4 Third gear 14 Synchronizer cone
5 Second gear wheel 15 Inner synchronizer ring

See Disassembly Detail 16 Synchronizer spring
6 Second gear synchronizer cone assembly 17 First, second and reverse gear
7 Snap ring synchronizer
8 First, second and reverse gear 18 Synchronizer lock

synchronizer hub assembly 19 Synchronizer hub
9 First gear wheel synchronizer cone
assembly
10 First gear wheel table(s).
2007.50 Focus 4/2007 G385343en

NOTE: Coat all components with clean transmission oil before assembly.
10
9 11
5
6 12
7 4
2
1
16
17 3
7 4
6 18
13
5
14 19
15
E53122
1 Synchronizer hub 12 First, second and reverse gear

synchronizer hub assembly
2 Synchronizer lock See Assembly Detail
3 First, second and reverse gear 13 Snap ring
synchronizer
14 Second gear wheel synchronizer cone
4 Synchronizer spring assembly
5 Inner synchronizer ring See Assembly Detail
6 Synchronizer cone 15 Second gear wheel
7 Outer synchronizer ring 16 Third gear
8 Output shaft 17 Snap ring

See Assembly Detail 18 Fourth gear
9 Output shaft rear taper roller bearing 19 Output shaft front taper roller bearing
10 First gear wheel 3. Using a suitable feeler gauge, measure the
See Assembly Detail clearance between the first gear wheel and
11 First gear wheel synchronizer cone the differential drive gear.
assembly • If the clearance is greater than the maximum
See Assembly Detail specification, disassemble the output shaft,
2007.50 Focus 4/2007 G385343en

• Standard clearance: 0.05 mm - 0.28 mm. • If the clearance is greater than the maximum
• Maximum clearance: 0.33 mm. specification, disassemble the output shaft,
E53106

clearance between the second and third gear.
E53107
Disassembly Details
Item 1 Output shaft front taper roller bearing • Shift the gears to first gear.
1. Using the special tools, remove the output
shaft front taper roller bearing.
205-311
205-295
205-310
308-196
E53117
E53116
Item 5 Second gear wheel

1. Using the special tools, remove the second
gear wheel and the third gear.
2007.50 Focus 4/2007 G385343en

Item 10 First gear wheel Item 11 Output shaft rear taper roller bearing
1. Using a suitable press, remove the first gear 1. Using the special tools, remove the output
wheel, the first gear wheel synchronizer cone shaft rear taper roller bearing.
assembly, and the first, second and reverse
gear synchronizer hub assembly.
205-295
308-196
E53118
204-158-01
E53119
Assembly Details
Item 8 Output shaft • Maximum runout: 0.015 mm
NOTE: Inspect the output shaft for damage and
wear and install new components as necessary.
measure the output shaft runout at second
gear wheel position.
• If the value is greater than the maximum
runout, install a new output shaft.
E53120
2. Measure the output shaft diameter where the

first and second gear wheel is located.
2007.50 Focus 4/2007 G385343en

1. First gear wheel location outer diameter: Item 9 Output shaft rear taper roller bearing
39.45 mm - 39.47 mm.
1. Using the special tool, install the output shaft
2. Second gear wheel location outer diameter: rear taper roller bearing.
35.15 mm - 35.17 mm.
1 2
205-080
1 2
E53121
E53123
3. Using a suitable dial indicator gauge, Item 10 First gear wheel

measure the inner diameter of the gear 1. Using the special tool and a suitable press,
wheels. install the first gear wheel, the first gear
• If the components are not with specification, wheel synchronizer cone assembly and the
install new components as necessary. first, second and reverse gear synchronizer
• First gear wheel inner diameter: 39.50 mm - hub assembly.
39.52 mm.
• Second gear wheel inner diameter: 35.20
mm - 35.22 mm. 205-080
E53124
Item 11 First gear wheel synchronizer cone

E53095
assembly
clearance between the first gear wheel
synchronizer cone assembly and the first
gear wheel.
specification, install a new first gear wheel
synchronizer ring.
2007.50 Focus 4/2007 G385343en

• Minimum clearance: 1 mm. • C: 5 mm.
E53099
E53091
Item 12 First, second and reverse gear 3. Install the synchronizer spring, make sure
synchronizer hub assembly that the hooks on the synchronizer are
seated in the groove.
NOTE: Inspect the third and fourth gear
synchronizer hub assembly for damage and wear
clearance between the first, second and
reverse gear synchronizer and the selector
fork.
specification, install a new first, second and
reverse gear synchronizer and a new selector
fork as a set.
• Standard clearance: 0.10 mm - 0.36 mm. E53098
Item 14 Second gear wheel synchronizer cone
assembly
clearance between the second gear
synchronizer cone assembly and the second
gear.
• If the clearance is not within the minimum
specification, install a new second gear
synchronizer ring.
E53092

• If the synchronizer lock size is not with
specification, install new synchronizer locks.
• A: 19 mm.
• B: 4.25 mm.
2007.50 Focus 4/2007 G385343en

• Minimum clearance: 1 mm.
E53091
Item 19 Output shaft front taper roller bearing

1. Using the special tools, install the output
shaft front taper roller bearing.
205-080
204-158-01
E53126
2007.50 Focus 4/2007 G385343en

Differential
Adapter for 204-158 (Thrust Collet for 205-295
pad) 308-196
204-158-01
1403801 16061
Installer, Differential Bearing General Equipment

205-080 Draft
Dial indicator gauge
205080 Materials
Name Specification
Tool) 1. Disassemble the components in the order
205-295 indicated in the following illustration(s) and
table(s).
15050A
1 2
7
8
10
9
3
4
3
6 5
E53075
2007.50 Focus 4/2007 G385344en


1 Pinion shaft retaining pin 8 Vehicle speed sensor (VSS) sensor ring
2 Pinion shaft
9 Differential lower taper roller bearing
3 Thrust elements See Disassembly Detail
4 Pinion gears 10 Differential case and ring gear
5 Thrust elements
6 Pinion side gears indicated in the following illustration(s) and
table(s).
7 Differential upper taper roller bearing
10 9
4
3
1
2
8
6
7
5
8 5 6
E53078
2007.50 Focus 4/2007 G385344en

Item Description • Attach the left and right-hand halfshaft into

the differential.
1 Differential case and ring gear • Support the halfshafts on wooden blocks.
2 Differential lower taper roller bearing • If the backlash is not within specification (0.0
See Assembly Detail - 0.1 mm), adjust it by installing thrust
elements between the differential case and
3 Vehicle speed sensor (VSS) sensor ring the pinion side gears.
See Assembly Detail • Thrust washer thickness: 2.0 mm, 2.1 mm,
4 Differential upper taper roller bearing 2.2 mm
See Assembly Detail • If it does not meet the specification even with
a 2.2 mm thrust element installed, replace
5 Pinion side gears the differential component.
6 Thrust elements
7 Pinion gears
8 Thrust elements
9 Pinion shaft
10 Pinion shaft retaining pin
See Assembly Detail
3.
CAUTION: Use thrust washers with the
same thickness on each side.
E53083
Using a suitable dial indicator gauge,
measure the backlash of both pinion gears.
Disassembly Details
2007.50 Focus 4/2007 G385344en

Item 7 Differential upper taper roller bearing Item 9 Differential lower taper roller bearing
1. Using the special tools, remove the 1. Using the special tools, remove the
differential upper taper roller bearing. differential lower taper roller bearing.
205-295
205-295
308-196
308-196
204-158-01
204-158-01
E53081
E53079
Assembly Details
Item 2 Differential lower taper roller bearing Item 3 Vehicle speed sensor (VSS) sensor ring
1. Using the special tool, install the differential 1. Install the vehicle speed sensor (VSS) sensor
lower taper roller bearing. ring in position.
205-080
E53077 E53080
2007.50 Focus 4/2007 G385344en

Item 4 Differential upper taper roller bearing
1.
CAUTION: Do not rest the differential on
the lower differential taper roller bearing.
upper taper roller bearing.
205-080
E53076
Item 10 Pinion shaft retaining pin

1. Using a suitable draft, install the pinion shaft
retaining pin in position.
E53082
2007.50 Focus 4/2007 G385344en

ASSEMBLY
Transaxle
Preload gauge Mounting Bracket for 303-435
205-067 303-435-06
21031B
15041
Installer, Drive Pinion Bearing Installer, Extension Housing

205-068 Bushing/Seal
308-045
15042 16015
Installer, Differential Bearing Rotator, Differential

205-080 308-165
205080
16072
Socket, Drive Pinion Nut Spacers, Transmission

205-175 Housing
308-206
15073 16069
Mounting Bracket, Measuring Fixture, Bearing

Engine/Differential Preload
205-329 308-627
15105A
E53840
Mounting Stand General Equipment

Feeler gauge
Materials
21187
Name Specification
2007.50 Focus 4/2007 G385345en

ASSEMBLY
Materials • Apply clean transmission fluid to all running

surfaces.
Name Specification
High-Temperature ESD-M1C220-A indicated in the following illustration(s) and
Grease table(s).
1. Clean and check all parts carefully before
assembly.
13 22 Nm 11
30 Nm 10
15
12
9 8
16
2 10 Nm 4
1
6 3
7
5
19
18
14
17
E53703
1 Fluid deflecting plate 11 Selector mechanism
2 Fluid deflecting plate retaining bolt 12 Selector mechanism retaining pin
3 Seal 13 Selector mechanism retaining bolts
4 Selector shaft 14 Differential seal

See Assembly Detail
5 Selector mechanism control end spring
washer 15 Differential bearing race adjustment shim
See Assembly Detail
6 Selector mechanism control end spring
16 Differential bearing race
7 Selector mechanism control end See Assembly Detail
8 Selector mechanism control end lock 17 Transaxle bearing race adjustment shim
9 Selector mechanism control end washer
10 Selector mechanism control end retaining
bolt
2007.50 Focus 4/2007 G385345en

ASSEMBLY

18 Transaxle bearing race adjustment shim 19 Transaxle bearing race
28 30 29 32 37
27
38
31 39
25 10 Nm 40
22 Nm 41
24
36
26
42 20
35
44 43
23 49 Nm 21 34
33
22
E53360
20 Fluid drain plug washer 32 Control rod
21 Fluid drain plug 33 Selector change arm
22 Reverse lever shaft plug 34 Selector change arm retaining pin
23 Reverse lever shaft 35 Selector
24 Reverse lever 36 Selector retaining pin
25 Reverse lever spring retaining pin 37 Sealing cap
26 Reverse lever spring 38 Differential guide plate bushing
27 Differential bearing race 39 Differential guide plate

See Assembly Detail 40 Differential guide plate retaining bolt
28 Differential seal 41 Differential guide plate retaining bolt
See Assembly Detail
42 Oil funnel
29 Vehicle speed sensor (VSS)
43 Output shaft bearing race
30 Transaxle breather See Assembly Detail
31 Transaxle breather cover 44 Input shaft seal
See Assembly Detail
2007.50 Focus 4/2007 G385345en

ASSEMBLY
53
72 25 Nm
54
21
71
59 55
58
70
68 47
69
45
67 13 Nm
60 46
66 48
49
62 51 52 56
65 64
63
61 50 57
E53410
45 Control rod 59 Push pin
46 Control rod end 60 Selector lever fork
47 Control rod end retaining pin 61 O-ring
48 Selector fork first/second gear 62 Selector lever

See Assembly Detail
49 Control rod bushing
63 Selector lever retaining pin
50 Control rod bushing retaining pin
64 Fifth and reverse gear shift rod snap ring
51 Shift lock
65 Fifth and reverse gear shift rod
52 Selector fork third/fourth gear
66 Fifth and reverse gear shift rod extension
53 Clutch housing See Assembly Detail
54 Differential 67 Fifth and reverse gear shift rod extension
55 Output shaft retaining bolt
See Assembly Detail 68 Reverse gear idler
56 Input shaft 69 Reverse gear idler lever
57 Selector fork assembly 70 Permanent magnet
See Assembly Detail
71 Neutral switch washer
58 Push pin spring
72 Neutral switch
2007.50 Focus 4/2007 G385345en

ASSEMBLY
77
150 Nm 94
75
84 83 22 Nm
76
76
74 73 78 22 Nm
81
85 96
80 25 Nm
86
87 79
88 91
82 12 Nm
92 93
97 10 Nm
90
89 150 Nm 95
E53702
73 Fifth gear synchronizer hub 90 Fifth gear wheel selector fork

See Assembly Detail
74 Fifth gear synchronizer lock
91 Fifth gear wheel retaining plate
75 Fifth gear synchronizer
92 Fifth gear wheel synchronizer cone
76 Fifth gear synchronizer spring
93 Fifth gear wheel synchronizer sleeve
77 Transaxle housing
94 Input shaft retaining nut
78 Transaxle housing retaining bolts See Assembly Detail
79 Reversing lamp switch washer 95 Output shaft retaining nut
80 Reversing lamp switch See Assembly Detail
81 Washer 96 Fifth gear housing cover
82 Retaining bolt 97 Fifth gear housing cover retaining bolts
83 Retaining bolt 3. Using a suitable dial indicator gauge,

measure the fifth gear thrust clearance.
84 Fifth gear
85 Fifth gear wheel sleeve specification, disassemble the transaxle,
86 Fifth gear wheel recheck all components for wear and damage
87 Fifth gear wheel synchronizer ring • Standard clearance: 0.06 mm - 0.26 mm.
88 Fifth gear wheel synchronizer hub
See Assembly Detail
89 Fifth gear wheel selector fork retaining pin
2007.50 Focus 4/2007 G385345en

ASSEMBLY
• Maximum clearance: 0.31 mm. 5. Using the special tools, remove the transaxle
from the mounting stand.
303-435
205-329
303-435-06
E53422
TIE41234
of grease
Assembly Details
Item 8 Selector mechanism control end lock Item 14 Differential seal
1. Using a suitable pipe, lock the selector shaft. 1. Using the special tool, install the differential
seal.
308-045
E53399
E53401
2. Install the selector mechanism control end
lock in the groove. Item 15 Differential bearing race adjustment
shim
1. Install the differential bearing race.
E53400
2007.50 Focus 4/2007 G385345en

ASSEMBLY
• Make sure the adjustment shims are 4. Install the special tool in the positions
removed. shown.
308-206
E53084
E53393
2. Install the differential. 5. Using the special tool, tighten the bolts to
specification.
308-206
E53085
308-206
E53394
3. Install the differential bearing race in the
special tool. 6. Using the special tool, settle the bearings.
• Install the special tool together with the • Rotate the special tool by the bars.
differential bearing on the differential lower
• Make sure the special tool gap is eliminated
taper roller bearing.
after the bearings are settled.
308-627
308-627
E53086
E53395
7. Using the special tools, measure the

differential preload.
2007.50 Focus 4/2007 G385345en

ASSEMBLY
• Required preload: 0.03 Nm - 2.00 Nm. 9. Remove the special tools.
308-206
205-067
308-165
E53396
308-206
E53394
8. Using the special tool and a suitable feeler 10. Install the selected adjusting shim and the
gauge, measure the clearance. differential bearing race.
Adjustment shim thickness (mm)
0.10 0.15 0.20 0.25
0.30 0.35 0.40 0.45
0.50 0.55 0.60 0.65
0.70 0.75 0.80 0.85
0.90 - - -
• Select the thickest adjustment shim nearest

to the measured clearance. E53398
11. Install the differential.

308-627
E53397
E53085
2007.50 Focus 4/2007 G385345en

ASSEMBLY
12. Install the transaxle housing to the clutch Item 17 Transaxle bearing race adjustment shim
housing and tighten the bolts to
1. Install the input shaft to the clutch housing.
specification.
2. Install the transaxle housing to the clutch
housing and tighten the bolts to
specification.
E53402
13. Using the special tools, measure the

E53402
differential preload.
• Required preload: 0.03 Nm - 2.00 Nm.
• If the preload is not within specification, measure the input shaft clearance.
repeat the differential preload measuring.
205-067
308-165
E53396
E53403

4. Select the closest adjustment shim on the
1. Using the special tool, install the differential thin side from the values given.
bearing race.
0.10 0.20 0.30
205-080
0.40 0.50 0.60
E53407
2007.50 Focus 4/2007 G385345en

ASSEMBLY
Item 18 Transaxle bearing race adjustment shim • Adjusting shim thickness range upper value:
output shaft end float + 0.08 mm (Example:
1. Install the oil funnel and the output shaft
0.22 mm + 0.08 mm = 0.30 mm)
bearing race to the clutch housing.
• Adjusting shim thickness range: 0.25 mm -
0.30 mm
5. Select the thickest adjustment shim in the
range from the values given.

0.15 0.20 0.25 0.30
0.35 0.40 0.45 0.50
0.55 0.60 0.65 0.70
E53404
• Adjusting shim thickness range: 0.25 mm -
2. Install the transaxle bearing race to the 0.30 mm. Select an 0.30 mm adjustment
transaxle housing. shim
Item 19 Transaxle bearing race

1. Using the special tool, install the transaxle
bearing race.
205-068
E53405

measure the output shaft end float.
E53408
• Example: output shaft end float 0.22 mm

bearing race.
205-080
E53406
4. Calculate the required adjusting shim

thickness range.
E53407
• Adjusting shim thickness range lower value:
output shaft end float + 0.03 mm (Example:
0.22 mm + 0.03 mm = 0.25 mm)
2007.50 Focus 4/2007 G385345en

ASSEMBLY
Item 28 Differential seal Item 55 Output shaft
1. Using the special tool, install the differential 1. Install the output shaft and the input shaft
seal. as an assembly.
308-045
E53401 E53411
Item 43 Output shaft bearing race Item 56 Input shaft

1. Using the special tool, install the output shaft 1. Install the input shaft and the output shaft
bearing race. as an assembly.
205-068
E53408 E53411
Item 44 Input shaft seal Item 57 Selector fork assembly

1. Using the special tool, install the input shaft 1. Shift to second gear and install the selector
seal. fork assembly as shown
205-068
E53409 E53412
2007.50 Focus 4/2007 G385345en

ASSEMBLY
2. Using a suitable scraper, install the push pin Item 62 Selector lever
spring and the push pin and hold it in
1. Install the selector lever.
position.
• Make sure the selector lever fork is fitted
between the selector change arm and the
control rod end.
• Align the selector lever pin hole with the
clutch housing pin hole.
E53413
3. Using a suitable scraper, push the selector

fork assembly with the control rod end
against the push pin. E53416
• The control rod lines up automatically with
the control rod coupling hole in the clutch Item 66 Fifth and reverse gear shift rod
housing. extension
1. Install the fifth and reverse gear shift rod
extension.
1. Install the reverse lever protrusion into the
fifth and reverse gear shift rod extension
groove.
2. Install the fifth and reverse gear shift rod into
the fifth and reverse gear shift rod extension.
1
E53414 2
4. Align the push pin with the control rod end

center groove.
• Shift the gears to neutral position.
• Turn the control rod end clockwise to set the
push pin.
E53418
2. Install the fifth and reverse gear shift rod

extension retaining bolt.
E53415
2007.50 Focus 4/2007 G385345en

ASSEMBLY
• Make sure the retaining bolt is properly • If the synchronizer lock measurements are
seated in the groove. less than specification, install new
synchronizer locks.
• A: 17 mm.
• B: 4.25 mm.
• C: 5 mm.
E53419
Item 69 Reverse gear idler lever

E53099
1. Install the reverse gear idler lever to the
marks.
Item 90 Fifth gear wheel selector fork

1. Install the fifth gear wheel selector fork
together with the fifth gear wheel
synchronizer hub assembly.
E53825
Item 88 Fifth gear wheel synchronizer hub

1. Assemble the fifth gear wheel synchronizer
hub.
E53421
• Top: fifth gear housing cover side
• Bottom: transaxle housing side Item 94 Input shaft retaining nut
lock the input shaft and install the input shaft
retaining nut.
205-175
E53420

E53783
2007.50 Focus 4/2007 G385345en

ASSEMBLY
Item 95 Output shaft retaining nut
lock the input shaft and install the output
shaft retaining nut.
205-175
E53783
2007.50 Focus 4/2007 G385345en

INSTALLATION
Transaxle(16 114 0)
Special Tool(s) Using a suitable transmission jack, position
Support Bar, Engine and install the transaxle.
303-290A
21140

303-290-13
TIE0028761
30329013

303-290-15
E42950
45 Nm
General Equipment
Retaining strap
Transmission jack
E52961
Materials
3. Remove the retaining strap and the
Name Specification
transmission jack.
Manual transmission WSD-M2C200-C 4. Lower the vehicle.
fluid
5. Install the transaxle upper retaining bolts.
Installation
All vehicles
1. CAUTIONS:
Use suitable retaining straps to secure 45 Nm
the transaxle on the transmission jack.
Make sure that the two locating dowels

are installed.
E52960
2007.50 Focus 4/2007 G420740en

INSTALLATION
6. Install the engine and transaxle rear mount Install the engine and transaxle rear mount.
retaining bracket.
80 Nm
TIE40728
E53291

1. Attach the gearshift cables to the bracket.
Lifting) 2. Attach the gearshift cables to the selector
mechanism.
8. Using the special tools, raise the engine and
transaxle assembly. 1
2
E52918

E0037886 Jacking and Lifting)
9. Lower the vehicle. Lifting (Description and Operation).
10. NOTE: Install new engine and transaxle rear 13. Remove the special tools.
mount retaining nuts.
NOTE: Do not tighten the engine and transaxle
rear mount retaining nuts at this stage.
E0037886
2007.50 Focus 4/2007 G420740en

INSTALLATION
14. Remove the special tools. 19.
NOTE: Make sure the spring clip is correctly
seated.
line.
E0037888
E53294
E0037887
16. Remove the special tools on both sides

105 Nm
E52954
21. NOTE: Install new exhaust flange nuts and

a new exhaust flange gasket.
303-290-13 Attach the exhaust flexible pipe to the
TIE0036685
17. Install the right-hand halfshaft. 51 Nm

Halfshafts, Removal and Installation). TIE40628
2007.50 Focus 4/2007 G420740en

INSTALLATION
22. Attach the exhaust flexible pipe to the • Install the left-hand side radiator support
crossmember exhaust hanger insulator. bracket retaining bolts.
25 Nm
E53293
TIE39009
23. Remove the support wrap or suitable splint 26. Lower the vehicle.
from the exhaust flexible pipe. 27. Install the starter motor.
Motor - 1.6L (Z6) (303-06 Starting System,
28. Tighten the engine and transaxle rear
mount retaining nuts.
103 Nm
TIE0014991 48 Nm

• Install the right-hand side radiator support
bracket retaining bolts.
E54696
29. Install the transaxle wiring harness bracket.
25 Nm
E53292
23 Nm
E53336
2007.50 Focus 4/2007 G420740en

INSTALLATION
30. Install the transaxle wiring harness. 34. Install the battery tray.
Installation).
10 Nm 36. Adjust the gearshift cables.
E53337
With: 5-Speed Manual Transmission
31. Connect the vehicle speed sensor (VSS) (F35M-R) (308-00 Manual
electrical connector. Transmission/Transaxle and Clutch -
transaxle until the transmission fluid level
is just below the bottom of the filler hole.
E53295 Vehicles with global closing

39. Initialize the power window motors.
32. Connect the reversing lamp and the neutral
switch electrical connectors.
Procedures).
E53286
33. Install the headlamp assembly.

2007.50 Focus 4/2007 G420740en

Manual Transmission/Transaxle External
Controls — Vehicles With: iB5/Manual
308-06A-1 Transaxle 308-06A-1
.
SECTION 308-06A Manual Transmission/Transaxle

External Controls — Vehicles With: iB5/Manual
Transaxle
CONTENTS PAGE
SPECIFICATIONS

External Controls................................................................................................................ 308-06A-3
Symptom Chart................................................................................................................... 308-06A-3
Pinpoint Tests..................................................................................................................... 308-06A-3

Gearshift Lever............................................................................................... (16 524 0) 308-06A-5
Gearshift Cables............................................................................................. (16 575 0) 308-06A-6
308-06A-2 Transaxle 308-06A-2
SPECIFICATIONS
Shift and selector cable bushing. 9 80
Gearshift mechanism to floor assembly 9 80
Exhaust flange bolts 47 35
Gearshift lever 5 44
2007.50 Focus 3/2007 G18149en

308-06A-3 Transaxle 308-06A-3
External Controls
2. Visually inspect for obvious signs of mechanical 5. If the concern is not visually evident, verify the
damage. symptom and refer to the Symptom Chart.
3. Make sure that the gearshift cables are correctly
routed and not under any tension from other
components.
Symptom Chart

• External controls do not • Gearshift cables incorrectly • ADJUST the gearshift cables.
operate freely. adjusted. REFER to: Gearshift Cable
Adjustment - Vehicles With:
5-Speed Manual Transmis-
sion (iB5) (308-00 Manual
Transmission/Transaxle and
Clutch - General Information,
• Gearshift lever damaged. • GO to Pinpoint Test A.
• Selector mechanism damaged.
• Gearshift cables damaged.
Pinpoint Tests
PINPOINT TEST A : STIFF GEARSHIFT
A1: CHECK THE GEARSHIFT LEVER
1 Detach the gearshift cables from the gearshift
lever.
• Is the gearshift lever difficult to operate?
→ Yes
Install a new gearshift lever.
REFER to: Gearshift Lever (308-06 Manual
- Vehicles With: iB5/Manual Transaxle,
→ No
GO to A2.
A2: CHECK THE GEARSHIFT CABLES
1 Attach the gearshift cables to the gearshift lever.
2007.50 Focus 3/2007 G37664en

308-06A-4 Transaxle 308-06A-4

2 Detach the gearshift cables from the transaxle.
→ Yes
Install new gearshift cables.
REFER to: Gearshift Cables (308-06 Manual
- Vehicles With: iB5/Manual Transaxle,
→ No
Install a new selector mechanism.
REFER to: Transaxle (308-03 Manual Trans-
Manual Transmission (iB5), Disassembly).
2007.50 Focus 3/2007 G37664en

308-06A-5 Transaxle 308-06A-5
Gearshift Lever(16 524 0)

Removal 2. Turn the shift cable abutment sleeve
counterclockwise and detach the shift cable
1. Remove the gearshift lever boot. from the bracket.
• Remove the gearshift lever knob.
E49962
E49959
2. Detach the gearshift cables from the • Discard the retaining bolts.
gearshift lever.
1. Detach the selector cable from the selector
lever.
2. Detach the shift cable from the shift lever.
11 Nm
2
E49963
Installation
E49961 1. NOTE: Install new gearshift lever retaining
bolts.
3. Detach the gearshift cables from the cable To install, reverse the removal procedure.
brackets.
1. Turn the selector cable abutment sleeve
For additional information, refer to: Gearshift
counterclockwise and detach the selector
Cable Adjustment - Vehicles With: 5-Speed
cable from the bracket.
Manual Transmission (iB5) (308-00 Manual
2007.50 Focus 3/2007 G419727en

308-06A-6 Transaxle 308-06A-6
Gearshift Cables(16 575 0)

Removal 4. Remove the gearshift cables cover.

and Operation).
2. Detach the gearshift cable heat shield and
move it backwards.
ELE0001700

transaxle.
1. Detach the gearshift cable and the selector
cable from the selector levers.
2. Turn the abutment sleeves counterclockwise
E50992 and detach the cables from the bracket.
3.
gearshift cables.
Detach the gearshift cables from the clip. 2
TIE0026442

7. Detach the gearshift cables from the front
retaining bracket.
TIE40780
E53226
2007.50 Focus 3/2007 G419728en

308-06A-7 Transaxle 308-06A-7
8. Detach the gearshift cables from the rear • Discard the gearshift cable bushing retaining
retaining bracket. nuts.
9 Nm
ELE0022812
E53227
9. Remove the gearshift lever. Installation

For additional information, refer to: Gearshift 1.
Lever (308-06 Manual CAUTION: Do not bend or kink the
Transmission/Transaxle External Controls gearshift cables.
- Vehicles With: iB5/Manual Transaxle, NOTE: Install new gearshift cable bushing retaining
Removal and Installation). nuts.
10. Cut the floor covering and the sound To install, reverse the removal procedure.
deadening material to gain access to the
gearshift cable bushing. 2. Adjust the gearshift cables.
Manual Transmission (iB5) (308-00 Manual
TIE0030582
11.
gearshift cables.
Remove the gearshift cables.
2007.50 Focus 3/2007 G419728en

Controls — Vehicles With: 5-Speed Manual
.
SECTION 308-06B Manual Transmission/Transaxle

External Controls — Vehicles With: 5-Speed Manual
Transmission (MTX-75)
CONTENTS PAGE
SPECIFICATIONS

External Controls................................................................................................................ 308-06B-3
Symptom Chart................................................................................................................... 308-06B-3
Pinpoint Tests..................................................................................................................... 308-06B-3

Gearshift Lever............................................................................................... (16 524 0) 308-06B-5
Gearshift Cables............................................................................................. (16 575 0) 308-06B-7
SPECIFICATIONS
Gearshift cable bushing retaining nuts 9 - 80
Gearshift linkage retaining bolts 11 8 -
2007.50 Focus 3/2007 G402269en

External Controls
2. Visually inspect for obvious signs of mechanical 5. If the concern is not visually evident, verify the
damage. symptom and refer to the Symptom Chart.
3. Make sure that the gearshift cables are correctly
routed and not under any tension from other
components.
Symptom Chart

• External controls do not • Gearshift cables incorrectly • ADJUST the gearshift cables.
operate freely. adjusted. REFER to: Gearshift Cable
Adjustment - Vehicles With:
5-Speed Manual Transmis-
sion (MTX-75) (308-00
Manual Transmis-
Procedures).
• Gearshift lever damaged. • GO to Pinpoint Test A.
• Selector mechanism damaged.
• Gearshift cables damaged.
Pinpoint Tests
PINPOINT TEST A : STIFF GEARSHIFT
A1: CHECK THE GEARSHIFT LEVER
1 Detach the gearshift cables from the gearshift
lever.
→ Yes
Install a new gearshift lever.
REFER to: Gearshift Lever (308-06 Manual
- Vehicles With: 5-Speed Manual Transmis-
sion (MTX-75), Removal and Installation).
→ No
GO to A2.
A2: CHECK THE GEARSHIFT CABLES
1 Attach the gearshift cables to the gearshift lever.
2007.50 Focus 3/2007 G388132en


2 Detach the gearshift cables from the transaxle.
→ Yes
Install new gearshift cables.
REFER to: Gearshift Cables (308-06 Manual
- Vehicles With: 5-Speed Manual Transmis-
sion (MTX-75), Removal and Installation).
→ No
Install a new selector mechanism.
REFER to: Transaxle (308-03 Manual Trans-
Manual Transmission (MTX-75), Disas-
sembly).
2007.50 Focus 3/2007 G388132en

Gearshift Lever(16 524 0)

Removal • Remove the gearshift lever gaiter.
1. Remove the center console.

Console - 3-Door (501-12 Instrument Panel
E49959

gearshift lever.
25 Nm 1. Detach the selector cable from the selector
lever.
2. Detach the gearshift cable from the gearshift
TIE44890 lever.
3. Remove the center console reinforcing 2

element right-hand bracket.
• Detach the wiring harness bracket from the 1
center console reinforcing element bracket.
E49961

25 Nm
gearshift lever.
TIE44891 catch counter-clockwise and detach from the
gearshift lever.
4. Unscrew the gearshift lever knob.
2007.50 Focus 3/2007 G402272en

2. Release the gearshift cable by turning the
gearshift lever.
E49962

• Discard the gearshift lever bolts.
11 Nm
E49963
Installation
1. NOTE: Install new gearshift lever bolts.
Install the components in the reverse order.
Manual Transmission (MTX-75) (308-00
Manual Transmission/Transaxle and Clutch
- General Information, General Procedures).
2007.50 Focus 3/2007 G402272en

Gearshift Cables(16 575 0)

Removal
1. Remove the air cleaner. For additional information, refer to: Jacking
For additional information, refer to: Air (100-02 Jacking and Lifting, Description
Cleaner - 2.0L Duratec-HE (MI4)/1.8L and Operation)
Duratec-HE (MI4) (303-12 Intake Air / Lifting (100-02 Jacking and Lifting,
Distribution and Filtering, Removal and Description and Operation).
Installation) 5. Detach the gearshift cable heat shield and
/ Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel move it backwards.
(303-12 Intake Air Distribution and Filtering,
2. Detach the gearshift cables from the selector
mechanism.
1. Press the selector cable retainer and detach
the selector cable from the selector lever.
2. Press the shift cable retainer and detach the
shift cable from the shift lever.
E50992
2
6.
gearshift cables.
Detach the gearshift cables from the clip.
E44563
3. Detach the gearshift cables from the cable

brackets.
abutment sleeve counterclockwise and
detach from the bracket.
2. Release the shift cable by turning the
TIE40780

8. Remove the floor console.
1 Console - 3-Door (501-12 Instrument Panel
TIE44564
2007.50 Focus 3/2007 G402273en

9. Remove the gearshift console reinforcing 2. Detach the shift cable from the shift lever.
2
25 Nm
E49961
TIE44890
13. Detach the gearshift cables from the cable
10. Remove the gearshift console reinforcing brackets.
element right-hand bracket. 1. Release the selector cable by turning the
• Detach the wiring harness from the retaining abutment sleeve counterclockwise and
bracket. detach from the bracket.
2. Release the shift cable by turning the
2
25 Nm
1
TIE44891
11. Remove the gearshift lever knob. E49962

• Remove the gearshift lever boot.
14.
gearshift cables.
NOTE: Cut the carpet and the insulation pad to
gain access to the gearshift cable bushing.
Remove the gearshift cables.
E49959

gearshift lever.
1. Detach the selector cable from the selector
lever.
2007.50 Focus 3/2007 G402273en

• Discard the gearshift cable bushing retaining
nuts.
9 Nm
ELE0022812
Installation
1. NOTE: Install new gearshift cable bushing
retaining nuts.
Manual Transmission (MTX-75) (308-00
Manual Transmission/Transaxle and Clutch
2007.50 Focus 3/2007 G402273en

309-00-1 Exhaust System 309-00-1
.
SECTION 309-00 Exhaust System

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 309-00-2

Exhaust System.................................................................................................................. 309-00-3

Catalytic Converter — 1.6L (Z6)......................................................................................... 309-00-4
Catalytic Converter — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4).............................. 309-00-21
Exhaust Flexible Pipe..................................................................................... (25 004 0) 309-00-38
SPECIFICATIONS
Item Specification
Grease SA-M1C9107-A
Catalytic converter heat shield retaining nuts and 10 - 89
bolts
Catalytic converter to turbocharger retaining clamp 25 18 -
- Vehicles with diesel engine
Catalytic converter to front muffler and tailpipe 51 38 -
assembly retaining nuts - Vehicles with diesel
engine
Catalytic converter to front muffler and tailpipe 48 35 -
assembly retaining nuts - Vehicles with petrol
engine
Catalytic converter support bracket retaining bolts 25 18 -
Exhaust manifold retaining nuts - Vehicles with 1.6L 43 32 -
(Z6)
Exhaust manifold retaining nuts 51 38 -
Heated oxygen sensor (HO2S) 47 35 -
Catalytic monitor sensor 47 35 -
Engine support insulator retaining bolt 80 59 -
Headlamp leveling front sensor bracket retaining 8 - 71
bolt
Power steering lines bracket retaining bolts 23 17 -
Front axle crossmember rear retaining bolt 275 203 -
2007.50 Focus 5/2007 G407506en

Exhaust System
General Equipment

• Fuse(s)
• Loose or corroded
connector(s)

2007.50 Focus 5/2007 G537385en

Catalytic Converter — 1.6L (Z6)

Special Tool(s) • Discard the retaining bolt.
205-316 (15-097A)
15097A

211-020 (13-006)
TIE0027063
13006 3. Remove the engine upper cover.
General Equipment
Transmission jack
Securing strap
TIE39686
For additional information, refer to: Cowl
Panel Grille (501-02 Front End Body Panels,
TIE38834
2. Detach the steering column shaft from the

1
E50990
2007.50 Focus 5/2007 G407508en

6. Disconnect the heated oxygen sensor (HO2S) 9. Disconnect the EGR valve electrical
and catalytic monitor sensor electrical connector.
connectors.
E52686
TIE0037613
10. Remove the EGR valve and EGR housing

7. Remove the exhaust manifold to exhaust gas assembly.
recirculation (EGR) valve tube.
Manifold to Exhaust Gas Recirculation
(EGR) Valve Tube (303-08 Engine Emission
Control - 1.6L (Z6), Removal and
Installation).
8. Remove the EGR valve outlet tube.
Gas Recirculation (EGR) Valve Outlet Tube
(303-08 Engine Emission Control - 1.6L
(Z6), Removal and Installation). E52687

table(s).
2007.50 Focus 5/2007 G407508en

4 4
5
1
1
6
7
E52688
1 Catalytic converter heat shield retaining 5 Catalytic monitor sensor

nuts and bolts See Removal Detail
2 Heated oxygen sensor (HO2S) 6 Catalytic converter to rear muffler flange

retaining nuts
3 Catalytic converter heat shield See Removal Detail
4 Exhaust manifold retaining nuts 7 Exhaust hanger insulators
See Removal Detail
2007.50 Focus 5/2007 G407508en

9
8
E52010
Item Description
See Removal Detail
See Removal Detail
2007.50 Focus 5/2007 G407508en

10
11
E51138
Item Description
bolt
See Removal Detail
2007.50 Focus 5/2007 G407508en

12
E52689
Item Description 12. Install the components in the order

12 Catalytic converter table(s).
See Removal Detail
2007.50 Focus 5/2007 G407508en

309-00-10 Exhaust System 309-00-10
5
3
E52690
1 Catalytic converter 4 Exhaust hanger insulators

See Installation Detail 5 Catalytic converter to rear muffler flange
retaining nuts
3 Catalytic converter to catalytic converter See Installation Detail
support bracket retaining bolts
2007.50 Focus 5/2007 G407508en

309-00-11 Exhaust System 309-00-11
80 Nm 7
E51141
Item Description
bolt
2007.50 Focus 5/2007 G407508en

309-00-12 Exhaust System 309-00-12
9
8
E51142
Item Description
2007.50 Focus 5/2007 G407508en

309-00-13 Exhaust System 309-00-13
10
10 Nm 16
47 Nm 14
15
10 Nm 16
11
12
13 47 Nm
E52691
10 Exhaust manifold retaining nuts 15 Catalytic converter heat shield

11 Catalytic converter to catalytic converter 16 Catalytic converter heat shield retaining

support bracket retaining bolts nuts and bolts
12 Catalytic converter to rear muffler flange
retaining nuts
13 Catalytic monitor sensor
14 Heated oxygen sensor (HO2S)
2007.50 Focus 5/2007 G407508en

309-00-14 Exhaust System 309-00-14
13. Install the EGR valve and EGR housing 17. Connect the HO2S and catalytic monitor
assembly. sensor electrical connectors.
47 Nm
E52692 TIE0037613
14. Connect the EGR valve electrical connector. 18. Install the bulkhead extension panel.
1. Attach the panel to the retaining clips.
2. Install the retaining screws and washers.
E52686
2
15. Install the EGR valve outlet tube. E52011

Gas Recirculation (EGR) Valve Outlet 19. Install the cowl panel grille.
Tube (303-08 Engine Emission Control - For additional information, refer to: Cowl
1.6L (Z6), Removal and Installation). Panel Grille (501-02 Front End Body
16. Install the exhaust manifold to EGR valve Panels, Removal and Installation).
tube. 20. Install the engine upper cover.
Manifold to Exhaust Gas Recirculation
(EGR) Valve Tube (303-08 Engine
Emission Control - 1.6L (Z6), Removal and
Installation).
TIE44765
2007.50 Focus 5/2007 G407508en

309-00-15 Exhaust System 309-00-15
21. Attach the steering column shaft to the
shaft to steering gear pinion bolt. Failure
to follow this instruction may result in
personal injury.
NOTE: Make sure the road wheels are in the
28 Nm
TIE0027064
Removal Details
Item 5 Catalytic monitor sensor Support the exhaust flexible pipe with a
and Operation)
Item 6 Catalytic converter to rear muffler flange

retaining nuts
1. Remove the floor panel brace.
TIE0014991
3.
support the muffler and exhaust tailpipe
hanger insulators.
E47678
2. CAUTION: Take care when removing the
flexible pipe may cause damage resulting in exhaust hanger insulators to prevent
failure. damage.
2007.50 Focus 5/2007 G407508en

309-00-16 Exhaust System 309-00-16
Item 8 Tie-rod end retaining nut Item 11 Front axle crossmember
1. Remove both front wheels and tires. 1. Remove the right-hand front fender splash
shield.
and Installation).
2.
sides.
E40674
2. Detach the steering gear to power steering

fluid reservoir return line from the vehicle
body.
TIE0026775
3.
E52679
3. Using a transmision jack and a wooden
211-020 4.
E52983

2007.50 Focus 5/2007 G407508en

309-00-17 Exhaust System 309-00-17
5. Remove the front axle crossmember bracket 7.
power steering lines, only lower the front
axle crossmember sufficiently to allow the
catalytic converter to be removed.
Lower the front axle crossmember.

1. Remove the catalytic converter to catalytic
converter support bracket retaining bolts.
TIE44500

for clarity).
E51402
2. With the aid of another technician, remove

the catalytic converter.
TIE39071
Item 2 Exhaust manifold retaining nuts Install the exhaust manifold retaining nuts.
1.
CAUTION: Never use jointing compound
forward of the catalytic converter.
NOTE: Install a new exhaust manifold gasket and
nuts.
NOTE: Do not fully tighten the exhaust manifold
E51144
2007.50 Focus 5/2007 G407508en

309-00-18 Exhaust System 309-00-18
Item 3 Catalytic converter to catalytic converter Install the catalytic converter to rear muffler
support bracket retaining bolts flange retaining bolts.
1. NOTE: Do not fully tighten the catalytic
converter to catalytic converter support
bracket retaining bolts at this stage.
NOTE: Install new catalytic converter to catalytic
Install the catalytic converter to catalytic
E50213

1.
E51402 Using a transmission jack and the special
Item 4 Exhaust hanger insulators crossmember.
1. 1. Insert the alignment pins through the front
CAUTION: Take care when installing the axle crossmember alignment holes.
exhaust hanger insulators to prevent
damage.
Check the exhaust hanger insulators for sleeve.
damage. Install new exhaust hanger 3. Raise the front axle crossmember engaging
insulators if necessary. the alignment pins into the chassis aligning
holes.
Item 5 Catalytic converter to rear muffler flange
retaining nuts
205-316
1. NOTE: Install a new catalytic converter to 2
rear muffler flange gasket and nuts. 1
NOTE: Do not fully tighten the catalytic converter
to rear muffler flange retaining nuts at this stage.
TIE0000859
2.
retaining bolts.
2007.50 Focus 5/2007 G407508en

309-00-19 Exhaust System 309-00-19
Install the front axle crossmember retaining 8. Install the right-hand front fender splash
bolts (transmission jack removed for clarity). shield.
115 Nm
275 Nm
TIE39072 E40674
3. Install the front axle crossmember bracket Item 8 Tie-rod end retaining nut
on both sides.

70 Nm 1. NOTE: Use a 5 mm Allen key to prevent the
bar on both sides.
TIE44501 2. Install both front wheels and tires.
4. Remove the special tool. and Tire (204-04 Wheels and Tires, Removal
and Installation).
6. Lower and remove the transmission jack and Item 10 Exhaust manifold retaining nuts
the wooden block.
1. Lower the vehicle to gain access to the
7. Attach the steering gear to power steering exhaust manifold retaining nuts and bolt.
fluid reservoir return line to the vehicle body.
2. Tighten the exhaust manifold retaining nuts.
43 Nm
E52679
E53299
2007.50 Focus 5/2007 G407508en

309-00-20 Exhaust System 309-00-20
3. Raise and support the vehicle. 2. Install the floor panel brace.
and Operation)
Item 11 Catalytic converter to catalytic

converter support bracket retaining bolts
1. Tighten the catalytic converter to catalytic 30 Nm
E47580
3.
failure.
25 Nm Remove the exhaust flexible pipe support
wrap or splint.
E51403
Item 12 Catalytic converter to rear muffler

flange retaining nuts
1. Fully tighten the catalytic converter to rear
muffler flange retaining nuts.
TIE0014991
48 Nm
Item 15 Catalytic converter heat shield
2. Feed the H2OS wiring harness and the
catalytic monitor sensor electrical wiring
harness through the catalytic converter heat
shield.
E50598
2007.50 Focus 5/2007 G407508en

309-00-21 Exhaust System 309-00-21
Catalytic Converter — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE

(MI4)
Special Tool(s) • Discard the retaining bolt.
205-316 (15-097A)
15097A

211-020 (13-006)
TIE0027063
13006 3. Remove the oil filler pipe.

• Release the securing clip and rotate the oil
filler pipe counterclockwise.
General Equipment
Transmission jack
Securing strap
Centralize the steering and lock it in position. TIE44766
TIE38834
2. Detach the steering column shaft from the TIE39686

For additional information, refer to: Cowl
Panel Grille (501-02 Front End Body Panels,
2007.50 Focus 5/2007 G418602en

309-00-22 Exhaust System 309-00-22
6. Remove the bulkhead extension panel. 7. Disconnect the heated oxygen sensor (HO2S)
and catalytic monitor sensor electrical
connectors.
1
E50990 TIE0037613

table(s).
2007.50 Focus 5/2007 G418602en

309-00-23 Exhaust System 309-00-23
4
6
7
E51409
1 Catalytic converter heat shield retaining 5 Catalytic monitor sensor

bolts See Removal Detail
2 Catalytic converter heat shield 6 Catalytic converter to rear muffler flange

retaining nuts
3 Heated oxygen sensor (HO2S) See Removal Detail
4 Exhaust manifold retaining nuts and bolt 7 Exhaust hanger insulators
See Removal Detail
2007.50 Focus 5/2007 G418602en

309-00-24 Exhaust System 309-00-24
9
8
E52010
Item Description
See Removal Detail
See Removal Detail
2007.50 Focus 5/2007 G418602en

309-00-25 Exhaust System 309-00-25
10
11
E51138
Item Description
bolt
See Removal Detail
2007.50 Focus 5/2007 G418602en

309-00-26 Exhaust System 309-00-26
12
E51410
Item Description 9. Install the components in the order indicated

in the following illustration(s) and table(s).
12 Catalytic converter
See Removal Detail
2007.50 Focus 5/2007 G418602en

309-00-27 Exhaust System 309-00-27
E51411
1 Catalytic converter 4 Exhaust hanger insulators

2 Exhaust manifold retaining nuts and bolt
See Installation Detail 5 Catalytic converter to rear muffler flange
retaining nuts
3 Catalytic converter to catalytic converter See Installation Detail
support bracket retaining bolts
2007.50 Focus 5/2007 G418602en

309-00-28 Exhaust System 309-00-28
80 Nm 7
E51141
Item Description
bolt
2007.50 Focus 5/2007 G418602en

309-00-29 Exhaust System 309-00-29
9
8
E51142
Item Description
2007.50 Focus 5/2007 G418602en

309-00-30 Exhaust System 309-00-30
48 Nm 14
10 Nm 16
15
10 Nm 16
10
12
11
13 47 Nm
E51412
10 Exhaust manifold retaining nuts and bolt 14 Heated oxygen sensor (HO2S)
11 Catalytic converter to catalytic converter 15 Catalytic converter heat shield

support bracket retaining bolts See Installation Detail
See Installation Detail 16 Catalytic converter heat shield retaining
12 Catalytic converter to rear muffler retaining bolts
nuts
13 Catalytic monitor sensor
2007.50 Focus 5/2007 G418602en

309-00-31 Exhaust System 309-00-31
10. Connect the heated oxygen sensor (HO2S) 14. Install the oil filler pipe.
and catalytic monitor sensor electrical
connectors.
TIE44766
TIE0037613
15.
shaft to steering gear pinion bolt. Failure
11. Install the bulkhead extension panel.
to follow this instruction may result in
1. Attach the panel to the retaining clips. personal injury.
2. Install the retaining screws and washers. NOTE: Make sure the road wheels are in the
1 Attach the steering column shaft to the
2
E52011
12. Install the cowl panel grille. 28 Nm

For additional information, refer to: Cowl TIE0027064
Panel Grille (501-02 Front End Body
Panels, Removal and Installation).
13. Install the engine upper cover.
TIE39686
2007.50 Focus 5/2007 G418602en

309-00-32 Exhaust System 309-00-32
Removal Details
Item 5 Catalytic monitor sensor • Discard the gasket and nuts.
(100-02 Jacking and Lifting, Description CAUTION: Take care when removing the
and Operation) exhaust hanger insulators to prevent
/ Lifting (100-02 Jacking and Lifting, damage.
Item 6 Catalytic converter to rear muffler flange 1. Remove both front wheels and tires.
retaining nuts
1. Remove the floor panel brace. and Tire (204-04, Removal and Installation).
2.
sides.
E47678
2.
failure.
suitable support wrap or suitable splint. TIE0026775
3.
211-020
TIE0014991
3.
hanger insulators.
E52983
2007.50 Focus 5/2007 G418602en

309-00-33 Exhaust System 309-00-33
Item 9 Stabilizer bar link retaining nut 3. Detach the power steering pressure and
return lines center bracket from the vehicle
body.

shield. 23 Nm
TIE45593
4. Using a suitable transmission jack and a

wooden block, support the front axle
crossmember, stabilizer bar and lower arm
assembly.
5.
E40674 WARNING: Make sure the front axle
2. Detach the power steering pressure and result in personal injury.
return lines front bracket from the vehicle
body. Using a suitable securing strap, secure the
23 Nm 6. Remove the front axle crossmember bracket
TIE45592
TIE44500
2007.50 Focus 5/2007 G418602en

309-00-34 Exhaust System 309-00-34
7. Remove the front axle crossmember Lower the front axle crossmember.
for clarity). Item 12 Catalytic converter
1. Remove the catalytic converter to catalytic
TIE39071
8. E51402
power steering lines, only lower the front
axle crossmember sufficiently to allow the 2. With the aid of another technician, remove
catalytic converter to be removed. the catalytic converter.
Item 2 Exhaust manifold retaining nuts and bolt Item 3 Catalytic converter to catalytic converter
1. support bracket retaining bolts
CAUTION: Never use jointing compound
forward of the catalytic converter. 1. NOTE: Do not fully tighten the catalytic
converter to catalytic converter support
NOTE: Install a new exhaust manifold gasket, nuts bracket retaining bolts at this stage.
and bolt.
NOTE: Install new catalytic converter to catalytic
NOTE: Do not fully tighten the exhaust manifold converter support bracket retaining bolts.
retaining nuts and bolt at this stage.
Install the catalytic converter to catalytic
Install the exhaust manifold retaining nuts converter support bracket retaining bolts.
and bolt.
E51402
E51413

1.
CAUTION: Take care when installing the
exhaust hanger insulators to prevent
damage.
2007.50 Focus 5/2007 G418602en

309-00-35 Exhaust System 309-00-35
Check the exhaust hanger insulators for 3. Raise the front axle crossmember engaging
damage. Install new exhaust hanger the alignment pins into the chassis aligning
insulators if necessary. holes.
Item 5 Catalytic converter to rear muffler flange 205-316

retaining nuts 2
1
1. NOTE: Coat the catalytic converter studs
with grease.
NOTE: Install a new exhaust flexible pipe to rear
muffler flange gasket and nuts.
3
NOTE: Do not fully tighten the exhaust flexible pipe
to rear muffler flange retaining nuts at this stage.
Install the exhaust flexible pipe to rear TIE0000859
2.
retaining bolts.
Install the front axle crossmember retaining
115 Nm
E50213

1.
jack. Failure to follow this instruction may 275 Nm
result in personal injury. TIE39072
Using a transmission jack and the special
tool, position and align the front axle 3. Install the front axle crossmember bracket
crossmember. retaining bolts on both sides.
sleeve.
70 Nm
TIE44501

2007.50 Focus 5/2007 G418602en

309-00-36 Exhaust System 309-00-36
6. Lower and remove the transmission jack and Attach the tie-rod end to the wheel knuckle
the wooden block. on both sides.
7. Attach the power steering pressure and
return lines center bracket to the vehicle Item 9 Stabilizer bar link retaining nut
body. 1. NOTE: Use a 5 mm Allen key to prevent the
bar on both sides.
2. Install both front wheels and tires.
23 Nm and Tire (204-04 Wheels and Tires, Removal
and Installation).
Item 10 Exhaust manifold retaining nuts and

bolt
TIE45593
1. Lower the vehicle to gain access to the
exhaust manifold retaining nuts and bolt.
8. Attach the power steering pressure and
2. Tighten the exhaust manifold nuts and bolt.
return lines front bracket to the vehicle body.
23 Nm
48 Nm
E51414
TIE45592

9. Install the right-hand front fender splash
shield. For additional information, refer to: Jacking
and Operation)
E40674

2007.50 Focus 5/2007 G418602en

309-00-37 Exhaust System 309-00-37
Item 11 Catalytic converter to catalytic Item 15 Catalytic converter heat shield
converter support bracket retaining bolts 1. Feed the heated oxygen sensors (H2OS)
1. Tighten the catalytic converter to catalytic wiring harness and the catalytic monitor
converter support bracket retaining bolts. sensor electrical wiring harness through the
heat shield.
25 Nm
E51403
Item 12 Catalytic converter to rear muffler

retaining nuts
1. Tighten the catalytic converter to rear muffler
flange retaining nuts.
48 Nm
E50598
30 Nm
E47580
Item 14 Heated oxygen sensor (HO2S)

2007.50 Focus 5/2007 G418602en

309-00-38 Exhaust System 309-00-38
Exhaust Flexible Pipe(25 004 0)

Materials
Name Specification
Grease SA-M1C9107-A
Removal
and Operation)
/ Lifting (100-02 Jacking and Lifting, E52892

2. 5. Detach the exhaust flexible pipe from the
CAUTION: Over bending of the exhaust crossmember exhaust hanger insulators.
failure.
TIE39009
6.
TIE0014991
hanger insulators.
3. Remove the floor panel brace.
Remove the exhaust flexible pipe.
E47678
E50213
2007.50 Focus 5/2007 G296272en

309-00-39 Exhaust System 309-00-39
Installation 4. Tighten the exhaust flexible pipe to rear
1. NOTE: Coat the catalytic converter studs
with grease.
NOTE: Coat the exhaust flexible pipe to rear
muffler flange studs with grease. 51 Nm
NOTE: Install new exhaust flexible pipe gaskets

and nuts.
NOTE: Do not fully tighten the exhaust flexible pipe
Install the exhaust flexible pipe.
2. Attach the exhaust flexible pipe to the
TIE40628
crossmember exhaust hanger insulators.
30 Nm
TIE39009
E47580
3. Tighten the exhaust flexible pipe to catalytic
converter retaining nuts.
6.
51 Nm failure.
Remove the exhaust flexible pipe support
wrap or splint.
TIE40367
TIE0014991
2007.50 Focus 5/2007 G296272en

310-00-1 Fuel System - General Information 310-00-1
.
SECTION 310-00 Fuel System - General Information

CONTENTS PAGE

Fuel System — 2.0L Duratec-HE (MI4)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma)/1.8L Duratec-HE (MI4)........................................................................................ 310-00-2
GENERAL PROCEDURES
Fuel System Pressure Check............................................................................................. 310-00-3
Fuel System Pressure Check............................................................................................. 310-00-3
Fuel System Pressure Release...................................................................... (23 420 0) 310-00-6
Quick Release Coupling..................................................................................................... 310-00-7
Spring Lock Couplings.................................................................................... (23 004 0) 310-00-12
Fuel Tank Draining.......................................................................................... (23 551 0) 310-00-15
Fuel System — 2.0L Duratec-HE (MI4)/1.4L Duratec-16V

(Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)
– Fuel level – Electrical
– Fuel leak(s) connector(s)
– Fuel line(s) – Wiring harness
– Fuel filter (if – Inertia fuel shutoff
equipped) (IFS) switch
– Fuel tank – Fuel pump module
– Fuel tank filler pipe
– Fuel filler cap

before proceeding to the next step
2007.50 Focus 3/2007 G348253en

GENERAL PROCEDURES
Fuel System Pressure Check

Test Hose for 310-025
310-025-18 (23-024-10)
31002518
Test Hose for 310-025

310-025-19A (23-024-11A)
E39140
31002519
3. NOTE: Fuel supply line connectors are white
or are identified by a white band. Fuel return
line connectors are red or are identified by
General Equipment a red band.
Worldwide Diagnostic System (WDS) (418-F224)
Disconnect the fuel supply line from the fuel
rail.
Fuel System Pressure Check For additional information, refer to: Quick
1. Release Coupling (310-00 Fuel System -
WARNING: Do not smoke or carry lighted General Information, General Procedures).
personal injury.
Failure to follow these instructions may result
in personal injury.
Release the fuel system pressure. E57954
System Pressure Release (310-00 Fuel 4. Connect the special tool to the fuel rail.
Procedures).
303-025-18
E57955
2007.50 Focus 3/2007 G458820en

GENERAL PROCEDURES
5. Connect the special tool to the fuel rail fuel Using the digital multimeter function in WDS,
supply line. start the engine and measure the fuel system
pressure.
12. Turn the ignition switch to position 0.
13. NOTE: The fuel system pressure should be
3.8 ± 0.2 bar after the ignition switch is
turned to position 0 and should not fall
below 2.0 bar after 5 to 10 minutes. If the
fuel system pressure drops below this level
a fuel pump module internal leak should be
suspected.
310-025-19A
Using the digital multimeter function in WDS,
E46833 turn the ignition switch to position II and
measure the fuel system pressure.
6. Connect the WDS pressure/vacuum 14. Release the fuel system pressure.
transducer adapter to the special tools. For additional information, refer to: Fuel
310-025-18 Procedures).
15. Disconnect the WDS pressure/vacuum
transducer from the WDS pressure/vacuum
transducer adapter.
16. Disconnect the WDS pressure/vacuum
310-025-19A transducer adapter from the special tools.
E46840
310-025-18
7. Connect the WDS pressure/vacuum

transducer to the WDS pressure/vacuum
transducer adapter.
8. 310-025-19A
WARNING: Allow the fuel to drain into a
suitable container.
E46840
NOTE: Make sure that the end of the bleed hose
is higher than the bleed valve to prevent air flowing
back into the fuel system.
17. Disconnect the special tool from the fuel
Turn the ignition switch to position II and rail fuel supply line.
open the valve on the bleed hose. Repeat the
process until no air bubbles can be seen in
the bleed hose.
9. Close the valve on the bleed hose.
10. With the fuel system pressure at zero
calibrate the WDS pressure/vacuum
transducer to display zero.
11. NOTE: The fuel system pressure should be
3.8 ± 0.2 bar after the ignition switch is 310-025-19A
turned to position II and it should maintain
this pressure when the engine is running.
E46833
2007.50 Focus 3/2007 G458820en

GENERAL PROCEDURES
18. Disconnect the special tool from the fuel
rail.
303-025-18
E57955
19. NOTE: Fuel supply line connectors are

white or are identified by a white band. Fuel
return line connectors are red or are
identified by a red band.
Connect the fuel supply line to the fuel rail.
E57954
E39140
2007.50 Focus 3/2007 G458820en

GENERAL PROCEDURES
Fuel System Pressure Release(23 420 0)

Release
1. WARNINGS:
or open flame of any type when working on
or near any fuel related components. Highly
may ignite. Failure to follow these
The fuel system remains pressurized for

a long time after the ignition is switched off.
The fuel pressure must be released before
attempting any repairs. Failure to follow this
Remove the fuel pump fuse.
2. Start the engine and allow to idle until the
engine stalls.
3. Crank the engine for approximately five
seconds to make sure the fuel injection
supply manifold pressure has been released.
4. Install the fuel pump fuse.
2007.50 Focus 3/2007 G18191en

GENERAL PROCEDURES
Quick Release Coupling

General Equipment 2. Disconnect the fuel line quick release
coupling.
Flat-bladed screwdriver
Disconnection 1
WARNINGS:
Do not carry lighted tobacco or open flame
of any type when working on or near any
fuel related components. Highly flammable
vapors are always present and can ignite. 2 1
VUE0004022
always observe fuel handling precautions. 3. Disconnect the fuel line quick release
Failure to follow these instructions may coupling.
result in personal injury. 1. Pull the fuel line quick release coupling
CAUTION: Fuel injection equipment is locking tang.
manufactured to very precise tolerances 2. Push the clip through the fuel line quick
and fine clearances. It is therefore essential release coupling to release the fuel line.
that absolute cleanliness is observed when
working with these components. Always
install blanking plugs to any open orifices
or lines.
2
NOTE: Fuel supply line connectors are white or
are identified by a white band. Fuel return line
connectors are red or are identified by a red band.
1. Release the fuel system pressure.
VUE0018848
Procedures).
2. Disconnect the fuel line quick release 4. Disconnect the fuel line quick release
coupling. coupling.
1. Press the fuel line quick release coupling 1. Press the fuel line quick release coupling
locking tangs. locking tangs.
2007.50 Focus 3/2007 G18192en

GENERAL PROCEDURES
2. Disconnect the fuel line quick release 7. Disconnect the fuel tank vent line quick
coupling. release coupling.
1 1
VUE0014718
E38211
5. Disconnect the fuel line quick release 8. Release the fuel line quick release coupling.
coupling.
• Press the fuel line quick release coupling
• Press the fuel line quick release coupling locking release collar.
buttons and pull the fuel line to disconnect.
E38174
VUE0032292
9. Disconnect the fuel line quick release

6. Release the fuel tank vent line quick release coupling.
coupling.
• Press the fuel tank vent line quick release
coupling locking release collar.
2
E38209
E38210
2007.50 Focus 3/2007 G18192en

GENERAL PROCEDURES
10. Using a suitable Flat-bladed screwdriver 2. Disconnect the fuel line from the fuel filter.
release the fuel line quick release coupling
secondary locking tang.
2
1
E53517
E42696
Connect
11. Operate the fuel line quick release coupling WARNINGS:

primary locking tang. Do not carry lighted tobacco or open flame
• Push the fuel line quick release coupling of any type when working on or near any
primary locking tang into from the fuel line fuel related components. Highly flammable
quick release coupling. vapors are always present and can ignite.
CAUTION: Fuel injection equipment is
manufactured to very precise tolerances
and fine clearances. It is therefore essential
that absolute cleanliness is observed when
E42697
working with these components. Always
install blanking plugs to any open orifices
12. Disconnect the fuel line from the fuel line or lines.
quick release coupling. NOTE: Fuel supply line connectors are white or
are identified by a white band. Fuel return line
connectors are red or are identified by a red band.
1. Push the connector on to the fuel filter.
E42698
13. Disconnect the fuel line from the fuel filter.

1. Press the collar into the connector body. E53518
2007.50 Focus 3/2007 G18192en

GENERAL PROCEDURES
2. Install the fuel line to the fuel line quick 5.
CAUTION: After installation , to make sure
release coupling.
that the vent line is fully seated, pull on the
line.
Install the fuel tank vent line quick release
coupling.
E42701
3.
CAUTION: Make sure the quick release
coupling primary locking tang clicks into E38273
place when installing.
Insert the fuel line quick release coupling 6.
CAUTION: Make sure the fuel line clicks
secondary locking tang into the fuel line
into place when installing the line. To make
quick release coupling.
sure that the fuel line is fully seated, pull on
the line.
Install the fuel line quick release coupling.
E42695
4.
CAUTION: After installation, to make sure VUE0032293
that the fuel line is fully seated, pull on the
line.
7. NOTE: Make sure the collar on the fuel line
Install the fuel line quick release coupling. is inserted fully into the fuel line quick
release coupling.
E38272
2007.50 Focus 3/2007 G18192en

GENERAL PROCEDURES
Install the fuel line quick release coupling. 2. Press the fuel line quick release coupling
locking tang into position.
2
VUE0014720
VUE0004016

is inserted fully into the fuel line quick
release coupling before the locking tang is
locked.
1. Install the fuel line quick release coupling
locking tang.
2. Rotate the fuel line quick release coupling
locking tang into position.
VUE0020869

is inserted fully into the fuel line quick
release coupling before the locking tang is
locked.
1. Install the fuel line quick release coupling.
2007.50 Focus 3/2007 G18192en

GENERAL PROCEDURES
Spring Lock Couplings(23 004 0)

Special Tool(s) This procedure involves fuel handling. Be
Disconnect Tool, Spring Lock prepared for fuel spillage at all times and
Coupling (3/8”yellow) always observe fuel handling precautions.
310-D004 (23-039) Failure to follow these instructions may
D87L9280B For additional information, refer to Fuel
System Pressure Release in this section.
Disconnect Tool, Spring Lock 2. Install the special tool to the fuel line.
Coupling (1/2”green)
310-D005 (23-040)
310-040
D87L9280B
Disconnect Tool, Spring Lock

Coupling (5/8” black)
412-038 (34-003)
VUE0028631
34003
3. NOTE: Both sides of the spring lock coupling

Disconnect Tool, Fuel Line fuel line must be pushed together to enable
(5/16”) the special tool to release the spring lock
310-040 (23-041) coupling locking tangs.
Slide the special tool into the spring lock
coupling to release the locking tangs.
23041
310-040
Disconnection
WARNINGS:
present and may ignite. Failure to follow VUE0028632
injury.
4. Disconnect the fuel line from the spring lock
The fuel system remains pressurized for a coupling.
long time after the ignition is switched off.
attempting any repairs. Failure to follow
injury.
2007.50 Focus 3/2007 G37678en

GENERAL PROCEDURES
• Allow the fuel to drain into a suitable 7. Close and push the fuel line spring lock
container. coupling tool into the open side of the cage.
VUE0028633 GV0907A
5. Remove the safety clips from the fuel line 8. Separate the fuel line spring lock coupling.
spring lock couplings.
GV0908A
DTV2304094

6. Install the special tool onto the fuel line
spring lock coupling.
GV0909A
GV0906A
Installation
WARNINGS:
2007.50 Focus 3/2007 G37678en

GENERAL PROCEDURES
present and may ignite. Failure to follow 3. Make sure the fuel line spring lock coupling
these instructions may result in personal is engaged by pulling on the lines.
injury.
The fuel system remains pressurized for a
injury.
GV0912A
1. Inspect and clean both fuel line spring lock
coupling ends. Install new O-rings and garter 4. NOTE: Make sure the collar on the fuel line
springs if necessary. is inserted fully into the fuel line spring lock
coupling and an audible click is heard.
Install the spring lock coupling to the fuel
line.
GV0910A
2. NOTE: Lubricate the O-rings seals with clean

VUE0028634
engine oil.
Insert the male fitting into the female end
and push until the garter spring snaps over
the flared end of the female fitting.
GV0911A
2007.50 Focus 3/2007 G37678en

GENERAL PROCEDURES
Fuel Tank Draining(23 551 0)

General Equipment Insert the fuel tank drainer evacuation pipe
down the fuel tank filler pipe and into the fuel
Fuel tank drainer
tank.
All vehicles
1. WARNINGS:
or open flame of any type when working on
or near any fuel related components. Highly
may ignite. Failure to follow these
The fuel system remains pressurized for

a long time after the ignition is switched off. E43587
The fuel pressure must be relieved before
attempting any repairs. Failure to follow 5.
these instructions may result in personal WARNING: The fuel tank drainer must be
injury. operated in accordance with the
manufacturer's instructions. Failure to follow
The evacuating area must be clearly this instruction may result in personal injury.
identified with signs warning against
smoking and the use of naked lights or Drain the fuel tank.
flames within the vicinity. Highly flammable
vapors are always present and may ignite.
Always disconnect the vehicle battery
ground cable before commencing any
service or repair procedure. Failure to follow
this instruction may result in personal injury.
Disconnect the battery ground cable.
2. Remove the fuel filler cap.
3.
WARNING: Always connect the fuel tank
drainer ground cable to the vehicle before
proceeding to the next step. Failure to follow
this instruction may result in personal injury.
Connect the fuel tank drainer ground cable
to the vehicle.
4. NOTE: Fuel filler hoses on petrol variants
are fitted with a secondary fuel filler pipe spit
back valve.
E43586
NOTE: To enable the hose to enter the fuel tank
it must pass through the fuel filler pipe spit back
valve/valves (if equipped). 6. Remove the pipe and disconnect the fuel
tank drainer ground cable.
2007.50 Focus 3/2007 G330038en

GENERAL PROCEDURES

Procedures).
2007.50 Focus 3/2007 G330038en

310-01-1 Fuel Tank and Lines 310-01-1
.
SECTION 310-01 Fuel Tank and Lines

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 310-01-2

Fuel Tank and Lines............................................................................................................ 310-01-3
Vehicles with diesel engine................................................................................................. 310-01-3
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine........................................................ 310-01-8
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine..................................................... 310-01-9
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine....................................................... 310-01-10
Vehicles with fuel additive system...................................................................................... 310-01-11
Vehicles with 1.6L Duratec-16V (Sigma) engine/1.6L Duratec-16V Ti-VCT (Sigma)
engine/1.8L Duratec-HE (MI4) engine or 2.0L Duratec-HE (MI4) engine......................... 310-01-14

Fuel Tank and Lines............................................................................................................ 310-01-20

Fuel Tank — 2.0L Duratec-HE (MI4)/1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT
(Sigma)/1.8L Duratec-HE (MI4)/2.5L Duratec-ST (VI5), Vehicles Without: Fuel Fired
Booster Heater.................................................................................................................. 310-01-21
Fuel Pump Module......................................................................................... (23 534 0) 310-01-31
Fuel Tank Filler Pipe........................................................................................................... 310-01-32
Fuel Filter — 2.0L Duratec-HE (MI4)/2.5L Duratec-ST (VI5).............................................. 310-01-40
Fuel Supply Line — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)/2.5L Duratec-ST
(VI5).................................................................................................................................. 310-01-42
Fuel Level Resistor Card.................................................................................................... 310-01-46
SPECIFICATIONS
Item Specification
6.5% Fuel Additive Cerium/Iron Concentration Fluid WSS-M99C127-A1

Fuel tank support strap retaining bolts 25 18 -
Fuel tank filler Pipe bracket retaining screw 10 - 89
Fuel additive tank retaining screws 8 - 71
Fuel additive system module retaining nuts 3 - 27
Fuel pump module locking ring 85 63 -
Fuel tank filler pipe retaining screw 10 - 89
Fuel tank filler hose retaining clamp 4 - 35
Fuel tank vent hose retaining clamp 4 - 35
Fuel filter retaining bracket retaining bolt - vehicles 5 - 44
with 1.6L Duratec-16V (Sigma) engine/1.6L
Duratec-16V Ti-VCT (Sigma) engine/1.8L Duratec-
HE (MI4) engine or 2.0L Duratec-HE (MI4) engine
Fuel filter shield retaining bolts - vehicles with 1.6L 10 - 89
Duratorq-TDCi (DV6) diesel engine
Fuel filter crash protection top shield - vehicles with 9 - 80
1.8L Duratorq-TDCi (Kent) diesel engine
Fuel filter crash protection shield - vehicles with 9 - 80
2.0L Duratorq-TDCi (DW10) diesel engine
Rear shock absorber lower retaining bolts 115 85 -
Rear axle crossmember retaining bolts 115 85 -
2007.50 Focus 3/2007 G330045en

Fuel Tank and Lines
System Overview
2007.50 Focus 3/2007 G385139en

1 2 3
3 7
16
15
9
14
10
13
12
11
E48387
1 Fuel level sensor 3 Fuel tank filler pipe retaining bolts
2 Fuel level sensor locking ring 4 Fuel tank filler pipe
2007.50 Focus 3/2007 G385139en

Item Description The fuel tank filler pipe is designed to fill the fuel
tank, it consists of a fuel tank filler pipe and fuel
5 Fuel tank vent pipe tank vent pipe. Located within the fuel tank filler
6 Fuel filler pipe spit back valve pipe is a fuel filler pipe spit back valve. The spit
back valves have been designed to reduce the
7 Fuel tank fuel additive injector (if possibility of fuel tank siphoning. To enable the
equipped) hose of the fuel tank draining equipment to enter
the fuel tank, it must pass through the fuel filler
8 Fuel tank
pipe spit back valve. For additional information on
9 Fuel tank roll - over valves fuel tank draining.
10 Fuel tank support straps For additional information, refer to: Fuel Tank
Draining (310-00 Fuel System - General
11 Fuel tank support straps retaining bolts Information, General Procedures).
12 Fuel filter to fuel tank fuel return line
13 Fuel tank to fuel filter fuel supply line
15 Fuel tank to fuel filter fuel supply line
16 Fuel level sensor seal
The fuel tank holds approximately 53 liters of
usable fuel and is of a plastic construction. It is
retained to the vehicle by means of two steel
support straps, the fuel tank supports straps are E43587
secured by three retaining bolts onto the underside
of the vehicle chassis. The fuel tank filler pipe vent pipe allows air to
escape from the tank when the fuel tank is being
filled.
2007.50 Focus 3/2007 G385139en

E48393
Item Description The fuel supply and return lines have either spring
lock couplings or quick release couplings at each
1 Fuel tank to fuel filter fuel supply line end to secure them to the fuel tank lines.
2 Fuel filter to fuel tank fuel return line For additional information, refer to: Quick Release
3 Fuel line retaining clips Coupling (310-00 Fuel System - General
Information, General Procedures)
4 Fuel line grounding clip / Spring Lock Couplings (310-00 Fuel System -
The fuel supply and return lines are constructed
from a steel material coated with nylon and are
retained by clips which are also made of plastic.
At the front of the vehicle there is a fuel line
grounding clip equipped with a conductive sleeve
2007.50 Focus 3/2007 G385139en

made of steel or conductive plastic which also
holds the fuel supply and return lines against the
body. This clip is made of a conductive material
which is designed to dissipate the static electricity
created when fuel travels through the fuel supply
and return lines.
E53087
Fuel tank ventilation is achieved by a fuel tank

roll-over valve which is installed into the top of the
fuel tank and will prevent fuel loss from the fuel
tank if the vehicle becomes inverted.
The fuel tank roll-over valve also acts as fuel tank
breather with filter. If this filter become blocked or E48395
restricted during the vehicle's lifetime the customer
will experience problems with draining the fuel tank The fuel level sensor is equipped with a fuel tank
and there could be a possibility of fuel tank sender unit. The fuel tank sender unit consists of
deformation. a mechanical float and a potentiometer. The
The fuel level sensor is located in the top of the potentiometer communicates the fuel level
fuel tank and retained by a fuel level sensor locking information via a float directly with the fuel gauge
ring and seal, a new seal must installed after the in the instrument cluster informing the driver the
fuel level sensor is removed. amount of fuel that is currently in the fuel tank.
NOTE: The fuel tank must be completely removed CAUTION: Make sure the fuel level sensor
from the vehicle before the fuel level sensor can float and arm are not damaged during the
be removed. removal or installation of the fuel level
sensor.
For additional information, refer to: Fuel Tank -
1.6L Duratorq-TDCi (DV) Diesel/1.8L NOTE: Make sure the arrows on the fuel tank and
Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi fuel level sensor are aligned correctly. Failure to
(DW) Diesel, Vehicles Without: Fuel Fired follow this may result in incorrect fuel gauge
Booster Heater/Fuel Additive Tank (310-01 Fuel reading.
Tank and Lines, Removal and Installation).
VUE0026718
2007.50 Focus 3/2007 G385139en

Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine
Fuel Filter
2 3
1
6
4
5
E48400
fuel filter inlet pipe. The fuel filter forms a single

Item Description
component with the housing and can only be
1 Fuel tank to fuel filter fuel supply line renewed as a complete unit.
2 Fuel heater sensor For additional information, refer to: Fuel Filter -
1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel
3 Fuel filter Tank and Lines, Removal and Installation).
4 Fuel filter retaining bracket When the temperature is below 15ºC, a valve
5 Water in fuel sensor (if equipped) inside the fuel filter opens allowing fuel which is
pre-heated by the fuel injection pump to be
6 Fuel filter drain outlet recirculated back through the fuel filter to the fuel
injection pump. This aids engine performance
during warm up.
The 1.6L Duratorq-TDCi (DV6) diesel engine fuel Fuel is delivered through the fuel supply lines to
filter is located above the gearbox and is attached the fuel filter. The fuel filter cleans the fuel of water
to the cylinder head by means of a fuel filter shield and contaminants. Unused fuel is returned to the
and fuel filter retaining bracket. The fuel filter has fuel pump supply line and eventually returned
an electric fuel heater which is located below the directly to the fuel tank.
2007.50 Focus 3/2007 G385139en

After the fuel filter has been replaced it must be For additional information, refer to: Fuel Filter -
bled with a hand pressure pump. Make sure that 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel
the arrows indicating the direction of fuel flow is Tank and Lines, Removal and Installation).
pointing towards the fuel filter.
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine
Fuel Filter
2
6
E59577
filter retaining bracket. The fuel filter has an electric

Item Description
fuel heater which is located next to the fuel pump
1 Fuel filter crash protection top shield fuel supply line.
2 Fuel filter fuel supply line When the temperature is below 15ºC, a valve
inside the fuel filter opens, allowing fuel which is
3 Fuel filter housing pre-heated by the fuel pump to be recirculated back
4 Fuel filter drain screw through the fuel filter to the fuel pump. This aids
engine performance during warm up.
5 Fuel filter to fuel pump fuel supply line
Fuel is delivered through the fuel supply line to the
6 Fuel filter electrical connector fuel filter. The fuel filter cleans the fuel of water and
contaminants. Unused fuel is returned to the fuel
7 Fuel filter bleed screw
tank through the fuel pump fuel return line.
The 1.8L Duratorq-TDCi (Kent) diesel engine fuel
filter is located above the transmission and is
attached to the cylinder head by means of a fuel
2007.50 Focus 3/2007 G385139en

When a new fuel filter has been installed it must For additional information, refer to: Fuel Filter -
be bled using a hand pressure pump. Make sure 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles
that the arrows indicating the direction of fuel flow Without: Water-in-Fuel Sensor (310-01 Fuel Tank
is pointing towards the fuel filter. and Lines, Removal and Installation).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine
Fuel Filter
1 2
6
E48401
Item Description CAUTION: The generator must be

protected from contamination. Failure to
1 Fuel tank to fuel filter fuel supply line follow this instruction may cause
2 Fuel filter to fuel tank fuel return line premature failure of the generator.
3 Fuel filter to fuel pump fuel supply line The 2.0L Duratorq-TDCi (DW) diesel engine fuel
filter is located above the generator and is attached
4 Fuel heater sensor to the cylinder head by means of a fuel filter crash
5 Water in fuel sensor (if equipped) protection shield, a fuel filter splash shield and a
fuel filter retaining bracket. The fuel filter has an
6 Fuel filter crash protection shield electric fuel heater which is located next to the fuel
filter inlet pipe.
7 Fuel filter
When the temperature is below 15ºC, a valve
8 Fuel filter retaining bracket inside the fuel filter opens allowing fuel which is
pre-heated by the fuel injection pump to be
recirculated back through the fuel filter to the fuel
injection pump. This aids engine performance
during warm up.
2007.50 Focus 3/2007 G385139en

Fuel is delivered through the fuel supply lines to Do not smoke or carry lighted tobacco or
the fuel filter. The fuel filter cleans the fuel of water open flame of any type when working on
and contaminants. Unused fuel is returned to the or near any fuel related components.
fuel tank through the fuel pump return line. Highly flammable vapors are always
The fuel filter is also equipped with a water-in-fuel
sensor which is located at the base of the fuel filter
injury.
housing. This sensor measures the amount of
water which has collected in the fuel filter element. CAUTION: Make sure the workshop area
If the quantity of water present is greater than 90 in which the vehicle is being worked on is
ml then a warning indicator located on the as clean and as dust free as possible.
instrument cluster is illuminated and the fuel filter Foreign matter from work on clutches,
element should then be drained of water. brakes or from machining or welding
When a new fuel filter has been fitted it must be operations can contaminate the fuel
bled with a hand pressure pump. Make sure that system and may result in later malfunction.
the arrows indicating the direction of fuel flow is The fuel additive system supports the diesel
pointing towards the fuel filter. particulate filter (DPF) to reduce the pollution
For additional information, refer to: Fuel Filter - generated by diesel vehicles by filtering solid
2.0L Duratorq-TDCi (DW) Diesel, Vehicles elements out of the exhaust gases to reach stage
Without: Water-in-Fuel Sensor (310-01 Fuel Tank 4 emission levels.
and Lines, Removal and Installation). The additive system consists of a fuel additive
system module, fuel additive tank to fuel tank line
and a fuel additive tank with integral dosing pump.
Vehicles with fuel additive system The fuel additive fluid is used to lower the
combustion temperature of the unburnt fuel
residues inside the DPF. The additive fluid, which
System Overview contains cerium and iron must be exactly mixed
with the fuel in the main fuel tank to achieve the
WARNINGS:
right level when entering the DPF.
Eye, hand, ear protection and protective
After fuel tank filling has been completed by the
clothing are required to be worn during
customer the fuel additive system module
any general service work or removal and
communicates information to the additive tank
installation of fuel additive system
which injects a calculated dose of additive fluid into
components. Failure to follow this
the main fuel tank when the vehicle reaches or
exceeds a speed of 40 kph or 4 minutes after the
In case of fuel additive fluid contact with fuel tank filling has been completed. The fuel
the skin or the eyes, flush immediately with additive system module uses signals and
water for a minimum of 15 minutes and information from the CAN-bus ,engine on/off signal,
seek prompt medical attention. Failure to vehicle speed sensors and fuel gauge value from
follow these instructions may result in instrument cluster. It will also initially receive a
personal injury. signal from the fuel filler pipe filler flap switch to
If fuel additive fluid is swallowed, call a indicate that a fill up procedure may be about to
physician immediately. rinse mouth occur.
immediately with water, do not induce Routine service interval maintenance is required
vomiting. Failure to follow these for this system.
For additional information, refer to: Fuel Additive
Always provide adequate ventilation when System Filling and Bleeding (310-00 Fuel System
working on the fuel additive fluid system - General Information, General Procedures).
or related components. Failure to follow
injury.
2007.50 Focus 3/2007 G385139en

3
2
E48411
1 Fuel additive tank to fuel tank line 3 Fuel additive system module
2 Fuel tank 4 Fuel filler flap magnet
2007.50 Focus 3/2007 G385139en

Item Description a signal from the fuel additive system module and
adds the correct amount of fuel additive to the main
5 Fuel filler flap switch fuel tank. The fuel additive tank and dosing pump
6 Fuel tank filler pipe are a one piece unit and cannot be serviced
separately.
7 Fuel additive tank vent and filler pipe
8 Fuel additive tank overflow port Tank (310-01 Fuel Tank and Lines, Removal and
Installation).
9 Fuel additive tank and dosing pump
The fuel additive system module controls the
The fuel additive tank holds approximately 1.4 liters amount and frequency of fuel additive fluid injecting
of usable fuel additive fluid and approximately 1.8 into the main fuel tank. It is retained to the vehicle
usable liters when completely refilled and is of a by means of two retaining nuts and is located
plastic construction. It is retained to the vehicle by underneath the rear seat carpet.
means of three retaining bolts which are fitted to
the top of the rear sub-frame on the underside of
System Module (310-01 Fuel Tank and Lines,
the vehicle chassis.
The fuel additive tank is also equipped with a
internal dosing pump which is an integral part of
the fuel additive tank. The dosing pump receives
2007.50 Focus 3/2007 G385139en

Vehicles with 1.6L Duratec-16V (Sigma) engine/1.6L Duratec-16V Ti-VCT (Sigma)
engine/1.8L Duratec-HE (MI4) engine or 2.0L Duratec-HE (MI4) engine
System Overview
2007.50 Focus 3/2007 G385139en

2
5
6
4
8
9
19
18
10
17 11
16 15
13
14
12
E48412
1 Fuel tank filler pipe 3 Fuel tank to fuel filter fuel supply line (if
equipped)
2 Fuel tank vent pipe
2007.50 Focus 3/2007 G385139en

Item Description
5 Fuel pump module locking ring
6 Fuel pump module
7 Fuel pump module seal
8 Fuel filter to fuel tank fuel return line (if
equipped)
9 Fuel tank roll - over valves
E43587
10 Fuel tank
11 Fuel tank to fuel injection supply manifold
fuel supply line
12 Evaporative emission canister pipe to
evaporative emission purge valve pipe
13 Evaporative emission canister pipe
14 Fuel tank support straps retaining bolts
15 Fuel tank support straps
16 Fuel filter (if equipped)
E48394
17 Fuel filter retaining bracket (if equipped)
Fuel tank ventilation is achieved by two fuel tank
18 Fuel filter to fuel supply line fuel supply roll - over valves venting through a back pressure
line (if equipped) valve and into an evaporative emission canister
19 Fuel filler pipe retaining screws which absorbs the fuel vapor. The fuel tank roll -
over valve are installed into the top of the fuel tank
The fuel tank holds approximately 55 liters of and will prevent fuel loss from the fuel tank if the
usable fuel and is of a plastic construction. It is vehicle becomes inverted.
retained to the vehicle by means of two steel
support straps, the fuel tank supports straps are
secured by three retaining bolts onto the underside
of the vehicle chassis.
The fuel tank filler pipe is designed to fill the fuel
tank it consists of a fuel tank filler pipe and fuel
tank vent pipe, located within the fuel tank filler
pipe is a fuel filler pipe spit back valve. The spit
back valve has been designed to reduce the
possibility of fuel tank siphoning. To enable the
hose of the fuel tank draining equipment to enter
the fuel tank, it must pass through the fuel filler
pipe spit back valve. For additional information on
fuel tank draining.
For additional information, refer to: Fuel Tank
The fuel tank filler pipe vent pipe allows air to
escape from the tank when the fuel tank is being
filled.
2007.50 Focus 3/2007 G385139en

The fuel pump is a turbine type pump which is an
integral part of the fuel pump module. The fuel tank
module fuel sender communicates directly with the
instrument cluster which drives the fuel gauge
informing the driver the amount of fuel that is
currently in the fuel tank.
VUE0026718
CAUTION: Make sure the fuel tank level

sensor float and arm are not damaged
during the installation of the fuel pump
module.
NOTE: Make sure the arrows on the fuel tank and
E48413
fuel pump module are aligned correctly. Failure to
follow this may result in incorrect fuel gauge
The fuel pump module is located in the top of the reading.
fuel tank and retained by a re-usable fuel tank The fuel tank must be completely removed from
locking ring. The fuel pump module seal must not the vehicle before the fuel pump module unit can
be re-used once removed from the fuel tank. be removed.
The fuel pump module consists of a fuel sender, For additional information, refer to: Fuel Tank -
a fuel filter and a high pressure fuel pump with 2.0L Duratec-HE (MI4)/1.6L Duratec-16V
pressure regulator. The fuel filter is designed to (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)/1.8L
reduce the amount of large fuel debris entering the Duratec-HE (MI4)/2.5L Duratec-ST (VI5),
main fuel system filter. The fuel tank module filter Vehicles Without: Fuel Fired Booster Heater
has been designed as a non serviceable item and (310-01 Fuel Tank and Lines, Removal and
will last the lifetime of the vehicle, if the fuel tank Installation).
module filter becomes blocked a new fuel pump
module must be installed
For additional information, refer to: Fuel Pump
Module (310-01 Fuel Tank and Lines, Removal
and Installation).
2007.50 Focus 3/2007 G385139en

E48393
Item Description The fuel supply line has either spring lock couplings
or quick release couplings at each end to secure
1 Fuel supply line it to the fuel tank.
2 Evaporative emission purge valve pipe to For additional information, refer to: Quick Release
evaporative emission canister Coupling (310-00 Fuel System - General
3 Fuel line retaining clips Information, General Procedures)
/ Spring Lock Couplings (310-00 Fuel System -
4 Fuel line grounding clip General Information, General Procedures).
The fuel supply line is constructed from a steel
material coated with nylon and is retained by clips
which are also made of plastic. At the front of the
vehicle there is a fuel line grounding clip equipped
with a conductive sleeve made of steel or
2007.50 Focus 3/2007 G385139en

conductive plastic which also holds the fuel supply
line against the body. This clip is made of a
conductive material which is designed to dissipate
the static electricity created when fuel travels
through the fuel supply line.
Vehicles with 1.6L Duratec-16V (Sigma)
engine/1.6L Duratec-16V Ti-VCT (Sigma)
engine/1.8L Duratec-HE (MI4) engine or 2.0L
Duratec-HE (MI4) engine are equipped with a
returnless fuel system. The returnless fuel system
eliminates fuel system recirculation therefore
reducing fuel heating and evaporative emissions.
A fuel pressure sensor located in the fuel tank
module controls a constant fuel rail pressure under
all driving conditions.
E48414
The inertia fuel shutoff (IFS) switch cuts off the

electrical supply to the fuel pump in the event of
an accident and is located in the right hand footwell
behind the front scuff plate trim panel.
For additional information, refer to: Front Scuff
Plate Trim Panel (501-05 Interior Trim and
Ornamentation, Removal and Installation).
2007.50 Focus 3/2007 G385139en

Fuel Tank and Lines

For vehicles with fuel additive tank.
REFER to: Fuel System - 1.6L Duratorq-TDCi (DV)
Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L
Duratorq-TDCi (DW) Diesel (310-00 Fuel System
- General Information, Diagnosis and Testing).
For vehicles with 1.6L Duratec-16V (Sigma)/1.8L
Duratec-HE (MI4)/2.0L Duratec-HE.
REFER to: Fuel System - 2.0L Duratec-HE
(MI4)/1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)
(310-00 Fuel System - General Information,
For vehicles with 1.6L Duratorq-TDCi (DV)
Diesel/2.0L Duratorq-TDCi (DW) Diesel.
REFER to: Fuel System - 1.6L Duratorq-TDCi (DV)
Duratorq-TDCi (DW) Diesel (310-00 Fuel System
- General Information, Diagnosis and Testing).
2007.50 Focus 3/2007 G330046en

Fuel Tank — 2.0L Duratec-HE (MI4)/1.6L Duratec-16V

(Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)/1.8L Duratec-HE
(MI4)/2.5L Duratec-ST (VI5), Vehicles Without: Fuel Fired
Booster Heater
Special Tool(s) 3. Raise and support the vehicle.
Wrench, Fuel Tank Sender For additional information, refer to: Lifting
Unit (100-02 Jacking and Lifting, Description
(310-069) 23-055 and Operation).
4. Detach the exhaust system from the middle
hanger insulator.
23055
General Equipment
Transmission jack
WARNINGS:
present and may ignite. Failure to follow TIE0002409
injury. 5. Remove the exhaust flange nuts.
This procedure involves fuel handling. Be • Discard the gasket and exhaust flange
prepared for fuel spillage at all times and retaining nuts.
The fuel system remains pressurized for a 51 Nm
injury.
TIE45903
Procedures). 6. NOTE: With the aid of another technician
support the exhaust.
2. Drain the fuel tank.
2007.50 Focus 3/2007 G295877en

Detach the exhaust system from the front 8. Remove the left hand side rear air deflector
hanger insulators. shield.
E0002411 E44187
7. NOTE: With the aid of another technician 9. Remove the components in the order
support the exhaust. indicated in the following illustration(s) and
table(s).
Position the exhaust to one side and secure
to the body with tie-straps.
E44188
2007.50 Focus 3/2007 G295877en

5 Nm
1 5 Nm
E42704
Item Description
1 Exhaust pipe center heat shield retaining
bolts
2 Fuel tank heat shield
2007.50 Focus 3/2007 G295877en

4
3 N
5 N
N 3
6 13
10
25 Nm
11 25 Nm
12
E42705
3 Fuel tank filler hose retaining clamps 7 Evaporative emission canister vent pipe
See Removal Detail quick release coupling
4 Fuel tank filler hose 8 Fuel line to fuel tank vent pipe quick
See Removal Detail release coupling
See Removal Detail
5 Fuel tank vent hose retaining clamp
See Removal Detail 9 Fuel tank fuel supply line quick release
See Installation Detail coupling
See Removal Detail
6 Fuel tank vent hose
See Removal Detail
2007.50 Focus 3/2007 G295877en


10 Evaporative emission canister to fuel tank 12 Fuel tank
vent pipe quick release coupling See Removal Detail
11 Fuel tank support straps 13 Fuel pump module electrical connector
18 85 Nm
19
17
N 20
15
21
16
N 14
E42706
2007.50 Focus 3/2007 G295877en


14 Fuel tank vent hose retaining clamp 19 Fuel pump module
15 Fuel tank vent hose 20 Fuel pump module seal
See Removal Detail
21 Fuel tank
17 Fuel supply line
See Removal Detail 11. Initialize the door window motors.
18 Fuel pump module locking ring
See Removal Detail
Procedures).
Removal Details
Item 3 Fuel tank filler hose retaining clamps Remove and discard the fuel tank filler hose
retaining clamp (rear sub-frame shown
1. NOTE: Make a note of the position of the fuel
tank filler hose retaining clamp. Make sure
that the new replacement screw type clamp
is positioned so that the screw head is in the
same position as as the original filler hose
retaining clamp.
Remove and discard the fuel tank filler hose
retaining clamp.
E41905
Item 4 Fuel tank filler hose

1.
CAUTION: When removing the fuel tank
filler hose, do not use any sharp edge tools
to lever off the pipes. Failure to follow this
E42738
instruction may result in damage to the filler
hose.
Remove the fuel tank filler hose.
tank filler hose retaining clamp. Make sure
is positioned so that the screw head is in the Item 5 Fuel tank vent hose retaining clamp
same position as as the original filler hose 1. NOTE: Make a note of the position of the fuel
retaining clamp. tank vent hose retaining clamp. Make sure
same position as as the original vent hose
retaining clamp.
2007.50 Focus 3/2007 G295877en

Remove and discard the fuel tank vent hose Item 9 Fuel tank fuel supply line quick release
retaining clamp (rear sub-frame shown coupling
1. Disconnect the fuel tank fuel supply line
Item 10 Evaporative emission canister to fuel

tank vent pipe quick release coupling
1. Disconnect the evaporative emission
canister to fuel tank vent pipe quick release
coupling from the fuel tank.
E41904
• Release the locking tangs
Item 6 Fuel tank vent hose

1.
CAUTION: When removing the fuel tank
vent hose, do not use any sharp edge tools
to lever off the pipes. Failure to follow this
instruction may result in damage to the vent
hose.
Disconnect the fuel tank vent hose from the
fuel tank filler pipe.
Item 7 Evaporative emission canister vent pipe E42737
quick release coupling

1. Disconnect the evaporative emission Item 11 Fuel tank support straps
canister vent pipe quick release coupling CAUTION: When supporting the fuel tank,
from the evaporative emission canister. use a suitable packing material to prevent
• Release the locking tangs damage to the underside of the fuel tank.
1. Place a suitable transmission jack under the
fuel tank.
E42709
Item 8 Fuel line to fuel tank vent pipe quick VUE0029441
release coupling
1. Disconnect the fuel line to fuel tank vent pipe Item 12 Fuel tank
CAUTION: When lowering the fuel tank, do
For additional information, refer to: Quick not place excessive strain on the fuel lines
Release Coupling (310-00 Fuel System - and wiring harness.
2007.50 Focus 3/2007 G295877en

1. Partially lower the fuel tank. Item 15 Fuel tank vent hose
1.
Item 13 Fuel pump module electrical connector CAUTION: When removing the fuel tank
vent hose, do not use any sharp edge tools
1. Disconnect the fuel pump module electrical to lever off the pipes. Failure to follow this
connector. instruction may result in damage to the vent
hose.
Remove the fuel tank vent hose from the fuel
tank.

1. Disconnect the fuel supply line quick release
coupling.
E42708
Item 18 Fuel pump module locking ring

Item 14 Fuel tank vent hose retaining clamp 1. Using the special tool, remove the fuel pump
1. NOTE: Make a note of the position of the fuel locking ring.
tank vent hose retaining clamp. Make sure
same position as as the original vent hose
retaining clamp.
Remove and discard the fuel tank vent hose
retaining clamp.
VUE0029439
Item 19 Fuel pump module

sensor float and arm are not damaged
during the removal of the fuel pump
module.
E42925
Item 19 Fuel pump module
1.
sensor float and arm are not damaged during
the installation of the fuel pump module.
2007.50 Focus 3/2007 G295877en

Make sure the arrows on the fuel tank and 1. Partially raise the fuel tank.
fuel pump module are aligned correctly.
Item 13 Fuel pump module electrical connector
1. Connect the fuel pump module electrical
connector.
VUE0026718
Item 18 Fuel pump module locking ring

E42708
1. Using the special tool, install the fuel pump
locking ring.
Item 11 Fuel tank support straps
85 Nm 1. Install the fuel tank support strap retaining
bolts and remove the transmission jack.
Item 5 Fuel tank vent hose retaining clamp

1. Install a new fuel tank filler hose retaining
clamp in the position shown (rear sub-frame
310-069
E44267
Item 14 Fuel tank vent hose retaining clamp

1. Install a new fuel tank vent hose retaining 4 Nm
clamp in the position shown.
E42011
4 Nm
E42926
Item 12 Fuel tank

CAUTION: When installing the fuel tank,
make sure the fuel lines do not get kinked
or trapped.
2007.50 Focus 3/2007 G295877en

Item 3 Fuel tank filler hose retaining clamps
clamp in the position shown.
4 Nm
E42739

clamp in the position shown (rear sub-frame
4 Nm
E42010
2007.50 Focus 3/2007 G295877en

Fuel Pump Module(23 534 0)

1. For vehicles fitted with petrol engines.
- 2.0L Duratec-HE (MI4)/1.6L Duratec-16V
(Sigma)/1.6L Duratec-16V Ti-VCT
(Sigma)/1.8L Duratec-HE (MI4)/2.5L
Duratec-ST (VI5), Vehicles Without: Fuel
Fired Booster Heater (310-01 Fuel Tank and
Lines, Removal and Installation).
2. For vehicles fitted with diesel engines
without fuel additive tank.
Duratorq-TDCi (Lynx) Diesel/2.0L
Duratorq-TDCi (DW) Diesel, Vehicles
Without: Fuel Fired Booster Heater/Fuel
Additive Tank (310-01 Fuel Tank and Lines,
3. For vehicles fitted with diesel engines with
fuel additive tank.
Duratorq-TDCi (DW) Diesel, Vehicles With:
Fuel Additive Tank, Vehicles Without: Fuel
2007.50 Focus 3/2007 G334281en

Fuel Tank Filler Pipe

General Equipment NOTE: After the fuel additive tank to fuel tank line
Transmission jack has been connected it must be bled. For additional
information on fuel additive tank to fuel tank line
bleeding, Refer to WDS.
WARNINGS:
1. Drain the fuel tank.
This procedure involves fuel additive
handling. Be prepared for fuel additive For additional information, refer to: Fuel Tank
spillage at all times and always observe Draining (310-00 Fuel System - General
fuel handling precautions. Failure to follow Information, General Procedures).
these instructions may result in personal 2. Remove the rear wheels and tires.
injury.
Eye, hand, ear protection and protective and Tire (204-04 Wheels and Tires, Removal
clothing are required to be worn during and Installation).
any general service or removal and
installation procedure of fuel additive 3. Remove the right-hand rear splash shield.
system components. Failure to follow this
In case of fuel additive fluid contact with
the skin or the eyes, flush immediately with
water for a minimum of 15 minutes and
seek prompt medical attention. Failure to
personal injury.
If fuel additive fluid is swallowed, call a
physician immediately. rinse mouth
immediately with water, do not induce
E44581
vomiting. Failure to follow these
4. Detach and disconnect the rear end wiring
Always provide adequate ventilation when
harness electrical connector.
working on the fuel additive fluid system
or related components. Failure to follow 1. Release the locking tang.
injury.
injury.
CAUTION: Make sure the workshop area
in which the vehicle is being worked on is E47409
as clean and as dust free as possible.
Foreign matter from work on clutches,
brakes or from machining or welding
operations can contaminate the fuel
system and may result in later malfunction.
2007.50 Focus 3/2007 G295879en

5. Detach the rear end wiring harness from the • Release the locking tangs.
chassis and fuel tank filler pipe clamp. • Drain the fluid into a suitable Oil drainer.
E47410 E45543
6. Disconnect the fuel additive tank to fuel tank 7. Remove the components in the order
line from the fuel additive tank (if equipped). indicated in the following illustration(s) and
table(s).
2007.50 Focus 3/2007 G295879en

2 115 Nm 115 Nm 2
115 Nm
7
3
5
3 1
115 Nm
115 Nm
10 Nm 4 115 Nm
1
E47482
1 Rear springs 4 Electronic parking brake retaining nut (if

See Removal Detail equipped)
2 Rear damper lower retaining bolt 5 Electronic parking brake cable

See Installation Detail 6 Exhaust
3 Rear lower arm See Removal Detail
See Removal Detail 7 Rear crossmember
2007.50 Focus 3/2007 G295879en

8
10 Nm
N 12
15
13
14
N 10 11
10 Nm
E41889
8 Fuel tank filler pipe cover 12 Fuel tank vent hose to fuel tank filler pipe
See Removal Detail retaining clamp
See Removal Detail
9 Fuel tank filler pipe cap See Installation Detail
See Removal Detail
13 Fuel tank vent hose to fuel tank filler pipe
10 Fuel tank filler hose to fuel tank filler pipe See Removal Detail
hose retaining clamp
See Removal Detail 14 Fuel tank filler pipe retaining bracket
See Installation Detail 15 Fuel tank filler pipe
11 Fuel tank filler hose to fuel tank filler pipe
See Removal Detail
2007.50 Focus 3/2007 G295879en

9. Initialize the door window motors. 10. NOTE: After the fuel additive tank to fuel
For additional information, refer to: Door tank line has been connected it must be
Window Motor Initialization (501-11 Glass, bled. For additional information on fuel
Frames and Mechanisms, General additive tank to fuel tank line bleeding,
Procedures). Refer to WDS.
Carry out the fuel additive tank to fuel tank
line bleed procedure. Refer to WDS and
follow the on screen instructions.
Removal Details
Item 1 Rear springs Item 2 Rear damper lower retaining bolt
1. 1. Place a suitable transmission jack under the
rear suspension and remove the rear damper
lower retaining bolts.
NOTE: After the spring has been compressed mark
the location of tool and spring to aid installation. 115 Nm
Using the special tools, compress the rear
springs.
E44184
204-215 Item 3 Rear lower arm

1. Lower the transmission jack and with the aid
of another technician, pull the rear lower arm
downwards to remove the rear spring.
Item 5 Electronic parking brake cable

1. Detach the electronic parking brake cable
from the retaining clips.
E44183
2007.50 Focus 3/2007 G295879en

Item 6 Exhaust Remove and discard the fuel tank filler hose
to fuel tank filler pipe hose retaining clamp.
1. Detach the exhaust system from the middle
hanger insulator.
E41905
TIE0002409
Item 11 Fuel tank filler hose to fuel tank filler
pipe
Item 7 Rear crossmember
1.
1. NOTE: The rear axle crossmember must be CAUTION: When removing the fuel tank
supported. filler hose to fuel tank filler pipe, do not use
Remove the rear axle crossmember retaining any sharp edge tools to lever off the pipes.
bolts. Failure to follow this instruction may result
in damage to the filler hose.
Disconnect the fuel tank filler hose from the
fuel tank filler pipe.
Item 12 Fuel tank vent hose to fuel tank filler

pipe retaining clamp
tank vent hose to fuel tank filler pipe
115 Nm 115 Nm retaining clamp. Make sure that the new
replacement screw type clamp is positioned
so that the screw head is in the same
E44518 position as as the original vent hose
retaining clamp.
Item 8 Fuel tank filler pipe cover Remove and discard the fuel tank vent hose
to fuel tank filler pipe retaining clamp.
1. Open the fuel tank filler pipe cover.
Item 9 Fuel tank filler pipe cap

1. Detach the fuel tank filler pipe cap from the
fuel filler pipe.

pipe hose retaining clamp
tank filler hose to fuel tank filler pipe hose
retaining clamp. Make sure that the new
replacement screw type clamp is positioned E41904
so that the screw head is in the same
position as as the original filler hose
retaining clamp.
2007.50 Focus 3/2007 G295879en

Item 13 Fuel tank vent hose to fuel tank filler any sharp edge tools to lever off the pipes.
pipe Failure to follow this instruction may result
in damage to the vent hose.
1.
CAUTION: When removing the fuel tank Disconnect the fuel tank vent hose from the
vent hose to fuel tank filler pipe, do not use fuel tank filler pipe.
Item 12 Fuel tank vent hose to fuel tank filler 1. With the aid of another technician, pull the
pipe retaining clamp rear lower arm downwards to install the rear
1. Install a new fuel tank filler hose to fuel tank spring and special tools.
filler pipe hose retaining clamp in the
position shown. Item 2 Rear damper lower retaining bolt
1. Place a suitable transmission jack under the
rear suspension and install the rear damper
lower retaining bolts.
4 Nm 115 Nm
E42011

pipe hose retaining clamp E44184
1. Install a new fuel tank filler hose to fuel tank

filler pipe hose retaining clamp in the Item 1 Rear springs
position shown. 1.
CAUTION: Make sure the top seat
spring seats.
4 Nm
E42010
Item 3 Rear lower arm

CAUTION: Make sure the top seat
spring seats.
2007.50 Focus 3/2007 G295879en

Using the special tools, release the
compression on the rear spring the rear
springs.
204-215
E44183
2007.50 Focus 3/2007 G295879en

Fuel Filter — 2.0L Duratec-HE (MI4)/2.5L Duratec-ST (VI5)

WARNINGS: 1. Depressurize the fuel system.
Do not smoke or carry lighted tobacco or For additional information, refer to: Fuel
open flame of any type when working on System Pressure Release (310-00 Fuel
or near any fuel related components. System - General Information, General
Highly flammable vapors are always Procedures).
these instructions may result in personal 2. Disconnect the battery ground cable.
injury. For additional information, refer to: Battery
This procedure involves fuel handling. Be Disconnect and Connect (414-01 Battery,
prepared for fuel spillage at all times and Mounting and Cables, General Procedures).
always observe fuel handling precautions. 3. Raise and support the vehicle.
The fuel system remains pressurized for a and Operation).
table(s).
injury.
3 2
E53908
2007.50 Focus 3/2007 G426883en


1 Fuel tank to fuel filter fuel supply line See Installation Detail
See Removal Detail
See Installation Detail 3 Fuel filter retaining bracket bolt
2 Fuel filter to fuel rail fuel supply line 4 Fuel filter

Removal Details
Item 1 Fuel tank to fuel filter fuel supply line
Item 2 Fuel filter to fuel rail fuel supply line
1. Disconnect the fuel tank to fuel filter fuel
supply line. 1. Disconnect the fuel filter to fuel rail fuel
supply line.
Release Coupling (310-00 Fuel System - For additional information, refer to: Quick
General Information, General Procedures). Release Coupling (310-00 Fuel System -
Item 2 Fuel filter to fuel rail fuel supply line
1. Connect the fuel filter to fuel rail fuel supply
line.
Item 1 Fuel tank to fuel filter fuel supply line

1. Connect the fuel tank to fuel filter fuel supply
line.
2007.50 Focus 3/2007 G426883en

Fuel Supply Line — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE

(MI4)/2.5L Duratec-ST (VI5)
WARNINGS:
open flame of any type when working on 1. Detach the cowl panel grille retaining clips.
or near any fuel related components. 2. Detach the cowl panel grille from the
Highly flammable mixtures are always windshield glass lower weatherstrip and
present and may ignite. Failure to follow remove.
injury. 1 2
NOTE: Make sure that the windshield wiper motor
is in the park position.
TIE40438
Mounting and Cables, General Procedures). 5. Remove the bulkhead extension panel.
2. Detach the brake fluid reservoir from the
bulkhead extension panel.
E39133
E39287
3. Remove the windshield wiper arms.
15 Nm
E41181
2007.50 Focus 3/2007 G295889en

6. Disconnect the fuel supply line quick release 7. Detach the fuel supply line from the fuel
coupling from the fuel supply line. supply line retaining clip.
E45612

E45611
For additional information, refer to: Lifting.
table(s).
2007.50 Focus 3/2007 G295889en

2 N
3 N
N 1
E45608
1 Fuel supply line earth retaining clip 5 Fuel supply line quick release coupling
2 Fuel supply line retaining clips 6 Fuel supply line

See Removal Detail
3 Fuel tank deflector shield retaining clips 11. Initialize the door window motors.
See Removal Detail
4 Fuel tank deflector shield Window Motor Initialization.
2007.50 Focus 3/2007 G295889en

Removal Details
Item 1 Fuel supply line earth retaining clip Item 5 Fuel supply line quick release coupling
1. Remove and discard the fuel supply line 1. Disconnect the fuel supply line quick release
earth retaining clip. coupling from the fuel tank fuel supply line.
E45609
Item 2 Fuel supply line retaining clips

1. Remove and discard the fuel supply line
retaining clips.
E38778
Item 3 Fuel tank deflector shield retaining clips

1. Remove and discard the fuel tank deflector
shield retaining clips.
E45610
2007.50 Focus 3/2007 G295889en

Fuel Level Resistor Card

Removal
All except vehicles with diesel engine • Release the locking tang at the rear of the
fuel level resistor card.
1. Remove the fuel pump and sender unit.
• Discard the fuel level resistor card.

2. Remove the fuel level sensor.
E55606
Fuel Additive Tank, Vehicles Without: Fuel Installation
Lines, Removal and Installation) All vehicles
/ Fuel Tank - 1.6L Duratorq-TDCi (DV)
Diesel/1.8L Duratorq-TDCi (Lynx) 1.
CAUTION: Do not touch the fuel level
Diesel/2.0L Duratorq-TDCi (DW) Diesel, resistor card surface with tools or hands.
Vehicles Without: Fuel Fired Booster Failure to follow this instruction may result
Heater/Fuel Additive Tank (310-01 Fuel in damage to the fuel level resistor card.
NOTE: An audible click will be heard when the fuel
level resistor card is correctly installed.
All vehicles
Install the new fuel level resistor card.
3. NOTE: Make a note of the position and colors
of the wiring before disconnecting the
electrical connectors to aid installation.
NOTE: Diesel engine variants only have 2 wires.
Disconnect the fuel level resistor card
E82837
2. NOTE: Diesel engine variants only have 2

wires.
E83488
4. Remove the fuel level resistor card.
2007.50 Focus 3/2007 G909426en

Connect the fuel level resistor card electrical
connectors to the noted positions.
E83488
3. Make sure that the float rod and arm are able
to sweep their full ranges without contacting
or fouling on any wires.

4. NOTE: Install a new fuel level sensor gasket.
Install the fuel level sensor.
Fuel Additive Tank, Vehicles Without: Fuel
Lines, Removal and Installation)
Diesel/2.0L Duratorq-TDCi (DW) Diesel,
Vehicles Without: Fuel Fired Booster
Heater/Fuel Additive Tank (310-01 Fuel

5. NOTE: Install a new fuel pump and sender
unit gasket.
Install the fuel pump and sender unit.
2007.50 Focus 3/2007 G909426en

310-02-1 Acceleration Control 310-02-1
.
SECTION 310-02 Acceleration Control

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 310-02-2

Acceleration Control........................................................................................................... 310-02-3
Symptom Chart................................................................................................................... 310-02-3

Accelerator Pedal............................................................................................................... 310-02-5
Accelerator Cable............................................................................................................... 310-02-8
SPECIFICATIONS

Accelerator pedal 8 - 71
retaining nuts
2007.50 Focus 3/2007 G330241en

Acceleration Control
1. Verify the customer concern. before proceeding to the next step
– Accelerator pedal – Wiring harness(s)
– Throttle body – Wiring harness
retaining clips
– Electrical
connector(s)
– Accelerator pedal
– Powertrain control
module (PCM)
– Electronic throttle
body
Symptom Chart

• Accelerator pedal is hard to • Accelerator pedal incorrectly • CHECK the accelerator pedal
depress or has a rough/raspy installed. for the correct installation.
or sticky feel
• Worn or damaged accelerator • INSTALL a new accelerator
pedal. pedal.
REFER to: Accelerator Pedal
(310-02 Acceleration Control,
• Accelerator pedal does not • Accelerator pedal incorrectly • CHECK the accelerator pedal
return freely installed. for the correct installation.
• Worn or damaged accelerator • INSTALL a new accelerator
pedal. pedal.
REFER to: Accelerator Pedal
(310-02 Acceleration Control,
• High engine idle speed • Damaged accelerator pedal. • Refer to WDS to diagnose the
system.
• Electronic throttle body. • Refer to WDS to diagnose the
system.
• PCM calibration. • Refer to WDS to diagnose the
system.
2007.50 Focus 3/2007 G330245en


• Poor idling • Electronic throttle body. • Refer to WDS to diagnose the
system.
• PCM calibration. • Refer to WDS to diagnose the
system.
2007.50 Focus 3/2007 G330245en

Accelerator Pedal
table(s).
Cables].
3 1
E40395
2007.50 Focus 3/2007 G307356en


1 Instrument panel lower trim panel 3 Instrument panel lower trim panel
retraining clips
2 Instrument panel insulation pad See Installation Detail
4 8 Nm 6
E41751

4 Accelerator pedal retaining nuts 4. Initialize the door window motors. For
See Installation Detail additional information, refer to
5 Accelerator pedal Mechanisms].
6 Accelerator pedal electrical connector
See Removal Detail
Removal Details
Item 6 Accelerator pedal electrical connector 1. Using a suitable marker, mark the accelerator
pedal electrical connector when it has been
NOTE: The accelerator pedal electrical connector
disconnected from the accelerator pedal
can only be disconnected 10 times during the
wiring harness.
lifetime of the accelerator pedal. Failure to follow
this instruction may cause damage to the
accelerator pedal electrical connector.
2007.50 Focus 3/2007 G307356en

Item 4 Accelerator pedal retaining nuts
1. Loosely install all the accelerator pedal
retaining nuts before tightning.

retraining clips
retraining clips to the instrument panel lower
trim panel.
2007.50 Focus 3/2007 G307356en

Accelerator Cable
Draw cord indicated in the following illustration(s) and
table(s).
3
5
6 1
E53056
1 Accelerator cable to throttle body 3 Accelerator cable to body retaining clip

See Removal Detail 4 Accelerator cable to accelerator pedal
2 Accelerator cable to intake manifold
retaining clip
2007.50 Focus 3/2007 G413469en


5 Accelerator cable to bulkhead retaining See Removal Detail
clip See Installation Detail
See Removal Detail
6 Accelerator cable
Removal Details
Item 1 Accelerator cable to throttle body
Item 5 Accelerator cable to bulkhead retaining
1. Detach the accelerator cable. clip
1. Detach the accelerator cable locking nut. 1. Release the accelerator cable to bulkhead
2. Pull the accelerator outer cable through the retaining clip tangs.
accelerator cable grommet.
3. Detach the accelerator cable grommet from
the accelerator cable support bracket.
4. Rotate the throttle lever clockwise and detach
the accelerator cable from the throttle lever.
2 E53058
4

1. Remove the accelerator cable.
E51890
• Attach a draw cord to the end of the
accelerator inner cable.
Item 4 Accelerator cable to accelerator pedal • From the engine bay, pull the accelerator
1. Detach the accelerator cable from the cable out of the bulkhead until the draw cord
accelerator pedal. can be detached from the accelerator inner
cable.
1. Pull the accelerator inner cable forward.
2. Lift the accelerator inner cable and grommet
out of the fork of the accelerator pedal.
E53057
2007.50 Focus 3/2007 G413469en

1. Install the accelerator cable.
• Attach the draw cord to the end of the
accelerator inner cable.
• From inside the vehicle, pull the accelerator
cable through the bulkhead.
• Remove the draw cord.
Item 1 Accelerator cable to throttle body

1. Adjust the accelerator cable.
1. Make sure the throttle body linkage is against
the throttle stop screw.
2. Adjust the throttle cable using the throttle
cable locking nuts.
3. Check the accelerator inner cable free play.
The free play should not be less than 1mm
and not exceed 3mm.
2 3
1
E53458
2007.50 Focus 3/2007 G413469en

310-03-1 Speed Control 310-03-1
.
SECTION 310-03 Speed Control

CONTENTS PAGE

Speed Control..................................................................................................................... 310-03-2
Diagnostic Trouble Code (DTC) Index............................................................................... 310-03-2

Speed Control Switch......................................................................................................... 310-03-15
310-03-2 Speed Control 310-03-2
Speed Control
1. Verify the customer concern by operating the before proceeding to the next step.
system. 4. NOTE: Not all passenger junction box (PJB)
2. Visually inspect for obvious signs of mechanical variants support the speed control system.
NOTE: If the PJB is configured for speed control
Visual Inspection Chart disable, speed control operation is not transmitted,
Mechanical Electrical no Diagnostic Trouble Codes (DTCs) are
generated.
– Brake pedal – Fuse(s)
If the cause is not visually evident, verify the
– Clutch pedal – Connections symptom and refer DTC index.
– Wiring harness 5. Connect the WDS to the data link connector
– Clockspring (DLC) located beneath the instrument panel and
– Loose or corroded select the vehicle to be tested from the WDS
electrical menu.
connector(s)
– Speed control switch
– Brake pedal position
(BPP) deactivation
switch
– Clutch pedal position
(CPP) deactivation
Switch
– Powertrain control
module (PCM)
– Central junction box
(CJB)
Diagnostic Trouble Code (DTC) Index
DTC Description Possible Source Action

PCM - B1483 BPP deactivation • BPP deactivation switch REFER to WDS.
switch fault. • Instrument cluster.
PCM - B2163 CPP deactivation • CPP deactivation switch REFER to WDS.

switch fault. • Instrument cluster.
2007.50 Focus 3/2007 G325352en

310-03-3 Speed Control 310-03-3

PJB - P0565 Speed control ON On button failure short circuit Make sure all speed
Signal control switch buttons
are released. CHECK
and CLEAR all current
PJB DTCs. CYCLE igni-
tion from OFF to ON.
CARRY out PJB selftest.
CHECK for PJB DTCs.
If DTCs are found. GO
to Pinpoint Test B. If no
DTCs are found, TEST
the system for normal
operation.
PJB - P0566 Speed control OFF OFF button failure short circuit Make sure all speed
are released. CHECK
CHECK for PJB DTCs.
operation.
PJB - P0567 Speed control RESUME button failure short circuit Make sure all speed
RESUME Signal control switch buttons
are released. CHECK
CHECK for PJB DTCs.
operation.
PJB - P0568 Speed control SET + SET + button failure short circuit Make sure all speed
are released. CHECK
CHECK for PJB DTCs.
operation.
2007.50 Focus 3/2007 G325352en

310-03-4 Speed Control 310-03-4

PJB - P0569 Speed control SET - SET - button failure short circuit Make sure all speed
are released. CHECK
CHECK for PJB DTCs.
operation.
PJB - P0579 Speed control multi- Input circuit in -range failure Make sure all speed
function input A circuit control switch buttons
range/performance are released. CHECK
CHECK for PJB DTCs.
operation.
PJB - P0581 Cruise control multi- Input circuit open circuit failure Make sure all speed
function input A circuit control switch buttons
high resistance are released. CHECK
CHECK for PJB DTCs.
operation.
1. If the DTCs retrieved are not related to the

concern, verify the symptom and refer to the
Symptom Chart.
Symptom Chart
2007.50 Focus 3/2007 G325352en

310-03-5 Speed Control 310-03-5

• The speed control is inoper- • Parking brake control switch • Check the alignment and func-
ative • Parking brake tion of the parking brake lever
and parking brake control
switch. INSTALL new parts as
• BPP deactivation switch. • Check the BPP switch for
correct operation. REFER to
WDS.
• CPP deactivation switch. • Check the BPP switch for
correct operation. REFER to
WDS.
• Speed control switch. • GO to Pinpoint Test B.
• Clockspring.
• PCM. • REFER to: Electronic Engine
and Testing).
• Speed control switch. • GO to Pinpoint Test B.
and Testing).
• Faulty communication between • REFER to: Electronic Engine
the modules - MS CAN bus Controls (303-14 Electronic
and Testing).
• Faulty communication between • REFER to: Electronic Engine
the modules - HS CAN bus Controls (303-14 Electronic
and Testing).
• The speed control does not • BPP deactivation switch. • REFER to WDS.
disengage when the brake
pedal is applied
and Testing).
• The speed control does not • CPP deactivation switch. • REFER to WDS.
disengage when the clutch
pedal is applied
2007.50 Focus 3/2007 G325352en

310-03-6 Speed Control 310-03-6

and Testing).
PINPOINT TEST A : THE SPEED CONTROL SWITCH READING IS INOPERATIVE

A1: CHECK THE SPEED CONTROL CIRCUIT FOR CORRECT OPERATION
1 Disconnect CJB C103.
2 Measure the resistance between the CJB C103
pin 18, circuit 8-PG13 (WH), harness side and
CJB C103 pin 10, circuit 9-PG13 (BN), harness
side.
• Is the resistance between 2088 and 2143
ohms?
→ Yes
GO to A2.
→ No
E56788 GO to Pinpoint Test B.
A2: CHECK THE SPEED CONTROL SWITCH OFF BUTTON FOR CORRECT OPERATION
side with the speed control switch in the OFF
position.
E56788
2007.50 Focus 3/2007 G325352en

310-03-7 Speed Control 310-03-7

2 Press and hold the speed control switch in the
OFF position.
→ Yes
GO to A3.
→ No
INSTALL a new speed control switch.
REFER to: Speed Control Switch (310-03
Speed Control, Removal and Installation).
A3: CHECK THE SPEED CONTROL SWITCH SET - BUTTON FOR CORRECT OPERATION
side with the speed control switch in the SET -
position.
E56788

SET - position.
• Is the resistance between 118 and 129 ohms?
→ Yes
GO to A4.
→ No
2007.50 Focus 3/2007 G325352en

310-03-8 Speed Control 310-03-8

A4: CHECK THE SPEED CONTROL SWITCH SET + BUTTON FOR CORRECT OPERATION
side with the speed control switch in the SET +
position.
E56788

SET + position.
• Is the resistance 297 and 318 ohms?
→ Yes
GO to A5.
→ No
A5: CHECK THE SPEED CONTROL SWITCH RESUME BUTTON FOR CORRECT OPERATION
side with the speed control switch in the
RESUME position.
E56788
2007.50 Focus 3/2007 G325352en

310-03-9 Speed Control 310-03-9

RESUME position.
→ Yes
GO to A6.
→ No
A6: CHECK THE SPEED CONTROL SWITCH ON BUTTON FOR CORRECT OPERATION
side with the speed control switch in the ON
position.
E56788

ON position.
ohms?
→ Yes
normal operation.
→ No
PINPOINT TEST B : CHECK SPEED CONTROL SWITCH CIRCUITS FOR HIGH RESISTANCE
B1: CHECK THE SPEED CONTROL CIRCUIT 9-PG13 (BN) FOR RESISTANCE
1 Disconnect Clockspring C896.
2007.50 Focus 3/2007 G325352en

310-03-10 Speed Control 310-03-10

pin 10, circuit 9-PG13 (BN), harness side and
the clockspring C896 pin 4, circuit 9-PG13 (BN),
harness side.
→ Yes
GO to B2.
→ No
B2: CHECK THE SPEED CONTROL CIRCUIT 8-PG13 (WH) FOR RESISTANCE
the clockspring C896 pin 5, circuit 8-PG13 (WH),
harness side.
→ Yes
GO to B3.
→ No
B3: CHECK THE SPEED CONTROL OFF SWITCH FOR CORRECT OPERATION
WARNING: To deactivate the air bag

module, refer to the procedure in Section
501-20B for the correct air bag module
deactivation procedure. Failure to follow
this instruction may result in personal
injury.
1 Remove the driver air bag module.
REFER to: Driver Air Bag Module - Vehicles
Built Up To: 06/2004 (501-20B, Removal and
Installation)
/ Driver Air Bag Module - Vehicles Built From:
06/2004 (501-20B, Removal and Installation).
2 Disconnect Speed control switch C921.
2007.50 Focus 3/2007 G325352en

310-03-11 Speed Control 310-03-11

3 Measure resistance between the speed control
switch C921 pin 2, and pin 3, harness side.
E43006

OFF position.
→ Yes
GO to B4.
→ No
B4: CHECK THE SPEED CONTROL SET - SWITCH FOR CORRECT OPERATION
E43006
2007.50 Focus 3/2007 G325352en

310-03-12 Speed Control 310-03-12

SET - position.
→ Yes
GO to B5.
→ No
B5: CHECK THE SPEED CONTROL SET + SWITCH FOR CORRECT OPERATION
E43006

SET + position.
• Is the resistance 299 and 312 ohms?
→ Yes
GO to B6.
→ No
2007.50 Focus 3/2007 G325352en

310-03-13 Speed Control 310-03-13

B6: CHECK THE SPEED CONTROL RESUME SWITCH FOR CORRECT OPERATION
E43006

RESUME position.
→ Yes
GO to B7.
→ No
B7: CHECK THE SPEED CONTROL SWITCH ON BUTTON FOR CORRECT OPERATION
E43006
2007.50 Focus 3/2007 G325352en

310-03-14 Speed Control 310-03-14

ON position.
ohms?
→ Yes
INSTALL a new clockspring.
REFER to: Clockspring - Vehicles Built Up To:
06/2004 (501-20B, Removal and Installation)
/ Clockspring - Vehicles Built From: 06/2004
(501-20B, Removal and Installation).
→ No
2007.50 Focus 3/2007 G325352en

310-03-15 Speed Control 310-03-15
Speed Control Switch

1. Remove the driver air bag module. For
table(s).
Section 501-20A [Safety Belt System] /
501-20B [Supplemental Restraint System].
1 2 Nm
2 Nm
2 2
E40402
2007.50 Focus 3/2007 G295915en

310-03-16 Speed Control 310-03-16

1 Speed control switch electrical connector See Installation Detail
2 Speed control switch wiring harness 3 Speed control switch
See Removal Detail
Removal Details
Item 2 Speed control switch wiring harness
1. Detach the speed control wiring harness
from the steering wheel back plate wiring
harness retainers.
Item 2 Speed control switch wiring harness
1.
CAUTION: Make sure the speed control
wiring harness is correctly attached to the
steering wheel back plate during installation.
damage to the speed control wiring harness.
Attach the speed control wiring harness to
the steering wheel back plate wiring harness
retainers.
2007.50 Focus 3/2007 G295915en

412-00-1 Climate Control System - General Information 412-00-1
.
SECTION 412-00 Climate Control System - General

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 412-00-2

Climate Control System...................................................................................................... 412-00-4
Refrigerant Circuit - Quick Check....................................................................................... 412-00-4
Sequence of A/C Request Signal....................................................................................... 412-00-5
Self-Diagnostic Mode - Vehicles with electronic automatic temperature control (EATC).... 412-00-6
Diagnostic Trouble Code (DTC) Index Chart - vehicles with electronic automatic
temperature control (EATC).............................................................................................. 412-00-6
Symptom Chart................................................................................................................... 412-00-7
Pinpoint Tests..................................................................................................................... 412-00-10
Component Tests................................................................................................................ 412-00-113
GENERAL PROCEDURES
Spring Lock Coupling.......................................................................................................... 412-00-115
Air Conditioning (A/C) Clutch Air Gap Adjustment......................................... (34 628 6) 412-00-117
Fluorescent Dye Leak Detection........................................................................................ 412-00-118
Electronic Leak Detection............................................................................... (34 620 7) 412-00-119
Air Conditioning (A/C) System Recovery, Evacuation and Charging............. (34 620 2) 412-00-120
Refrigerant Oil Adding.................................................................................... (34 621 1) 412-00-122
Contaminated Refrigerant Handling............................................................... (34 620 9) 412-00-123
Air Distribution System Cleaning........................................................................................ 412-00-124
Vacuum Leak Detection.................................................................................. (34 620 3) 412-00-126
SPECIFICATIONS
Item Specification
R134a refrigerant WSH-M17B19-A
Air conditioning compressor oil WSH-M1C231-B
Ford A/C cleaning agent F4AZ-19579A -
Fluorescent leak detector additive 164-R-3712 -
Refrigerant Capacities (when charging)

Grammes
Air Conditioning (A/C) System 600 ± 15
Refrigerant Oil Fill Quantities

Milliliters
Air Conditioning (A/C) System 200
Addition of Refrigerant Oil (When new components are installed)

CAUTIONS:
The refrigerant oil top-up quantity must not exceed the refrigerant oil fill quantity.
If other A/C components are being renewed in addition to the A/C compressor, there is no
need to top up with additional refrigerant oil, apart from filling the compressor.
Because factory fill quantities differ, the refrigerant oil must be drained from the new A/C
compressor.
Milliliters
When all lines and components are replaced. add 200.
Air conditioning (A/C) compressor - if the quantity of refrigerant oil drained add 150.
from the faulty compressor is less than 150 ml
Air conditioning compressor (if the amount of refrigerant oil drained from the add 200.
faulty compressor is more than 150 ml)
Air conditioning condenser add 30.
Air conditioning (A/C) evaporator core add 30.
A/C dehydrator add 90.
Every time if refrigerant oil is collected after refrigerant is extracted. Add the same quantity as
the quantity that was
collected.
Air Conditioning (A/C) Clutch

mm
A/C clutch air gap (vehicles with diesel engine built from 08/2005 and vehicles 0.35 - 0.75
with petrol engine)
A/C clutch air gap (vehicles with diesel engine, built until 08/2005) 0.4 - 0.8
2007.50 Focus 3/2007 G410700en

SPECIFICATIONS
A/C compressor drive plate bolt (vehicles with petrol 13 10 -
engine)
A/C compressor drive plate bolt (vehicles with diesel 22 16 -
engine)
2007.50 Focus 3/2007 G410700en

Climate Control System

Refer to Wiring Diagrams Section 412-00, for error memory) using the WDS. If an error code
schematic and connector information. is displayed, CORRECT the cause using the
Special Tool(s) WDS. TEST the system for normal operation.
Terminal Probe Kit 5. If there is no error code displayed, VERIFY the
418-S035 symptom and REFER to the symptom chart.
6. After the test or elimination of a concern CHECK
all modules that are installed on the vehicle by
using the WDS. ERASE all error codes. CARRY
29011A a road test of the vehicle. CHECK all modules
again.
General Equipment
Refrigerant Circuit - Quick Check
Digital Multimeter (compatible with K-type thermo-
couple) WARNING: The air conditioning systems
Worldwide Diagnostic System (WDS) is filled with refrigerant R134a. Observe
"Health and Safety Precautions". For
Refrigerant center further information
Temperature sensor - Fluke 80 PK-8 (FSE number REFER to: Health and Safety Precautions
260 4102 001 07) (100-00 General Information, Description
and Operation).
NOTE: All readings should to be taken at normal
Inspection and Verification ambient temperature with the engine at normal
operating temperature.
NOTE: Vehicles without DVD Navigation System
with Touchscreen, the electronic automatic Refrigerant Circuit Check
temperature control (EATC) module is integrated
into the climate control assembly. WARNING: Under certain circumstances,
refrigerant lines and A/C components may
1. VERIFY the customer concern. be extremely hot or cold. Exercising care,
2. Visually INSPECT for obvious signs of touch the refrigerant lines or A/C
mechanical or electrical damage. components in order to check this. Failure
NOTE: Make sure correct locking of the wiring to follow this instruction may lead to injury.
harness connector. During operation of the air conditioning (A/C)
system, the following conditions shows be
Visual Inspection Chart apparent:
• The refrigerant line from the A/C compressor to
• Refrigerant lines • Fuses the A/C condenser should be hot.
• Condenser • Wiring harness • The refrigerant line from the refrigerant
• Coolant level • Connectors condenser to the fixed orifice tube should be
warm, but cooler than the previously mentioned
• Drive belt
refrigerant line.
• Compressor
• Determine the difference in temperature
upstream and downstream of the A/C condenser
3. If an obvious cause for an observed or reported by measuring the temperatures. The
concern is found, CORRECT the cause (if temperature difference should be more than
possible) before proceeding to the next step. 20°, depending on the ambient temperature. If
TEST the system for normal operation. the temperature difference is less, check the
4. If the cause is not visually evident, CHECK the condenser for contamination or damage to the
powertrain control module (PCM), the generic fins as well as operation of the radiator fan.
electronic module (GEM) and the instrument
cluster (vehicles with EATC: read out the EATC
2007.50 Focus 3/2007 G427113en

• The refrigerant line between the fixed orifice • No or poor cooling performance:
tube and the evaporator core must be cold from – Blockage or restriction in one of the
the installation position of the fixed orifice tube. refrigerant lines or in the suction accumulator:
Depending on the weather, the refrigerant line By comparing temperatures at the refrigerant
may also be iced up on the outside. lines or at the suction accumulator, the
• The refrigerant line between the evaporator core location of the blockage or restriction can
and the A/C compressor should be cold, easily be identified. The blockage or
including the suction accumulator. restriction is located at the point where the
temperature difference is identified. Note: A
Evaporator Outlet Temperature Test temperature difference in the area of the
In order to check the A/C output, the temperature fixed orifice tube is normal. Once the
of the evaporator core outlet line must be location of the blockage or restriction has
measured. The following preparations must be been detected, check the relevant component
taken for this purpose: and install new parts as necessary.
• Sudden poor cooling performance. After the
• Open all windows.
compressor has been switched off for
• Set the air distribution to the defrost/dashboard approximately 5 minutes, the cooling
position and open all the ventilation nozzles. performance returns to normal:
• DO NOT switch on recirculated air. – Fixed orifice tube iced up. The cause for an
• Select lowest blower switch setting. iced-up fixed orifice tube is moisture in the
• Select lowest temperature setting. system. In order to ensure that moisture is
completely removed from the refrigerant
NOTE: The temperature measurements cannot be circuit, evacuation time must be extended to
carried out using a non-contact thermometer. 2-3 hours and a new suction accumulator
Incorrect measurements result owing to surface must be installed. For further information
reflection.
REFER to: Air Conditioning (A/C) System
Connect temperature sensor (Fluke 80 PK-8) to Recovery, Evacuation and Charging
the evaporator core outlet line. The temperature (412-00 Climate Control System - General
sensor must be positioned as closely as possible Information, General Procedures).
to the evaporator core. Connect the temperature
sensor to the digital multimeter.
Start the engine and allow it to run at idle speed Sequence of A/C Request Signal
for several minutes.
NOTE: Vehicles without DVD Navigation System
Switch on the A/C system. with Touchscreen, the electronic automatic
After three minutes, measure the surface temperature control (EATC) module is integrated
temperature of the evaporator core outlet line. into the climate control assembly.
If the temperature measured is 4° C or lower, the NOTE: The generic electronic module (GEM) is
A/C system is OK. If the temperature is higher, the an integral part of the central junction box (CJB).
A/C system may be under-filled. For further After actuating the ON/OFF switch integrated into
information the climate control assembly, an A/C request signal
REFER to: Air Conditioning (A/C) System is sent to the GEM from the climate control
Recovery, Evacuation and Charging (412-00 assembly (vehicles with EATC module).
Climate Control System - General Information, From there, the signal is sent to the instrument
General Procedures). cluster via the MS CAN-bus. A gateway is installed
in the instrument cluster which establishes the
Frequent faults and their causes
connection between the MS CAN-bus and the HS
Should a customer express concern about poor CAN-bus.
cooling performance of the A/C system it must be After the signal has been converted in the gateway,
ensured that actuation of the temperature door(s) it is relayed to the powertrain control module (PCM)
is functioning correctly. via the HS CAN-bus. Once all the required
2007.50 Focus 3/2007 G427113en

parameters have been met, the PCM switches on Example: Left display indicates "90", right display
the refrigerant compressor and thus the A/C system indicates "27" - diagnostic trouble code read out
via the refrigerant compressor clutch relay. 9027. The following table gives information on the
possible DTC's and their corresponding meanings.
Self-Diagnosis Mode can be stopped at any time
Self-Diagnostic Mode - Vehicles with by PRESSING any button on the EATC module.
electronic automatic temperature
control (EATC) NOTE: If the "Defrost" button is pressed to end the
Self-Diagnosis Mode, all DTC's in the error memory
The climate control system features a will be deleted!
self-diagnosis function which can detect and store
Reading out of stored faults
both current permanent faults as well as
intermittent faults which have occurred during On the climate control assembly, PRESS the "OFF"
normal operation of the vehicle. It is also possible and "FOOTWELL" buttons simultaneously for
to read out these faults via the display of the EATC. exactly 2 seconds, then PRESS "HEADROOM"
To read out the fault memory, the ignition key must within 1.5 seconds. Any stored faults are displayed
be turned to the "ON" position and the battery on the EATC display and should be noted for safety
voltage must be between 9 V and 16 V. reasons. By PRESSING the "DEFROST" button,
the fault memory is cleared and the Self-Diagnosis
Activation of self-diagnosis Mode is ended. To end the Self-Diagnosis Mode
On the climate control assembly, PRESS the "OFF" without clearing the DTC's, PRESS any other
and "FOOTWELL" buttons simultaneously for button on the EATC module.
exactly 2 seconds, then PRESS "AUTO" within
Reading out the software version
1.5 seconds. The self-diagnosis which then starts
lasts a few seconds. An animated display appears On the EATC module, PRESS the "OFF" and
in the EATC display during this time. Any faults "FOOTWELL" buttons simultaneously for exactly
found are displayed on both displays in the form 2 seconds, then PRESS "A/C" within 1.5 seconds.
of diagnostic trouble codes. The software version is displayed on the EATC
display. The output mode is ended by PRESSING
any button.
Diagnostic Trouble Code (DTC) Index Chart - vehicles with electronic automatic
temperature control (EATC)
Diagnostic trouble code (DTC) index chart for electronic automatic temperature control (EATC)
DTC Description Action
9027 Air discharge temperature sensor - GO to Pinpoint Test M.
center register right-hand circuit short to
ground
9028 Air discharge temperature sensor - GO to Pinpoint Test M.
center register right-hand open circuit
9029 Air discharge temperature sensor - foot- GO to Pinpoint Test N.
well right-hand circuit short to ground
9030 Air discharge temperature sensor - foot- GO to Pinpoint Test N.
well right-hand open circuit
9200 Climate control pushbutton failure CLEAR the error memory and TEST the
If the concern occurs again INSTALL a
new EATC module.
2007.50 Focus 3/2007 G427113en

DTC Description Action

9242 Recirculation blend door actuator circuit GO to Pinpoint Test F.
failure
9251 In-vehicle temperature sensor open GO to Pinpoint Test P.
circuit
9253 In-vehicle temperature sensor circuit GO to Pinpoint Test P.
short to ground
9259 Sunload sensor left-hand open circuit GO to Pinpoint Test O.
9261 Sunload sensor left-hand circuit short to GO to Pinpoint Test O.
ground
9262 Defrost vent/register blend door actuator GO to Pinpoint Test J.
circuit failure
9263 Air distribution door actuator circuit failure GO to Pinpoint Test I.
9342 EATC module internal failure CLEAR the error memory and TEST the
If the concern occurs again INSTALL a
new EATC module.
9676 Voltage out of range (Nominal voltage: GO to Pinpoint Test D.
9 V - 16 V)
A266 Temperature blend door actuator left- GO to Pinpoint Test G.
hand circuit failure
A267 Temperature blend door actuator right- GO to Pinpoint Test H.
hand circuit failure
A297 Air discharge temperature sensor - GO to Pinpoint Test K.
center register left-hand open circuit
A298 Air discharge temperature sensor - GO to Pinpoint Test K.
center register left-hand circuit short to
ground
A299 Air discharge temperature sensor - foot- GO to Pinpoint Test L.
well left-hand open circuit
A307 Air discharge temperature sensor - foot- GO to Pinpoint Test L.
well left-hand circuit short to ground
A308 In-vehicle temperature sensor blower GO to Pinpoint Test Q.
motor circuit failure
A426 Sunload sensor right-hand open circuit GO to Pinpoint Test O.
A427 Sunload sensor right-hand circuit short GO to Pinpoint Test O.
to ground
A516 Blower motor control module circuit GO to Pinpoint Test E.
failure
Symptom Chart
Symptom Chart
2007.50 Focus 3/2007 G427113en

NOTE: The generic electronic module (GEM) is an integral part of the central junction box (CJB).
• Blower motor without/incorrect • Fuse(s) • GO to Pinpoint Test A.
function - vehicles without • Circuit(s)
electronic automatic temper- • Blower motor
ature control (EATC) • Blower motor resistor
• Blower relay
• Generic electronic module
(GEM)
• Malfunction of the recirculation • Fuse(s) • Vehicles without electronic
blend door • Circuit(s) automatic temperature control
• Climate control assembly (EATC): GO to Pinpoint Test B.
• Recirculation blend door actu- • Vehicles with electronic auto-
ator matic temperature control
• Recirculation blend door (EATC): GO to Pinpoint Test F.
• Air conditioning (A/C) is inoper- • Fuse(s) • GO to Pinpoint Test C.
ative (all other functions of • Circuit(s)
climate control assembly OK) • Climate control assembly or
electronic automatic temper-
ature control module (EATC)
• Air conditioning high-pressure
switch
• Air conditioning pressure
transducer
• Air conditioning low-pressure
switch
• Air conditioning clutch relay
• Air conditioning clutch
• Refrigerant quantity
(GEM)
(PCM)
• Instrument cluster
• Climate control assembly inop- • Fuse(s) • GO to Pinpoint Test D.
erative - vehicles with elec- • Circuit(s)
tronic automatic temperature • Electronic automatic temper-
control (EATC) without DVD ature control (EATC) module
Navigation System with
Touchscreen
• Blower motor without/incorrect • Fuse(s) • GO to Pinpoint Test E.
function - vehicles with elec- • Circuit(s)
tronic automatic temperature • Electronic automatic temper-
control (EATC) (all other func- ature control (EATC) module
tions of climate control • Blower
assembly OK) • Blower relay
(GEM)
• Central junction box (CJB)
2007.50 Focus 3/2007 G427113en


• Malfunction of temperature • Circuit(s) • GO to Pinpoint Test G.
blend door left-hand - vehicles • Temperature blend door actu-
with electronic automatic ator left-hand
temperature control (EATC) • Temperature blend door left-
hand
• Electronic automatic temper-
ature control (EATC) module
• Malfunction of temperature • Circuit(s) • GO to Pinpoint Test H.
blend door right-hand - vehicles • Temperature blend door actu-
with electronic automatic ator right-hand
temperature control (EATC) • Temperature blend door right-
hand
• Electronic automatic temper-
• Malfunction of air distribution • Circuit(s) • GO to Pinpoint Test I.
door - vehicles with electronic • Air distribution door actuator
automatic temperature control • Air distribution door
(EATC) • Electronic automatic temper-
• Malfunction of defrost • Circuit(s) • GO to Pinpoint Test J.
vent/register blend door - • Defrost vent/register blend door
vehicles with electronic auto- actuator
matic temperature control • Defrost vent/register blend door
(EATC) • Electronic automatic temper-
• Air discharge temperature • Circuit(s) • GO to Pinpoint Test K.
sensor - center register left- • Air discharge temperature
hand circuit failure - vehicles sensor - center register left-
with electronic automatic hand
temperature control (EATC) • Electronic automatic temper-
• Air discharge temperature • Circuit(s) • GO to Pinpoint Test L.
sensor - footwell left-hand • Air discharge temperature
circuit failure - vehicles with sensor - footwell left-hand
electronic automatic temper- • Electronic automatic temper-
ature control (EATC) ature control (EATC) module
• Air discharge temperature • Circuit(s) • GO to Pinpoint Test M.
sensor - center register right- • Air discharge temperature
hand circuit failure - vehicles sensor - center register right-
with electronic automatic hand
temperature control (EATC) • Electronic automatic temper-
• Air discharge temperature • Circuit(s) • GO to Pinpoint Test N.
sensor - footwell right-hand • Air discharge temperature
circuit failure - vehicles with sensor - footwell right-hand
2007.50 Focus 3/2007 G427113en


• Sunload sensor circuit failure - • Circuit(s) • GO to Pinpoint Test O.
vehicles with electronic auto- • Sunload sensor
matic temperature control • Electronic automatic temper-
(EATC) ature control (EATC) module
• In-vehicle temperature sensor • Circuit(s) • GO to Pinpoint Test P.
circuit failure - vehicles with • In-vehicle temperature sensor
• In-vehicle temperature sensor • Circuit(s) • GO to Pinpoint Test Q.
blower motor circuit failure - • In-vehicle temperature sensor
vehicles with electronic auto- • Electronic automatic temper-
matic temperature control ature control (EATC) module
(EATC)
Pinpoint Tests
PINPOINT TEST A : BLOWER MOTOR WITHOUT/INCORRECT FUNCTION - VEHICLES WITHOUT
ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
A1: CHECK ALL SPEED SETTINGS OF THE BLOWER MOTOR
2 Switch the blower motor switch through all
speed settings.
• Is the blower motor inoperative in all speed
settings?
→ Yes
GO to A2.
→ No
- The blower motor is only inoperative in
switch position 4:
GO to A13.
- The blower motor is inoperative in switch
positions 1, 2 and/or 3:
GO to A14.
A2: CHECK FUSE F10
2007.50 Focus 3/2007 G427113en


2 CHECK fuse F10 (BJB).
• Is the fuse OK?
→ Yes
GO to A3.
→ No
INSTALL a new fuse F10 (30 A). TEST the
system for normal operation. If the fuse blows
again, LOCATE and REPAIR the short using
the wiring diagrams.
A3: CHECK THE VOLTAGE AT FUSE F10
1 Connect fuse F10 (BJB).
2 Measure the voltage between fuse F10 (30 A)
and ground.
→ Yes
GO to A4.
→ No
REPAIR the power supply of fuse F10 using
the wiring diagrams. TEST the system for
normal operation.
A4: CHECK THE VOLTAGE AT THE BLOWER MOTOR RELAY
1 Disconnect blower motor relay of socket C1010
(BJB).
2 Measure the voltage between the blower motor
relay, socket C1010, pin 1, circuit 30-FA23 (RD),
VFE0016041
2007.50 Focus 3/2007 G427113en


• Is battery voltage indicated in both measure-
ments?
→ Yes
GO to A5.
→ No
- One measurement indicated no battery
VFE0015930 voltage:
LOCATE and REPAIR the open in the relevant
circuit between the blower motor relay and
splice S119 using the wiring diagrams. TEST
- No measurement indicated battery voltage:
LOCATE and REPAIR the open in circuit 30-
FA23A (RD) between splice S119 and fuse
F10 using the wiring diagrams. TEST the
A5: CHECK THE CIRCUIT OF THE BLOWER MOTOR
1 Switch the blower motor switch to position "0".
2 Connect a fused jumper wire (30 A) at the
blower motor relay, socket C1010, between pin
3 and pin 5, harness side.
VFE0013150
3 Switch the blower motor switch to position "4".

• Does the blower motor operate?
→ Yes
GO to A6.
→ No
GO to A8.
2007.50 Focus 3/2007 G427113en


A6: CHECK THE BLOWER MOTOR RELAY
1 Check the blower motor relay according to the
component test at the end of this section.
• Is the blower motor relay OK?
→ Yes
GO to A7.
→ No
INSTALL a new blower motor relay. TEST the
A7: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR RELAY AND THE CJB FOR OPEN
1 Disconnect connector C95 from CJB.
2 Measure the resistance between the blower
motor relay, socket C1010, pin 2, circuit 31S-
FA23 (BK/BU), harness side and CJB,
connector C95, pin 32, circuit 31S-FA23
(BK/BU), harness side.
→ Yes
CHECK the CJB, if necessary INSTALL a new
the CJB. TEST the system for normal opera-
VFE0037804
tion.
→ No
LOCATE and REPAIR the open in circuit 31S-
FA23 (BK/BU) between the blower motor relay
and the CJB using the wiring diagrams. TEST
A8: CHECK THE VOLTAGE AT THE BLOWER MOTOR SWITCH (PIN 4)
1 Disconnect connector C380 of blower motor
switch.
blower motor relay, socket C1010, between pin
3 and pin 5, harness side.
VFE0013150
2007.50 Focus 3/2007 G427113en


switch, connector C380, pin 4, circuit 31S-FA33
(BK/OG), harness side and ground.
→ Yes
GO to A9.
→ No
GO to A11.
E53612
A9: CHECK THE GROUND CONNECTION OF THE BLOWER MOTOR SWITCH

motor switch, connector C380, pin 5, circuit 31-
FA25 (BK), harness side and ground.
→ Yes
GO to A10.
→ No
LOCATE and REPAIR the open in the circuit
between the blower motor switch and ground
VFE0037931 G20 using the wiring diagrams. TEST the
A10: CHECK THE BLOWER MOTOR SWITCH

1 Connect blower motor relay on socket C1010.
blower motor switch, connector C380, between
pin 4, circuit 31S-FA33 (BK/OG), harness side
and pin 5, circuit 31-FA25 (BK), harness side.
E53934
2007.50 Focus 3/2007 G427113en


• Does the blower motor operate?
→ Yes
INSTALL a new blower motor switch. TEST
→ No
INSTALL a new blower motor. TEST the
A11: CHECK THE VOLTAGE AT THE BLOWER MOTOR
1 Disconnect connector C789 of blower motor.
2 Connect blower motor relay on socket C1010.
4 Measure the voltage between the blower motor,
connector C789, pin 1, circuit 15-FA18
→ Yes
GO to A12.
→ No
LOCATE and REPAIR open in circuit 15-FA18
(GN/OG) the between blower motor relay and
VFE0028910 the blower motor using the wiring diagrams.
A12: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER MOTOR SWITCH
FOR OPEN
motor, connector C789, pin 2, circuit 31S-FA18
(BK/RD), harness side and the blower motor
(BK/OG), harness side.
→ Yes
VFE0037930 → No
FA18 (BK/RD) between the blower motor and
2007.50 Focus 3/2007 G427113en


A13: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER MOTOR SWITCH
FOR OPEN (4TH SPEED INOPERATIVE)
resistor.
switch.
motor resistor, connector C470, pin 4, circuit
31S-FA33A (BK/OG), harness side and the
blower motor switch, connector C380, pin 4,
circuit 31S-FA33 (BK/OG), harness side.
→ Yes
E53611 → No
FA33 (BK/OG) between the blower motor
switch and splice S24 using the wiring
diagrams. TEST the system for normal opera-
tion.
A14: CHECK THE BLOWER MOTOR SWITCH
switch.
(BK/BU), harness side and ground.
VFE0037932

(BK/YE), harness side and ground.
2007.50 Focus 3/2007 G427113en


(BK/WH), harness side and ground.
• Is battery voltage indicated in all measure-
ments?
→ Yes
→ No
- No battery voltage is indicated:
GO to A15.
- No battery voltage is indicated in one/two
measurements:
GO to A16.
A15: CHECK THE VOLTAGE AT THE BLOWER MOTOR RESISTOR
resistor .
resistor, connector C470, pin 4, circuit 31S-
FA33A (BK/OG), harness side and ground.
→ Yes
INSTALL a new blower motor resistor. TEST
→ No
E0037933 FA33A (BK/OG) between the blower motor
resistor and splice S24 using the wiring
tion.
A16: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR RESISTOR AND THE BLOWER
MOTOR SWITCH FOR OPEN
resistor .
2007.50 Focus 3/2007 G427113en


31S-FA32 (BK/BU), harness side and the blower
motor switch, connector C380, pin 3, circuit 31S-
FA32 (BK/BU), harness side.
E0037934

31S-FA31 (BK/YE), harness side and the blower
motor switch, connector C380, pin 2, circuit 31S-
FA31 (BK/YE), harness side.
E0037935

31S-FA30 (BK/WH), harness side and the
blower motor switch, connector C380, pin 1,
circuit 31S-FA30 (BK/WH), harness side.
• Is the resistance less than 2 ohms in all
measurements?
→ Yes
INSTALL a new blower motor resistor. TEST
E0037936
→ No
circuit between the blower motor resistor and
the blower motor switch using the wiring
tion.
2007.50 Focus 3/2007 G427113en

PINPOINT TEST B : MALFUNCTION OF THE RECIRCULATION BLEND DOOR - VEHICLES WITHOUT
NOTE: The recirculation blend door is actuated by a DC motor. This is activated for a maximum of 7
seconds by the climate control assembly following actuation of the recirculated air button. Opening and
closing of the recirculation blend door is carried out by reversing the polarity of the applied voltage.
NOTE: Recirculated air mode is not available or will be deactivated if the air distribution control is set
to "defrost/demist windscreen".
B1: CHECK FUSE F43

2 CHECK fuse F43 (CJB).
• Is the fuse OK?
→ Yes
GO to B2.
→ No
B2: CHECK THE VOLTAGE AT FUSE F43
1 Connect fuse F43 (CJB).
and ground.
→ Yes
GO to B3.
→ No
normal operation.
B3: CHECK FUSE F70
• Is the fuse OK?
→ Yes
GO to B4.
→ No
2007.50 Focus 3/2007 G427113en


B4: CHECK THE VOLTAGE AT FUSE F70
and ground.
→ Yes
GO to B5.
→ No
normal operation.
B5: CHECK THE VOLTAGE AT THE RECIRCULATION BLEND DOOR ACTUATOR
2 Disconnect connector C538 of recirculation
blend door actuator.
4 Set the air distribution control to footwell.
5 Measure the voltage at the recirculation blend
door actuator, connector C538, between pin 2
and pin 4, harness side.
VFE0028920
2007.50 Focus 3/2007 G427113en


6 Actuate the recirculated air switch several times
during the measurement.
• Is a voltage of more than 10 V indicated with
alternating polarity?
→ Yes
CHECK the recirculation blend door for soft
running and correct operation. If the recircula-
tion blend door is OK, INSTALL a new recircu-
lation blend door actuator. TEST the system
→ No
GO to B6.
B6: CHECK THE VOLTAGE AT THE CLIMATE CONTROL ASSEMBLY (PIN 1)
2 Disconnect connector C378 of climate control
assembly.
3 Measure the voltage between the climate control
assembly, connector C378, pin 1, circuit 29-
FA13 (OG), harness side and ground.
→ Yes
GO to B8.
→ No
GO to B7.
E53613
B7: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE CJB FOR
OPEN
1 Disconnect connector C102 of CJB.
2007.50 Focus 3/2007 G427113en


2 Measure the resistance between the climate
control assembly, connector C378, pin 1, circuit
29-FA13 (OG), harness side and the CJB,
connector C102, pin 10, circuit 29-FA13 (OG),
harness side.
→ Yes
CJB. TEST the system for normal operation.
E53614 → No
between the climate control assembly and the
CJB using the wiring diagrams. TEST the
B8: CHECK THE VOLTAGE AT THE CLIMATE CONTROL ASSEMBLY (PIN 8)
FA13 (GN/RD), harness side and ground.
→ Yes
GO to B10.
→ No
GO to B9.
VFE0037937
B9: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE CJB FOR
OPEN
2007.50 Focus 3/2007 G427113en


15-FA13 (GN/RD), harness side and the CJB,
connector C102, pin 5, circuit 15-DA4 (GN/BK),
harness side.
→ Yes
E53615 → No
between the climate control assembly and the
CJB using the wiring diagrams. TEST the
B10: CHECK THE GROUND CONNECTION OF THE CLIMATE CONTROL ASSEMBLY
91-FA13 (BK/OG), harness side and ground.
→ Yes
GO to B11.
→ No
FA13 (BK/OG) between the climate control
VFE0037938 assembly and splice S12 using the wiring
tion.
B11: CHECK THE CIRCUIT BETWEEN THE RECIRCULATION BLEND DOOR ACTUATOR AND
THE CLIMATE CONTROL ASSEMBLY FOR OPEN
1 Measure the resistance between the recircula-
tion blend door actuator, connector C538, pin 2
(right-hand drive vehicles: pin 4), circuit 32-FA76
(WH/BU), harness side and the climate control
FA76 (WH/BU), harness side.
VFE0037939
2007.50 Focus 3/2007 G427113en


2 Measure the resistance between the recircula-
tion blend door actuator, connector C538, pin 4
(right-hand drive vehicles: pin 2), circuit 33-FA76
(YE/BU), harness side and the climate control
FA76 (YE/BU), harness side.
• Is the resistance less than 2 ohms in both
measurements?
→ Yes
VFE0037940 GO to B12.
→ No
circuit between the climate control assembly
and the recirculation blend door actuator using
normal operation.
B12: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE RECIRCU-
LATION BLEND DOOR ACTUATOR FOR SHORT TO POWER
FA76 (WH/BU), harness side and ground.
E53616

FA76 (YE/BU), harness side and ground.
• Is any voltage indicated?
→ Yes
LOCATE and REPAIR the short to power in
the relevant circuit between the climate control
assembly and the recirculation blend door
actuator using the wiring diagrams. TEST the
→ No
GO to B13.
2007.50 Focus 3/2007 G427113en


B13: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE RECIRCU-
LATION BLEND DOOR ACTUATOR FOR SHORT TO GROUND
2 Measure the resistance the between climate
32-FA76 (WH/BU), harness side and ground.
E53617

33-FA76 (YE/BU), harness side and ground.
• Is the resistance greater than 10,000 ohms in
both measurements?
→ Yes
CHECK the climate control assembly, if
necessary INSTALL a new climate control
assembly. TEST the system for normal oper-
ation.
→ No
LOCATE and REPAIR the short to ground in
the relevant circuit between the climate control
assembly and the recirculation blend door
actuator using the wiring diagrams. TEST the
PINPOINT TEST C : AIR CONDITIONING (A/C) IS INOPERATIVE (ALL OTHER FUNCTIONS OF

CLIMATE CONTROL ASSEMBLY OK)
NOTE: Vehicles without DVD Navigation System with Touchscreen, the electronic automatic temperature
control (EATC) module is integrated into the climate control assembly.
C1: CHECK FUSE F27

2007.50 Focus 3/2007 G427113en


• Is the fuse OK?
→ Yes
GO to C2.
→ No
C2: CHECK THE VOLTAGE AT FUSE F27
and ground.
→ Yes
GO to C3.
→ No
normal operation.
C3: CHECK FUSE F35
• Is the fuse OK?
→ Yes
GO to C4.
→ No
C4: CHECK THE VOLTAGE AT FUSE F35
2007.50 Focus 3/2007 G427113en


and ground.
→ Yes
GO to C5.
→ No
normal operation.
C5: CHECK VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY
2 Disconnect air conditioning clutch relay socket
C1011 (BJB).
3 Measure the voltage between the air condi-
tioning clutch relay, socket C1011, pin 3, circuit
30-FA2 (RD), harness side and ground.
→ Yes
GO to C6.
→ No
FA2 (RD) between fuse F27 and the air
VFE0016004 conditioning clutch relay using the wiring
tion.
C6: CHECK THE CONTROL VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY
15-FA11 (GN/YE), harness side and ground.
→ Yes
GO to C7.
→ No
FA11 (GN/YE) between fuse F35 and the air
VFE0016104 conditioning clutch relay using the wiring
tion.
C7: CHECK CIRCUIT OF THE AIR CONDITIONING CLUTCH
2007.50 Focus 3/2007 G427113en


2 Connect a fused jumper wire (10 A) at the air
conditioning clutch relay , socket C1011,
between pin 3 and pin 5, harness side.
VFE0019865
3 Check the function of the air conditioning clutch.

• Does the air conditioning clutch operate?
→ Yes
GO to C14.
→ No
- Vehicles with 1.8L and 2.0L engine:
GO to C8.
- Vehicles with diesel engine:
GO to C10.
- Vehicles with 1.6L engine:
GO to C12.
C8: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING CLUTCH RELAY AND THE AIR
CONDITIONING CLUTCH FOR OPEN - VEHICLES WITH 1.8L AND 2.0L ENGINE
1 Disconnect connector C952 of air conditioning
clutch.
2 Measure the resistance between the air condi-
tioning clutch relay , socket C1011, pin 5, circuit
15S-FA6 (GN/YE), harness side and the air
conditioning clutch, connector C952, pin 1,
circuit 15S-FA6 (GN/YE), harness side.
→ Yes
GO to C9.
→ No
E53618
FA6 (GN/YE) between the air conditioning
clutch relay and the air conditioning clutch
using the wiring diagrams. TEST the system
2007.50 Focus 3/2007 G427113en


C9: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING CLUTCH - VEHICLES
WITH 1.8L AND 2.0L ENGINE
tioning clutch, connector C952, pin 2, circuit 31-
FA6A (BK), harness side and ground.
→ Yes
INSTALL a new air conditioning clutch. TEST
→ No
E53619 FA6 (BK) between the air conditioning clutch
and ground G57 using the wiring diagrams.
CONDITIONING CLUTCH FOR OPEN - VEHICLES WITH DIESEL ENGINE
clutch.
conditioning clutch, connector C957, pin 2,
circuit 15S-FA6A (GN/YE), harness side.
→ Yes
GO to C11.
→ No
E53620 LOCATE and REPAIR the open in circuit
between the air conditioning clutch relay and
the air conditioning clutch using the wiring
tion.
2007.50 Focus 3/2007 G427113en


WITH DIESEL ENGINE
tioning clutch, connector C957, pin 1, circuit 31-
→ Yes
→ No
CONDITIONING CLUTCH FOR OPEN - VEHICLES WITH 1.6L ENGINE
clutch.
conditioning clutch, connector C951, pin A,
circuit 15S-FA6A (GN/YE), harness side.
→ Yes
GO to C11.
→ No
E53618
LOCATE and REPAIR the open in circuit
between the air conditioning clutch relay and
the air conditioning clutch using the wiring
tion.
2007.50 Focus 3/2007 G427113en


WITH 1.6L ENGINE
tioning clutch, connector C951, pin B, circuit 31-
→ Yes
→ No
C14: CHECK THE A/C REQUEST SIGNAL AT THE POWERTRAIN CONTROL MODULE (PCM)
1 Connect the diagnostic tool.
2 Turn on the blower motor.
3 Switch on the A/C system.
4 Using the diagnostic tester, select the PCM and
check in the datalogger whether an A/C request
signal is displayed.
• Is an A/C request signal displayed in the
datalogger of the PCM?
→ Yes
GO to C19.
→ No
- Vehicles without EATC:
GO to C15.
- Vehicles with EATC:
CHECK the EATC module, if necessary
INSTALL a new EATC module. TEST the
C15: CHECK THE A/C REQUEST SIGNAL AT THE GENERIC ELECTRONIC MODULE (GEM)
NOTE: The generic electronic module (GEM) is an integral part of the central junction box (CJB).
1 Turn on the blower motor.

2007.50 Focus 3/2007 G427113en


3 Using the diagnostic tester, select the GEM and
check in the datalogger whether an A/C request
signal is displayed.
• Is an A/C request signal displayed in the
datalogger of the GEM?
→ Yes
CHECK the GEM, if necessary INSTALL a
new CJB. TEST the system for normal opera-
tion.
→ No
GO to C16.
C16: CHECK THE A/C ON/OFF SWITCH SIGNAL AT THE GEM
4 Turn the blower motor switch to position "1".
6 Measure the voltage between the CJB,
connector C103, pin 13, circuit 8-FA9 (WH/GN),
→ Yes
CHECK the GEM, if necessary INSTALL a
new CJB. TEST the system for normal opera-
tion.
→ No
VFE0037943 GO to C17.
C17: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE CJB FOR
OPEN
2 Disconnect connector C378 of climate control
assembly.
2007.50 Focus 3/2007 G427113en


8-FA9 (WH/GN), harness side and the CJB,
connector C103, pin 13, circuit 8-FA9 (WH/GN).
→ Yes
GO to C18.
→ No
VFE0037944 FA9 (WH/GN) between the climate control
assembly and the CJB using the wiring
tion.
C18: CHECK THE CIRCUIT BETWEEN THE CLIMATE CONTROL ASSEMBLY AND THE CJB FOR
SHORT TO GROUND
8-FA9 (WH/GN), harness side and ground.
• Is a resistance greater than 10,000 ohms?
→ Yes
CHECK the climate control assembly, if
necessary INSTALL a new climate control
assembly. TEST the system for normal oper-
ation.
VFE0037945 → No
LOCATE and REPAIR the short in circuit 8-
FA9 (WH/GN) between the climate control
assembly and the CJB using the wiring
tion.
C19: CHECK THE VOLTAGE AT THE AIR CONDITIONING LOW-PRESSURE SWITCH
low-pressure switch.
3 Start the engine and run it at idle speed.
2007.50 Focus 3/2007 G427113en


tioning low-pressure switch, connector C692,
pin 4, circuit 91S-RE8 (BK/YE), harness side
and ground.
→ Yes
GO to C24.
→ No
- Vehicles with 2.0L diesel engine:
E0011398 GO to C20.
GO to C21.
- Vehicles with 1.6L engine and manual
transmission :
GO to C22.
- Vehicles with 1.6L engine and automatic
transmission:
GO to C23.
C20: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING LOW-PRESSURE SWITCH AND
THE PCM FOR OPEN - VEHICLES WITH 2.0L DIESEL ENGINE
2 Disconnect connector C418 of PCM.
and the PCM, connector C418, pin H2, circuit
91S-RE8 (BK/YE), harness side.
→ Yes
CHECK the PCM, if necessary INSTALL a
new PCM. TEST the system for normal oper-
ation.
E0037947
→ No
RE8 (BK/YE) between the air conditioning low-
pressure switch and the PCM using the wiring
tion.
THE PCM FOR OPEN - VEHICLES WITH 1.8L AND 2.0L ENGINE
2007.50 Focus 3/2007 G427113en


and the PCM, connector C690, pin 13, circuit
91S-RE8A (BK/YE), harness side.
→ Yes
ation.
E46224
→ No
between the air conditioning low-pressure
switch and the PCM using the wiring
tion.
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE AND MANUAL TRANSMISSION
and the PCM, connector C681, pin R, circuit
→ Yes
ation.
E54921
→ No
tion.
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE AND AUTOMATIC TRANSMISSION
2007.50 Focus 3/2007 G427113en


and the PCM, connector C682, pin R, circuit
→ Yes
ation.
E54921
→ No
tion.
C24: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING LOW-PRESSURE SWITCH
pin 1, circuit 91S-FA17 (BK/RD) (vehicles with
diesel engine: circuit 91S-FA17A (BK/RD)),
→ Yes
GO to C25.
→ No
VFE0023413 - Vehicles with diesel engine:
GO to C41.
- All except vehicles with diesel engine:
LOCATE and REPAIR the open circuit
switch and ground G31 using the wiring
tion.
2007.50 Focus 3/2007 G427113en


C25: CHECK THE AIR CONDITIONING LOW-PRESSURE SWITCH
1 Measure the resistance at the air conditioning
low-pressure switch, connector C692, between
pin 1 and pin 4, component side.
→ Yes
GO to C26.
→ No
CHECK refrigerant quantity.
VFE0015915
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-
00 Climate Control System - General
If the refrigerant quantity is in accordance with
manufacturer's specifications, INSTALL a new
air conditioning low-pressure switch. TEST
C26: CHECK THE AIR CONDITIONING CLUTCH RELAY
1 Check the air conditioning clutch relay according
to the component test at the end of this section.
• Is the air conditioning clutch relay OK?
→ Yes
- Vehicles with diesel engine:
GO to C27.
- All except vehicles with diesel engine:
GO to C28.
→ No
INSTALL a new air conditioning clutch relay.
C27: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING CLUTCH RELAY AND THE PCM
FOR OPEN - VEHICLES WITH DIESEL ENGINE
2007.50 Focus 3/2007 G427113en


2 Measure the resistance between the PCM,
connector C418, pin D4, circuit 31S-FA11
(BK/YE), harness side and the air conditioning
clutch relay, socket C1011, pin 2, circuit 31S-
→ Yes
ation.
E0037951
→ No
FA11 (BK/YE), between the PCM and the air
conditioning clutch relay using the wiring
tion.
C28: CHECK THE VOLTAGE AT THE AIR CONDITIONING PRESSURE TRANSDUCER
pressure transducer.
pin 2, circuit 7-FA88 (YE/VT), harness side and
ground.
• Is the voltage of approximately 5 volts?
→ Yes
GO to C29.
→ No
- Vehicles with 1.6L engine:
E0011401 GO to C37.
- Vehicles with 1.8L and 2.0L engine
GO to C38.
2007.50 Focus 3/2007 G427113en


C29: CHECK THE CONTROL VOLTAGE AT THE AIR CONDITIONING PRESSURE TRANSDUCER
tioning pressure transducer, connector C965,
pin 3, circuit 8-FA88 (WH/VT), harness side and
ground.
• Is a voltage of approximately 4 V indicated?
→ Yes
GO to C30.
→ No
VFE0038807
transmission:
GO to C31.
transmission:
GO to C32.
GO to C35.
C30: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING PRESSURE TRANSDUCER
pin 1, circuit 9-FA88 (BN/WH), harness side and
ground.
→ Yes
transmission:
GO to C33.
VFE0023413
transmission:
GO to C34.
GO to C36.
→ No
transmission:
GO to C39.
GO to C40.
C31: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING PRESSURE TRANSDUCER AND
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE AND MANUAL TRANSMISSION
2007.50 Focus 3/2007 G427113en


the PCM, connector C681, pin U, circuit 8-
FA88A (WH/VT), harness side.
→ Yes
ation.
E54922
→ No
between the air conditioning pressure trans-
ducer and the PCM using the wiring diagrams.
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE AND AUTOMATIC TRANSMISSION
the PCM, connector C682, pin U, circuit 8-
FA88A (WH/VT), harness side.
→ Yes
ation.
E54922
→ No
FOR OPEN - VEHICLES WITH 1.6L ENGINE AND MANUAL TRANSMISSION
2007.50 Focus 3/2007 G427113en


connector C681, pin AL, circuit 31S-FA11A
→ Yes
ation.
E54923
→ No
between the PCM and the air conditioning
clutch relay using the wiring diagrams. TEST
FOR OPEN - VEHICLES WITH 1.6L ENGINE AND AUTOMATIC TRANSMISSION
connector C682, pin AL, circuit 31S-FA11A
→ Yes
ation.
E54923
→ No
2007.50 Focus 3/2007 G427113en


the PCM, connector C690, pin 13, circuit 8-FA88
(WH/VT), harness side.
→ Yes
VFE0038809 ation.
→ No
FA88 (WH/VT) between the air conditioning
pressure transducer and the PCM using the
wiring diagrams. TEST the system for normal
operation.
FOR OPEN - VEHICLES WITH 1.8L AND 2.0L ENGINE
connector C690, pin 1, circuit 31S-FA11A
→ Yes
VFE0037952
ation.
→ No
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE
2007.50 Focus 3/2007 G427113en


the PCM, connector C680, pin V, circuit 7-RJ28
(YE), harness side.
→ Yes
ation.
E54924
→ No
the PCM, connector C690, pin 28, circuit 7-FA88
(YE/VT), harness side.
→ Yes
ation.
E45663
→ No
FA88 (YE/VT) between the air conditioning
pressure transducer and the PCM using the
operation.
THE PCM FOR OPEN - VEHICLES WITH 1.6L ENGINE
2007.50 Focus 3/2007 G427113en


the PCM, connector C680, pin AX, circuit 9-RE8
(BN), harness side.
→ Yes
ation.
E54925
→ No
ducer and splice S63 using the wiring
tion.
the PCM, connector C690, pin 25, circuit 9-RE8
(BN), harness side.
→ Yes
ation.
E45664
→ No
FA88 (BN/WH) between the air conditioning
pressure transducer and splice S63 using the
operation.
C41: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING HIGH-PRESSURE SWITCH
high-pressure switch.
2007.50 Focus 3/2007 G427113en


tioning high-pressure switch, connector 882, pin
1, circuit 91-FA38 (BK/OG), harness side and
ground.
→ Yes
GO to C42.
→ No
VFE0037954 FA38 (BK/OG) between the air conditioning
high-pressure switch and ground G31 using
normal operation.
C42: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING HIGH-PRESSURE SWITCH AND
THE AIR CONDITIONING LOW-PRESSURE SWITCH FOR OPEN
tioning high-pressure switch, connector 882, pin
4, circuit 91S-FA17 (BK/RD), harness side and
the air conditioning low-pressure switch,
(BK/RD), harness side.
→ Yes
INSTALL a new air conditioning high-pressure
VFE0037955
switch. TEST the system for normal operation.
→ No
FA17 (BK/RD) between the air conditioning
high-pressure switch and the air conditioning
low-pressure switch using the wiring diagrams.
2007.50 Focus 3/2007 G427113en

PINPOINT TEST D : CLIMATE CONTROL ASSEMBLY INOPERATIVE - VEHICLES WITH ELECTRONIC
AUTOMATIC TEMPERATURE CONTROL (EATC) WITHOUT DVD NAVIGATIONSYSTEM WITH
TOUCHSCREEN
D1: CHECK THE CHARGING SYSTEM
1 Check the charging system.
REFER to: Charging System (414-00 Charging
System - General Information, Diagnosis and
Testing).
• Is the charging system OK?
→ Yes
GO to D2.
→ No
REPAIR the charging system. TEST the
system for normal opeartion.
D2: CHECK FUSE F43
• Is the fuse OK?
→ Yes
GO to D3.
→ No
D3: CHECK THE VOLTAGE AT FUSE F43
and ground.
→ Yes
GO to D4.
→ No
normal operation.
D4: CHECK THE VOLTAGE AT THE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
(EATC) MODULE
1 Disconnect connector C539 of EATC module.
2007.50 Focus 3/2007 G427113en


2 Measure the voltage between the EATC module,
(OG/BK), harness side and ground.
→ Yes
GO to D6.
→ No
GO to D5.
VFE0037956
D5: CHECK THE CIRCUIT BETWEEN THE EATC MODULE AND THE CJB FOR OPEN
2 Measure the resistance between the EATC
module, connector C539, pin 11, circuit 29-FA94
(OG/BK), harness side and the CJB, connector
C102, pin 10, circuit 29-FA94 (OG/BK), harness
side.
→ Yes
VFE0037957 → No
FA94 (OG/BK) between the EATC module
D6: CHECK THE GROUND CONNECTION OF THE EATC MODULE
(BK/GN), harness side and ground.
→ Yes
→ No
VFE0037958 LOCATE and REPAIR the open in circuit 91-
FA94 (BK/GN) between the EATC module
and splice S12 using the wiring diagrams.
2007.50 Focus 3/2007 G427113en

PINPOINT TEST E : BLOWER MOTOR WITHOUT/INCORRECT FUNCTION - VEHICLES WITH
ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) (ALL OTHER FUNCTIONS OF
CLIMATE CONTROL ASSEMBLY OK)
E1: CHECK FUSE F10

• Is the fuse OK?
→ Yes
GO to E2.
→ No
E2: CHECK THE VOLTAGE AT FUSE F10
and ground.
→ Yes
GO to E3.
→ No
normal operation.
E3: CHECK THE VOLTAGE AT THE BLOWER MOTOR
1 Disconnect connector C537 of blower motor.
2007.50 Focus 3/2007 G427113en


3 Measure the voltage between the blower motor,
connector C537, pin 1, circuit 15-FA18A
→ Yes
GO to E4.
→ No
GO to E9.
VFE0037959
E4: CHECK THE GROUND CONNECTION OF THE BLOWER MOTOR

motor, connector C537, pin 6, circuit 31-FA45
(BK), harness side and ground.
→ Yes
GO to E5.
→ No
between the blower motor and ground G20
VFE0037960 using the wiring diagrams. TEST the system
E5: CHECK THE CIRCUITS BETWEEN THE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
(EATC) MODULE AND THE BLOWER MOTOR FOR OPEN
module, connector C540, pin 15, circuit 49S-
FA45 (BU/WH), harness side and the blower
motor, connector C537, pin 2, circuit 49S-FA45
(BU/WH), harness side.
VFE0037961
2007.50 Focus 3/2007 G427113en


(BN/BU), harness side and the blower motor,
connector C537, pin 3, circuit 9-FA45 (BN/BU),
harness side.
measurements?
→ Yes
GO to E6.
VFE0037962 → No
circuit between the EATC module and the
blower motor using the wiring diagrams. TEST
E6: CHECK THE CIRCUITS BETWEEN THE EATC MODULE AND THE BLOWER MOTOR FOR
SHORT
FA45 (BU/WH), harness side and the EATC
(BN/BU), harness side.
→ Yes
GO to E7.
→ No
VFE0037963 LOCATE and REPAIR the short in the circuits
between the EATC module and the blower
motor using the wiring diagrams. TEST the
SHORT TO POWER
(BU/WH), harness side and ground.
VFE0037964
2007.50 Focus 3/2007 G427113en


connector C540, pin 16, circuit 9-FA45 (BN/BU),
→ Yes
the relevant circuit between the EATC module
and the blower motor using the wiring
tion.
→ No
GO to E8.
SHORT TO GROUND
FA45 (BU/WH), harness side and ground.
VFE0037965

(BN/BU), harness side and ground.
both measurements?
→ Yes
system for normal operation. If the blower
motor is still inoperative, INSTALL a new
EATC module.
→ No
LOCATE and REPAIR the short in the relevant
circuit between the EATC module and the
E9: CHECK THE VOLTAGE AT THE BLOWER MOTOR RELAY
2007.50 Focus 3/2007 G427113en


2 Disconnect blower motor relay of socket C1010
(BJB).
VFE0016041

• Is battery voltage indicated in both measure-
ments?
→ Yes
GO to E10.
→ No
- Battery voltage is not indicated in one
VFE0015930 measurement:
circuit between the blower motor relay and
- No battery voltage is indicated:
FA23A (RD) between splice S119 and fuse
F10 using the wiring diagrams. TEST the
2007.50 Focus 3/2007 G427113en


E10: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR RELAY AND THE BLOWER MOTOR
FOR OPEN
motor relay, socket C1010, pin 5, circuit 15-
FA18 (GN/OG), harness side and the blower
motor, connector C537, pin 1, circuit 15-FA18A
(GN/OG), harness side.
→ Yes
GO to E11.
→ No
VFE0037966 LOCATE and REPAIR the open in the circuit
between the blower motor relay and the
E11: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR RELAY AND THE CJB FOR OPEN
motor relay, socket C1010, pin 2, circuit 31S-
FA23 (BK/BU), harness side and the CJB,
(BK/BU), harness side.
→ Yes
GO to E12.
→ No
VFE0037967 LOCATE and REPAIR the open in circuit 31S-
FA23 (BK/BU) between the blower motor relay
E12: CHECK THE BLOWER MOTOR RELAY
1 Check the blower motor relay according to the
component test at the end of this section.
• Is the blower motor relay OK?
→ Yes
→ No
INSTALL a new blower motor relay. TEST the
2007.50 Focus 3/2007 G427113en

PINPOINT TEST F : MALFUNCTION OF THE RECIRCULATION BLEND DOOR - VEHICLES WITH
NOTE: Recirculated air mode is not available or will be deactivated if the air distribution control is set
to "defrost/demist windscreen".
NOTE: Make sure that the recirculation blend door is mechanically OK.
F1: CHECK THE VOLTAGE AT THE RECIRCULATION BLEND DOOR ACTUATOR

2 Disconnect connector C541 of recirculation
blend door actuator.
4 Measure the voltage between the recirculation
blend door actuator, connector C541, pin 2,
circuit 15S-FA42 (GN/YE), harness side and
ground.
→ Yes
- Left-hand drive vehicles:
GO to F3.
- Right-hand drive vehicles:
VFE0037968
GO to F4.
→ No
GO to F2.
F2: CHECK THE CIRCUIT BETWEEN THE RECIRCULATION BLEND DOOR ACTUATOR AND THE
EATC MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


FA42 (GN/YE), harness side and the recircula-
tion blend door actuator, connector C541, pin
2, circuit 15S-FA42 (GN/YE), harness side.
→ Yes
VFE0037969
→ No
FA42 (GN/YE) between the EATC module
and the recirculation blend door actuator using
normal operation.
F3: CHECK THE CIRCUITS BETWEEN THE RECIRCULATION BLEND DOOR ACTUATOR AND
THE EATC MODULE FOR OPEN - LEFT-HAND DRIVE VEHICLES
module, connector C539, pin 1, circuit 31S-FA54
(BK/BU), harness side and the recirculation
circuit 31S-FA54 (BK/BU), harness side.
E53622

(BK/OG), harness side and the recirculation
circuit 31S-FA55 (BK/OG), harness side.
E53623
2007.50 Focus 3/2007 G427113en


FA56 (BK/GN), harness side and the recircula-
4, circuit 31S-FA56 (BK/GN), harness side.
E53624

FA57 (BK/RD), harness side and the recircula-
6, circuit 31S-FA57 (BK/RD), harness side.
measurements?
→ Yes
GO to F5.
E53625 → No
circuit between the recirculation blend door
actuator and the EATC module using the
operation.
THE EATC MODULE FOR OPEN - RIGHT-HAND DRIVE VEHICLES
FA54A (BK/BU), harness side and the recircula-
4, circuit 31S-FA54A (BK/BU), harness side.
E53626
2007.50 Focus 3/2007 G427113en


FA55A (BK/OG), harness side and the recircu-
lation blend door actuator, connector C541, pin
6, circuit 31S-FA55A (BK/OG), harness side.
E53627

FA56A (BK/GN), harness side and the recircu-
lation blend door actuator, connector C541, pin
1, circuit 31S-FA56A (BK/GN), harness side.
E53628

FA57A (BK/RD), harness side and the recircula-
3, circuit 31S-FA57A (BK/RD), harness side.
measurements?
→ Yes
GO to F5.
E53629 → No
circuit between the recirculation blend door
operation.
THE EATC MODULE FOR SHORT TO POWER
2007.50 Focus 3/2007 G427113en


(BK/BU) (right-hand drive vehicles: circuit 31S-
FA54A (BK/BU)), harness side and ground.
VFE0037974

(BK/OG) (right-hand drive vehicles: circuit 31S-
FA55A (BK/OG)), harness side and ground.
(BK/GN) (right-hand drive vehicles: circuit 31S-
FA56A (BK/GN)), harness side and ground.
(BK/RD) (right-hand drive vehicles: circuit 31S-
FA57A (BK/RD)), harness side and ground.
→ Yes
LOCATE and REPAIR short to power in the
relevant circuit(s) between the recirculation
blend door actuator and the EATC module
→ No
GO to F6.
THE EATC MODULE FOR SHORT TO GROUND
2007.50 Focus 3/2007 G427113en


(BK/BU) (Right-hand drive vehicles: circuit 31S-
FA54A (BK/BU)), harness side and ground.
VFE0037975

(BK/OG) (Right-hand drive vehicles: circuit 31S-
FA55A (BK/OG)), harness side and ground.
FA56 (BK/GN) (Right-hand drive vehicles: circuit
31S-FA56A (BK/GN)), harness side and ground.
FA57 (BK/RD) (Right-hand drive vehicles: circuit
31S-FA57A (BK/RD)), harness side and ground.
FA42 (GN/YE), harness side and ground.
all measurements?
→ Yes
GO to F7.
→ No
E53630 circuit(s) between the recirculation blend door
operation.
2007.50 Focus 3/2007 G427113en


THE EATC MODULE FOR SHORT
(BK/BU) (Right-hand drive vehicles: 31S-FA54A
(BK/BU)), harness side and the EATC module,
(GN/YE), harness side.
VFE0037976

(BK/OG) (Right-hand drive vehicles: 31S-FA55A
(BK/OG)), harness side.
VFE0037977

(BK/GN) (Right-hand drive vehicles: 31S-FA56A
(BK/GN)), harness side.
VFE0037978
2007.50 Focus 3/2007 G427113en


(BK/RD) (Right-hand drive vehicles: 31S-FA57A
(BK/RD)), harness side.
VFE0037979

FA42 (GN/YE), harness side and the EATC
(BK/OG)), harness side.
VFE0037980

FA56 (BK/GN) (Right-hand drive vehicles: 31S-
FA56A (BK/GN)), harness side.
VFE0037981
2007.50 Focus 3/2007 G427113en


FA57 (BK/RD) (Right-hand drive vehicles: 31S-
FA57A (BK/RD)), harness side.
VFE0037982

(BK/OG)), harness side and the EATC module,
(BK/GN) (Right-hand drive vehicles: 31S-FA56A
(BK/GN)), harness side.
VFE0037983

(BK/OG)), harness side and the EATC module,
(BK/RD) (Right-hand drive vehicles: 31S-FA57A
(BK/RD)), harness side.
VFE0037984
2007.50 Focus 3/2007 G427113en


FA56 (BK/GN) (Right-hand drive vehicles: 31S-
FA56A (BK/GN)), harness side and the EATC
FA57 (BK/RD) (Right-hand drive vehicles: 31S-
FA57A (BK/RD)), harness side.
all measurements?
VFE0037985
→ Yes
INSTALL a new recirculation blend door
actuator. TEST the system for normal opera-
tion.
→ No
LOCATE and REPAIR the short between the
relevant circuits between the recirculation
blend door actuator and the EATC module
PINPOINT TEST G : MALFUNCTION OF TEMPERATURE BLEND DOOR LEFT-HAND - VEHICLES

WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
NOTE: Make sure that the temperature blend door left is mechanically OK.
G1: CHECK THE VOLTAGE AT THE TEMPERATURE BLEND DOOR ACTUATOR LEFT-HAND
2 Disconnect connector C553 of temperature
blend door actuator left-hand.
4 Measure the voltage between the temperature
blend door actuator left-hand, connector C553,
pin 2, circuit 15S-FA46 (GN/BU), harness side
and ground.
→ Yes
GO to G3.
→ No
GO to G2.
VFE0037968
2007.50 Focus 3/2007 G427113en


G2: CHECK THE CIRCUIT BETWEEN THE TEMPERATURE BLEND DOOR ACTUATOR LEFT-
HAND AND THE EATC MODULE FOR OPEN
FA46 (GN/BU), harness side and the temper-
ature blend door actuator left-hand, connector
C553, pin 2, circuit 15S-FA46 (GN/BU), harness
side.
→ Yes
VFE0037986
→ No
FA46 (GN/BU) between the EATC module
and the temperature blend door actuator left-
hand using the wiring diagrams. TEST the
G3: CHECK THE CIRCUITS BETWEEN THE TEMPERATURE BLEND DOOR ACTUATOR LEFT-
(BK/OG), harness side and the temperature
pin 1, circuit 31S-FA58 (BK/OG), harness side.
VFE0037987
2007.50 Focus 3/2007 G427113en


(BK/GN), harness side and the temperature
pin 3, circuit 31S-FA59 (BK/GN), harness side.
VFE0037988

FA60 (BK/RD), harness side and the temper-
C553, pin 4, circuit 31S-FA60 (BK/RD), harness
side.
VFE0037989

FA61 (BK/WH), harness side and the temper-
C553, pin 6, circuit 31S-FA61 (BK/WH), harness
side.
measurements?
→ Yes
VFE0037990
GO to G4.
→ No
circuit between the temperature blend door
actuator left-hand and the EATC module using
normal operation.
HAND AND THE EATC MODULE FOR SHORT TO POWER
2007.50 Focus 3/2007 G427113en


VFE0037991

→ Yes
relevant circuit(s) between the temperature
blend door actuator left-hand and the EATC
module using the wiring diagrams. TEST the
→ No
GO to G5.
HAND AND THE EATC MODULE FOR SHORT TO GROUND
E53631
2007.50 Focus 3/2007 G427113en


FA60 (BK/RD), harness side and ground.
FA61 (BK/WH), harness side and ground.
FA46 (GN/BU), harness side and ground.
all measurements?
→ Yes
GO to G6.
→ No
LOCATE and REPAIR short to ground in the
HAND AND THE EATC MODULE FOR SHORT
(BK/OG), harness side and the EATC module,
(GN/BU), harness side.
VFE0037993
2007.50 Focus 3/2007 G427113en


VFE0037994

VFE0037995

(BK/WH), harness side.
VFE0037996
2007.50 Focus 3/2007 G427113en


FA46 (GN/BU), harness side and the EATC
VFE0037997

FA60 (BK/RD), harness side.
VFE0037998

FA61 (BK/WH), harness side.
VFE0037999
2007.50 Focus 3/2007 G427113en


(BK/GN), harness side and the EATC module,
VFE0038000

VFE0038001

FA60 (BK/RD), harness side and the EATC
FA61 (BK/WH), harness side.
all measurements?
→ Yes
INSTALL a new temperature blend door
VFE0038002
actuator left-hand. TEST the system for
normal operation.
→ No
relevant circuits between the temperature
2007.50 Focus 3/2007 G427113en

PINPOINT TEST H : MALFUNCTION OF TEMPERATURE BLEND DOOR RIGHT-HAND - VEHICLES
NOTE: Make sure that the temperature blend door right-hand is mechanically OK.
H1: CHECK THE VOLTAGE AT THE TEMPERATURE BLEND DOOR ACTUATOR RIGHT-HAND
2 Disconnect connector C534 of temperature
blend door actuator right-hand.
4 Measure the voltage between the temperature
blend door actuator right-hand, connector C534,
pin 2, circuit 15S-FB9 (GN/RD), harness side
and ground.
→ Yes
GO to H3.
→ No
GO to H2.
VFE0037968
H2: CHECK THE CIRCUIT BETWEEN THE TEMPERATURE BLEND DOOR ACTUATOR RIGHT-
FB9 (GN/RD), harness side and the temperature
pin 2, circuit 15S-FB9 (GN/RD), harness side.
→ Yes
VFE0038003
→ No
FB9 (GN/RD) between the EATC module and
the temperature blend door actuator right-hand
2007.50 Focus 3/2007 G427113en


H3: CHECK THE CIRCUITS BETWEEN THE TEMPERATURE BLEND DOOR ACTUATOR RIGHT-
module, connector C539, pin 9, circuit 31S-FB10
(BK/GN), harness side and the temperature
pin 1, circuit 31S-FB10 (BK/GN), harness side.
VFE0038004

FB11 (BK/RD), harness side and the temper-
ature blend door actuator right-hand, connector
C534, pin 3, circuit 31S-FB11 (BK/RD), harness
side.
VFE0038005

FB12 (BK/WH), harness side and the temper-
C534, pin 4, circuit 31S-FB12 (BK/WH), harness
side.
VFE0038006
2007.50 Focus 3/2007 G427113en


FB13 (BK/YE), harness side and the temper-
C534, pin 6, circuit 31S-FB13 (BK/YE), harness
side.
measurements?
→ Yes
VFE0038007
GO to H4.
→ No
circuit between the temperature blend door
actuator right-hand and the EATC module
HAND AND THE EATC MODULE FOR SHORT TO POWER
connector C539, pin 9, circuit 31S-FB10
VFE0038009

2007.50 Focus 3/2007 G427113en


(BK/YE), harness side and ground.
→ Yes
blend door actuator right-hand and the EATC
→ No
GO to H5.
HAND AND THE EATC MODULE FOR SHORT TO GROUND
E53632

FB11 (BK/RD), harness side and ground.
FB12 (BK/WH), harness side and ground.
FB13 (BK/YE), harness side and ground.
2007.50 Focus 3/2007 G427113en


FB9 (GN/RD), harness side and ground.
all measurements?
→ Yes
GO to H6.
→ No
LOCATE and RECTIFY short to ground in the
HAND AND THE EATC MODULE FOR SHORT
(GN/RD), harness side.
VFE0038010

E0038011
2007.50 Focus 3/2007 G427113en


VFE0038012

(BK/YE), harness side.
VFE0038013

FB9 (GN/RD), harness side and the EATC
FB11 (BK/RD), harness side.
VFE0038014
2007.50 Focus 3/2007 G427113en


FB12 (BK/WH), harness side.
VFE0038015

FB13 (BK/YE), harness side.
VFE0038016

FB11 (BK/RD), harness side and the EATC
VFE0038017
2007.50 Focus 3/2007 G427113en


VFE0038018

FB12 (BK/WH), harness side and the EATC
all measurements?
→ Yes
INSTALL a new temperature blend door
VFE0038019
actuator right-hand. TEST the system for
normal operation.
→ No
relevant circuits between the temperature
PINPOINT TEST I : MALFUNCTION OF AIR DISTRIBUTION DOOR - VEHICLES WITH ELECTRONIC

AUTOMATIC TEMPERATURE CONTROL (EATC)
NOTE: Make sure that the air distribution door is mechanically OK.
I1: CHECK THE VOLTAGE AT THE AIR DISTRIBUTION DOOR ACTUATOR

2 Disconnect connector C533 of air distribution
door actuator.
2007.50 Focus 3/2007 G427113en


4 Measure the voltage between the air distribution
door actuator, connector C533, pin 2, circuit
15S-FB19 (GN/YE), harness side and ground.
→ Yes
GO to I3.
→ No
GO to I2.
VFE0037968
I2: CHECK THE CIRCUIT BETWEEN THE AIR DISTRIBUTION DOOR ACTUATOR AND THE EATC
MODULE FOR OPEN
FB19 (GN/YE), harness side and the air
distributor door actuator, connector C533, pin
2, circuit 15S-FB19 (GN/YE), harness side.
→ Yes
VFE0038020
→ No
FB19 (GN/YE) between the EATC module
and the air distribution door actuator using the
operation.
I3: CHECK THE CIRCUITS BETWEEN THE AIR DISTRIBUTION DOOR ACTUATOR AND THE EATC
MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


(BK/BU), harness side and the air distribution
31S-FB20 (BK/BU), harness side.
VFE0038021

(BK/OG), harness side and the air distribution
31S-FB21 (BK/OG), harness side.
VFE0038022

FB22 (BK/GN), harness side and the air distri-
bution door actuator, connector C533, pin 4,
circuit 31S-FB22 (BK/GN), harness side.
VFE0038023
2007.50 Focus 3/2007 G427113en


FB23 (BK/RD), harness side and the air distribu-
tion door actuator, connector C533, pin 6, circuit
31S-FB23 (BK/RD), harness side.
measurements?
→ Yes
GO to I4.
VFE0038024 → No
circuit between the air distribution door actu-
ator and the EATC module using the wiring
tion.
MODULE FOR SHORT TO POWER
VFE0038025

2007.50 Focus 3/2007 G427113en


→ Yes
relevant circuit(s) between the air distribution
door actuator and the EATC module using the
operation.
→ No
GO to I5.
MODULE FOR SHORT TO GROUND
E53633

FB22 (BK/GN), harness side and ground.
2007.50 Focus 3/2007 G427113en


FB19 (GN/YE), harness side and ground.
all measurements?
→ Yes
GO to I6.
→ No
relevant circuit(s) between the air distribution
operation.
MODULE FOR SHORT
(BK/BU), harness side and the EATC module,
(GN/YE), harness side.
VFE0038027

VFE0038028
2007.50 Focus 3/2007 G427113en


VFE0038029

VFE0038030

FB19 (GN/YE), harness side and the EATC
VFE0038031
2007.50 Focus 3/2007 G427113en


FB22 (BK/GN), harness side.
VFE0038032

VFE0038033

VFE0038034
2007.50 Focus 3/2007 G427113en


VFE0038035

FB22 (BK/GN), harness side and the EATC
all measurements?
→ Yes
INSTALL a new air distribution door actuator.
VFE0038036
→ No
circuits between the air distribution door
operation.
PINPOINT TEST J : MALFUNCTION OF DEFROST VENT/REGISTER BLEND DOOR - VEHICLES

NOTE: Make sure that the defrost vent/register blend door is mechanically OK.
J1: CHECK THE VOLTAGE AT THE DEFROST VENT/REGISTER BLEND DOOR ACTUATOR
2 Disconnect connector C532 of defrost
vent/register blend door actuator.
2007.50 Focus 3/2007 G427113en


4 Measure the voltage between the defrost
vent/register blend door actuator, connector
C532, pin 2, circuit 15S-FB14 (GN/BU), harness
side and ground.
→ Yes
GO to J3.
→ No
GO to J2.
VFE0037968
J2: CHECK THE CIRCUIT BETWEEN THE DEFROST VENT/REGISTER BLEND DOOR ACTUATOR
AND THE EATC MODULE FOR OPEN
FB14 (GN/BU), harness side and the defrost
C532, pin 2, circuit 15S-FB14 (GN/BU), harness
side.
→ Yes
VFE0038037
→ No
FB14 (GN/BU) between the EATC module
and the defrost vent/register blend door actu-
ator using the wiring diagrams. TEST the
J3: CHECK THE CIRCUITS BETWEEN THE DEFROST VENT/REGISTER BLEND DOOR ACTUATOR
AND THE EATC MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


(BK/OG), harness side and the defrost
C532, pin 1, circuit 31S-FB15 (BK/OG), harness
side.
VFE0038038

(BK/GN), harness side and the defrost
C532, pin 3, circuit 31S-FB16 (BK/GN), harness
side.
VFE0038039

FB17 (BK/RD), harness side and the defrost
C532, pin 4, circuit 31S-FB17 (BK/RD), harness
side.
VFE0038040
2007.50 Focus 3/2007 G427113en


FB18 (BK/WH), harness side and the defrost
C532, pin 6, circuit 31S-FB18 (BK/WH), harness
side.
measurements?
→ Yes
VFE0038041
GO to J4.
→ No
circuit between the defrost vent/register blend
operation.
AND THE EATC MODULE FOR SHORT TO POWER
VFE0038042

2007.50 Focus 3/2007 G427113en


→ Yes
relevant circuit(s) between the defrost
vent/register blend door actuator and the
EATC module using the wiring diagrams.
→ No
GO to J5.
AND THE EATC MODULE FOR SHORT TO GROUND
E53634

FB18 (BK/WH), harness side and ground.
2007.50 Focus 3/2007 G427113en


FB14 (GN/BU), harness side and ground.
all measurements?
→ Yes
GO to J6.
→ No
relevant circuit(s) between the defrost
vent/register blend door actuator and the
AND THE EATC MODULE FOR SHORT
(GN/BU), harness side.
VFE0038044

VFE0038045
2007.50 Focus 3/2007 G427113en


VFE0038046

VFE0038047

FB14 (GN/BU), harness side and the EATC
VFE0038048
2007.50 Focus 3/2007 G427113en


VFE0038049

VFE0038050

VFE0038051
2007.50 Focus 3/2007 G427113en


VFE0038052

all measurements?
→ Yes
INSTALL a new defrost vent/register blend
VFE0038053
door actuator. TEST the system for normal
operation.
→ No
circuits between the defrost vent/register blend
operation.
PINPOINT TEST K : AIR DISCHARGE TEMPERATURE SENSOR - CENTER REGISTER LEFT-HAND

CIRCUIT FAILURE - VEHICLES WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
(EATC)
K1: CHECK THE VOLTAGE AT THE AIR DISCHARGE TEMPERATURE SENSOR - CENTER
REGISTER LEFT-HAND
2 Disconnect connector C542 of air discharge
temperature sensor - center register left-hand.
2007.50 Focus 3/2007 G427113en


5 Measure the voltage between the air discharge
temperature sensor - center register left-hand,
→ Yes
GO to K3.
→ No
- No voltage is indicated:
VFE0038054 GO to K2.
- Battery voltage is indicated:
the circuit 8-FA47 (WH/GN) between the
EATC module and the air discharge temper-
ature sensor - center register left-hand using
the wiring diagrams. If there is no short to
power, CHECK the EATC module, if neces-
sary INSTALL a new EATC module. TEST the
K2: CHECK THE CIRCUIT BETWEEN THE AIR DISCHARGE TEMPERATURE SENSOR - CENTER
REGISTER LEFT-HAND AND THE EATC MODULE FOR OPEN
3 Measure the resistance between the air
discharge temperature sensor - center register
left-hand, connector C542, pin 1, circuit 8-FA47
(WH/GN), harness side and the EATC module,
(WH/GN), harness side.
→ Yes
VFE0038056
→ No
FA47 (WH/GN) between the air discharge
temperature sensor - center register left-hand
and the EATC module using the wiring
tion.
REGISTER LEFT-HAND AND THE EATC MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


left-hand, connector C542, pin 3, circuit 9-FA47
(BN/GN), harness side and the EATC module,
(BN/GN), harness side.
→ Yes
GO to K4.
VFE0038057 → No
between the air discharge temperature sensor
- center register left-hand and the EATC
REGISTER LEFT-HAND AND THE EATC MODULE FOR SHORT
→ Yes
GO to K5.
→ No
REGISTER LEFT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
E49853
2007.50 Focus 3/2007 G427113en


module, connector C540, pin 20, circuit 9-FA47A
(BN/GN), harness side and ground.
both measurements?
→ Yes
INSTALL a new air discharge temperature
sensor - center register left-hand. TEST the
→ No
LOCATE and REPAIR the short in the circuits
PINPOINT TEST L : AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL LEFT-HAND CIRCUIT

FAILURE - VEHICLES WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
L1: CHECK THE VOLTAGE AT THE AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL
LEFT-HAND
temperature sensor - footwell left-hand.
2007.50 Focus 3/2007 G427113en


temperature sensor - footwell left-hand,
→ Yes
GO to L3.
→ No
VFE0038054 GO to L2.
the circuit 8-FA48 (WH/GN) between the
EATC module and the air discharge temper-
ature sensor - footwell left-hand using the
wiring diagrams. If there is no short to power,
L2: CHECK THE CIRCUIT BETWEEN THE AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL
LEFT-HAND AND THE EATC MODULE FOR OPEN
discharge temperature sensor - footwell left-
hand, connector C544, pin 1, circuit 8-FA48
harness side.
→ Yes
VFE0038806 INSTALL a new EATC module. TEST the
→ No
FA48 (WH/GN) between the air discharge
temperature sensor - footwell left-hand and
the EATC module using the wiring diagrams.
LEFT-HAND AND THE EATC MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


discharge temperature sensor - footwell left-
(BN/GN), harness side and the EATC module,
→ Yes
GO to L4.
VFE0038057 → No
- footwell left-hand and the EATC module
LEFT-HAND AND THE EATC MODULE FOR SHORT
→ Yes
GO to L5.
→ No
E45662 LOCATE and REPAIR the short in the circuits
LEFT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
E49854
2007.50 Focus 3/2007 G427113en


both measurements?
→ Yes
sensor - footwell left-hand. TEST the system
→ No
PINPOINT TEST M : AIR DISCHARGE TEMPERATURE SENSOR - CENTER REGISTER RIGHT-HAND

CIRCUIT FAILURE - VEHICLES WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
(EATC)
M1: CHECK THE VOLTAGE AT THE AIR DISCHARGE TEMPERATURE SENSOR - CENTER
REGISTER RIGHT-HAND
temperature sensor - center register right-hand.
2007.50 Focus 3/2007 G427113en


temperature sensor - center register right-hand,
connector C543, pin 1, circuit 8-FA52 (WH/BK),
→ Yes
GO to M3.
→ No
VFE0038054 GO to M2.
the circuit 8-FA52 (WH/BK) between the EATC
module and the air discharge temperature
sensor - center register right-hand using the
wiring diagrams. If there is no short to power,
M2: CHECK THE CIRCUIT BETWEEN THE AIR DISCHARGE TEMPERATURE SENSOR - CENTER
REGISTER RIGHT-HAND AND THE EATC MODULE FOR OPEN
right-hand, connector C543, pin 1, circuit 8-FA52
(WH/BK), harness side and the EATC module,
harness side.
→ Yes
VFE0038059
→ No
FA52 (WH/BK) between the air discharge
temperature sensor - center register right-hand
tion.
REGISTER RIGHT-HAND AND THE EATC MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


right-hand, connector C543, pin 3, circuit 9-FA52
(BN/YE), harness side and the EATC module,
→ Yes
GO to M4.
VFE0038057 → No
- center register right-hand and the EATC
REGISTER RIGHT-HAND AND THE EATC MODULE FOR SHORT
→ Yes
GO to M5.
→ No
REGISTER RIGHT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
(WH/BK), harness side and ground.
E49855
2007.50 Focus 3/2007 G427113en


both measurements?
→ Yes
sensor - center register right-hand. TEST the
→ No
PINPOINT TEST N : AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL RIGHT-HAND CIRCUIT

FAILURE - VEHICLES WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
N1: CHECK THE VOLTAGE AT THE AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL
RIGHT-HAND
temperature sensor - footwell right-hand.
2007.50 Focus 3/2007 G427113en


temperature sensor - footwell right-hand,
• Is a voltage of approximately 5 V measured?
→ Yes
GO to N3.
→ No
VFE0038054 GO to N2.
the circuit 8-FA51 (WH/BK) between the EATC
module and the air discharge temperature
sensor - footwell right-hand using the wiring
diagrams. If there is no short to power,
N2: CHECK THE CIRCUIT BETWEEN THE AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL
RIGHT-HAND AND THE EATC MODULE FOR OPEN
discharge temperature sensor - footwell right-
harness side.
→ Yes
VFE0038796 INSTALL a new EATC module. TEST the
→ No
FA51 (WH/BK) between the air discharge
temperature sensor - footwell right-hand and
the EATC module using the wiring diagrams.
RIGHT-HAND AND THE EATC MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


discharge temperature sensor - footwell right-
(BN/YE), harness side and the EATC module,
→ Yes
GO to N4.
VFE0038057 → No
- footwell right-hand and the EATC module
N4: CHECK THE CIRCUIT BETWEEN AIR DISCHARGE TEMPERATURE SENSOR - FOOTWELL
RIGHT-HAND AND EATC MODULE FOR SHORT
→ Yes
GO to N5.
→ No
E45665 LOCATE and REPAIR the short in the circuits
RIGHT-HAND AND THE EATC MODULE FOR SHORT TO GROUND
(WH/BK), harness side and ground.
E49856
2007.50 Focus 3/2007 G427113en


both measurements?
→ Yes
sensor - footwell right-hand. TEST the system
→ No
PINPOINT TEST O : SUNLOAD SENSOR CIRCUIT FAILURE - VEHICLES WITH ELECTRONIC

AUTOMATIC TEMPERATURE CONTROL (EATC)
O1: CHECK THE VOLTAGE AT THE SUNLOAD SENSOR

2 Disconnect connector C554 of sunload sensor.
5 Measure the voltage between the sunload
sensor, connector C554, pin 1, circuit 8-FA53
(WH/BU), harness side and ground.
VFE0038786
2007.50 Focus 3/2007 G427113en


6 Measure the voltage between the sunload
(GY/VT), harness side and ground.
• Is a voltage of approximately 5 V indicated in
both measurements?
→ Yes
GO to O4.
→ No
- No voltage is indicated in one/two measure-
ment(s):
GO to O2.
- Battery voltage is indicated in one/two
measurement(s):
the circuit between the EATC module and the
sunload sensor using the wiring diagrams. If
there is no short to power, CHECK the EATC
module, if necessary INSTALL a new EATC
module. TEST the system for normal opera-
tion.
O2: CHECK THE CIRCUITS BETWEEN THE SUNLOAD SENSOR AND THE EATC MODULE FOR
OPEN
3 Measure the resistance between the sunload
(WH/BU), harness side and the EATC module,
(WH/BU), harness side.
VFE0038792
2007.50 Focus 3/2007 G427113en


(GY/VT), harness side and the EATC module,
(GY/VT), harness side.
measurements?
→ Yes
GO to O3.
VFE0038793 → No
circuit between the sunload sensor and the
O3: CHECK THE CIRCUITS BETWEEN THE SUNLOAD SENSOR AND THE EATC MODULE FOR
A SHORT TO GROUND
(WH/BU), harness side and ground.
E49857

(GY/VT), harness side and ground.
• Is the resistance greater than 10,000 Ohm in
both measurements?
→ Yes
→ No
circuit between the sunload sensor and the
2007.50 Focus 3/2007 G427113en


O4: CHECK THE CIRCUIT BETWEEN THE SUNLOAD SENSOR AND THE EATC MODULE FOR
OPEN (GROUND CONNECTION)
(BN/BU), harness side and the EATC module,
connector C540, pin 17, circuit 9-FA1 (BN/RD),
harness side.
→ Yes
INSTALL a new sunload sensor. TEST the
system for normal operation. If the system is
VFE0038795
still inoperative, CHECK the EATC module, if
necessary INSTALL a new EATC module.
→ No
between the sunload sensor and the EATC
PINPOINT TEST P : IN-VEHICLE TEMPERATURE SENSOR CIRCUIT FAILURE - VEHICLES WITH

P1: CHECK THE VOLTAGE AT THE IN-VEHICLE TEMPERATURE SENSOR

2 Disconnect connector C776 of in-vehicle
temperature sensor.
2007.50 Focus 3/2007 G427113en


5 Measure the voltage between the in-vehicle
temperature sensor, connector C776, pin 4,
circuit 8-FA95 (WH/GN), harness side and
ground.
→ Yes
GO to P2.
→ No
VFE0038067 GO to P3.
the circuit between the EATC module and the
in-vehicle temperature sensor using the wiring
diagrams. If there is no short to power,
P2: CHECK THE CIRCUIT BETWEEN THE IN-VEHICLE TEMPERATURE SENSOR AND THE EATC
MODULE FOR OPEN (GROUND CONNECTION)
2 Measure the resistance between the in-vehicle
circuit 9-FA95 (BN/GN), harness side and the
EATC module, connector C540, pin 17, circuit
9-FA1 (BN/RD), harness side.
→ Yes
INSTALL a new in-vehicle temperature sensor.
VFE0038069
system is still inoperative, CHECK the EATC
tion.
→ No
between the in-vehicle temperature sensor
tion.
MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


circuit 8-FA95 (WH/GN), harness side and the
8-FA95 (WH/GN), harness side.
→ Yes
GO to P4.
→ No
VFE0038070 LOCATE and REPAIR the open in circuit 8-
FA95 (WH/GN) between the in-vehicle
temperature sensor and the EATC module
MODULE FOR SHORT TO GROUND
(WH/GN), harness side and ground
→ Yes
→ No
E53635 LOCATE and REPAIR the short to ground in
circuit 8-FA95 (WH/GN) between the in-
vehicle temperature sensor and the EATC
PINPOINT TEST Q : IN-VEHICLE TEMPERATURE SENSOR BLOWER MOTOR CIRCUIT FAILURE

- VEHICLES WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
Q1: CHECK THE VOLTAGE AT THE IN-VEHICLE TEMPERATURE SENSOR

2 Disconnect connector C776 of in-vehicle
temperature sensor.
2007.50 Focus 3/2007 G427113en


5 Measure the voltage between the in-vehicle
circuit 15S-FA95 (GN/BK), harness side and
ground.
→ Yes
GO to Q2.
→ No
GO to Q3.
VFE0038071
Q2: CHECK THE CIRCUIT BETWEEN THE IN-VEHICLE TEMPERATURE SENSOR AND THE EATC
MODULE FOR OPEN (GROUND CONNECTION)
circuit 31-FA95 (BK), harness side and the
31-FA95 (BK), harness side.
→ Yes
INSTALL a new in-vehicle temperature sensor.
VFE0038073
system is still inoperative, CHECK the EATC
tion.
→ No
FA95 (BK) between the in-vehicle temperature
sensor and the EATC module using the wiring
tion.
Q3: CHECK THE CIRCUIT BETWEEN THE IN-VEHICLE TEMPERATURE SENSOR AND THE EATC
MODULE FOR OPEN
2007.50 Focus 3/2007 G427113en


circuit 15S-FA95 (GN/BK), harness side and
the EATC module, connector C540, pin 1, circuit
15S-FA95 (GN/BK), harness side.
→ Yes
VFE0038074
→ No
FA95 (GN/BK) between the in-vehicle
temperature sensor and the EATC module
Component Tests
Blower motor relay
VFE0037802
2. Check the normally open contact in the switched

state:
VFE0031236
1. Use a 1 Amp. fused test cable to connect pin
1. Check the normally open contact in the 1 of the blower motor relay, component side,
unswitched state: to the battery positive terminal.
1. Measure the resistance at the blower motor 2. Use a test cable to connect pin 2 of the
relay, between pin 3 and pin 5, component blower motor relay, component side, to the
side. battery ground terminal.
2. Is the resistance greater than 10,000 ohms? 3. Measure the resistance at the blower motor
relay, between pin 3 and pin 5, component
3. If yes, go to 2.
side.
4. If no, INSTALL a new blower motor relay.
4. Is the resistance less than 2 ohms?
5. If yes, then the blower motor relay is OK.
6. If no, INSTALL a new blower motor relay.
2007.50 Focus 3/2007 G427113en

Air conditioning clutch relay
VFE0022882
3. Check the normally open contact in the

unswitched state:
1. Measure the resistance at the air conditioning
clutch relay, between pin 3 and pin 5,
component side.
2. Is the resistance greater than 10,000 ohms?
3. If yes, go to 4.
4. If no, INSTALL a new air conditioning clutch
relay.
VFE0022883

state:
1. Use a 1 Amp. fused test cable to connect pin
1 of the air conditioning clutch relay,
component side, to the battery positive
terminal.
2. Use a test cable to connect pin 2 of the air
conditioning clutch relay, component side, to
the battery ground terminal.
3. Measure the resistance at the air conditioning
clutch relay, between pin 3 and pin 5,
component side.
4. Is the resistance less than 2 ohms?
5. If yes, then the air conditioning clutch relay
is OK.
6. If no, INSTALL a new air conditioning clutch
relay.
2007.50 Focus 3/2007 G427113en

GENERAL PROCEDURES
Spring Lock Coupling

• Check the clamping spring for damage.
1. NOTE: Select special tool to suit the line
diameter. • Carefully pull out any damaged clamping
springs using a thin piece of wire and install
Fit the special tool. new one.
• Fit the special tool so that the inner collar can
be guided into the clamping spring.
ELM3402007
ELM3402005 5. NOTE: Clean the connections using

refrigerant oil and a lint-free cloth.
2. Press the special tool into the clamping Press the indicator ring into the clamping
spring. spring.
VFE0021643 VFE0021645
3. Disconnect the refrigerant line. 6. NOTE: Install new refrigerant line O-ring
• Discard the O-ring seals. seals.
NOTE: Coat the refrigerant line O-ring seals in
clean refrigerant oil prior to installation.
Connect the refrigerant lines.
VFE0021644
4. Connect the refrigerant line.
2007.50 Focus 3/2007 G18266en

GENERAL PROCEDURES
• Check that the clamping spring engages
correctly.
VFE0021646
2007.50 Focus 3/2007 G18266en

GENERAL PROCEDURES
Air Conditioning (A/C) Clutch Air Gap Adjustment(34 628 6)

• Air gap A
Materials
Name Specification
A
Spacer washer set
1
1. Measurement for recessed pulley
Check the air gap A between the drive plate 2
and the pulley at 60 degree intervals around
the circumferance of the pulley, while
operating the A/C clutch several times by 3
means of a 5A fused jumper wire connected
between the battery positive terminal, A/C V3402038
clutch and battery ground. For additional
information, refer to Specifications in this
section. 3. Remove the drive plate.
1. Belt pulley
2. Drive plate
• Air gap A (the difference measured between
the A/C clutch engaged and disengaged)
V3401024
1
4. Correct air gap A as necessary using spacer
washers.
E47467
5. Install the drive plate. For additional
2. Measurement for non recessed pulley section.
Check the air gap A between the drive plate 6. Check air gap A as described in step 1 or
and the pulley at 60 degrees intervals around step 2. Repeat steps 3-5 if necessary.
the circumference. For additional
section.
1. Belt pulley
2. Spacer washer
3. Drive plate
2007.50 Focus 3/2007 G18268en

GENERAL PROCEDURES
Fluorescent Dye Leak Detection

General Equipment
UV Spot Lamp
Manifold Gauge Set
Fluorescent Dye Injector
NOTE: Vehicles built 07/1999 onwards have a
fluorescent tracer dye tablet inserted into the air
conditioning (A/C) system. If tracer dye is present,
there is a green cross on the suction accumulator.
NOTE: On vehicles built up to 07/1999 tracer dye
must be added.
1. Using the dye injector, add 7.4 ml of
Fluorescent Tracer Dye.
NOTE: Some vehicles may have signs of
refrigerant oil at the spring lock couplers. This may
be caused from the assembly process which
applies to the fittings before installation to aid in
assembly. When a spring lock coupler is suspected
of leaking, always wipe the fitting clean and verify
the leak with R-134a Automatic Calibration Halogen
Leak Detector.
NOTE: The exact location of leaks can be
pinpointed by the bright yellow - green glow of the
tracer dye. Since more than one leak may exist,
always inspect each component.
2. Check for leaks using a 120 Watt UV Spot
Lamp. Always scan all components, fittings
and lines of the A/C system.
3. After the leak is found and repaired, remove
any traces of dye with a general purpose oil
solvent.
4. Verify the repair by operating the system for
some minutes and inspecting with the UV
lamp again.
2007.50 Focus 3/2007 G18269en

GENERAL PROCEDURES
Electronic Leak Detection(34 620 7)

General Equipment
Automatic Calibration Halogen Leak Detector
Manifold Gauge Set
Refrigerant Identifier
WARNING: Good ventilation before leak
detection is necessary in the area where it
is to be performed. If the surrounding air
is contaminated with refrigerant gas, the
leak detector will indicate this gas all the
time. Odors from other chemicals such as
antifreeze, diesel fuel, disc brake cleaner,
or other cleaning solvents can cause the
same problem. While leak detection air
movement must be prevented.
1.
CAUTION: The refrigerant identification
equipment must be used before the manifold
gauge set is installed, otherwise the manifold
gauge may become contaminated.
Contaminated refrigerant must be disposed
of as special waste. The manufacturer's
instructions must be followed when working
with the service unit.
NOTE: Both manifold gauges should indicate
4,1-5,5 bar at 24°C with the engine off.
Attach the manifold gauge set to the service
gauge port valves.
1. For the leak test, close the manual valves on
the gauge set.
2. If little or no pressure is indicated, charge the
system with approx. 300g of refrigerant.
For additional information, refer to Air
Conditioning (A/C) System Recovery,
Evacuation and Charging in this section.
2. Use R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant
system. Follow the instructions included with
leak detector for handling and operation
techniques.
3. If a leak is found, recover the A/C system.
2007.50 Focus 3/2007 G18270en

GENERAL PROCEDURES
Air Conditioning (A/C) System Recovery, Evacuation and

Charging(34 620 2)
General Equipment Connect the refrigerant center lines to the
A/C charging connections.
Refrigerant center
4.
Refrigerant analyzer WARNING: When recovering the
refrigerant do not allow it to enter the
1. atmosphere under any circumstances.
CAUTION: The refrigerant analyzer must
be used before recovery, otherwise the Failure to follow these instructions may
refrigerant center may become contaminated. result in personal injury.
Contaminated refrigerant must be disposed NOTE: When removing components of the air
of as hazardous waste. Always follow the conditioning system, calculate the residual quantity
manufacturer's instructions when using the of refrigerant oil.
refrigerant center and the refrigerant
For additional information, refer to: Refrigerant Oil
analyzer.
Adding (412-00, General Procedures).
Unscrew and remove the protective caps
Recover the refrigerant from the A/C system
from the A/C charging connections.
via the low-pressure connection in
1. Low-pressure connection accordance with the refrigerant centre
2. High-pressure connection manufacturer's instructions.
5. CAUTIONS:
1 The A/C system must be evacuated for
about 30 minutes before recharging, to
ensure that it operates correctly.
If moisture was able to enter an open

system over an extended period (several
hours), install a new suction accumulator
2 and increase the evacuation time to 2-3
hours.
Evacuate the A/C system according to the
refrigerant center manufacturer's
2. Pull back the catches of the quick-fit unions instructions.
on the refrigerant center lines. 6. NOTE: If an air conditioning system that was
filled with refrigerant is being evacuated,
some refrigerant will still be in the refrigerant
oil in the compressor. This remaining
refrigerant may evaporate, causing a slight
increase in pressure during the leak test. The
system is leak-free, provided that this
pressure increase does not exceed 20 mbar
(2 kPa, 0.29 psi).
Perform the leak test.
1. For the leak test, close the hand valves on
the pressure gauge set, switch off the
VFE0031288
refrigerant center vacuum pump and observe
the low pressure gauge.
3. NOTE: Larger inner diameter for
high-pressure side. Smaller inner diameter
for low-pressure side.
2007.50 Focus 3/2007 G413427en

GENERAL PROCEDURES
2. Locate any leaks in the A/C refrigerant circuit 10.
WARNING: Do not detach the
using a leak tester. For additional information,
high-pressure hose when the A/C system
refer to: (412-00 )
is switched on. Failure to follow these
Flourescent Dye Leak Detection instructions may result in personal injury.
Disconnect the refrigerant center.
Electronic Leak Detection
(General Procedures). 1. Close the shut-off valves.
7. Top up with refrigerant oil. 2. Switch off the refrigerant center.
3. Disconnect the service unit line from the A/C
For additional information, refer to: charging connection.
Refrigerant Oil Adding (412-00, 4. Attach the protective caps to the charging
General Procedures). valves.
CAUTION: The A/C system must always be
evacuated before charging. Failure to
observe this instruction can cause damage
to the A/C system.
8. NOTE: Depending on the type of refrigerant
centre and the equipment (with or without
heated filling cylinder), the air conditioning
system is either charged with liquid via the
high-pressure connection or with gas
through the low-pressure connection.
NOTE: Charge quantity on sticker in engine
compartment.
Charging the A/C system (with liquid) via the
high-pressure connection.
1. Open the shut-off valve on the high-pressure
side.
2. Switch the refrigerant center to "Fill" mode
and fill with the prescribed quantity of liquid
refrigerant (R134a).
9.
CAUTION: Only gaseous charging of the
air conditioning system is performed via the
low-pressure connection. Failure to follow
these instructions may cause damage to the
compressor.
Charging the A/C system via the
low-pressure connection.
1. Open the shut-off valve on the low-pressure
side.
2. Switch the refrigerant center to "Fill" mode
and charge with gaseous refrigerant.
3. Top up with the remaining amount of
refrigerant with the A/C system switched on.
For this purpose, run the engine at approx.
1200-1500 rpm. Switch the air conditioning
to maximum cooling power and fresh air
mode. Set the blower to maximum speed.
Fill with the remainder of the prescribed fill
quantity.
2007.50 Focus 3/2007 G413427en

GENERAL PROCEDURES
Refrigerant Oil Adding(34 621 1)

CAUTION: Collect the refrigerant oil in a
clean measuring cylinder.
1. NOTE: This step only needs to be carried out
when replacing the A/C compressor.
NOTE: Rotate the compressor shaft at least 6 to
8 turns when draining the refrigerant oil.
Drain the refrigerant oil from the defective
A/C compressor and dispose of it.
2.
CAUTION: If the refrigerant oil is not to
be reused within 15 minutes of draining it
from the new compressor, store it in a closed
and sealed container to prevent ingress of
moisture.
NOTE: The refrigerant oil from the new A/C
compressor needs to be drained because the fill
capacities at the factory are not always the same.
NOTE: Rotate the compressor shaft at least 6 to
8 turns when draining the refrigerant oil.
Drain the refrigerant oil from the new A/C
compressor.
3. CAUTIONS:
The amount of refrigerant oil topped up
must not exceed the refrigerant oil fill
capacity.
If other A/C components are being

renewed in addition to the A/C compressor,
there is no need to top up with additional
refrigerant oil, apart from filling the
compressor.
Add the calculated quantity of new
refrigerant oil. See: Specifications (412-00
Heating, Ventilation, Air-Conditioning -
General information, Specifications).
2007.50 Focus 3/2007 G21702en

GENERAL PROCEDURES
Contaminated Refrigerant Handling(34 620 9)

CAUTION: Any R134a or R12 refrigerant
which is contaminated with unsuitable
refrigerant should be extracted only by
means of a suitable servicing unit designed
for the purpose of collecting and storing
contaminated refrigerant, so that the
spread to other vehicles can be prevented.
1. Use refrigerant identification equipment to
check that there is contaminated refrigerant
in the air conditioning system.
2. Inform the customer about the additional
cost to repairing the system caused by the
contamination.
3. Extract the contaminated refrigerant.
2007.50 Focus 3/2007 G18273en

GENERAL PROCEDURES
Air Distribution System Cleaning

General Equipment 9. To dry out the system, switch off the air
conditioning system and ventilate the vehicle
Spray gun with hose
for approx. 15 minutes.
Materials 10. Switch off the engine.
Name Specification
Only Focus to MY 2004.75 and Galaxy
Odour eliminating agent
(240 ml) (TOX Number 11. Remove the blower motor.
142040)
Only Ka, Fiesta 96 to MY 2002.25 and Puma
All vehicles 12. Remove the blower motor resistor
1.
WARNING: Avoid contact with eyes and Only Fiesta from MY 2002.25, Focus C-Max
skin; wear gloves and respiratory protection. and Focus from MY 2004.75 with pollen filter
Ensure that you perform this operation in a 13. Remove the pollen filter.
well ventilated room. Keep all vehicle doors
and windows open for the duration of the
operation. Do not inhale vapors under any Only Fiesta from MY 2002.25, Focus C-Max
circumstances. Do not smoke and avoid and Focus from MY 2004.75 without pollen
open fire and unprotected light sources. filter
Avoid contact with eyes and skin; wear 14. Remove the pollen filter housing cover.
gloves and respiratory protection. Ensure
that you perform this operation in a well All vehicles
ventilated room. Keep all vehicle doors and
windows open for the duration of the 15. Fill the spray gun with the odour eliminating
operation. Do not inhale vapors under any agent (240 ml).
circumstances. Do not smoke and avoid 16.
WARNING: The maximum pressure of
open fire and unprotected light sources.
13.5 bar must not be exceeded. Failure to
Failure to observe this instruction can lead
observe this instruction can lead to injuries.
to injuries.
Use the tyre inflator to apply pressure of 5.5
NOTE: The odour eliminating agent can remove
to 10 bar (operating pressure) to the spray
deposits in the heater housing but cannot prevent
gun.
odours that are distributed by the ventilation
system, for example those caused by damp 17. Insert the hose of the spray gun as far as
carpets. possible into the opening created by
removal of the above component and point
Precisely locate the musty or damp odour.
it in the direction of the evaporator.
2. Disconnect the low pressure switch
18. By moving the hose, spray the odour
connector.
eliminating agent over the entire surface of
3. Turn on the ignition. the evaporator.
4. Open all ventilation nozzles. 19. Spray all of the odour eliminating agent into
5. Set the temperature control to maximum the opening.
heating power. • Allow the odour eliminating agent to take
6. Set the blower motor control switch to the effect for 10 minutes.
highest setting. 20. Install the components in reverse order.
7. Set the air distribution control to the fresh 21. Start the engine, switch off the air
air position. conditioning system and ventilate the
8. Start the engine and let it warm up to vehicle for approx. 15 minutes.
operating temperature. 22. Open all ventilation nozzles.
2007.50 Focus 3/2007 G21704en

GENERAL PROCEDURES
23. Set the temperature control to maximum
heating power.
24. Set the blower motor control switch to the
highest setting.
25. Set the air distribution control to the fresh
air position.
26. Switch off the engine.
27. Connect the low pressure switch connector.
28. Ventilate the vehicle with the doors open
for another 30 minutes.
2007.50 Focus 3/2007 G21704en

GENERAL PROCEDURES
Vacuum Leak Detection(34 620 3)

1. Drain the air conditioning (A/C) system.
2007.50 Focus 3/2007 G18275en

412-01-1 Air Distribution and Filtering 412-01-1
.
SECTION 412-01 Air Distribution and Filtering

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 412-01-2

Air Distribution and Filtering............................................................................................... 412-01-3
Pollen filter.......................................................................................................................... 412-01-3

Air Distribution and Filtering............................................................................................... 412-01-4

Pollen Filter — LHD............................................................................................................ 412-01-5
SPECIFICATIONS
Tightening Torques
Accelerator pedal retaining nuts 9 - 80
2007.50 Focus 3/2007 G334171en

Air Distribution and Filtering

Pollen filter
E51903
The fresh air flowing into the vehicle through the

air intake housing is cleaned of dirt particles which
are larger than 0.003mm and of pollen by passing
it through a pollen filter which is located on the
left-hand side of the heater core/ evaporator
housing (LHD and RHD vehicles).
The pollen filter must be changed at intervals in
accordance with the service schedule.
A special production pollen filter is installed in the
factory and this must be cut off when the filter is
changed. The service pollen filter is flexible and
can be pushed together during installation or
removal.
2007.50 Focus 3/2007 G413397en

Air Distribution and Filtering

REFER to: Climate Control System - 3-Door
(412-00 Climate Control System - General
2007.50 Focus 3/2007 G167127en

Pollen Filter — LHD

table(s).
4 5
E52778
1 Accelerator pedal retaining nuts 4 Pollen filter housing cover

See Removal Detail
2 Accelerator pedal
5 Pollen filter
3 Pollen filter housing cover retaining bolts
Removal Details
Item 4 Pollen filter housing cover
1. Remove the pollen filter housing cover.
1. Unclip the pollen filter housing cover from
the heater core and evaporator core housing.
2007.50 Focus 3/2007 G413576en

2. Pull out the pollen filter housing cover.
E52779
2007.50 Focus 3/2007 G413576en

412-02-1 Heating and Ventilation 412-02-1
.
SECTION 412-02 Heating and Ventilation

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 412-02-2

Heating and Ventilation....................................................................................................... 412-02-3
Heater Core and Evaporator Core Housing....................................................................... 412-02-3


Blower Motor....................................................................................................................... 412-02-9
Heater Core and Evaporator Core Housing....................................................................... 412-02-15
Heater Core — LHD........................................................................................................... 412-02-29

Heater Core and Evaporator Core Housing — Vehicles With: Manual Temperature
Control.............................................................................................................................. 412-02-33
Heater Core and Evaporator Core Housing — Vehicles With: Automatic Temperature
Control.............................................................................................................................. 412-02-37
SPECIFICATIONS
Item Specification
Refrigerant oil WSH-M1C231-B
Reinforcing element bolts 22 16 -
Bolts, reinforcing element bracket 25 18 -
Steering column shaft joint bolt 28 21 -
Dashboard crossmember outer bolts 25 18 -
Dashboard crossmember inner bolts 20 15 -
Clutch pedal bracket retaining nuts 25 18 -
Steering column bracket bolts 25 18 -
Bolt for refrigerant lines to A/C evaporator 25 18 -
Door check strap bolt 23 17 -
Door hinge bolts 15 11 -
Dashboard crossmember side bolts 80 59 -
Bolts for windshield wiper motor with linkage 7 - 62
Nuts, windshield wiper arms 22 16 -
2007.50 Focus 3/2007 G414744en

Heating and Ventilation

Heater Core and Evaporator Core
Housing Heater core
The heater core and evaporator core housing
contains the blower motor, the pollen filter, the
heater core, the evaporator core (on vehicles with
air conditioning (A/C)), the electric booster heater
(if equipped) and various diverter flaps.
Blower motor
CAUTION: Do not put the blower motor

down on the blower motor fan wheel.
E51904
412-131 The heater core is accessible from the right-hand

side of the heater core and evaporator core
housing (LHD and RHD). It can be removed and
installed with the heater core and evaporator core
housing installed. During removal, the coolant pipes
of the production heater core must be sawn
through. During servicing, a heater core with
separate coolant pipes is installed.
E41533
Evaporator core
To prevent damage to the fan wheel vanes, the
fan wheel must not be touched. For this reason, a
special tool (412-131) has been introduced for
removal and installation of the blower motor. This
tool is pushed onto the central shaft in order to lift
out the blower motor.
E51905
The evaporator core is located on the right-hand

side of the heater core and evaporator core
housing (LHD and RHD). During servicing, it can
only be removed with the heater core and
evaporator core housing removed .
2007.50 Focus 3/2007 G413398en

Overview
7
1
3
4
E46563
1 Blower motor 5 Electric booster heater (if equipped)
2 Pollen filter 6 Temperature blend door motor
3 Evaporator core 7 Air distribution door - defroster vents
4 Heater core 8 Air distribution door - center vents

9 Air distribution door - footwell
2007.50 Focus 3/2007 G413398en

Air flow - defroster vents
1 2
E46564
Item Description
1 Warm air
2 Cold air
2007.50 Focus 3/2007 G413398en

Air flow - center vents
1 2
E46565
Item Description
1 Warm air
2 Cold air
2007.50 Focus 3/2007 G413398en

Air flow - footwell
1 2
E46566
Item Description
1 Warm air
2 Cold air
2007.50 Focus 3/2007 G413398en


REFER to Section 412-00 [Climate Control System
- General Information].
2007.50 Focus 3/2007 G21715en

Blower Motor
Special Tool(s) 1. Remove the components in the order
Remover/Installer, Blower indicated in the following illustration(s) and
Motor table(s).
412-131
E42948
CAUTIONS:
Do not touch the blower motor fan wheel in order to prevent damage to the fan wheel blades.
Failure to follow this instruction may result in an imbalance of the fan wheel.
Do not lay the blower motor down on the blower motor fan wheel.
3 5 6
E51448
1 Footwell side trim 4 Glove compartment

See Removal Detail
2 Glove compartment bolts
See Removal Detail 5 Auxiliary audio input connector
3 Glove compartment cooling tube (if 6 Passenger airbag deactivation switch

equipped) connector (if equipped)
See Removal Detail
2007.50 Focus 3/2007 G413578en

E52782
Item Description
7 Glove compartment lid damper (detach)
8 Glove compartment lid
2007.50 Focus 3/2007 G413578en

10
E53811
Item Description
9 CJB bracket nuts
10 CJB bracket
2007.50 Focus 3/2007 G413578en

12
13
11
E53832

11 Air inlet blend door housing bolts
12 Air inlet blend door housing
See Removal Detail
13 Blower motor
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G413578en

Item 2 Glove compartment bolts Disconnect the engine wiring harness
connectors from the CJB and secure the CJB
1. Push the glove compartment bolt covers
to one side.
downwards.
E54016
E52787
2. Detach the central junction box (CJB) from

Item 3 Glove compartment cooling tube (if
the instrument panel console. equipped)
1. Detach the glove compartment cooling tube
from the glove compartment.
E51609
E49732
3. Detach the CJB from the bracket.
1. Turn the CJB downwards.
2. Pull the CJB out of the bracket .
Item 4 Glove compartment
1. Remove the navigation system digital
versatile disc (DVD) unit access door (if
equipped).
1
E41529
4. NOTE: RHD vehicles only

E51195
2007.50 Focus 3/2007 G413578en

Item 12 Air inlet blend door housing 2. Release the blower motor.
1. Disconnect the air inlet blend door actuator 1. Press the release button.
connector. 2. Turn the blower motor counter-clockwise to
the stop.
1
E52988 2
E52792
Item 13 Blower motor

3. Using the special tool, remove the blower
1. Disconnect the blower motor connector. motor from the passenger's side.
412-131
E53899 E41533
Item 13 Blower motor • Turn the blower motor into the installation
position with the aid of another technician
1. NOTE: Note the top position on the blower
from the driver's side, insert and turn
motor.
clockwise as far as possible.
Using the special tool, bring the blower
motor into the installation position from the
passenger's side. 412-131
E41533
2007.50 Focus 3/2007 G413578en

Heater Core and Evaporator Core Housing

1. Disconnect the battery ground cable. 5. Remove the instrument panel.
For additional information, refer to: Battery For additional information, refer to:
Disconnect and Connect (414-01 Battery, Instrument Panel - Vehicles With:
Mounting and Cables, General Procedures). Passenger Air Bag (501-12, Removal and
2. Drain the cooling system. Installation)
/ Instrument Panel - Vehicles Without:
For additional information, refer to: Cooling Passenger Air Bag (501-12, Removal and
System Draining, Filling and Bleeding Installation).
(303-03C, General Procedures)
/ Cooling System Draining, Filling and 6. Remove the right and left-hand A-pillar trim
Bleeding - 2.0L (303-03E, General panel.
Procedures) For additional information, refer to: A-Pillar
/ Cooling System Draining, Filling and Trim Panel (501-05, Removal and
Bleeding (303-03F, General Procedures). Installation).
3. Drain the air conditioning system. 7. Remove the right and left-hand front scuff
For additional information, refer to: Air plate trim panel.
Conditioning (A/C) System Recovery, For additional information, refer to: Front
Evacuation and Charging (412-00, General Scuff Plate Trim Panel (501-05, Removal
Procedures). and Installation).
4. Remove the engine cover (2.0L diesel engine 8. Remove the components in the order
shown). indicated in the following illustration(s) and
table(s).
E51432
2007.50 Focus 3/2007 G421036en

23 Nm 1
N 2 15 Nm
80 Nm 4
E52944
1 Door check strap bolt 3 Front door (driver's door shown)

See Removal Detail
2 Door hinge bolts
See Removal Detail 4 Instrument panel console side bolts
2007.50 Focus 3/2007 G421036en

CAUTION: Ensure that the windshield wiper motor is in the park position.
22 Nm 5
7 Nm 9
7
10
E52919
5 Windshield wiper arm nuts 8 Cowl grille
6 Windshield wiper arms 9 Windshield wiper linkage bolts

See Installation Detail 10 Windshield wiper motor with linkage
7 Cowl grille clips
2007.50 Focus 3/2007 G421036en

CAUTIONS:
Close off the coolant lines to prevent fluid loss or dirt ingress.
Close off the refrigerant lines and the evaporator to prevent dirt ingress.
NOTE: Discard the refrigerant line O-ring seals.
14 25 Nm
13 11
12 25 Nm
E52728
11 Coolant lines 13 Refrigerant lines

See Removal Detail 14 Steering column bracket upper bolts
12 Refrigerant lines bolt
2007.50 Focus 3/2007 G421036en

16 21
17
20
19 25 Nm
18
28 Nm 15 N
22
23
19 25 Nm
E52729
15 Steering column shaft joint bolt 19 Instrument panel console bracket bolts
See Installation Detail 20 Instrument panel console bracket
16 Front footwell air duct bolt 21 Rear footwell air duct
17 Front footwell air duct 22 Passenger compartment wiring harness
18 Heater core and evaporator core housing connector
side bolt 23 Ground cable bolts
2007.50 Focus 3/2007 G421036en

25 Nm 27
25
24
24
28
26
24
25 Nm 27
25 Nm 27
E52984
24 Instrument panel wiring harness retaining 26 Heater core and evaporator core housing
clips side bolt
25 Ground cable bolt 27 Instrument panel console bracket bolts

28 Instrument panel console bracket
2007.50 Focus 3/2007 G421036en

30
29
31
32
33
34
E52985
29 Front footwell air duct bolt 32 Engine compartment wiring harness

connector
30 Front footwell air duct
33 Passenger compartment wiring harness
31 Instrument panel wiring harness connector
connectors
34 Ground cable bolt
2007.50 Focus 3/2007 G421036en

36
35
E52986
Item Description
35 Heater core upper cover bolts
36 Heater core upper cover
2007.50 Focus 3/2007 G421036en

39
37 20 Nm
38 25 Nm
E52993
Item Description
37 Instrument panel console inner bolts
38 Instrument panel console outer bolts
See Removal Detail
39 Instrument panel console
See Removal Detail
2007.50 Focus 3/2007 G421036en

CAUTION: Ensure that no coolant gets into the footwell in order to prevent soiling of the
carpet.
41
40
E52987

40 Heater core and evaporator core housing NOTE: Install new refrigerant line O-rings.
water drain pipe NOTE: Coat the refrigerant line O-rings with clean
41 Heater core and evaporator core housing refrigerant oil before installation.
Removal Details
Item 2 Door hinge bolts Item 3 Front door (driver's door shown)
1. Support the door using a trolley jack with 1. Detach the front door wiring harness
the aid of another technician. connector from the A-pillar.
TIE41214 TIE41215
2007.50 Focus 3/2007 G421036en

2. Disconnect the front door wiring harness • Pull the bulkhead extension from the clips.
connector.
E51551
TIE41216
3. Turn the coolant line snap ring
Item 4 Instrument panel console side bolts counter-clockwise to the stop and detach
the coolant line.
1.
CAUTION: Do not remove the instrument
panel console side bolts. Item 38 Instrument panel console outer bolts
Loosen the instrument panel console right 1. Support the heater core and evaporator core
and left-hand side bolts. housing with wooden blocks.
Item 11 Coolant lines

1.
NOTE: Only vehicles with 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma) or diesel engine
Detach the brake fluid retainer from the
bulkhead extension and secure it to one side.
E43091
2. Disconnect the air inlet blend door actuator

connector.
E51433
2. NOTE: Only vehicles with 1.4L Duratec-16V

(Sigma)/1.6L Duratec-16V (Sigma) or diesel
engine
E52988
Remove the bulkhead extension.
2007.50 Focus 3/2007 G421036en

3. Disconnect the blower motor resistor 7. Pull the instrument panel console forward
connector (if fitted) and the blower motor to the stop.
connector.
E43093
E43095
Item 39 Instrument panel console

4. Mark the position of the instrument panel
1. Disconnect the airbag module connector.
console relative to the A-pillars (left-hand
side shown). • Unclip the center console wiring harness.
E0026811 E43087
5. Install M10 x 120 mm guide bolts in the right 2. Detach the steering column shaft joint from
and left-hand A-pillar. the steering column shaft.
E43094
E43092
6. Remove the instrument panel console right 3. NOTE: Vehicles with EATC only
and left-hand side bolts.
2007.50 Focus 3/2007 G421036en

Disconnect the right-hand temperature blend 6. Disconnect the antenna cable connector.
door actuator connector and the defrost
blend door actuator connector.
E52735
E52989
7. Disconnect the antenna cable cellular phone
connector (if fitted).
4. NOTE: Vehicles with EATC only
Disconnect the left-hand temperature blend
door actuator connector and the air
distribution door actuator connector.
E52736
8. Disconnect the roof console connector.
E43098

Disconnect the air outlet temperature sensor
connector.
E53662
9. Remove the right and left-hand M10 x 120

mm guide bolts.
E43099
2007.50 Focus 3/2007 G421036en

Item 38 Instrument panel console outer bolts
1. Align the instrument panel console to the
A-pillars (left-hand side shown).
E0026811
Item 15 Steering column shaft joint bolt

shaft joint bolt. Failure to observe this
instruction can lead to injury.
Item 6 Windshield wiper arms

CAUTION: Move the windshield wiper
motor to park position before installing the
windshield wiper arms.
Item 2 Door hinge bolts

1. Apply thread locking compound to the door
hinge bolts.
2007.50 Focus 3/2007 G421036en

Heater Core — LHD

2. Remove the instrument panel.
Instrument Panel - Vehicles With:
Passenger Air Bag (501-12, Removal and
(303-03C Engine Cooling - 1.8L Duratec-HE
Installation)
/ Instrument Panel - Vehicles Without:
Procedures)
Passenger Air Bag (501-12 Instrument
/ Cooling System Draining, Filling and
Panel and Console, Removal and
Bleeding - 2.0L (303-03E Engine Cooling -
Installation).
2.0L Duratorq-TDCi (DW) Diesel, General
Procedures) 3. Remove the components in the order
/ Cooling System Draining, Filling and indicated in the following illustration(s) and
Bleeding (303-03F Engine Cooling - 1.6L table(s).
(Z6), General Procedures).
2007.50 Focus 3/2007 G414186en

25 Nm 4
2
25 Nm 4
25 Nm 4
E53000
1 Instrument panel wiring harness retaining 3 Heater core / evaporator core housing side
clips bolt

2007.50 Focus 3/2007 G414186en

CAUTIONS:
Ensure that no coolant gets into the footwell in order to prevent soiling of the carpet.
Close off the heater core and coolant lines to prevent fluid loss or dirt ingress.
8 7
6
10
E53001
6 Bulkhead aperture cover section bolts 9 Coolant line retaining clips

See Removal Detail
7 Bulkhead aperture cover section
10 Coolant lines
8 Bulkhead aperture spacer
2007.50 Focus 3/2007 G414186en

12
13 11
E53002

11 Heater core bracket bolts
12 Heater core bracket
13 Heater core
Removal Details
Item 9 Coolant line retaining clips
1. Release the coolant line retaining clips.
• Push the coolant lines forwards.
E43110
2007.50 Focus 3/2007 G414186en

Heater Core and Evaporator Core Housing — Vehicles With:

Manual Temperature Control
Special Tool(s) 1. Disassemble the components in the order
Motor table(s).
412-131
E42948
11 10
14
13
12
7
6
5
4
9
8
2
3
E53664
2007.50 Focus 3/2007 G414202en


1 Pollen filter housing cover bolts 8 Temperature blend door actuator bolts
2 Pollen filter housing cover 9 Temperature blend door actuator
10 Air inlet blend door actuator bolts
3 Pollen filter
11 Air inlet blend door actuator
4 Blower motor resistor bolts
12 Air inlet blend door housing bolts
5 Blower motor resistor
13 Air inlet blend door housing
6 Air distribution door actuator bolts
14 Blower motor
7 Air distribution door actuator See Disassembly Detail
See Assembly Detail
17 16
18
15
28 27 5 Nm 19
31
30
26 20
29
21 22
25
23
24
E53665
2007.50 Focus 3/2007 G414202en


15 Bulkhead aperture cover section bolts 25 Heater core
16 Bulkhead aperture cover section 26 Evaporator core housing cover bolts
17 Bulkhead aperture spacer 27 Evaporator core housing cover
18 Heater core and evaporator core housing 28 Evaporator core
gasket
29 Heater core and evaporator core lower
19 Evaporator core refrigerant line bolts housing bolts
20 Evaporator core refrigerant lines 30 Heater core and evaporator core lower
housing clips
21 Coolant line retaining clips
See Disassembly Detail 31 Heater core and evaporator core lower
housing
22 Coolant lines
23 Heater core bracket bolts 2. To assemble, reverse the disassembly
procedure.
24 Heater core bracket
Disassembly Details
Item 2 Pollen filter housing cover 2. Turn the blower motor clockwise as far as
possible.
2 1
E41540
1
2. Remove the blower motor using the special
tool.
E52779
Item 14 Blower motor 412-131

1. NOTE: On LHD vehicles, turn the blower
motor counter-clockwise to release.
Release the blower motor.
1. Press release button.
E41533
2007.50 Focus 3/2007 G414202en

Item 21 Coolant line retaining clips
1. Release the coolant line retaining clips.
E44774
Assembly Details
motor clockwise to lock.
NOTE: Note top position on blower motor.
Move the blower motor into the installation
position using the special tool.
• Turn the blower motor into the installation
position, insert and turn counter-clockwise
as far as possible.
412-131
E41533
2007.50 Focus 3/2007 G414202en

Heater Core and Evaporator Core Housing — Vehicles With:

Automatic Temperature Control
Special Tool(s) 1. Disassemble the components in the order
Motor table(s).
412-131
E42948
10
11
13 14
12
15
7
4 5 6
2 3
E53756
2007.50 Focus 3/2007 G414203en


1 Pollen filter housing cover bolts 9 Passenger-side temperature blend door
actuator
2 Pollen filter housing cover
See Disassembly Detail 10 Air inlet blend door actuator bolts
3 Pollen filter 11 Air inlet blend door actuator
4 Air distribution door actuator bolts 12 Air inlet blend door housing bolts
5 Air distribution door actuator 13 Air inlet blend door housing
6 Air distribution control assembly bolts 14 Blower motor
7 Air distribution control assembly See Assembly Detail
8 Passenger-side temperature blend door 15 Air outlet temperature sensor
actuator bolts See Disassembly Detail
2007.50 Focus 3/2007 G414203en

34
33
36
35
18 17
19
16
29 5 Nm 20
32 31
27 21
30
23
22 28
26
24
25
E53757
16 Bulkhead aperture cover section bolts 22 Coolant line retaining clips

17 Bulkhead aperture cover section
23 Coolant lines
18 Bulkhead aperture spacer
24 Heater core bracket bolts
19 Heater core and evaporator core housing
gasket 25 Heater core bracket
20 Evaporator core refrigerant line bolts 26 Heater core
21 Evaporator core refrigerant lines 27 Evaporator core housing cover bolts

28 Evaporator core housing cover
2007.50 Focus 3/2007 G414203en


29 Evaporator core 34 Defroster jet/air vent distribution blend
door actuator
housing bolts 35 Driver-side temperature blend door
actuator bolts
housing clips 36 Driver-side temperature blend door
actuator
housing 2. To assemble, reverse the disassembly
33 Defroster jet/air vent distribution blend procedure.
door actuator bolts
Disassembly Details
Item 2 Pollen filter housing cover 2. Turn the blower motor clockwise as far as
possible.
2 1
E41540
1
2. Remove the blower motor using the special
tool.
E52779
Item 14 Blower motor 412-131

motor counter-clockwise to release.
Release the blower motor.
1. Press release button.
E41533
2007.50 Focus 3/2007 G414203en

Item 15 Air outlet temperature sensor Item 22 Coolant line retaining clips
1. Turn the air outlet temperature sensor 1. Release the coolant line retaining clips.
clockwise through 90 degrees and pull out.
E44774
E44281
Assembly Details
motor clockwise to lock.
NOTE: Note top position on blower motor.
Move the blower motor into the installation
position using the special tool.
• Turn the blower motor into the installation
position, insert and turn counter-clockwise
as far as possible.
412-131
E41533
2007.50 Focus 3/2007 G414203en

412-03-1 Air Conditioning 412-03-1
.
SECTION 412-03 Air Conditioning

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 412-03-2

Air Conditioning.................................................................................................................. 412-03-4
Temperature control............................................................................................................ 412-03-4

Air Conditioning.................................................................................................................. 412-03-8

Air Conditioning (A/C) Compressor — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE
(MI4)............................................................................................................. (34 626 4) 412-03-9
Air Conditioning (A/C) Compressor — 1.6L (Z6)............................................ (34 626 4) 412-03-13
Clutch and Clutch Field Coil — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE
(MI4)/1.6L (Z6).............................................................................................. (34 628 0) 412-03-16
Compressor to Condenser Discharge Line — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE
(MI4).................................................................................................................................. 412-03-17
Evaporator Core Orifice.................................................................................. (34 624 4) 412-03-19
Suction Accumulator....................................................................................... (34 630 4) 412-03-21
Condenser Core............................................................................................. (34 632 4) 412-03-23
Condenser to Evaporator Line............................................................................................ 412-03-26
Low-Pressure Cutoff Switch........................................................................... (34 629 0) 412-03-30
High-Pressure Cutoff Switch.......................................................................... (34 631 0) 412-03-33
Evaporator Core — LHD................................................................................ (34 622 7) 412-03-36
Evaporator Outlet Line........................................................................................................ 412-03-40
SPECIFICATIONS
Item Specification
Refrigerant oil WSH-M1C231-B
A/C Compressor
Type
A/C compressor (vehicles with petrol engine) VS16
A/C compressor (vehicles with diesel engine) 7V16
Evaporator Core Orifice

Color
Evaporator core orifice Red
Tightening Torques
Refrigerant lines to air conditioning compressor 20 15 -
Refrigerant lines to A/C suction accumulator 8 - 71
Refrigerant line to A/C condenser 8 - 71
Bolt for refrigerant lines to A/C evaporator 25 18 -
Bolts for refrigerant lines to A/C evaporator 5 - 44
A/C compressor bolts 25 18 -
A/C condenser bolts. 25 18 -
A/C compressor drive plate bolt (vehicles with petrol 13 10 -
engine)
A/C compressor drive plate bolt (vehicles with diesel 22 16 -
engine)
Evaporator core orifice tube threaded connection 25 18 -
A/C suction accumulator bolts 25 18 -
A/C suction accumulator nuts 25 18 -
Refrigerant line bracket bolts 25 18 -
High-pressure switch 8 - 71
Low-pressure switch 2.5 - 23
Wiper linkage bolt 7 - 62
Windshield wiper arm nuts 22 16 -
Clutch pedal bracket nuts 25 18 -
Radiator crossmember 25 18 -
Power steering fluid cooler bracket bolt. 9 - 80
Power steering fluid cooler 9 - 80
2007.50 Focus 5/2007 G414206en

SPECIFICATIONS

Accessory drive belt pulley with bracket 25 18 -
2007.50 Focus 5/2007 G414206en

Air Conditioning
Temperature control
Electronic automatic temperature control
Three versions are available:
(EATC)
• Vehicles with manual temperature control
without air conditioning
• Vehicles with manual temperature control with
air conditioning
• Vehicles with electronic temperature control with
two-zone air conditioning
Depending upon engine model, two different air
conditioning compressors are used:
• Visteon VS16 variable-stroke compressor in
vehicles with diesel engines built from 08/2005
and vehicles with petrol engines
E51908
• Sanden SD7V16 variable-stroke compressor in
vehicles with diesel engines built up to 08/2005 The Electronic Automatic Temperature Control
(EATC) controls the passenger compartment
temperature automatically for two zones according
Manual temperature control to the settings made by the driver/front passenger.
The pushbuttons are located in the floor console
instrument panel beneath the multimedia system,
or they are integrated in the touch-screen of the
navigation device where applicable.
The temperature is regulated by changing the
positions of the distribution flaps of the heating and
ventilation system.
Five individual stepper motors are used to control
the following components:
• Temperature control air flaps (2 stepper motors,
E51907 one on each side)
• Air distribution door (footwell/instrument panel)
The manual temperature control is located on the
• Defroster flap
floor console instrument panel.
• Air inlet blend door
One button actuates the air conditioning (if
equipped) and one the air inlet blend door. The The following functions can be controlled
blower speed, the passenger compartment automatically:
temperature and the air distribution are adjusted • Temperature
by means of three rotary controls. • Blower setting
The air conditioning control request signal is • Air distribution
transmitted to the Generic Electronic Module • Air conditioning
(GEM). Data transmission to the GEM is performed • Recirculated air mode
via a single-wire lead. From the GEM this signal is
relayed via the CAN bus to the instrument cluster, Automatic mode is exited by switching off the
and from there on to the Powertrain Control Module system.
(PCM).
2007.50 Focus 5/2007 G413400en

Automatic mode is partially exited when one of the Air distribution: Automatic mode
following buttons is pressed, in which case any
functions which have not been selected continue In automatic mode the air distribution setting is
to operate automatically: determined on the basis of the driver requests as
• Air distribution a function of the following input variables:
• Blower setting • Passenger compartment temperature
• Recirculated air mode • Ambient temperature
• Defrost • Sun load
• Air conditioning status
Automatic control is reactivated by pressing the
"Auto" button or by pressing the corresponding • Coolant temperature
button again. The automatic mode is not exited • Vehicle speed
when the temperature is adjusted or the Air Cold air comes out of the instrument panel air vents
Conditioning (A/C) button is pressed. during air conditioning operation. During warm-up
phase warm air is directed into the footwell.
Blower controller: Automatic mode When the vehicle and the engine are cold, air is
directed onto the windshield to prevent cold air
Based on driver preference, the blower setting is from entering the footwell.
determined as a function of the following input The air only comes out of the footwell and defroster
variables in automatic mode: vents once the preselected temperature has been
• Passenger compartment temperature reached.
• Ambient temperature When the air conditioning system is switched off
• Sun load (no A/C symbol) the air flow is directed into the
• Coolant temperature footwell to prevent the windows from misting up.
• Vehicle speed In order to achieve maximum cooling of the interior
air in the case of high passenger compartment and
ambient temperatures, the system switches to
Blower controller: Manual operation recirculated air in automatic mode. After reaching
the temperature set, the system automatically
The first time a blower control button is pressed, switches back to fresh air intake. The recirculated
the blower symbol is switched on and the automatic air warning indicator does not illuminate when
symbol switched off. Each time a blower control automatic recirculated air control is activated.
button is pressed subsequently, the blower speed
is set one step higher or lower. Continuous
pressing of a button adjusts the blower speed by Air distribution: Manual operation
one step every 0.4 seconds.
Continuous pressing of the button to adjust the Each manual operation causes the automatic
blower speed downwards does not switch off the display to extinguish and activates the LED of the
blower. The OFF button needs to be pressed to relevant button, and the previously selected
do this. settings are stored.
Seven blower speed settings can be adjusted The air distribution modes (windshield, instrument
manually. In the "Defrost" setting the blower panel and footwell) can be selected individually or
operates at 80% of the maximum speed, unless together, i.e. one/two/three mode(s) can be
the maximum value was selected beforehand. selected or deselected by pressing the
corresponding buttons.
Operating one of the previously selected buttons
switches off the relevant mode. If all modes are
deactivated, the system reverts automatically to
automatic mode and adopts the previously selected
settings.
2007.50 Focus 5/2007 G413400en

Defrost Recirculated air mode
Selection of the "Defrost" mode has the following Selection of the "Auto" mode results in automatic
effects: recirculated air control without the recirculated air
• The LED is switched on for the "Defrost" button LED being switched on.
and the symbol for automatic mode goes out. Pressing the "Recirculated air" button while the
• The system changes over to the specified flap LED is switched off selects recirculated air mode;
position for maximum warm air temperature, pressing the button again cancels the recirculated
and the "HI" symbol is displayed. air mode and returns the air inlet blend door to the
• The air conditioning and the A/C symbol are fresh air position.
switched on. Recirculated air mode is activated automatically
• All the modes currently selected manually are by switching the system off (pressing the "OFF"
stored, terminated and the LEDs are button). After the system has been activated (i.e.
deactivated. any button has been pressed), the previous
• The air inlet blend door is moved to the "fresh settings are called back up.
air" position, and the previously selected
recirculated air mode is deactivated.
Temperature adjustment
• The blower speed is set to 80% of the maximum
value or remains at a higher setting if it was In "dual mode" the driver and front passenger
selected beforehand. temperature settings are combined together. As a
• The windshield and rear window heating are result, any adjustment of the control elements on
switched on. the driver's side will adjust the temperature on both
"Defrost" mode is terminated and all the previously sides of the vehicle.
stored modes are activated when one of the The temperature can be individually adjusted by
following settings is selected: pressing the driver's side control elements.
• The "Auto" button is pressed. Press the "Auto" button for longer than two seconds
• Temperature controllers are actuated. to switch back and forth between dual temperature
• The "Defrost" button is pressed again (if it was controls and individual temperature controls. The
previously set to "OFF" then the system display then switches from "Auto" to "Mono".
switches over to "Auto"). The temperature can be adjusted in steps of 0.5
• One of the air distribution buttons is pressed. °C between 16 °C and 28 °C. Temperature values
outside this range are indicated on the display with
either "LO" or "HI".
ECO mode
The maximum difference between the temperature
The EATC transmits the A/C request signal to the on the driver's and front passenger's sides is 4 °C
GEM via the CAN bus. The signal is then relayed in "Auto" mode. If a greater difference is selected
by the GEM via the instrument cluster to the PCM, then the opposite side automatically tracks the new
which actuates the A/C compressor clutch and the temperature setting with a difference of 4 °C.
cooler fan motor. The EATC request can be When "HI" or "LO" are selected the same
interrupted by the PCM, e.g. during full load temperature settings are set on both sides. On both
operation. sides of the vehicle the temperature is set to 28°C
In the "Auto A/C" mode, the air conditioning is when any button is pressed after the "HI" mode is
activated when the user's temperature selection switched off, and similarly the temperature is set
makes this necessary. to 16 °C on both sides when any button is pressed
after the "LO" mode is switched off.
Pressing the "A/C" button in "Auto A/C" mode
switches the system to the "ECO" status and the In the "HI" setting the system limits the maximum
compressor is switched off. temperature to 28 °C.
Each press of the button increases or decreases
the temperature by one step. Continuous pressing
of the button changes the temperature setting every
0.4 seconds.
2007.50 Focus 5/2007 G413400en

In vehicles with "Bluetooth & Voice Control" Special service modes
function (activation via the "Voice" button on the
steering column stalk) the temperature and blower By pressing the appropriate buttons on the control
speed can be modified via the voice function. panel, various special service modes can be
selected in the EATC module:
• Read out stored Diagnostic Trouble Code
External controller - EATC (DTC): The DTCs are displayed in the EATC.
In order to start read-out of the stored faults, the
"OFF" and "Footwell" buttons must be pressed
and held for two seconds. Release the buttons
and press the "Headroom" button within 1.5
seconds.
• Activate on-board diagnostic: Start the self-test
(re-calibration is performed). Any faults found
are displayed in the form of trouble codes on
both displays. Press the "OFF" and "Footwell"
buttons for two seconds. Release both buttons
and then press the "Auto" button within 1.5
seconds.
E51909
• Read out the software version indicated on both
In vehicles equipped with the touch-screen DVD displays: Press the "Off" and "Footwell" buttons
navigation system, the control components for the for two seconds, release them and then press
EATC are integrated in the unit. The information the "A/C" button within 1.5 seconds.
exchange takes place on the mid-speed CAN bus • To delete the trouble codes and exit the
(MS-CAN). diagnostic mode press the "Defrost" button. To
The following display values are transmitted via exit the diagnostic mode without deleting the
the MS CAN bus: trouble codes press any other button.
• Blower setting
• Temperature on the driver's side System off
• Temperature on the front passenger's side
• A/C or ECO When the system is switched off the blower motor,
A/C compressor, LCD and LEDs are also shut off.
• Diagnostic code The air inlet blend door is moved to the fresh air
The following warning indicators are actuated via position.
the MS CAN bus: The EATC module stores both the dual and the
• Air distribution manual temperature blend door position settings.
• Recirculated air, Auto, Defrost Pressing "OFF" again starts the system with the
The following request signals are transmitted via previously-stored settings.
the MS CAN bus:
• Raise/lower blower setting
• Temperature adjustment
• Manual air distribution
• Diagnostic information
Switch over from Celsius to Fahrenheit
Adjustment between Celsius and Fahrenheit is

performed via the instrument cluster display and
is transmitted to the EATC module via the MS CAN
bus.
2007.50 Focus 5/2007 G413400en

Air Conditioning
REFER to: Climate Control System - 3-Door
(412-00 Climate Control System - General
2007.50 Focus 5/2007 G167186en

Air Conditioning (A/C) Compressor — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4)(34 626 4)
1. Evacuate the air conditioning (A/C) system.
compressor belt.
For additional information, refer to: Air Cond-
itioning (A/C) System Recovery, Evacuation
Accessory Drive Belt - 1.8L
and Charging (412-00, General Procedures).
(303-05, Removal and Installation).
table(s).
2007.50 Focus 5/2007 G421020en

CAUTION: Cap the refrigerant lines and the A/C compressor to prevent dirt ingress.
N 4
2
20 Nm
13
14
20 Nm
N 7 12
5
6
10
15
15 Nm 9
11 25 Nm
25 Nm 8
E39115
1 A/C compressor clutch connector 5 Bolt for A/C compressor refrigerant line to
condenser
2 Bolt for A/C compressor refrigerant line to
dehydrator 6 A/C compressor refrigerant line to
condenser
3 A/C compressor refrigerant line to
dehydrator 7 Seal for A/C compressor refrigerant line
to condenser
4 Seal for A/C compressor refrigerant line
to dehydrator 8 Air Conditioning (A/C) compressor
retaining bolts
2007.50 Focus 5/2007 G421020en


9 Bolt, A/C compressor heat shield 14 Air conditioning compressor pulley
See Removal Detail
10 A/C compressor heat shield See Installation Detail
11 A/C compressor retaining bolt 15 A/C compressor solenoid coil
12 A/C compressor See Removal Detail
13 A/C compressor drive plate
5. Check the A/C clutch air gap.
Air Conditioning (A/C) Clutch Air Gap
Adjustment (412-00, General Procedures).
Removal Details
Item 13 A/C compressor drive plate • Discard the pulley snap ring.
1. Remove the A/C compressor drive plate bolt
13 Nm
V3401025
VFE0036717
Item 15 A/C compressor solenoid coil
Item 14 Air conditioning compressor pulley 1. Remove the clutch field coil snap ring.
1. NOTE: If necessary, remove a seized A/C

compressor pulley using a suitable remover.
Remove the A/C compressor pulley snap
ring.
• Remove the distance washers.
VFE0037235
2. NOTE: Mark the installation position of the

A/C compressor clutch connector in relation
to the compressor housing.
2007.50 Focus 5/2007 G421020en

Detach the solenoid coil.
VFE0037236
Item 15 A/C compressor solenoid coil
CAUTION: Do not tilt the clutch field coil
when installing in the A/C compressor.
NOTE: Installation position of the A/C compressor
clutch connector in relation to the compressor
housing.
Item 14 Air conditioning compressor pulley

NOTE: Install a new A/C compressor pulley snap
ring.
2007.50 Focus 5/2007 G421020en

Air Conditioning (A/C) Compressor — 1.6L (Z6)(34 626 4)

1. Drain the air conditioning system.
Accessory Drive Belt - 1.6L (Z6) (303-05,
Evacuation and Charging (412-00 Climate
Control System - General Information, 3. Remove the components in the order
General Procedures). indicated in the following illustration(s) and
table(s).
CAUTION: Seal the refrigerant lines and the A/C compressor to prevent dirt ingress.
25 Nm 7
1
3
2 20 Nm
4 20 Nm 6 N
5 6 N
8
25 Nm 7
E53111
1 A/C compressor clutch connector 5 A/C compressor refrigerant line to suction

accumulator
2 Nut for A/C compressor refrigerant line to
condenser 6 A/C compressor refrigerant line seals
3 A/C compressor refrigerant line to 7 A/C compressor bolts

condenser 8 A/C compressor
4 Nut for A/C compressor refrigerant line to
suction accumulator
2007.50 Focus 5/2007 G414207en

10
25 Nm 9
13 Nm 11
12
13
E53112

9 Accessory drive belt pulley bracket bolts 5. Check the A/C clutch air gap.
10 Accessory drive belt pulley with bracket For additional information, refer to: Air
Conditioning (A/C) Clutch Air Gap
11 A/C compressor drive plate bolt Adjustment (412-00, General Procedures).
12 A/C compressor drive plate
13 A/C compressor pulley
See Removal Detail
Removal Details
Item 13 A/C compressor pulley • Discard the pulley snap ring.
Remove the A/C compressor pulley snap
ring.
• Remove the spacer washers.
V3401025
2007.50 Focus 5/2007 G414207en

2. Remove the solenoid coil snap ring. Remove the solenoid coil.
VFE0037235 VFE0037236
3. NOTE: Mark the installation position of the

Item 13 A/C compressor pulley
CAUTION: Do not tilt the solenoid coil
housing.
ring.
2007.50 Focus 5/2007 G414207en

Clutch and Clutch Field Coil — 2.0L Duratec-HE (MI4)/1.8L

Duratec-HE (MI4)/1.6L (Z6)(34 628 0)
Removal 4. Remove the clutch field coil snap ring.
1. Remove the A/C compressor.

Conditioning (A/C) Compressor - 1.6L (Z6)
(412-03 Air Conditioning, Removal and
Installation)
/ Air Conditioning (A/C) Compressor - 2.0L
(412-03 Air Conditioning, Removal and
Installation).
2. Remove the A/C compressor drive plate.
VFE0037235
13 Nm 5. NOTE: Mark the installation position of the

Remove the clutch field coil.
VFE0036717

Remove the A/C compressor pulley.
• Remove the distance washers. VFE0037236
• Discard the pulley snap ring.
Installation
CAUTION: Do not tilt the clutch field coil
housing.
ring.
V3401025 1. Install the components in the reverse order.
2. Check the A/C clutch air gap.
Conditioning (A/C) Clutch Air Gap
Adjustment (412-00 Climate Control System
2007.50 Focus 5/2007 G414211en

Compressor to Condenser Discharge Line — 2.0L Duratec-HE

For additional information, refer to: Air Cond- table(s).
CAUTION: Close off the A/C condenser to stop dirt from entering.
1 20 Nm
E53822
Item Description
1 Nut, refrigerant line to A/C condenser
2007.50 Focus 5/2007 G422496en

CAUTION: Close off the A/C compressor to stop dirt from entering.
20 Nm 2
E53824

2 Bolt, refrigerant line to A/C compressor NOTE: Install new refrigerant line O-rings.
See Removal Detail NOTE: Coat the refrigerant line O-rings with clean
3 Outlet line, compressor to condenser refrigerant oil before installation.
4 Bracket, compressor outlet line to

condenser (unclip)
Removal Details
Item 2 Bolt, refrigerant line to A/C compressor 2. Remove the engine undershield.
Lifting (100-02, Description and
Operation).
VFE0035742
2007.50 Focus 5/2007 G422496en

Evaporator Core Orifice(34 624 4)

Special Tool(s) Remove the windshield wiper arms.
Remover/Installer, Fixed
Orifice
412-034 (34-004) 22 Nm
34004
Remover, Broken Orifice

412-035 (34-005)
E51548
34005
4. Remove the cowl grille.
Removal
All vehicles
2. Remove the engine cover (2.0L diesel E51549
shown).
5.
contact with the paintwork, rinse off the
affected areas with cold water without delay.
Detach the brake fluid reservoir from the
bulkhead extension and tie it back to one
side.
E51432

3.
CAUTION: Ensure that the windshield
wiper motor is in the park position.
E51550
6. Remove the bulkhead extension.
2007.50 Focus 5/2007 G410626en

• Pull the bulkhead extension out of the clips. 9. NOTE: This step is necessary if the
evaporator core orifice is broken.
Using the special tools, remove the broken
fixed orifice tube.
412-034
412-035
E51551
All vehicles
7. VFV9510034
CAUTION: Close off the refrigerant line
to stop dirt from entering.
Remove the refrigerant line fixed orifice tube. Installation
• Discard the O-rings. All vehicles
1. NOTE: Install new refrigerant line O-rings.
25 Nm
NOTE: Coat the refrigerant line O-rings with clean
refrigerant oil before installation.
Install the components in reverse order.

2.
WARNING: Move the windshield wiper
motor to the parked position before installing
the wiper arms.
E51553
Check the angle of the windshield wiper arms
in relation to the windshield.
8. Using the special tool, remove the fixed
orifice tube. For additional information, refer to: Windshield
Wiper Blade and Pivot Arm Adjustment
• Hook the special tool into the fixed orifice
(501-16, General Procedures).
tube, turn it clockwise and remove the fixed
orifice tube.
412-034
VFV9410034
2007.50 Focus 5/2007 G410626en

Suction Accumulator(34 630 4)

1. Remove the right-hand headlamp assembly.
Headlamp Assembly (417-01, Removal and
Installation).
table(s).
CAUTION: Close off the refrigerant lines and the dehydrator to prevent contamination.
2 8 Nm 4
6 N
N 3
25 Nm
7
25 Nm
8 Nm
8
1
25 Nm
10
9
E38934
2007.50 Focus 5/2007 G421025en


1 Nut, dehydrator refrigerant line to 6 Seal, dehydrator refrigerant line to
evaporator condenser
2 Refrigerant line, dehydrator to evaporator 7 Nut, dehydrator
3 Seal, dehydrator refrigerant line to 8 Dehydrator rear bolt
evaporator See Removal Detail
4 Nut, dehydrator refrigerant line to 9 Dehydrator front bolt
condenser
10 Dehydrator
5 Dehydrator refrigerant line to condenser
Removal Details
Item 8 Dehydrator rear bolt
Lifting (100-02, Description and
Operation).
2. Remove the right-hand wheelhouse cover
(shown with wheel removed for clarity).
VFE0037199
2007.50 Focus 5/2007 G421025en

Condenser Core(34 632 4)

For additional information, refer to: Air table(s).
Control System - General Information,
CAUTION: Cap the refrigerant lines and the condenser core to prevent dirt ingress.
8 Nm 4
1 8 Nm
5
6 N
2
N 3
E38936
1 Nut for condenser core refrigerant line to 5 Condenser core refrigerant line to
fixed orifice tube compressor
2 Condenser core refrigerant line to fixed 6 Seal for condenser core refrigerant line to
orifice tube compressor
3 Seal for condenser core refrigerant line to 7 Capacitor

fixed orifice tube See Removal Detail
4 Nut for condenser core refrigerant line to 3. To install, reverse the removal procedure.
compressor
Removal Details
2007.50 Focus 5/2007 G421028en

Item 7 Capacitor 2. Remove the front bolts.
and Operation).
2. Remove the engine undershield. 25 Nm 2
25 Nm 1
E47172
6. NOTE: For vehicles with automatic

transmission only
Detach the air deflectors from the front
bumper cover.
VFE0035742
3. Remove the lower radiator cover.
E47173
TIE40814
transmission only
Remove the air deflector on both sides
4. NOTE: Only vehicles with a 2.5L or diesel (left-hand side shown).
engine
Remove the charge air cooler. For additional
information, refer to:
Charge Air Cooler (303-12B, Removal and
Installation),
Charge Air Cooler - 1.6L Duratorq-TDCi (DV)
(303-12A, Removal and Installation).
transmission only
Loosen the radiator crossmember (left side TIE40823
shown).
1. Loosen the rear bolts by four turns. 8. NOTE: For vehicles with automatic
transmission only
Unclip left-hand side of transmission fluid
cooler.
2007.50 Focus 5/2007 G421028en

• Pull the clip forwards and hold, then pull the 11. Detach the power steering fluid cooler from
transmission fluid cooler upwards out of the the radiator crossmember and secure to
bracket. one side.
9 Nm
TIE45230 TIE45685
9. NOTE: For vehicles with automatic 12. Push the condenser core upwards out of
transmission only the mountings and remove it downwards.
Unclip the transmission fluid cooler on the
right-hand side and secure to one side.
• Pull the clip forwards and hold, then pull the
bracket.
TIE45231
10. Remove the power steering fluid cooler

bracket bolt.
9 Nm
TIE45684
2007.50 Focus 5/2007 G421028en

Condenser to Evaporator Line

Special Tool(s) 2. Remove the engine cover (2.0L diesel
shown).
Hose Clamp
303-397
24003
General Equipment
Hose clamp - coolant hose
For additional information, refer to: Air Cond- E51432

and Charging (412-00, General Procedures). 3. Remove the components in the order
table(s).
CAUTION: Make sure that the windshield wiper motor is in the park position.
NOTE: Vehicles with diesel engines only
22 Nm 1
3
4
5
6 5
E51430
2007.50 Focus 5/2007 G422498en


1 Windshield wiper arm nuts 4 Cowl panel grille
2 Windshield wiper arms 5 Bulkhead extension screws
6 Bulkhead extension
3 Clips, cowl panel grille See Removal Detail
E53819
Item Description
7 Coolant hose, coolant reservoir (only 1.6L
diesel engine)
See Removal Detail
8 Coolant expansion tank
See Removal Detail
2007.50 Focus 5/2007 G422498en

CAUTION: Close off the A/C condenser and A/C evaporator to stop dirt from entering.
10 25 Nm
12
13
8 Nm 11
E53820
NOTE: Install new refrigerant line O-rings.

Item Description
9 High pressure switch connector refrigerant oil before installation.
10 Bolt, refrigerant line to A/C evaporator 5. NOTE: Vehicles with diesel engines only
11 Nut, refrigerant line to A/C condenser Check the angle of the windshield wiper arms
12 Condenser refrigerant line bracket to the in relation to the windshield.
evaporator (unclip) For additional information, refer to: Windshield
Wiper Blade and Pivot Arm Adjustment
13 Condenser refrigerant line to evaporator
2007.50 Focus 5/2007 G422498en

Removal Details
Item 6 Bulkhead extension Clamp the coolant hose shut.
1.
contact with the paintwork, the affected area
must be washed down immediately with cold
water.
side.
E57608
Item 8 Coolant expansion tank

1. Unclip the coolant expansion tank and place
to one side.
E51433
Item 7 Coolant hose, coolant reservoir (only

1.6L diesel engine)
1. Empty the coolant expansion tank.
2.
CAUTION: Close off the coolant hose
from the expansion tank using a hose clamp,
so that coolant is prevented from escaping E57873
from the coolant hose.
motor to the parked position before
installing the wiper arms.
2007.50 Focus 5/2007 G422498en

Low-Pressure Cutoff Switch(34 629 0)

1. Remove the engine cover (2.0L diesel 2. Remove the components in the order
table(s).
E51432
22 Nm 1
3
4
5
6 5
E51430

See Installation Detail 6 Bulkhead extension
2007.50 Focus 5/2007 G410623en

CAUTION: After removing the low pressure switch, make sure that the low pressure switch
valve is completely closed, in order to prevent refrigerant from escaping. Failure to observe
this instruction can lead to injury.
7
8 2.5 Nm
N 9
E51431
4. NOTE: Vehicles with diesel engines only

Item Description
Check the angle of the windshield wiper arms
7 Low pressure switch connector in relation to the windshield.
8 Low-pressure switch For additional information, refer to: Windshield
9 Low pressure switch seal Wiper Blade and Pivot Arm Adjustment
Removal Details
Item 6 Bulkhead extension
1.
water.
2007.50 Focus 5/2007 G410623en

side.
E51433
2007.50 Focus 5/2007 G410623en

High-Pressure Cutoff Switch(34 631 0)

1. Remove the engine cover (2.0L diesel 2. Remove the components in the order
table(s).
E51432
22 Nm 1
3
4
5
6 5
E51430

2007.50 Focus 5/2007 G410624en

CAUTION: Make sure that the high-pressure cutoff switch valve closes completely after
removal of the high-pressure cutoff switch to prevent loss of refrigerant. Failure to observe
this instruction can lead to injury.
8 7
8 Nm
N 9
E51435
4. NOTE: Vehicles with diesel engines only

Item Description
Check the angle of the wiper arms to the
7 High pressure switch connector windscreen.
8 High Pressure Switch For additional information, refer to: Windshield
9 High pressure switch seal Wiper Blade and Pivot Arm Adjustment
Removal Details
1.
water.
2007.50 Focus 5/2007 G410624en

side.
E51433
2007.50 Focus 5/2007 G410624en

Evaporator Core — LHD(34 622 7)

3. Remove the engine cover (2.0L Diesel engine
1. Drain the air conditioning system.
shown).
Control System - General Information,
2. Remove the heater core.
For additional information, refer to: Heater
Core - LHD (412-02 Heating and Ventilation,
E51432

table(s).
NOTE: Only vehicles with 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) or diesel engine.
22 Nm 1
3
4
5
6 5
E53060
2007.50 Focus 5/2007 G414212en


2 Windshield wiper arms 5 Bulkhead extension bolts
6 Bulkhead extension
3 Cowl grille clips See Removal Detail
25 Nm 7
E53061
Item Description
7 Refrigerant lines bolt
8 Refrigerant lines
2007.50 Focus 5/2007 G414212en

11
10 5 Nm 9
5 Nm 9
11
13
12
E53062

9 Evaporator core refrigerant lines bolts NOTE: Lubricate the refrigerant line O-ring seals
with clean refrigerant oil before installation.
10 Evaporator core refrigerant lines
NOTE: Install new refrigerant line O-ring seals.
11 Evaporator core cover bolts
12 Evaporator core cover
13 Evaporator core
2007.50 Focus 5/2007 G414212en

Removal Details
Item 6 Bulkhead extension • Pull the bulkhead extension from the clips.
1.
NOTE: Only vehicles with 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma) or diesel
engine.
Detach the brake fluid retainer from the
bulkhead extension and secure it to one side.
E51433
2007.50 Focus 5/2007 G414212en

Evaporator Outlet Line

Special Tool(s) 2. Remove the right-hand headlamp assembly.
Remover/Installer, Coolant For additional information, refer to:
Hose Clamp Headlamp Assembly (417-01, Removal and
303-397 Installation).
3. Remove the engine cover (2.0L diesel
24003
shown).
Disconnect Tool, Spring Lock

Coupling 3/4" (white)
412-040
34002
General Equipment
E51432
Hose clamp - coolant hose
1. Evacuate the air conditioning (A/C) system. 4. Remove the components in the order
For additional information, refer to: Air Cond- indicated in the following illustration(s) and
itioning (A/C) System Recovery, Evacuation table(s).
2007.50 Focus 5/2007 G422499en

22 Nm 1
3
4
5
6 5
E51430

2007.50 Focus 5/2007 G422499en

E53819
Item Description
7 Coolant hose, coolant reservoir (only 1.6L
diesel engine)
See Removal Detail
8 Coolant expansion tank
See Removal Detail
2007.50 Focus 5/2007 G422499en

CAUTION: Close off the A/C dehydrator and evaporator to stop dirt from entering.
12
13
10 25 Nm
8 Nm 11
E53821
NOTE: Install new refrigerant line O-rings.

Item Description
9 Low pressure switch connector refrigerant oil before installation.
10 Bolt, refrigerant line to A/C evaporator 6. NOTE: Vehicles with diesel engines only
11 Nut, refrigerant line to A/C dehydrator Check the angle of the windshield wiper arms
See Removal Detail in relation to the windshield.
12 Bracket, evaporator refrigerant outlet line For additional information, refer to: Windshield
(unclip) Wiper Blade and Pivot Arm Adjustment
13 Refrigerant outlet line, evaporator
Removal Details
1.
water.
2007.50 Focus 5/2007 G422499en

Detach the brake fluid reservoir from the Item 8 Coolant expansion tank
1. Unclip the coolant expansion tank and place
side.
to one side.
E51433
E57873
Item 7 Coolant hose, coolant reservoir (only Item 11 Nut, refrigerant line to A/C dehydrator
1.6L diesel engine)
1. Empty the coolant expansion tank.
(Sigma) or 1.6L Duratec-16V (Sigma)
2.
CAUTION: Close off the coolant hose Remove the retaining clip of the A/C line.
from the expansion tank using a hose clamp,
so that coolant is prevented from escaping
from the coolant hose.
Clamp the coolant hose shut.
E53917

(Sigma) or 1.6L Duratec-16V (Sigma)
E57608
Disconnect the refrigerant line from the
dehydrator using the special tool.
412-040
E53918
2007.50 Focus 5/2007 G422499en

2007.50 Focus 5/2007 G422499en

412-04-1 Control Components 412-04-1
.
SECTION 412-04 Control Components

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 412-04-2

Control Components........................................................................................................... 412-04-3

Control Components........................................................................................................... 412-04-6

Climate Control Assembly — Vehicles With: Manual Temperature Control....................... 412-04-7
Climate Control Assembly — Vehicles With: Automatic Temperature Control................... 412-04-9
Blower Motor Switch........................................................................................................... 412-04-11
Center Register Air Discharge Temperature Sensor - Driver Side..................................... 412-04-13
Center Register Air Discharge Temperature Sensor - Passenger Side.............................. 412-04-15
Defrost Vent/Register Blend Door Actuator — LHD........................................................... 412-04-19
Footwell Air Discharge Temperature Sensor - Driver Side................................................. 412-04-23
Footwell Air Discharge Temperature Sensor - Passenger Side......................................... 412-04-27
Air Inlet Blend Door Actuator.............................................................................................. 412-04-40
Footwell Vent/Duct Blend Door Actuator — LHD............................................................... 412-04-46
Temperature Blend Door Actuator...................................................................................... 412-04-58
Blower Motor Resistor — LHD........................................................................................... 412-04-70
Blower Motor Resistor — Vehicles Built From: 10/2005, Vehicles With: Dual Automatic
Temperature Control......................................................................................................... 412-04-72
SPECIFICATIONS
Tightening Torques
Bolts, reinforcing element 22 16 -
Bolts, reinforcing element bracket 25 18 -
Steering column shaft joint bolt 28 21 -
Dashboard crossmember outer bolts 25 18 -
Dashboard crossmember inner bolts 20 15 -
Clutch pedal bracket retaining nuts 25 18 -
Door check strap bolt 23 17 -
Door hinge bolts 15 11 -
Dashboard crossmember side bolts 80 59 -
Bolts for windshield wiper motor with linkage 7 - 62
Windshield wiper arm nuts 22 16 -
2007.50 Focus 3/2007 G371327en

Control Components
Control panel - heating/air conditioning -
Control panel - heating/air conditioning - vehicles equipped with automatic
vehicles equipped with manual temperature temperature control
control
E51908
E51907 Vehicles with automatic temperature control have

a control panel with buttons to control the following
The heating and air conditioning is controlled by
functions:
three rotating switches on vehicles equipped with
manual temperature control. Movement of the air • Switching the air conditioning on and off
distribution doors is carried out by the air • Temperature adjustment for the driver's side /
distribution door/temperature blend door control front passenger's side
unit, which is connected to the control panel by a • Switching the windshield defrost function on and
drive. Movement of the temperature blend door is off
also performed by the air distribution
• Switching the electronic automatic temperature
door/temperature blend door control unit, which is
control system and the dual mode on and off
connected to the control panel by a actuating cable.
• Air distribution
In addition, on the control panel there is an
• Blower control
operating switch for the recirculated air mode and
an on/off switch for the air conditioning system. • Switching off the dual automatic temperature
control system
• Recirculated air control
2007.50 Focus 3/2007 G414217en

Overview - heater/evaporator housing - vehicles equipped with manual temperature
control
1 4
6 2
7
5
E53802
1 Actuator - air inlet blend door 5 Actuating lever - air distribution door -
footwell
2 Control unit - air distribution door /
temperature blend door 6 Actuating lever - air distribution door -
defrost nozzles
3 Actuating lever - temperature blend door
7 Drive - air distribution door
4 Actuating lever - air distribution door -
central nozzles 8 Actuating cable - temperature blend door
2007.50 Focus 3/2007 G414217en

Overview - heater/evaporator housing - vehicles equipped with automatic temperature
control
4
2 5 8
7
3 6
E53803
Item Description
1 Air vent temperature sensors
2 Actuator - defroster nozzle / air distribution
door - air vent
3 Actuator - right-hand temperature blend
door
4 Actuator - air inlet blend door
5 Actuator - air distribution door
6 Actuator - left-hand temperature blend
door
7 Actuating unit - air distribution door
central nozzles
footwell
2007.50 Focus 3/2007 G414217en

Control Components
REFER to: Climate Control System (412-00
Climate Control System - General Information,
2007.50 Focus 3/2007 G167212en

Climate Control Assembly — Vehicles With: Manual Temperature

Control
1. Remove the audio unit.
Audio Unit (415-01, Removal and
Installation).
5 6
E51160
2007.50 Focus 3/2007 G410627en


1 Instrument panel console screws 5 Heating / air conditioning control panel
electrical connectors
See Removal Detail 6 Cable, temperature flap
See Removal Detail
3 Heating / air conditioning control panel
screws 7 Rod - air distribution flap
4 Heating / air conditioning control panel 3. To install, reverse the removal procedure.
Removal Details
1. Unclip the instrument panel console.
E51161
Item 6 Cable, temperature flap

1. Detach the temperature flap cable from the
adjusting mechanism.
VFE0035756
2007.50 Focus 3/2007 G410627en

Climate Control Assembly — Vehicles With: Automatic

Temperature Control
1. Remove the audio unit.
Audio Unit (415-01, Removal and
Installation).
E51162
2007.50 Focus 3/2007 G410628en


1 Instrument panel console screws 4 Heating / air conditioning control panel
2 Instrument panel console 5 Heating / air conditioning control panel
See Removal Detail electrical connectors
3 Heating / air conditioning control panel 3. To install, reverse the removal procedure.
screws
Removal Details
1. Unclip the instrument panel console.
E51163
2007.50 Focus 3/2007 G410628en

Blower Motor Switch

1. Remove the heater/air conditioning control
panel.
table(s).
Climate Control Assembly - Vehicles
With: Manual Temperature Control
(412-04, Removal and Installation).
CAUTION: Ensure that the blower motor switch is set to switch position 1 during installation
and removal, in order to prevent damage to the control panel electronics.
NOTE: The rear cover of the climate control assembly is shown removed for clarity.

1 Blower motor switch rotary knob
2 Blower motor switch cover
See Removal Detail
3 Blower motor switch
Removal Details
Item 2 Blower motor switch cover
1. Remove the blower motor switch cover.
2007.50 Focus 3/2007 G413296en

• Cut through the retaining tabs.
E47185
Item 2 Blower motor switch cover
1. NOTE: The service kit for the motor blower
switch contains a modified cover which can
be attached to the climate control assembly
rear cover by means of the two screws
provided.
Install the blower motor switch together with
the blower motor switch cover.
E49370
2007.50 Focus 3/2007 G413296en

Center Register Air Discharge Temperature Sensor - Driver Side

1. Remove the instrument cluster.
Instrument Cluster (413-01, Removal and
Installation).
E51627

1 Electrical connector, air outlet temperature
sensor, centre nozzles, driver's side
2 Air outlet temperature sensor, centre
nozzles, driver's side
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G413276en

Item 2 Air outlet temperature sensor, centre
nozzles, driver's side
1. Turn the air outlet temperature sensor
clockwise through 90 degrees and remove.
E51628
2007.50 Focus 3/2007 G413276en

Center Register Air Discharge Temperature Sensor - Passenger

Side
table(s).
3 5 6
E51448
1 Footwell trim panel 4 Glove compartment

See Removal Detail
2 Glove compartment screws
See Removal Detail 5 Electrical connector, audio unit input (if
equipped)
3 Hose, glove compartment cooling (if
equipped) 6 Passenger air bag deactivation (PAD)
See Removal Detail switch electrical connector (if equipped)
2007.50 Focus 3/2007 G413278en

E52782
Item Description
7 Opening damper, glove compartment
cover (unhook)
8 Glove compartment cover
2007.50 Focus 3/2007 G413278en

10
E51652

sensor, centre nozzles, passenger's side
10 Air outlet temperature sensor, centre
nozzles, passenger's side
See Removal Detail
Removal Details
Item 2 Glove compartment screws Item 3 Hose, glove compartment cooling (if
1. Fold down the covering caps of the screws equipped)
for the glove compartment. NOTE: Only vehicles with glove compartment
cooling
E52787
2007.50 Focus 3/2007 G413278en

1. Detach the central junction box (CJB) from Item 10 Air outlet temperature sensor, centre
the reinforcing element. nozzles, passenger's side
anti-clockwise through 90 degrees and
remove.
E51609
2. Detach the glove compartment cooling hose

from the glove compartment. E51653
E49732
Item 4 Glove compartment

1. Remove the access flap for the navigation
system DVD mechanism (if equipped).
E51195
2007.50 Focus 3/2007 G413278en

Defrost Vent/Register Blend Door Actuator — LHD

table(s).
3 5 6
E51448
1 Footwell trim panel 4 Glove compartment

See Removal Detail
2 Glove compartment screws
See Removal Detail 5 Electrical connector, audio unit input (if
equipped)
3 Hose, glove compartment cooling (if
equipped) 6 Passenger air bag deactivation (PAD)
See Removal Detail switch electrical connector (if equipped)
2007.50 Focus 3/2007 G413294en

E52782
Item Description
7 Opening damper, glove compartment
cover (unhook)
8 Glove compartment cover
2007.50 Focus 3/2007 G413294en

9
11
10
E51660

9 Bolts, defrost nozzle / air vent distribution
flap actuator
See Removal Detail
10 Connector, defrost nozzle / air vent
distribution flap actuator
11 Actuator - defrost nozzle / air vent
distribution flap
Removal Details
2007.50 Focus 3/2007 G413294en

Item 2 Glove compartment screws Item 4 Glove compartment
1. Fold down the covering caps of the screws 1. Remove the access flap for the navigation
for the glove compartment. system DVD mechanism (if equipped).
E52787 E51195
Item 3 Hose, glove compartment cooling (if Item 9 Bolts, defrost nozzle / air vent
equipped) distribution flap actuator
NOTE: Only vehicles with glove compartment 1. Unclip the dashboard wiring harness and
cooling slide it to one side.
the reinforcing element.
E51661
E51609
2. Detach the glove compartment cooling hose

E49732
2007.50 Focus 3/2007 G413294en

Footwell Air Discharge Temperature Sensor - Driver Side

table(s).
E51710
Item Description
1 Bolt, lower dashboard cover
2 Lower dashboard cover
3 Data link connector (DLC)
See Removal Detail
2007.50 Focus 3/2007 G413274en

4
8 5
9
6
10 7
E51711
4 Remote control, audio unit (if equipped) 7 Steering column lower cover
See Removal Detail 8 Bolts, dashboard
5 Remote control electrical connector, audio 9 Bolts, front footwell air duct
unit (if equipped)
6 Bolts, steering column lower cover
2007.50 Focus 3/2007 G413274en

11
12
E51712

sensor, driver's side footwell
12 Air outlet temperature sensor, driver's side
footwell
See Removal Detail
Removal Details
Item 3 Data link connector (DLC) Item 4 Remote control, audio unit (if equipped)
1. Detach the DLC from the lower dashboard 1. Detach the audio unit remote control from
cover. the steering column lower cover.
TIE44539
2007.50 Focus 3/2007 G413274en

locking tang.
TIE0020032
Item 12 Air outlet temperature sensor, driver's

side footwell
clockwise through 90 degrees and remove
it.
E51713
2007.50 Focus 3/2007 G413274en

Footwell Air Discharge Temperature Sensor - Passenger Side

3. Remove the right and left-hand A-pillar trim
1. Remove the engine cover (2.0L diesel engine
panel.
shown).
For additional information, refer to: A-Pillar
Trim Panel (501-05 Interior Trim and
4. Remove the right and left-hand front scuff
plate trim panel.
Installation).
E51432
table(s).
Instrument Panel (501-12 Instrument Panel
2007.50 Focus 3/2007 G426612en

23 Nm 1
N 2 15 Nm
80 Nm 4
E52944

See Removal Detail
2 Door hinge bolts
2007.50 Focus 3/2007 G426612en

22 Nm 5
7 Nm 9
10
25 Nm 11
E53128

7 Cowl grille clips 11 Steering column bracket upper bolts
2007.50 Focus 3/2007 G426612en

13 18
14
17
16 25 Nm
15
28 Nm 12 N
19
20
16 25 Nm
E53129
2007.50 Focus 3/2007 G426612en

25 Nm 24
22
21
21
25
23
21
25 Nm 24
25 Nm 24
E55011
clips side bolt

2007.50 Focus 3/2007 G426612en

27
26
28
29
30
31
E55012

connector
connectors
2007.50 Focus 3/2007 G426612en

33
32
E55013
Item Description
2007.50 Focus 3/2007 G426612en

36
34 20 Nm
35 25 Nm
E55014
Item Description
See Removal Detail
See Removal Detail
2007.50 Focus 3/2007 G426612en

37
E55015

37 Footwell Air Discharge Temperature
Sensor - Passenger Side
See Removal Detail
Removal Details
TIE41214 TIE41215
2007.50 Focus 3/2007 G426612en

2. Disconnect the front door wiring harness 3. Disconnect the blower motor resistor
connector. connector (if fitted) and the blower motor
connector.
TIE41216
E43095
Item 4 Instrument panel console side bolts

1.
CAUTION: Do not remove the instrument console relative to the A-pillars (left-hand
panel console side bolts. side shown).
Loosen the instrument panel console right

1. Support the heater core and evaporator core
housing with wooden blocks.
E0026811
5. Install M10 x 120 mm guide bolts in the right

and left-hand A-pillar.
E43091

connector.
E43092
6. Remove the instrument panel console right

E52988
2007.50 Focus 3/2007 G426612en

7. Pull the instrument panel console forward Disconnect the right-hand temperature blend
to the stop. door actuator connector and the defrost
E43093
E52989

• Unclip the center console wiring harness.
E43087
E43098
2. Detach the steering column shaft joint from
the steering column shaft.
connector.
E43094

E43099
2007.50 Focus 3/2007 G426612en

6. Disconnect the antenna cable connector. 8. Disconnect the roof console connector.
E52735 E53662
7. Disconnect the antenna cable cellular phone 9. Remove the right and left-hand M10 x 120
connector (if fitted). mm guide bolts.
Item 37 Footwell Air Discharge Temperature

Sensor - Passenger Side
clockwise through 90 degrees and remove.
E52736
E52957
2007.50 Focus 3/2007 G426612en

1. Align the instrument panel console to the
E0026811
Item 12 Steering column shaft joint bolt



hinge bolts.
2007.50 Focus 3/2007 G426612en

Air Inlet Blend Door Actuator

table(s).
3 5 6
E51448
1 Footwell side trim 4 Glove compartment

See Removal Detail
2 Glove compartment bolts
See Removal Detail 5 Auxiliary audio input connector
3 Glove compartment cooling tube (if 6 Passenger airbag deactivation switch

equipped) connector (if equipped)
See Removal Detail
2007.50 Focus 3/2007 G414218en

E52782
Item Description
7 Glove compartment lid damper (detach)
8 Glove compartment lid
2007.50 Focus 3/2007 G414218en

10
E53811
Item Description
9 CJB bracket nuts
10 CJB bracket
2007.50 Focus 3/2007 G414218en

13
14
12
11
E53907
11 Air inlet blend door housing bolts 13 Air inlet blend door actuator bolts
12 Air inlet blend door housing 14 Air inlet blend door actuator
Removal Details
2007.50 Focus 3/2007 G414218en

Item 2 Glove compartment bolts Item 3 Glove compartment cooling tube (if
1. Push the glove compartment bolt covers equipped)
downwards. 1. Detach the glove compartment cooling tube
E52787
E49732

the instrument panel console. Item 4 Glove compartment
1. Remove the navigation system digital
versatile disc (DVD) unit access door (if
equipped).
E51609
3. Detach the CJB from the bracket.

1. Turn the CJB downwards. E51195
2. Pull the CJB out of the bracket .

Item 12 Air inlet blend door housing
1. Turn the air inlet blend door housing
downwards to gain access to the air inlet
blend door actuator bolts.
1
E41529
4. NOTE: RHD vehicles only

Disconnect the engine wiring harness
connectors from the CJB and secure the CJB
to one side.
2007.50 Focus 3/2007 G414218en

Item 14 Air inlet blend door actuator
1. Detach the air inlet blend door actuator
connector.
E52988
2007.50 Focus 3/2007 G414218en

Footwell Vent/Duct Blend Door Actuator — LHD

panel.
shown).
plate trim panel.
Installation).
E51432
table(s).
2007.50 Focus 3/2007 G426646en

23 Nm 1
N 2 15 Nm
80 Nm 4
E52944

See Removal Detail
2 Door hinge bolts
2007.50 Focus 3/2007 G426646en

22 Nm 5
7 Nm 9
10
25 Nm 11
E53128

2007.50 Focus 3/2007 G426646en

13 18
14
17
16 25 Nm
15
28 Nm 12 N
19
20
16 25 Nm
E53129
2007.50 Focus 3/2007 G426646en

25 Nm 24
22
21
21
25
23
21
25 Nm 24
25 Nm 24
E55011
clips side bolt

2007.50 Focus 3/2007 G426646en

27
26
28
29
30
31
E55012

connector
connectors
2007.50 Focus 3/2007 G426646en

33
32
E55013
Item Description
2007.50 Focus 3/2007 G426646en

36
34 20 Nm
35 25 Nm
E55014
Item Description
See Removal Detail
See Removal Detail
2007.50 Focus 3/2007 G426646en

38
37
E55026

37 Footwell vent/duct blend door actuator
bolts
38 Footwell vent/duct blend door actuator
Removal Details
TIE41214 TIE41215
2007.50 Focus 3/2007 G426646en

connector.
TIE41216
E43095

1.

E0026811

E43091

connector.
E43092

E52988
2007.50 Focus 3/2007 G426646en

E43093
E52989

E43087
E43098
connector.
E43094

E43099
2007.50 Focus 3/2007 G426646en

E52735 E53662
E52736
Item 35 Instrument panel console outer bolts Item 12 Steering column shaft joint bolt
1. Align the instrument panel console to the WARNING: Install a new steering column
A-pillars (left-hand side shown). shaft joint bolt. Failure to observe this


hinge bolts.
E0026811
2007.50 Focus 3/2007 G426646en

Temperature Blend Door Actuator

panel.
shown).
plate trim panel.
Installation).
E51432
table(s).
2007.50 Focus 3/2007 G426647en

23 Nm 1
N 2 15 Nm
80 Nm 4
E52944

See Removal Detail
2 Door hinge bolts
2007.50 Focus 3/2007 G426647en

22 Nm 5
7 Nm 9
10
25 Nm 11
E53128

2007.50 Focus 3/2007 G426647en

13 18
14
17
16 25 Nm
15
28 Nm 12 N
19
20
16 25 Nm
E53129
2007.50 Focus 3/2007 G426647en

25 Nm 24
22
21
21
25
23
21
25 Nm 24
25 Nm 24
E55011
clips side bolt

2007.50 Focus 3/2007 G426647en

27
26
28
29
30
31
E55012

connector
connectors
2007.50 Focus 3/2007 G426647en

33
32
E55013
Item Description
2007.50 Focus 3/2007 G426647en

36
34 20 Nm
35 25 Nm
E55014
Item Description
See Removal Detail
See Removal Detail
2007.50 Focus 3/2007 G426647en

38
37
E55032

37 Temperature blend door actuator bolts
38 Temperature blend door actuator
Removal Details
TIE41214 TIE41215
2007.50 Focus 3/2007 G426647en

connector.
TIE41216
E43095

1.

E0026811

E43091

connector.
E43092

E52988
2007.50 Focus 3/2007 G426647en

E43093
E52989

E43087
E43098
connector.
E43094

E43099
2007.50 Focus 3/2007 G426647en

E52735 E53662
E52736
Item 35 Instrument panel console outer bolts Item 12 Steering column shaft joint bolt
1. Align the instrument panel console to the WARNING: Install a new steering column
A-pillars (left-hand side shown). shaft joint bolt. Failure to observe this


hinge bolts.
E0026811
2007.50 Focus 3/2007 G426647en

Blower Motor Resistor — LHD

WARNING: Never perform operations on 1. Remove the blower motor.
the blower motor resistor before the blower For additional information, refer to: Blower
motor resistor has cooled to ambient Motor (412-02 Heating and Ventilation,
temperature. Failure to observe this Removal and Installation).
table(s).
NOTE: Remove blower motor resistor through blower motor housing from passenger's side.
2
1
E53814

1 Blower motor resistor bolts
3 Blower motor resistor connector
See Removal Detail
Removal Details
2007.50 Focus 3/2007 G414219en

Item 3 Blower motor resistor connector blower motor resistor connector and
disconnect the connector.
1. Pull down the blower motor resistor with
Item 3 Blower motor resistor connector
NOTE: Connect the blower motor resistor
connector after installing the blower motor resistor.
2007.50 Focus 3/2007 G414219en

Blower Motor Resistor — Vehicles Built From: 10/2005, Vehicles

With: Dual Automatic Temperature Control
NOTE: Four guide bolts (M10 x 120 mm) are 2. Remove the dash panel.
required for removal of the dash panel together For additional information, refer to:
with the dash panel crossmember. Instrument panel (501-12, Removal and
1. Remove the engine cover (2.0L diesel engine Installation).
shown). 3. Remove the left and right-hand A-pillar trim.
4. Remove the left and right-hand entry trim
panel.
Installation).
table(s).
2007.50 Focus 3/2007 G851390en

23 Nm 1
N 2 15 Nm
80 Nm 4
E52944
1 Door arrester bolt 3 Front doors (driver's door shown)

See Removal Detail
2 Door hinge bolts
See Removal Detail 4 Side bolts on the dash panel crossmember
2007.50 Focus 3/2007 G851390en

22 Nm 5
7 Nm 9
10
25 Nm 11
E53128
5 Windshield wiper arm nuts 8 Cowl screen
6 Windshield wiper arms 9 Bolts, windshield wiper motor with linkage

7 Cowl screen clips 11 Upper bolts, steering column bracket
2007.50 Focus 3/2007 G851390en

13 18
14
17
16 25 Nm
15
28 Nm 12 N
19
20
16 25 Nm
E53129
12 Bolts, steering spindle connecting joint 16 Bolts, reinforcement element holder

See Installation Detail 17 Reinforcement element holder
13 Bolt, footwell air duct 18 Air duct, rear footwell
14 Footwell air duct 19 Connector, passenger compartment wiring
15 Bolt, heat exchanger/evaporator housing harness
20 Ground cable bolts
2007.50 Focus 3/2007 G851390en

WARNING: Never perform any work on the electric booster heater before the heater element
of the electric booster heater has cooled down to normal ambient temperature. Failure to
observe this instruction can lead to injury.
25 25 Nm
22
23
22
26
27 21 24
22
27
25 25 Nm
25 Nm 25
E53130
21 Bolts, heat exchanger/evaporator housing 24 Retaining clip, engine compartment wiring

harness (if equipped)
22 Retaining clips, instrument panel wiring
harness 25 Bolts, reinforcing element bracket
23 Ground cable bolt 26 Bracket, reinforcing element

27 Connector - electric booster heater (if
equipped)
2007.50 Focus 3/2007 G851390en

29 28
30 31
32
33
E53131
28 Bolts, footwell air duct 31 Connector - engine compartment wiring

harness
29 Footwell air duct
30 Instrument panel wiring harness connector connector
33 Ground wire bolt
2007.50 Focus 3/2007 G851390en

35
34
E53132
Item Description
34 Remove the heater core upper cover bolts
2007.50 Focus 3/2007 G851390en

38
36 20 Nm
37 25 Nm
E53133
Item Description
36 Dashboard crossmember inner bolts
37 Dashboard crossmember outer bolts
See Removal Detail
39
38 Dashboard crossmember 40
See Removal Detail
E76160
Item Description
39 Blower motor resistor retaining bolts
Removal Details
2007.50 Focus 3/2007 G851390en

Item 2 Door hinge bolts Loosen the dashboard crossmember right
1. Support the door using a trolley jack with
the aid of another technician.
Item 37 Dashboard crossmember outer bolts
1. Support the heater housing with wooden
blocks.
TIE41214
Item 3 Front doors (driver's door shown)

E43091
1. Detach the front door wiring harness
connector from the A-pillar.
2. Detach the air recirculation flap actuator
connector.
TIE41215
E43096
2. Detach the front door wiring harness
connector.
3. Disconnect the connector from the blower
motor resistor and the connector from the
blower motor.
TIE41216
Item 4 Side bolts on the dash panel E43095

crossmember
1.
CAUTION: Do not remove the dashboard
crossmember side bolts.
2007.50 Focus 3/2007 G851390en

4. Mark the position of the dashboard Item 38 Dashboard crossmember
crossmember relative to the A-pillars
• Unclip the center console wiring harness and
pull it out.
E0026811
E43087
5. After removing the outer bolts of the
dashboard crossmember, screw in two M10
x 120 mm guide bolts each into the right and 2. Detach the steering column shaft joint from
left-hand A-pillars (shown without dashboard the steering column shaft.
crossmember for clarity).
E43094
E43092
3. Detach the right-hand temperature flap
6. Remove the dashboard crossmember right actuator connector and the defrost flap
and left-hand side bolts. actuator connector.
7. Pull the dashboard crossmember forwards

until it reaches a stop.
E43097
E43093
2007.50 Focus 3/2007 G851390en

4. Detach the left-hand temperature flap 7. Separate the car telephone antenna cable
actuator connector and the air distribution push-fit connector (if equipped).
flap actuator connector.
E52736
E43098
8. Detach the overhead console wiring harness

5. Detach the air outlet temperature sensor connector.
connector.
E53662
E43099
9. Remove the right and left-hand M10 x 120

6. Separate the radio antenna cable push-fit mm guide bolts.
connector.
E52735
2007.50 Focus 3/2007 G851390en

Item 37 Dashboard crossmember outer bolts
1. Align the dashboard crossmember to the
E0026811
Item 12 Bolts, steering spindle connecting joint

instruction can lead to injuries.


hinge bolts.
2007.50 Focus 3/2007 G851390en

413-00-1 Instrument Cluster and Panel Illumination 413-00-1
.
SECTION 413-00 Instrument Cluster and Panel

Illumination
CONTENTS PAGE

Instrument Cluster and Panel Illumination.......................................................................... 413-00-2
Instrument Cluster and Dimmable Backlighting ................................................................ 413-00-2
Symptom Chart................................................................................................................... 413-00-2
Pinpoint Tests..................................................................................................................... 413-00-3
Instrument Cluster and Panel Illumination

Refer to Wiring Diagrams Section 413-00, for • audio unit
• navigation system display module
• instrument cluster
Principles of Operation • climate control module
• hazard switch
NOTE: A new instrument cluster must be
configured. • traction control system disable switch
• right-hand and left-hand heated front seat
REFER to: Instrument Cluster (413-01 Instrument
switch(es)
Cluster, Removal and Installation).
The instrument cluster and panel illumination
consists of dimmable and non-dimmable Inspection and Verification
illumination. The dimmable panel illumination is
controlled by the panel illumination switch (part of 1. Verify the customer concern.
the headlamp switch), which allows the brightness 2. Visually inspect for obvious signs of mechanical
level of the backlights to be adjusted dependent or electrical damage.
on the customer preference. When the headlamp
switch is in the parking lamps ON or headlamps Visual Inspection Chart
ON position, the intensity of the backlighting can Mechanical Electrical
be adjusted using the panel dimmer switch. The
– Engine/engine – Fuse(s)
non dimmable illumination allows for full intensity
compartment or – Loose or corroded
dependant on the ignition switch position.
underbody compon- connector(s)
ents
– Instrument cluster
Instrument Cluster and Dimmable – Fluid levels
– Wiring Harness
Backlighting – Accessory installa-
– Circuit
tion
The dimmable illumination utilizes light emitting – LED(s)
diodes (LEDs) and bulb(s). The following dimmable – Bulb(s)
components are backlight using LEDs only:
• ashtray 3. If an obvious cause for an observed or reported
• cigar lighter concern is found, correct the cause (if possible)
• transmission control lever before proceeding to the next step
• heater control panel 4. If the cause is not visually evident, verify the
Symptom Chart
Symptom Chart
• The control illumination is • Fuse. • GO to Pinpoint Test A.
inoperative • Headlamp switch.
• Circuit.
• The Instrument cluster illumina- • Circuit(s). • GO to Pinpoint Test B.
tion is inoperative • Instrument cluster.
• The climate control illumination • Circuit(s). • GO to Pinpoint Test C.
is inoperative • Climate control assembly.
• The audio system illumination • Circuit(s). • GO to Pinpoint Test D.
is inoperative • Audio unit.
2007.50 Focus 3/2007 G167228en


• The navigation system display • Circuit(s). • GO to Pinpoint Test E.
module illumination (vehicles • Navigation system display
with DVD Navigation System module.
with Touchscreen) is inoper-
ative
• The gearshift illumination is • Circuit(s). • GO to Pinpoint Test F.
inoperative • Transmission Selector Lever.
• The cigar lighter illumination is • Circuit(s). • GO to Pinpoint Test G.
inoperative • Cigar lighter.
• The traction control switch illu- • Circuit(s). • GO to Pinpoint Test H.
mination is inoperative • Traction control switch.
• The hazard switch illumination • Circuit(s). • GO to Pinpoint Test I.
is inoperative • Hazard switch.
• The front seat heater switch(es) • Circuit(s). • GO to Pinpoint Test J.
illumination is inoperative • Front seat heater switch(es).
• The front window defrost switch • Circuit(s). • GO to Pinpoint Test K.
illumination is inoperative • Front window defrost switch.
• The rear window defrost switch • Circuit(s). • GO to Pinpoint Test L.
illumination is inoperative • Rear window defrost switch.
• The rear auxiliary audio control • Circuit(s). • GO to Pinpoint Test M.
illumination is inoperative • Rear auxiliary audio control.
• The instrument panel illumina- • Dimmer switch. • INSTALL a new head-
tion does not dim lamp/dimmer switch unit.
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A : THE CONTROL ILLUMINATION IS INOPERATIVE
A1: CHECK PARKING LAMP OPERATION
2007.50 Focus 3/2007 G167228en


2 Place the side lamps in the ON position.
• Do the side lamps and license plate lamps
illuminate?
→ Yes
INSTALL a new headlamp switch. TEST the
→ No
CHECK fuse F49 (10A).
If the fuse is OK then diagnose exterior
lighting.
REFER to: Headlamps - 3-Door (417-01
Exterior Lighting, Diagnosis and Testing).
If the fuse has failed, INSTALL a new fuse.
fuse fails again, CHECK for a short to ground,
REPAIR as necessary.
PINPOINT TEST B : THE INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE

B1: CHECK THE INSTRUMENT CLUSTER ILLUMINATION
1 Place the headlamp switch in the headlamps
ON position.
• Is only the instrument cluster illumination
inoperative?
→ Yes
Place the headlamp switch in the OFF posi-
tion. GO to B2.
→ No
If the exterior lighting is inoperative,
REFER to: Headlamps - 3-Door (417-01
Exterior Lighting, Diagnosis and Testing).
If all of the control illumination is inoperative,
GO to Pinpoint Test A.
B2: CHECK CIRCUIT 29S-GG14 (OG) FOR VOLTAGE
1 Disconnect Instrument Cluster C809.
2 Make sure that the illumination dimmer switch
is in the full illumination position.
3 Place the headlamp switch in the headlamp ON
position.
2007.50 Focus 3/2007 G167228en


4 Measure the voltage between the instrument
cluster C809 pin 9, circuit 29S-GG14 (OG),
→ Yes
GO to B3.
→ No
normal operation.
E44987
B3: CHECK CIRCUIT 91-GG14 (BK/OG) FOR OPEN

1 Place the headlamp switch in the OFF position.
2 Measure the resistance between instrument
cluster C809 pin 6, circuit 91-GG14 (BK/OG),
→ Yes
INSTALL a new instrument cluster.
REFER to: Instrument Cluster (413-01 Instru-
ment Cluster, Removal and Installation).
E44988
→ No
normal operation.
PINPOINT TEST C : THE CLIMATE CONTROL ILLUMINATION IS INOPERATIVE

C1: CHECK CIRCUIT 29S-LE10 (OG/GN) FOR VOLTAGE
1 Disconnect Climate Control Assembly C378 -
vehicles without electronic automatic temper-
ature control (EATC) module or C540 - vehicles
with electronic automatic temperature control
(EATC) module.
2007.50 Focus 3/2007 G167228en


assembly C378 (vehicles without electronic
automatic temperature control (EATC) module)
or C540 (vehicles with electronic automatic
temperature control (EATC) module) pin 3,
circuit 29S-LE10 (OG/GN), harness side and
ground.
→ Yes
V Vehicles without electronic automatic
temperature control (EATC) module. GO to
C2.
Vehicles with electronic automatic temperature
control (EATC) module. GO to C3.
→ No
normal operation.
E44989
C2: CHECK CIRCUIT 91-FA13 (BK/OG) TO GROUND

control assembly C378 pin 4, circuit 91-FA13
→ Yes
INSTALL a new climate control assembly.
REFER to: Climate Control Assembly -
Vehicles With: Manual Temperature Control
(412-04 Control Components, Removal and
E44990 Installation).
→ No
normal operation.
C3: CHECK CIRCUIT 91-FA94 (BK/GN) TO GROUND
2 Connect Climate Control Assembly C540.
2007.50 Focus 3/2007 G167228en


3 Disconnect Climate Control Assembly C539.
control assembly C539 pin 24, circuit 91-FA94
→ Yes
INSTALL a new climate control assembly.
REFER to: Climate Control Assembly -
Vehicles With: Automatic Temperature
Control (412-04 Control Components,
E44991 Removal and Installation).
→ No
normal operation.
PINPOINT TEST D : THE AUDIO SYSTEM ILLUMINATION IS INOPERATIVE

D1: CHECK VOLTAGE TO THE AUDIO UNIT CIRCUIT 29S-LK34 (OG/BK)
2 Disconnect Audio Unit C442.
ON position.
5 Measure the voltage between audio unit C442
pin 14, circuit 29S-LK34 (OG/BK), harness side
and ground.
V
→ Yes
GO to D2.
→ No
normal operation.
E44992
D2: CHECK CIRCUIT 91-MD5 (BK/BU) TO GROUND

2007.50 Focus 3/2007 G167228en


2 Measure the resistance between the audio unit
C442 pin 11, circuit 91-MD5 (BK/BU), harness
side and ground.
→ Yes
INSTALL a new audio unit.
REFER to: Audio Unit (415-01 Audio Unit,
E44993
→ No
normal operation.
PINPOINT TEST E : THE NAVIGATION SYSTEM DISPLAY MODULE ILLUMINATION (VEHICLES

WITH DVD NAVIGATION SYSTEM WITH TOUCHSCREEN) IS INOPERATIVE
E1: CHECK VOLTAGE TO THE NAVIGATION SYSTEM DISPLAY MODULE CIRCUIT 29S-LK40
(OG/BU)
2 Disconnect Navigation System Display Module
C487.
ON position.
5 Measure the voltage between navigation system
display module C487 pin 3, circuit 29S-LK40
(OG/BU), harness side and ground.
V
→ Yes
GO to D2.
→ No
normal operation.
E44994
E2: CHECK THE NAVIGATION SYSTEM DISPLAY MODULE GROUND CIRCUITS FOR OPEN
2007.50 Focus 3/2007 G167228en


2 Measure the resistance between the navigation
system display module C487 pin 11, circuit 91-
GK49 (BK/GN), harness side and ground; and
between the navigation system display module
C487 pin 12, circuit 91-GK49A (BK/GN),
→ Yes
INSTALL a new navigation system display
module.
E42112
REFER to: Audio Unit - Vehicles With: DVD
Navigation System with Touchscreen (415-
01 Audio Unit, Removal and Installation).
→ No
REPAIR circuit 91-GK49 (BK/GN) or 91-
GK49A (BK/GN). TEST the system for normal
operation.
PINPOINT TEST F : THE GEARSHIFT ILLUMINATION IS INOPERATIVE

F1: CHECK CIRCUIT 29S-PF35 (OG/BK) FOR VOLTAGE
1 Disconnect Transmission Selector Lever C383.
ON position.
5 Measure the voltage between the transmission
selector lever C383 pin 2, circuit 29S-PF35

→ Yes
GO to F2.
→ No
normal operation.
E44995
F2: CHECK CIRCUIT 31-PF35 (BK) FOR VOLTAGE

2007.50 Focus 3/2007 G167228en


2 Measure the voltage between the transmission
selector lever C383 pin 4, circuit 31-PF35 (BK),
→ Yes
INSTALL a new transmission selector lever.
REFER to: Selector Lever (307-05A, Removal
and Installation).
TEST the system for normal opertion.
E44996
→ No
normal operation.
PINPOINT TEST G : THE CIGAR LIGHTER ILLUMINATION IS INOPERATIVE

G1: CHECK CIRCUIT 29S-LK15 (OG) FOR VOLTAGE
1 Disconnect Cigar Lighter C160.
4 Place the headlamp switch in the headlamp ON
position.
5 Measure the voltage between the cigar lighter
C160 pin 1, circuit 29S-LK15 (OG), harness side
and ground.
→ Yes
→ No
normal operation.
GK5220A
G2: CHECK CIRCUIT 31-HA6 (BK) FOR OPEN

1 Connect Cigar Lighter C160.
2 Disconnect Cigar Lighter C912.
2007.50 Focus 3/2007 G167228en


3 Measure the resistance between the cigar lighter
C912 pin 1, circuit 31-HA6 (BK), harness side
and ground.
→ Yes
INSTALL a new cigar lighter. TEST the system
→ No
GK5221A
normal operation.
PINPOINT TEST H : THE TRACTION CONTROL SWITCH ILLUMINATION IS INOPERATIVE

H1: CHECK CIRCUIT 29S-LH45 (OG/WH) FOR VOLTAGE
1 Disconnect Traction Control Switch C717.
4 Place the headlamp switch in the ON position.
5 Measure the voltage between the traction
control switch C717 pin 3, circuit 29S-LH45
(OG/WH) harness side and ground.
V
→ Yes
GO to H2.
→ No
normal operation.
E44997
H2: CHECK CIRCUIT 91-CF54 (BK/WH) FOR OPEN

2007.50 Focus 3/2007 G167228en


2 Measure the resistance between the traction
control switch C717 pin 2, circuit 91-CF54
→ Yes
INSTALL a new traction control switch. TEST
→ No
PINPOINT TEST I : THE HAZARD SWITCH ILLUMINATION IS INOPERATIVE

I1: CHECK CIRCUIT 29S-LH54 (OG/GN) FOR VOLTAGE
1 Disconnect Hazard Switch C455.
5 Measure the voltage between the hazard switch
C455 pin 5, circuit 29S-LH54 (OG/GN), harness
side and ground.
→ Yes
GO to I2.
→ No
normal operation.
E44999
I2: CHECK CIRCUIT 91-LG8 (BK/OG) FOR OPEN

2007.50 Focus 3/2007 G167228en


2 Measure the resistance between hazard switch
C455 pin 2, circuit 91-LG8 (BK/OG), harness
side and ground.
→ Yes
INSTALL a new hazard switch. TEST the
→ No
PINPOINT TEST J : THE FRONT SEAT HEATER SWITCH ILLUMINATION IS INOPERATIVE

J1: CHECK INOPERATIVE FRONT SEAT HEATER SWITCH FOR VOLTAGE
1 Disconnect Inoperative Front Seat Heater
Switch - C694 (driver side) or C695 (passenger
side).
5 Measure the voltage between the inoperative
front seat heater switch:
– C694 (driver side) pin 1, circuit 29S-LH29
V (OG/YE), harness side and ground.
– C695 (passenger side) pin 1, circuit 29S-LH43
(OG/BU), harness side and ground.
→ Yes
GO to J2.
E45000 → No
REPAIR circuit 29S-LH29 (OG/YE) or circuit
29S-LH43 (OG/BU) as necessary. TEST the
2007.50 Focus 3/2007 G167228en


J2: CHECK GROUND TO INOPERATIVE FRONT SEAT HEATER SWITCH FOR OPEN
1 Measure the resistance between the inoperative
front seat heater switch:
– C694 (driver side) pin 2, circuit 31-LH29 (BK),
– C695 (passenger side) pin 2, circuit 31-LH43
(BK), harness side and ground.
→ Yes
INSTALL a new front seat heater switch. TEST
E44998
→ No
REPAIR circuit 31-LH29 (BK) or circuit 31-
LH43 (BK) as necessary. TEST the system
PINPOINT TEST K : THE FRONT WINDOW DEFROST SWITCH ILLUMINATION IS INOPERATIVE

K1: CHECK THE FRONT WINDOW DEFROST SWITCH FOR VOLTAGE
1 Disconnect Front Window Defrost Switch C382.
5 Measure the voltage between the front window
defrost switch C382 pin 3, circuit 29S-HB9
(OG/WH), harness side and ground.
V
→ Yes
GO to K2.
→ No
REPAIR the circuit 29S-HB9 (OG/WH). TEST
E44997
K2: CHECK CIRCUIT 91-HB9 (BK/WH) FOR OPEN

2007.50 Focus 3/2007 G167228en


2 Measure the resistance between the front
window defrost switch C382 pin 2, circuit 91-
HB9 (BK/WH), harness side and ground.
→ Yes
INSTALL a new front window defrost switch.
→ No
PINPOINT TEST L : THE REAR WINDOW DEFROST SWITCH ILLUMINATION IS INOPERATIVE

L1: CHECK THE REAR WINDOW DEFROST SWITCH FOR VOLTAGE
1 Disconnect Rear Window Defrost Switch C381.
5 Measure the voltage between the rear window
defrost switch C381 pin 3, circuit 29S-HB22
V
→ Yes
GO to L2.
→ No
REPAIR the circuit 29S-HB22 (OG/BK). TEST
E44997
L2: CHECK CIRCUIT 91-HB22 (BK/GN) FOR OPEN

2007.50 Focus 3/2007 G167228en


2 Measure the resistance between the rear
window defrost switch C381 pin 2, circuit 91-
HB9 (BK/GN), harness side and ground.
→ Yes
INSTALL a new rear window defrost switch.
→ No
PINPOINT TEST M : THE REAR AUXILAIRY AUDIO CONTROL ILLUMINATION IS INOPERATIVE

M1: CHECK THE REAR AUXILAIRY AUDIO CONTROL FOR VOLTAGE
1 Disconnect Rear Auxilairy Audio Control C451.
5 Measure the voltage between the rear auxilairy
audio control C451 pin 2, circuit 29S-MD16
(OG/GN), harness side and ground.
V
→ Yes
GO to M2.
→ No
REPAIR the circuit 29S-MD16 (OG/GN). TEST
E45001
M2: CHECK CIRCUIT 91-MD16 (BK/RD) FOR GROUND

2007.50 Focus 3/2007 G167228en


2 Measure the resistance between the rear auxil-
iary audio control C451 pin 3, circuit 91-MD16
→ Yes
INSTALL a new rear auxilairy audio control.
REFER to: Rear Auxiliary Audio Controls (415-
01, Removal and Installation).
E42142
→ No
normal operation.
2007.50 Focus 3/2007 G167228en

413-01-1 Instrument Cluster 413-01-1
.
SECTION 413-01 Instrument Cluster

CONTENTS PAGE

Instrument Cluster.............................................................................................................. 413-01-2
Self-Diagnostic Mode. Vehicles with low series instrument cluster.................................... 413-01-2
Self-Diagnostic Mode. Vehicles with mid or high series instrument cluster........................ 413-01-5
Symptom Chart................................................................................................................... 413-01-10
Pinpoint Tests..................................................................................................................... 413-01-12
Configuration of the Instrument Cluster.............................................................................. 413-01-38

Instrument Cluster.............................................................................................................. 413-01-40
Instrument Cluster
Refer to Wiring Diagrams Section 413-01, for Verify the following warning indicators are
schematic and connector information. working correctly:
General Equipment • Charging.
Worldwide Diagnostic System (WDS) • Turn signals.
• Headlamps.
Inspection and Verification 5. If the cause is not visually evident, verify the
symptom and enter the instrument cluster
1. Verify the customer concern. Self-Diagnostic Mode.
or electrical damage. Self-Diagnostic Mode. Vehicles with low
series instrument cluster
– Engine oil filter – Fuse(s)
– Engine oil level – Wiring harness
– Engine coolant level – Electrical
– Oil pressure switch connector(s)
– Engine coolant level – Instrument cluster
– Coolant thermostat – Light emitting
diode(s) (LED)(s)
– Engine coolant
temperature (ECT)
sensor E40589
– Fuel gauge
– Collapsed or NOTE: The instrument cluster tripmeter reset
damaged fuel tank button is located on the right-hand side of the
instrument cluster lens.
– Recirculation hose
– Fuel tank filler 1. To enter the instrument cluster Self-Diagnostic
pipe/hose Mode. Simultaneously press and hold the
tripmeter RESET button and turn the ignition
– Indicated fuel level switch from position 0, to position II.
– Fuel lines 2. Entry to the Self-Diagnostic Mode is confirmed
– Fuel tank filler cap when 'tESt' is displayed in the odometer
– Fuel filter (external to tripmeter liquid crystal display (LCD). The
the fuel tank) tripmeter reset button must be released within
– Fuel tank three seconds of 'tESt' being displayed or the
instrument cluster will exit the Self-Diagnostic
– Door adjustment
mode.
3. To navigate through or skip any of the
3. If an obvious cause for an observed or reported instrument cluster Self-Diagnostic Mode tests,
concern is found, correct the cause (if possible) press the tripmeter RESET button. If the reset
before proceeding to the next step. button is depressed for more than 3 seconds
4. NOTE: If none of the following warning between tests, the instrument cluster will exit
indicators are operating correctly this may the Self-Diagnostic Mode.
indicate a concern with the central junction 4. The Self-Diagnostic Mode is deactivated when
box (CJB). If only one or two of the following the ignition switch is turned to the OFF position
warning indicators are not operating or low battery voltage is detected.
correctly this may indicate an instrument 5. If input data to the instrument cluster is missing
cluster concern. or invalid, the tripmeter LCD will display '----'
2007.50 Focus 3/2007 G167234en

6. If the Self-Diagnostic Mode cannot be accessed, NOTE: Additional tests are available after the
use the WDS to diagnose the instrument cluster. following Self-Diagnostic Mode tests, but are not
applicable for this diagnostic.
Test Odometer Display Gauge/Indicator/Display Description

Tested
1. Self-Diagnostic tESt Instrument cluster Establishes Self-Diagnostic
entry Mode.
2. Gauge sweep gAgE Tachometer, speedo- All gauges go through a full
meter, temperature and up and down pointer sweep
fuel smoothness check. The
pointers should take 3
seconds to achieve full
sweep and 3 seconds to
return to the rest position.
3. Odometer LCD 888888 Odometer LCD Fills in the LCDs of the
odometer display.
4. Indicator LED(s) LeD Indicators and warning Illuminates all the LED
indicators warning indicators that are
controlled by the instrument
cluster.
5. ROM level r XXXX /FAIL Instrument cluster read Displays the instrument
only memory (ROM) cluster ROM level and type.
6. Not required ErXXXX - Not required.
7. Not required E XX /FAIL - Not required.
8. Manufacturing dtXXXX Instrument cluster manu- Displays the instrument
date facturing date cluster date of manufacture.
9. Diagnostic • dtc then XXX DTCs Display the individual DTCs
trouble code (DTC) • nonE at 1 second intervals.
REFER to the WDS to
diagnose the instrument
cluster.
10. Vehicle speed SPXXXX Speedometer Displays the speed signal
mph input in miles per hour.
11. Vehicle speed SPXXXX Speedometer Displays the speed signal
km/h input in kilometers per hour.
12. Not required SgXXXX - Not required.
13. Engine speed tAXXXX Tachometer Displays the engine speed
input signal (RPM)
14. Not required tgXXXX - Not required.
15. Odometer count od XXX Odometer Displays the odometer
rolling count
2007.50 Focus 3/2007 G167234en

Test Odometer Display Gauge/Indicator/Display Description

Tested
16. Fuel volume F XXX Fuel sender system • Displays the fuel volume
signal input.
• 000 - 009 Short circuit
• 010 - 254 Normal range
• 255 open circuit
17. Not required FgXXXX - Not required.

18. Not required FL XX - Not required.
19. Fuel level FP XX Fuel gauge • Displays the fuel average
percentage percentage level.
• Range of display 00 to
64
• 64 being 100% full
• FF will be displayed for
invalid data
20. Engine coolant XXX C ECT • Displays the engine

temperature (ETC) coolant temperature as
a decimal.
• Range 0 to 254
• 255 would indicate
invalid data
21. Not required XXX Cg - Not required.

22. Battery voltage btXXX Battery voltage Displays battery voltage
input.
23. to 28. Not A0-XX to A5-XX - Not required.
required
29. to 42. Not PA-HH to Pn-HH - Not required.
required
43. to 46. Not P1 XX to P4 XX - Not required.
required
47. Distance to dtEXXX Trip computer Displays the distance to fuel
empty tank empty.
48. Fuel economy rAFEXX Trip computer Displays the rolling average
fuel economy in miles per
UK gallon.
2007.50 Focus 3/2007 G167234en

Self-Diagnostic Mode. Vehicles with NOTE: The set button is located on the steering
mid or high series instrument cluster column left hand multifunction switch.
1. To enter the instrument cluster Self-Diagnostic
Mode. Simultaneously press and hold the SET
button and turn the ignition switch from position
0, to position II.
2. Entry to the Self-Diagnostic Mode is confirmed
when 'TEST' is displayed in the odometer
tripmeter liquid crystal display (LCD). The
tripmeter set button must be released within
three seconds of 'TEST' being displayed or the
instrument cluster will exit the Self-Diagnostic
Mode.
3. To navigate through or skip any of the
instrument cluster Self-Diagnostic Mode tests,
press the SET button. If the set button is
depressed for more than 3 seconds between
tests, the instrument cluster will exit the
Self-Diagnostic Mode.
4. The Self-Diagnostic Mode is deactivated when
the ignition switch is turned to the OFF position
or low battery voltage is detected.
5. If input data to the instrument cluster is missing
or invalid, the tripmeter LCD will display '----'
6. If the Self-Diagnostic Mode cannot be accessed,
use the WDS to diagnose the instrument cluster.
E40590 NOTE: Additional tests are available after the
following Self-Diagnostic Mode tests, but are not
applicable for this diagnostic.
Self-Diagnostic Mode
Test Odometer Display Gauge/Indicator/ Description
Display Tested
1. Self-Diagnostic • TEST Instrument cluster Establishes Self-
entry • no display Diagnostic Mode.
2. Gauge sweep • GAUGE SWEEP Tachometer, speedo- All gauges go through a

• no display meter, temperature and full up and down pointer
fuel sweep smoothness check.
The pointers should take
3 seconds to achieve full
sweep and 3 seconds to
return to the rest position.
3. Odometer LCD Filled in black Odometer LCD Fills in the LCDs of the
odometer display.
4. Indicator LED(s) • LED TEST Indicators and warning Illuminates all the LED
• no display indicators warning indicators that are
controlled by the instru-
ment cluster.
2007.50 Focus 3/2007 G167234en


Display Tested
5. ROM level • ROM LEVEL Instrument cluster read Displays the instrument
• XXXX / FAIL only memory (ROM) cluster ROM level and
type.
6. Not required • NVM TARGET ROM - Not required.
• XXXX
7. Not required • NVM EEPROM LVL - Not required.

• XXXX / FAIL
8. Manufacturing • MANUFACTURE Instrument cluster manu- Displays the instrument

date • HOURS XXXX facturing date cluster date of manufac-
ture.
9. Diagnostic • DTC #NN DTCs Display the individual
trouble code (DTC) • XXXX DTCs at 1 second inter-
vals. REFER to the WDS
to diagnose the instrument
cluster.
10. Vehicle speed • ROAD SPEED Speedometer Displays the speed signal
mph • XXX.X MPH input in miles per hour.
11. Vehicle speed • ROAD SPEED Speedometer Displays the speed signal
km/h • XXX.X KM/H input in kilometers per
hour.
12. Not required • SPEEDO GAUGE - Not required.
• XXXX
13. Engine speed • ENGINE SPEED Tachometer Displays the engine speed
• XXXX input signal (RPM)
14. Not required • TACHO GAUGE - Not required.

• XXXX
15. Odometer count • ODO ROLL COUNT Odometer Displays the odometer
• XXX rolling count
16. Fuel volume • FUEL A/D INPUT Fuel sender system • Displays the fuel
• XXX volume signal input.
• 000 - 009 Short circuit
• 010 - 254 Normal
range
• 255 open circuit
17. Not required • FUEL GAUGE - Not required.

• XXXX
18. Not required • FUEL FLOW - Not required.

• XXXX
2007.50 Focus 3/2007 G167234en


Display Tested
19. Fuel level • FUEL PERCENT Fuel gauge • Displays the fuel
percentage • XXXX average percentage
level.
• Range of display 00 to
64
• 64 being 100% full
• FF will be displayed for
invalid data
20. Engine coolant • ENGINE TEMP ECT • Displays the engine

temperature (ECT) • XXX C coolant temperature as
a decimal.
• Range 0 to 254
• 255 would indicate
invalid data
21. Not required • TEMP GAUGE - Not required.

• XXXX
22. Battery voltage • BATTERY Battery voltage Displays battery voltage

• XX.X input.
23. to 28. Not • A/D INPUT 00 to A/D - Not required.

required INPUT 05
• XX
29. to 42. Not • PORT A to PORT N - Not required.

required • XX
43. to 46. Not • PERSONALITY 01 to - Not required.

required PERSONALITY 04
• XX
47. Distance to • DIST. TO EMPTY Information and message Displays the distance to
empty • XXX MILES center fuel tank empty.
48. Fuel economy • RAFE Information and message Displays the rolling
• XXX MPG center average fuel economy in
miles per UK gallon.
2007.50 Focus 3/2007 G167234en

Instrument Cluster DTC Index Chart
Self Diagnostic DTC Description Source Action
Mode Displayed
DTC
115A P115A Low Fuel Level - Instrument cluster • If the fuel gauge
Forced Limited shows EMPTY
Power and the Distance
To Empty = 0
kilometers/miles:
Delete the DTC
and the
customer can
refill the fuel
tank. NO further
action must be
taken.
• If the fuel gauge
shows more
than EMPTY
and/or the
Distance To
Empty is greater
than 0 kilo-
meters/miles GO
to Pinpoint Test
F.
115B P115B Low Fuel Level - Instrument cluster • If the fuel gauge
Forced Engine shows EMPTY
Shutdown and the Distance
To Empty = 0:
Delete the DTC
and the
customer can
refill the fuel
tank. NO further
action must be
taken.
• If the fuel gauge
shows more
than Empty
and/or the
Distance To
Empty is greater
than 0 kilo-
meters/miles GO
to Pinpoint Test
F.
9202 B1202 Fuel pump and Instrument cluster GO to Pinpoint Test

sender unit/fuel A.
level sensor open
circuit
2007.50 Focus 3/2007 G167234en

Self Diagnostic DTC Description Source Action

Mode Displayed
DTC
9204 B1204 Fuel pump and Instrument cluster GO to Pinpoint Test
sender unit/fuel A.
level sensor short
to ground
9317 B1317 Battery voltage high Instrument cluster REFER to the WDS
(greater than 16V)
9318 B1318 Battery voltage low Instrument cluster REFER to the WDS
(less than 10V)
9342 B1342 PCM is defective Instrument cluster REFER to the WDS
A477 B2477 Module configura- Instrument cluster REFER to the WDS
tion failure
E196 U2196 Invalid data for Instrument cluster REFER to the WDS
engine RPM
(Invalid CAN
message)
vehicle speed
(Invalid CAN
message)
E198 U2198 Invalid data for fuel Instrument cluster REFER to the WDS
pulse (Invalid CAN
message)
engine coolant
temperature
(Invalid CAN
message)
odometer (Invalid
CAN message)
ambient temper-
ature (Invalid CAN
message)
7. The self-diagnostic mode is to act as a guide to 8. For any fuel gauge concerns, REFER to the
establish if the concern is instrument cluster Symptom Chart.
related. For any concerns not related to the fuel
gauge, REFER to the WDS to continue
diagnostics.
2007.50 Focus 3/2007 G167234en

Symptom Chart

• The fuel gauge pointer does • The fuel gauge considers unin- • No action required. Do not
not move down at a constant dicated full and empty reserve install a new component.
rate (Full to 3/4 and 1/4 to as part of the indicated volume.
empty periods vary) The pointer catches up with the
real volume outside of these
areas.
• Information and message • The fuel gauge considers unin- • No action required. Do not
center inconsistent with the fuel dicated full and empty reserve install a new component.
gauge as part of the indicated volume.
The pointer catches up with the
real volume outside of these
areas.
• A certain amount of fuel is not
indicated or not useable
respectively and is needed to
avoid unintended engine hesit-
ations at low fuel levels. This
amount is carline and engine
type dependent.
• The low fuel warning indicator • This is dependant on the drive • No action required. Do not
illuminates too early style. The on-board computer install a new component.
calculates the average
consumption and illuminates
the low fuel warning indicator
when there is 80 Km (50 miles)
of fuel left in the fuel tank. The
on-board computer does not
consider a more economical
drive style after a higher fuel
consumption, but keeps the
Distance To Empty (DTE)
constant until the fuel level has
caught up with the remaining
DTE.
• The fuel gauge pointer moves • A certain amount of unindicated • No action required. Do not
too quickly off the full position fuel is normal and is dependent install a new component.
or needs too long to move off on fuel tank geometry and the
the full position after refuelling fuel station filler nozzle shutoff
behaviour
• Indicated fuel level does not • A certain amount of fuel is not • No action required. Do not
match the amount of fuel indicated or not useable install a new component.
expected to be in the fuel tank respectively and is needed to
type dependent.
2007.50 Focus 3/2007 G167234en


• Indicated fuel level does not • A certain amount of fuel is not • No action required. Do not
match the amount of fuel indicated or not useable install a new component.
expected to be in the fuel tank respectively and is needed to
type dependent.
• Fuel gauge shows less than full • Fuel tank refilled with the igni- • Refilling with the ignition OFF
(even when refilled/trickle filled) tion ON next time will cure the concern.
Do not install a new
component.
• Fuel tank only filled up to the • Advise the customer to fill the
1st click on the fuel station fuel tank up to the 3rd click on
filling nozzle. the fuel station filling nozzle. Do
not install a new component.
• Superseded ROM level in the • GO to Pinpoint Test A.
instrument cluster
• Fuel gauge pointer sticking at
times or does not move over
the complete range
• Instrument cluster not receiving
or processing input signals
correctly
• Recirculation hose incorrectly
routed
• Float arm obstructed or colli-
sion between the fuel fired
booster heater pipe (if
equipped) and the float arm
• Fuel tank does not reach
correct fuel level
• Fuel level resistor card
• Fuel gauge shows empty even • Fuel gauge pointer sticking at • GO to Pinpoint Test B.
when refilled times or does not move over
the complete range
• Open circuit
• Short circuit
• Instrument cluster not receiving
or processing input signals
correctly
• Fuel gauge shows 1/4, ½ or is • Fuel gauge pointer sticking at • GO to Pinpoint Test C.
stuck at a specific position times or does not move over
the complete range
2007.50 Focus 3/2007 G167234en


• Fuel gauge pointer delayed in • Fuel tank refilled with the igni- • Refilling with the ignition OFF
moving up when the fuel tank tion ON next time will cure the concern.
is refilled Do not install a new
component.
• Fuel gauge pointer sticking at • GO to Pinpoint Test D.
times or does not move over
the complete range
• Fuel gauge pointer fluctuates • Fuel gauge pointer sticking at • GO to Pinpoint Test E.
up and down while driving on times or does not move over
straight/flat roads the complete range
Pinpoint Tests
measurements.
PINPOINT TEST A : FUEL GAUGE SHOWS LESS THAN FULL (EVEN WHEN REFILLED/TRICKLE
FILLED)
A1: CHECK THE INSTRUMENT CLUSTER ROM LEVEL (HIGH SERIES INSTRUMENT CLUSTER
ONLY)
1 Carry out the instrument cluster Self-Diagnostic
Mode and scroll to the ROM LEVEL
• Is the ROM LEVEL 040D, 0422, 0423 or 0424?
→ Yes
REFER to the WDS. SELECT Toolbox/Module
Programming/Module Reprogramming/HEC.
FLASH the instrument cluster with ROM
LEVEL 0425 or later. Test the system for
normal operation.
→ No
GO to A2.
2007.50 Focus 3/2007 G167234en


A2: CHECK THE OPERATION OF THE FUEL GAUGE POINTER
NOTE: The fuel gauge pointer should move

smoothly from empty to full in 2.5 seconds. At the
maximum full position, the fuel gauge pointer must
be on the full mark and not below it.
Mode.
• Does the fuel gauge pointer operate correctly?
→ Yes
GO to A3.
→ No
REFER to the WDS. SELECT Guided
Diagnostic/Body/Instrument Panel and
Console/Instrument Cluster/Fuel Gauge and
follow the instructions on the display.
A3: CHECK THE INSTRUMENT CLUSTER IS RECEIVING AND PROCESSING INPUT SIGNALS
CORRECTLY
1 With the vehicle on level ground, fill the fuel tank
up to the 1st click on the fuel station filler nozzle,
making sure that at least 10 liters of fuel is
added (with the ignition switch OFF).
2 Make sure that the fuel gauge pointer is on the
FULL mark.
Mode and scroll to the FUEL A/D and the FUEL
PERCENT tests and note the readings.
• Is the FUEL A/D less than or equal to 17 with
the pointer showing FULL?
• Is the FUEL PERCENT greater than or equal
to 5F, 60, 61, 62, 63, 64 with the pointer
showing FULL?
→ Yes
Suspect fuel tank not filled correctly previ-
ously. Re-verify the customer concern.
→ No
GO to A4.
A4: CHECK THE FUEL GAUGE WIRING
1 Remove the instrument cluster.
2007.50 Focus 3/2007 G167234en


2 Measure the resistance between the instrument
cluster C809 pin 8, circuit 8-GA7 (WH/RD),
harness side and pin 7, circuit 9-GA7 (BN/RD),
harness side.
• Is the resistance less than 13.5 Ohms?
→ Yes
E83653
→ No
GO to A5.
A5: CHECK THAT THE FUEL REACHES THE CORRECT FILL LEVEL
NOTE: Make a note of the amount of fuel required

to reach the 3rd click on the fuel station filler nozzle.
1 Fill the fuel tank up to the 3rd click on the fuel
station filler nozzle.
• Does the fuel gauge pointer show FULL with
more than 3 liters of fuel added?
→ Yes
GO to A6.
→ No
If the amount of fuel added is less than 3 liters,
the customer may have refuelled at a fuel
station with a too high fill rate. Advise
customer to fill up to the 3rd click on the fuel
station filler nozzle. Do not install a new
component.
If the fuel gauge pointer still shows less than
FULL, Vehicles with fuel fired booster heater
GO to A7. Vehicles without fuel fired booster
heater GO to A8.
A6: CHECK THE ROUTING OF THE RECIRCULATION HOSE
1 Raise and support the vehicle.
REFER to: Lifting (100-02 Jacking and Lifting,
2007.50 Focus 3/2007 G167234en


2 Inspect the recirculation hose routing to make
sure that the top of the hose is not lower than
the valve on the fuel tank.
• Is the recirculation hose correctly routed?
→ Yes
Vehicles with fuel fired booster heater GO to
A7.
Vehicles without fuel fired booster heater GO
to A8.
E83714 → No
INSTALL the recirculation hose correctly. Test
A7: CHECK THE ORIENTATION OF THE FUEL FIRED BOOSTER HEATER PORT (IF EQUIPPED)
1 Remove the fuel tank.
REFER to: Fuel Tank - 2.0L Duratec-HE
(MI4)/1.6L Duratec-16V (Sigma)/1.6L Duratec-
16V Ti-VCT (Sigma)/1.8L Duratec-HE
(MI4)/2.5L Duratec-ST (VI5), Vehicles Without:
Fuel Fired Booster Heater (310-01 Fuel Tank
and Lines, Removal and Installation)
Vehicles With: Fuel Additive Tank, Vehicles
Without: Fuel Fired Booster Heater (310-01
Fuel Tank and Lines, Removal and Installa-
tion)
Duratorq-TDCi (DW) Diesel, Vehicles Without:
Fuel Fired Booster Heater/Fuel Additive Tank
(310-01 Fuel Tank and Lines, Removal and
Installation).
2 Check that the fuel fired booster heater port
locating pin is correctly located into the slot.
• Is the fuel fired booster heater port correctly
installed?
→ Yes
GO to A8.
→ No
INSTALL the fuel fired booster heater port
correctly. Test the system for normal opera-
E83675 tion.
2007.50 Focus 3/2007 G167234en


A8: TEST THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR
1 Measure the resistance between the fuel pump
and sender unit/fuel level sensor C732 pin 2,
component side and pin 4, component side with
the fuel tank upright on a level surface and with
the fuel tank inverted on a level surface.
• Is the resistance between 200 Ohms and 206
Ohms with the fuel tank in the upright position
and between 7.7 Ohms and 9.3 Ohms in the
inverted position?
→ Yes
E83280
INSTALL the fuel tank.
Duratec-16V Ti-VCT (Sigma)/1.8L Duratec-
HE (MI4)/2.5L Duratec-ST (VI5), Vehicles
tion)
tion)
Test the system for normal operation.
→ No
GO to A9.
A9: FLOAT ARM OBSTRUCTED OR COLLISION BETWEEN THE FUEL FIRED BOOSTER HEATER
PIPE (IF EQUIPPED) AND THE FLOAT ARM.
1 Remove the fuel pump and sender unit/fuel level
sensor.
2007.50 Focus 3/2007 G167234en


2 Check whether the fuel fired booster heater pipe
(if equipped) or any foreign material is
obstructing the float arm.
E83680
3 Check for any foreign material or obstruction

that prevents the float arm from moving
correctly.
• Is there any sign of foreign material or causes
of obstruction?
→ Yes
REMOVE the foreign material or the cause of
the obstruction. Test the system for normal
operation.
→ No
GO to A10.
A10: TEST THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR
the float arm at the empty and the full positions.
Ohms with the float in the empty position and
between 7.7 Ohms and 9.3 Ohms in the full
position?
→ Yes
INSTALL the original fuel pump and sender
E83280
unit/fuel level sensor. Test the system for
normal operation.
→ No
INSTALL a new fuel level resistor card.
REFER to: Fuel Level Resistor Card (310-01
tion).
2007.50 Focus 3/2007 G167234en

PINPOINT TEST B : FUEL GAUGE SHOWS EMPTY EVEN WHEN REFILLED
B1: CHECK THE OPERATION OF THE FUEL GAUGE POINTER

Mode.
→ Yes
GO to B2.
→ No
B2: CHECK THE INSTRUMENT CLUSTER FOR OPEN CIRCUIT DTC
1 Using the WDS, check for DTC B1202 or carry
out the instrument cluster Self-Diagnostic Mode
and check for DTC 9202.
• Is DTC B1202 or DTC 9202 displayed?
→ Yes
GO to B3.
→ No
GO to B7.
B3: CHECK THE INSTRUMENT CLUSTER WIRING FOR OPEN CIRCUIT
2007.50 Focus 3/2007 G167234en


harness side.
• Is the resistance greater than 218 Ohms?
→ Yes
GO to B4.
→ No
CHECK the electrical connector for corrosion
E83653 and a secure connection, if OK, REFER to the
WDS. SELECT Guided
B4: TEST THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR
tion)
Installation).
the float arm at the empty and the full positions.
• Is the resistance greater than 218 Ohms?
→ Yes
E83280 tion).
→ No
GO to B5.
2007.50 Focus 3/2007 G167234en


B5: CHECK CIRCUITS 8-GA7 (WH/RD) AND 9-GA7 (BN/RD) FOR OPEN CIRCUIT
• instrument cluster C809 pin 8, circuit 8-GA7
(WH/RD), harness side and the fuel pump and
sender unit/fuel level sensor C732 pin 2, circuit
8-GA7 (WH/RD), harness side.
• instrument cluster C809 pin 7, circuit 9-GA7
(BN/RD), harness side and the fuel pump and
sender unit/fuel level sensor C732 pin 4, circuit
9-GA7 (BN/RD), harness side.
• Are the resistances less than 1 Ohm?
E83682
→ Yes
GO to B6.
→ No
REPAIR circuit 8-GA7 (WH/RD) or circuit 9-
GA7 (BN/RD) as necessary. Test the system
B6: CHECK THE INSTRUMENT CLUSTER FOR SHORT CIRCUIT DTC
1 Using the WDS, check for DTC B1202 or carry
out the instrument cluster Self-Diagnostic Mode
and check for DTC 9202.
• Is DTC B1204 or DTC 9204 displayed?
→ Yes
GO to B7.
→ No
GO to B9.
B7: CHECK THE FUEL GAUGE WIRING
harness side.
• Is the resistance less than 5 Ohms?
→ Yes
GO to B8.
→ No
E83653 Diagnostic/Body/Instrument Panel and
2007.50 Focus 3/2007 G167234en


B8: TEST THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR
component side and pin 4, component side.
→ Yes
tion).
E83280 Test the system for normal operation.
→ No
GO to B9.
B9: CHECK THE INSTRUMENT CLUSTER IS PROCESSING INPUT SIGNALS CORRECTLY
Mode and scroll to the FUEL A/D and the FUEL
PERCENT tests and note the readings.
• Is the FUEL A/D greater than or equal to 181
with the pointer showing FULL?
• Is the FUEL PERCENT less than or equal to
08 with the pointer showing FULL?
→ Yes
Suspect fuel tank not filled correctly previ-
ously. Re-verify the customer complaint.
→ No
GO to B10.
B10: FLOAT ARM OBSTRUCTED OR COLLISION BETWEEN THE FUEL FIRED BOOSTER HEATER
sensor.
E83680
2007.50 Focus 3/2007 G167234en


correctly.
of obstruction?
→ Yes
operation.
→ No
tion).
PINPOINT TEST C : FUEL GAUGE SHOWS 1/4, ½ OR IS STUCK AT A SPECIFIC POSITION

C1: CHECK THE OPERATION OF THE FUEL GAUGE POINTER

Mode.
→ Yes
Vehicles with fuel fired booster heater, GO to
C2.
Vehicles without fuel fired booster heater, GO
to C3.
→ No
2007.50 Focus 3/2007 G167234en


C2: CHECK THE ORIENTATION OF THE FUEL FIRED BOOSTER HEATER PORT (IF EQUIPPED)
tion)
Installation).
installed?
→ Yes
GO to C3.
→ No
E83675 tion.
2007.50 Focus 3/2007 G167234en


C3: TEST THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR
tion)
Installation).
2007.50 Focus 3/2007 G167234en


inverted position?
→ Yes
E83280
tion)
tion)
→ No
GO to C4.
C4: FLOAT ARM OBSTRUCTED OR COLLISION BETWEEN THE FUEL FIRED BOOSTER HEATER
sensor.
2007.50 Focus 3/2007 G167234en


E83680

correctly.
of obstruction?
→ Yes
operation.
→ No
tion).
2007.50 Focus 3/2007 G167234en

PINPOINT TEST D : FUEL GAUGE POINTER DELAYED IN MOVING UP WHEN THE FUEL TANK IS
REFILLED
D1: CHECK THE OPERATION OF THE FUEL GAUGE POINTER

Mode.
→ Yes
D2.
to D3.
→ No
D2: CHECK THE ORIENTATION OF THE FUEL FIRED BOOSTER HEATER PORT (IF EQUIPPED)
tion)
Installation).
2007.50 Focus 3/2007 G167234en


installed?
→ Yes
GO to D3.
→ No
E83675 tion.
D3: TEST THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR
tion)
Installation).
2007.50 Focus 3/2007 G167234en


inverted position?
→ Yes
E83280
tion)
tion)
→ No
GO to D4.
D4: FLOAT ARM OBSTRUCTED OR COLLISION BETWEEN THE FUEL FIRED BOOSTER HEATER
sensor.
2007.50 Focus 3/2007 G167234en


E83680

correctly.
of obstruction?
→ Yes
operation.
→ No
tion).
2007.50 Focus 3/2007 G167234en

PINPOINT TEST E : FUEL GAUGE POINTER FLUCTUATES UP AND DOWN WHILE DRIVING ON
STRAIGHT/FLAT ROADS
E1: CHECK THE OPERATION OF THE FUEL GAUGE POINTER

Mode.
→ Yes
E2.
to E3.
→ No
E2: CHECK THE ORIENTATION OF THE FUEL FIRED BOOSTER HEATER PORT (IF EQUIPPED)
tion)
Installation).
2007.50 Focus 3/2007 G167234en


installed?
→ Yes
GO to E3.
→ No
E83675 tion.
E3: TEST THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR
tion)
Installation).
2007.50 Focus 3/2007 G167234en


inverted position?
→ Yes
E83280
tion)
tion)
→ No
GO to E4.
E4: FLOAT ARM OBSTRUCTED OR COLLISION BETWEEN THE FUEL FIRED BOOSTER HEATER
sensor.
2007.50 Focus 3/2007 G167234en


E83680

correctly.
of obstruction?
→ Yes
operation.
→ No
tion).
2007.50 Focus 3/2007 G167234en

PINPOINT TEST F : VEHICLE RUNS OUT OF FUEL BUT THE FUEL GAUGE INDICATES A QUANTITY
OF FUEL LEFT IN THE FUEL TANK
F1: CHECK THE OPERATION OF THE FUEL GAUGE POINTER

Mode.
→ Yes
F2.
to F3.
→ No
F2: CHECK THE ORIENTATION OF THE FUEL FIRED BOOSTER HEATER PORT (IF EQUIPPED)
tion)
Installation).
2007.50 Focus 3/2007 G167234en


installed?
→ Yes
GO to F3.
→ No
E83675 tion.
F3: TEST THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR
tion)
Installation).
2007.50 Focus 3/2007 G167234en


inverted position?
→ Yes
E83280
tion)
tion)
→ No
GO to F4.
F4: FLOAT ARM OBSTRUCTED OR COLLISION BETWEEN THE FUEL FIRED BOOSTER HEATER
sensor.
2007.50 Focus 3/2007 G167234en


E83680

correctly.
of obstruction?
→ Yes
operation.
→ No
tion).
Configuration of the Instrument Cluster The following features will need to be configured
when a new instrument cluster is installed:
The instrument cluster is a programmable module, • Anti-lock Brake System (ABS)
which must be configured by selecting the
Programmable Module Installation Routine on the • All wheel drive
WDS. • Keyless vehicle entry
NOTE: When the new instrument cluster has been • Electronic power assisted steering
configured with the odometer value, its • Trip computer
configuration cannot be decreased or matched. A • Voice control
new configuration will result in an increase in the • Parking aid
displayed odometer value by a minimum of two
• Belt minder
units.
• Safety belt not fastened
NOTE: The odometer value must be recorded from
• Right hand drive
the original instrument cluster before removal.
• Overspeed warning
If the odometer value cannot be obtained from
• Reverse warning
the original instrument cluster (display failure)
the customer should supply the approximate • Turbocharger boost pressure
value. • Speed control
• Auxiliary heater
2007.50 Focus 3/2007 G167234en

• Suspension control
• Washer fluid sensor
• Navigation
• Fuel cap release
• Engine type
• Display language
In addition the new instrument cluster will require
the original odometer value to be entered.
After the installation and configuration of a new
instrument cluster. The passive anti-theft system
(PATS) will require programming by selecting the
Security Access routine on the WDS.
2007.50 Focus 3/2007 G167234en

Instrument Cluster
Special Tool(s) NOTE: If a new instrument cluster is to be
Remover, Door Trim Panel installed, connect WDS and upload the instrument
501-028A (43-001A) cluster configuration information using the
programmable modules installation routine prior to
commencing the removal of the instrument cluster.
NOTE: If a new instrument cluster is to be
installed, the odometer value must be recorded
43001A from the original instrument cluster before removal
as this will be required when configuring the new
CAUTION: At no time should the battery instrument cluster. If the odometer value cannot
positive terminal be connected with the be obtained from the instrument cluster (display
audio unit disconnected. The clock failure), the customer should supply the
function of the audio unit is controlled by approximate odometer value.
communication with the instrument cluster 1. Disconnect the battery ground cable.
via the control area network (CAN). If the
battery positive terminal is connected with For additional information, refer to: Battery
the audio unit disconnected, the Disconnect and Connect (414-01 Battery,
instrument cluster will cancel the clock Mounting and Cables, General Procedures).
function and --:-- will be displayed when 2. Remove the components in the order
the audio unit is installed. indicated in the following illustration(s) and
table(s).
2007.50 Focus 3/2007 G295919en

5 3
6
2
1
E39786
1 Steering column adjustment lever 5 Instrument cluster

2 Instrument cluster bezel gaiter to steering 6 Instrument cluster electrical connector

column upper shroud See Removal Detail
3 Instrument cluster bezel 3. To install, reverse the removal procedure.

See Removal Detail NOTE: If a new instrument cluster is being
4 Instrument cluster retaining screws installed, connect WDS and download the
instrument cluster configuration information to the
newly installed instrument cluster using the
programmable modules installation routine.
2007.50 Focus 3/2007 G295919en

NOTE: If a new instrument cluster is being installed instrument cluster to the PATS system.
installed, connect WDS and configure the newly
Removal Details
Item 1 Steering column adjustment lever 2. Detach the self locating electrical connector.
1. Adjust the steering column to its maximum
extension and lowest position.
Item 3 Instrument cluster bezel 1
VUE0032757
E39787
1. Pull the instrument cluster bezel forward.
Item 5 Instrument cluster

CAUTION: Make sure the instrument
cluster lens is protected by a clean soft
cloth. Failure to follow this instruction may
result in damage to the instrument cluster
lens.
1. Using the special tool, detach the instrument
cluster from the instrument panel.
E44139
Item 6 Instrument cluster electrical connector

1. Disconnect the instrument cluster electrical
connector.
1. Press the locking tang.
2007.50 Focus 3/2007 G295919en

413-06-1 Horn 413-06-1
.
SECTION 413-06 Horn

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 413-06-2

Horn.................................................................................................................................... 413-06-3
Pinpoint Tests..................................................................................................................... 413-06-3

Horn.................................................................................................................................... 413-06-11
Horn Switch.................................................................................................... (33 523 0) 413-06-12
413-06-2 Horn 413-06-2
SPECIFICATIONS

Horn retaining bolt 25 18 -
2007.50 Focus 3/2007 G167236en

413-06-3 Horn 413-06-3
Horn
Principles of Operation Visual Inspection Chart
The horn system consists of a relay, a steering Electrical
wheel switch and two horns. The horns receive • Fuse(s)
voltage from the switched side of the relay, and
• Wiring harness
the relay switch is controlled on its ground side by
the steering wheel switch. • Electrical connector(s)
• Horn switch
The horn relay, is located in the Battery junction
box (BJB) and is supplied with a permanent voltage • Horns
from the battery. • Clockspring
The steering wheel horn switch shares the steering • Horn relay
wheel clockspring circuit with the air-bag circuit. • BJB
Each of these systems work completely
independent of each other. 3. If an obvious cause for an observed or reported
Inspection and Verification before proceeding to the next step.
1. Verify the customer concern. symptom and refer to the Symptom Chart.
Symptom Chart
• The horns are inoperative • Circuit(s). • GO to Pinpoint Test A.
• Horns.
• Horn relay.
• Clockspring.
• Horn switch.
• The horns are always on • Horn relay. • GO to Pinpoint Test B.
• Horn switch.
• Circuit(s).
• Clockspring.
• One horn is inoperative • Circuit(s). • GO to Pinpoint Test C.
• Horns.
Pinpoint Tests
PINPOINT TEST A : THE HORN IS INOPERATIVE
A1: CHECK POWER TO THE HORN
1 Disconnect Horn C72.
2007.50 Focus 3/2007 G461798en

413-06-4 Horn 413-06-4

3 Measure the voltage between the horn C73 pin
1, circuit 29S-GJ1B (OG/BU), harness side and
ground while pressing the horn switch.
→ Yes
GO to A2.
→ No
GO to A3.
A2: CHECK GROUND TO THE HORN

3 Measure the resistance between the horn C74
pin 1, circuit 31-GJ1C (BK), harness side and
ground.
→ Yes
INSTALL new horns.
REFER to: Horn (413-06 Horn, Removal and
Installation).
→ No
REPAIR circuit 31-GJ1C (BK). TEST the
A3: CHECK POWER TO THE HORN RELAY
1 Disconnect Horn Relay C1002.
2 Measure the voltage between the horn relay
C1002 pin 1, harness side and ground; and horn
relay C1002 pin 3, harness side and ground.
• Are the voltages greater than 10 volts?
→ Yes
GO to A4.
→ No
INSTALL a new BJB. TEST the system for
normal operation.
2007.50 Focus 3/2007 G461798en

413-06-5 Horn 413-06-5

A4: CHECK HORN SWITCH CIRCUIT FOR OPEN CIRCUIT
1 Measure the resistance between the horn relay
C1002 pin 2, circuit 91S-GJ7 (BK/BU), harness
side and ground while pressing the horn switch.
→ Yes
GO to A5.
→ No
GO to A6.
A5: CHECK CIRCUIT 29S-GJ1 (OG/BU) FOR OPEN CIRCUIT

1 Measure the resistance between the horn relay
C1002 pin 5, circuit 29S-GJ1 (OG/BU), harness
side and horn C73 pin 1, circuit 29S-GJ1B
(OG/BU), harness side.
→ Yes
INSTALL a new horn relay. TEST the system
→ No
normal operation.
A6: CHECK CIRCUIT 91S-GJ7 (BK/BU) FOR OPEN CIRCUIT
WARNING: To deactivate the driver air bag, refer to the procedure in section 501-20B for
the correct air bag deactivation procedure. Failure to follow this instruction, may result in
personal injury.

2 Measure the resistance between the clockspring
side and horn relay C1002 pin 2, circuit 91S-
GJ7 (BK/BU), harness side.
→ Yes
GO to A7.
→ No
normal operation.
2007.50 Focus 3/2007 G461798en

413-06-6 Horn 413-06-6

A7: CHECK CIRCUIT 91-PG30 (BK/WH) FOR OPEN CIRCUIT
C896 pin 7, circuit 91-PG30 (BK/WH), harness
side and ground.
→ Yes
GO to A8.
→ No
normal operation.
A8: CHECK THE HORN SWITCH

1 Detach the drivers air bag module.
REFER to: Driver Air Bag Module (501-20
Supplemental Restraint System, Removal and
Installation).
C921 pin 4, Harness side and clockspring C921
pin 5, harness side while pressing the horn
switch.
→ Yes
REFER to: Clockspring (501-20 Supplemental
Restraint System, Removal and Installation).
→ No
INSTALL a new driver air bag module.
Supplemental Restraint System, Removal
and Installation).
2007.50 Focus 3/2007 G461798en

413-06-7 Horn 413-06-7
PINPOINT TEST B : THE HORN IS ALWAYS ON
B1: CHECK CIRCUIT 29S-GJ1B (OG/BU) FOR SHORT TO BATTERY POSITIVE
1 Disconnect Horn Relay C1002.
• Do the horns stop sounding with the horn relay
C1002 disconnected?
→ Yes
GO to B2.
→ No
normal operation.
B2: CHECK THE HORN SWITCH CIRCUIT FOR CONTINUITY
WARNING: To deactivate the driver air bag, refer to the procedure in section 501-20B for
the correct air bag deactivation procedure. Failure to follow this instruction, may result in
personal injury.

C896 pin 6, circuit 91S-GJ7 (BK/BU),
component side and clockspring C896 pin 7,
circuit 91-PG30 (BK/WH), component side.
→ Yes
GO to B3.
→ No
VUE0031959
and Installation).
B3: CHECK HORN SWITCH CIRCUIT FOR SHORT TO GROUND
component side and ground.
→ Yes
GO to B4.
→ No
GO to B5.
VUE0031958
2007.50 Focus 3/2007 G461798en

413-06-8 Horn 413-06-8

B4: CHECK CIRCUIT 91S-GJ7 FOR SHORT TO GROUND
side and ground.
→ Yes
INSTALL a new horn relay. TEST the system
→ No
normal operation.
B5: CHECK THE CLOCKSPRING FOR A SHORT TO GROUND

component side and ground.
→ Yes
and Installation).
→ No
REFER to: Clockspring (501-20 Supplemental
Restraint System, Removal and Installation).
PINPOINT TEST C : ONE HORN IS INOPERATIVE

C1: CHECK HORN H1 FOR CORRECT OPERATION
2007.50 Focus 3/2007 G461798en

413-06-9 Horn 413-06-9

3 Press the horn switch.
• Does the horn (H4) sound with the horn (H1)
disconnected?
→ Yes
INSTALL a new horn (H1).
Installation).
→ No
GO to C2.
C2: CHECK HORN H4 FOR CORRECT OPERATION
3 Connect Horn C73.
NOTE: Connect the horn electrical connector to
horn (H4) instead of horn (H1).
4 Connect Horn C74.

NOTE: Connect the horn electrical connector to
horn (H4) instead of horn (H1).
5 Press the horn switch.

• Does the horn (H4) sound with the horn (H1)
disconnected?
→ Yes
GO to C3.
→ No
INSTALL a new horn (H4).
Installation).
C3: CHECK CIRCUIT 29S-GJ1C FOR OPEN CIRCUIT
2007.50 Focus 3/2007 G461798en

413-06-10 Horn 413-06-10

2 Measure the resistance between the horn C73
pin 1, circuit 29S-GJ1B (OG/BU), harness side
and horn C72 pin 1, circuit 29S-GJ1C (OG/BU),
harness side.
→ Yes
REPAIR the circuit 31-GJ1B (BK). TEST the
→ No
REPAIR the circuit 29S-GJ1C (OG/BU). TEST
2007.50 Focus 3/2007 G461798en

413-06-11 Horn 413-06-11
Horn
and Operation).

table(s).
Item Description
1 Horn electrical connectors
2 Horn wiring harness retaining clip
3 Horn
2007.50 Focus 3/2007 G461799en

413-06-12 Horn 413-06-12
Horn Switch(33 523 0)

1. The horn switch is an integral part of the
drivers air bag module. Remove the driver
air bag module. For additional information,
refer to Section 501-20A [Safety Belt System]
/ 501-20B [Supplemental Restraint System].
2007.50 Focus 3/2007 G167240en

413-07-1 Clock 413-07-1
.
SECTION 413-07 Clock

CONTENTS PAGE

Clock................................................................................................................................... 413-07-2

Clock............................................................................................................... (33 374 0) 413-07-3
413-07-2 Clock 413-07-2
Clock
NOTE: The clock and instrument cluster are one
component and can not be diagnosed separately.
REFER to Section 413-01 [Instrument Cluster].
2007.50 Focus 3/2007 G167257en

413-07-3 Clock 413-07-3
Clock(33 374 0)
1. NOTE: The clock and instrument cluster are
one component and can not be removed
separately.
Section 413-01 [Instrument Cluster].
2007.50 Focus 3/2007 G328600en

413-08-1 Information and Message Center 413-08-1
.
SECTION 413-08 Information and Message Center

CONTENTS PAGE

Information and Message Center....................................................................................... 413-08-2

Message Center............................................................................................. (33 367 0) 413-08-3
Information and Message Center

NOTE: The information and message center and
the instrument cluster are one component and can
not be diagnosed separately.
REFER to Section 413-01 [Instrument Cluster].
2007.50 Focus 3/2007 G167260en

Message Center(33 367 0)

NOTE: The message center and the instrument
cluster are one component and can not be removed
separately.
1. Remove the instrument cluster. For
Section 413-01 [Instrument Cluster].
2007.50 Focus 3/2007 G167261en

413-09-1 Warning Devices 413-09-1
.
SECTION 413-09 Warning Devices

CONTENTS PAGE

Warning Devices................................................................................................................. 413-09-2
Symptom Chart................................................................................................................... 413-09-2
GENERAL PROCEDURES
Safety Belt Minder Deactivating/Activating......................................................................... 413-09-5
Preparation......................................................................................................................... 413-09-5
Deactivating/Activating....................................................................................................... 413-09-5
Warning Devices
Refer to Wiring Diagrams Section 501-20A, for 3. If an obvious cause for an observed or reported
schematic and connector information. concern is found, correct the cause (if possible)
General Equipment before proceeding to the next step.
Worldwide Diagnostic System (WDS) 4. If the cause is not visually evident, retrieve the
Diagnostic Trouble Codes (DTCs) using
Worldwide Diagnostic System (WDS).
Inspection and Verification 5. If DTC B2433 is displayed by WDS.
REFER to: Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS)
2. Visually inspect for obvious signs of mechanical (501-20B Supplemental Restraint System,
or electrical damage. Diagnosis and Testing).
Visual Inspection Chart 6. If no DTCs are displayed relating to the
symptom, refer to the Symptom Chart.
– Safety belt buckle – Wiring harness
– Electrical
connector(s)
– Safety belt buckle
switch
– Restraints control
module
Symptom Chart
Symptom Chart
• The safety belt indicator does • Driver safety belt buckle switch. • GO to Pinpoint Test A.
not illuminate • Circuit(s).
• Restraints Control Module
(RCM).
• The safety belt indicator is illu- • Driver safety belt buckle switch. • GO to Pinpoint Test B.
minated continuously • Circuit(s).
• RCM.
PINPOINT TEST A : THE SAFETY BELT INDICATOR DOES NOT ILLUMINATE

A1: CHECK THE SAFETY BELT BUCKLE SWITCH CIRCUIT FOR OPEN CIRCUIT
WARNING: To avoid accidental deployment, the RCM backup power supply must be depleted.
Wait at least one minute after disconnecting the battery ground cable(s) before commencing
any repair or adjustment to the supplemental restraint system (SRS), or any component(s)
adjacent to the SRS sensors. Failure to follow these instructions may result in personal
injury.
1 Deactivate the SRS.

2 Unfasten the driver safety belt.
2007.50 Focus 3/2007 G410786en


3 Disconnect Restraints Control Module (RCM)
C423.
4 Measure the resistance between the RCM C423
pin 25, circuit 8-JA54 (WH), harness side and
C423 pin 34, circuit 9-JA54 (BN), harness side.
→ Yes
INSTALL a new RCM.
REFER to: Restraints Control Module (RCM)
(501-20 Supplemental Restraint System,
E51623 TEST the system for normal operation.
→ No
GO to A2.
A2: CHECK CIRCUIT 8-JA54 (WH) FOR OPEN CIRCUIT
1 Disconnect Safety Belt Buckle Switch C335.
2 Measure the resistance between the driver seat
C30 pin 14, circuit 8-JA54 (WH), harness side
and the RCM C423 pin 25, circuit 8-JA54 (WH),
harness side.
→ Yes
GO to A3.
→ No
REPAIR circuit 8-JA54 (WH). TEST the
E51624 system for normal operation.
A3: CHECK CIRCUIT 9-JA54 (BN) FOR OPEN CIRCUIT

1 Measure the resistance between the drivers
seat C30 pin 13, circuit 9-JA54 (BN), harness
side and the RCM C423, pin 34 (BN) harness
side.
→ Yes
INSTALL a new driver safety belt buckle and
pretensioner.
REFER to: Safety Belt Buckle and Preten-
E51625 sioner (501-20 Safety Belt System, Removal
and Installation).
→ No
REPAIR circuit 9-JA54 (BN). TEST the system
2007.50 Focus 3/2007 G410786en

PINPOINT TEST B : THE SAFETY BELT INDICATOR IS ILLUMINATED CONTINUOUSLY.
B1: CHECK THE DRIVER SAFETY BELT SWITCH
WARNING: To avoid accidental deployment, the RCM backup power supply must be depleted.
Wait at least one minute after disconnecting the battery ground cable(s) before commencing
any repair or adjustment to the SRS, or any component(s) adjacent to the SRS sensors.
Failure to follow these instructions may result in personal injury.
1 Deactivate the SRS.

3 Disconnect Safety Belt Buckle Switch C335.
• Is the safety belt indicator illuminated?
→ Yes
GO to B2.
→ No
INSTALL a new safety belt buckle and
pretensioner.
REFER to: Safety Belt Buckle and Preten-
sioner (501-20 Safety Belt System, Removal
and Installation).
B2: CHECK CIRCUIT 8-JA54 (WH) AND FOR SHORT TO GROUND
2 Disconnect RCM C423.
3 Measure the resistance between the RCM C423
pin 25, circuit 8-JA54 (WH), harness side and
ground.
→ Yes
INSTALL a new RCM.
REFER to: Restraints Control Module (RCM)
(501-20 Supplemental Restraint System,
→ No
REPAIR circuit 8-JA54. TEST the system for
normal operation.
2007.50 Focus 3/2007 G410786en

GENERAL PROCEDURES
Safety Belt Minder Deactivating/Activating

Preparation
1. Apply the parking brake.
2. Place the transmission selector lever in P
(Park) - vehicles with automatic transmission
or the neutral position - vehicles with manual
transmission.
3. Turn the ignition switch to the 0 position.
4. Close all the vehicle doors from the inside
of the vehicle.
5. Unbuckle the drivers safety belt.
Deactivating/Activating
NOTE: Deactivation of the belt minder may also
be carried out using WDS. Follow the instructions
on the screen.
1. Turn the ignition switch to position II. (Do
not start the engine).
2. The safety belt warning indicator will
extinguish within 10 seconds.
3. NOTE: Step 3 must be completed within 60
seconds or the procedure must be repeated.
Buckle then unbuckle the safety belt nine
times, ending with the safety belt unbuckled.
4. The safety belt warning indicator flashes
three times to confirm the belt minder status
change.
5. To activate the belt minder, repeat Steps 1
through 3.
6. After confirmation, the
deactivation/activation procedure is
complete.
2007.50 Focus 3/2007 G167271en

413-13-1 Parking Aid 413-13-1
.
SECTION 413-13 Parking Aid

CONTENTS PAGE

Parking Aid......................................................................................................................... 413-13-2
Component location............................................................................................................ 413-13-2
Description and operation................................................................................................... 413-13-4
Front and rear parking aid speaker.................................................................................... 413-13-4
Rear parking aid speaker................................................................................................... 413-13-5
Parking aid module............................................................................................................. 413-13-5
Front parking aid activate/deactivate switch....................................................................... 413-13-5
Front parking aid sensors................................................................................................... 413-13-6
Rear parking aid sensors.................................................................................................... 413-13-7

Parking Aid......................................................................................................................... 413-13-8
Pinpoint Tests..................................................................................................................... 413-13-9
GENERAL PROCEDURES
Azimuth System Check....................................................................................................... 413-13-27
Rear Parking Aid................................................................................................................ 413-13-27
Elevation System Check..................................................................................................... 413-13-29
Rear Parking Aid................................................................................................................ 413-13-29

Parking Aid Speaker........................................................................................................... 413-13-31
Parking Aid Module............................................................................................................. 413-13-37
413-13-2 Parking Aid 413-13-2
Parking Aid
Component location
4-Door
1 2 3 4
7 6 5
E92175
1 Front parking aid sensor and holder. 4 Parking aid module.
2 Rear parking aid speaker. 5 Rear parking aid sensor(s) and holder(s).
3 Front and rear parking aid speaker(s).
2007.50 Focus 3/2007 G964150en

413-13-3 Parking Aid 413-13-3

6 Front parking aid activate/deactivate 7 Front parking aid sensor and holder.
switch.
5-Door
1 2 3 4
7 6 5
E92171
1 Front parking aid sensor and holder. 5 Rear parking aid sensor(s) and holder(s).
2 Rear parking aid speaker. 6 Front parking aid activate/deactivate

switch.
3 Front and rear parking aid speaker(s).
7 Front parking aid sensor and holder.
4 Parking aid module.
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413-13-4 Parking Aid 413-13-4
Description and operation If, after the initial detection of an object, there is no
decrease in distance between the object and the
Two levels of parking aid system are available, a vehicle, the audible status of the warning tones
rear parking aid system or a front and rear parking remain constant.
aid system. The parking aid module continues to monitor the
The parking aid system provides an audible distance and will resume emitting the appropriate
warning to the driver when any obstacles are in warning tones through the parking aid speaker(s)
the path of the vehicle during forward or reverse if a decrease in distance is detected.
parking manoeuvres. The parking aid system The front parking aid system is
consists of three ultrasonic parking aid sensors activated/deactivated when the driver presses the
and holders in the rear bumper and two ultrasonic front parking aid activate/deactivate switch.
parking aid sensors and holders in the front
bumper, a parking aid module, parking aid The parking aid system can detect when a trailer
speaker(s) and a front parking aid is connected to the vehicle by a message output
activate/deactivate switch. on the medium speed controller area network
(CAN) bus. When the parking aid module detects
At low speeds, the parking aid module uses the that a trailer is connected to the vehicle, the rear
parking aid sensors to monitor the area around the parking aid sensors are disabled to prevent
front and rear bumpers. If an object is detected constant warnings due to the close proximity of the
within a monitored area, the parking aid module trailer.
outputs a warning tone using the parking aid
speaker(s). Objects very close to the ground may
not be detected, but because of their low height Front and rear parking aid speaker
will not cause damage to the vehicle.
The parking aid module communicates through
discrete signals with the parking aid speaker(s).
The parking aid speaker(s) output the applicable
warning tones when an object is detected.
In the combined mode, the parking aid sensor emit
a series of ultrasonic impulses and switch to
receiver mode to receive the echo reflected by an
obstacle within the detection range. The received
echo signals are amplified and converted from an
analogue signal to a digital signal by the parking
aid sensor. The digital signal is passed to the E92172
parking aid module and compared with
pre-programmed data stored in an EEPROM within For vehicles with four doors, the front and rear
the parking aid module. The parking aid module parking aid speaker is located behind the trim panel
receives this data through the signal line from the adjacent to the right-hand side of the rear seat
parking aid sensor and calculates the distance from backrest. For vehicles with five doors, the front and
the object using the elapsed time between the rear parking aid speaker is located behind the
transmitted and received impulse. parcel shelf right-hand support panel.
In receiver mode, the parking aid sensor receive For additional information, refer to: Parking Aid
impulses that were emitted by adjacent parking aid Speaker (413-13 Parking Aid, Removal and
sensor(s). The parking aid module uses this Installation).
information to determine the distance of the object.
If no objects are detected, there are no further
warning tones. If an object is detected, repeated
audible tones are emitted from the parking aid
speaker(s) as appropriate. The time delay between
the tones decreases as the distance between the
object and the vehicle decreases, until at
approximately 250 mm (10 inches), the audible
tone becomes continuous.
2007.50 Focus 3/2007 G964150en

413-13-5 Parking Aid 413-13-5
Rear parking aid speaker activate/deactivate switch and parking aid
speaker(s). The parking aid module is located
behind the right-hand loadspace trim panel.
For additional information, refer to: Parking Aid
Module (413-13 Parking Aid, Removal and
Installation).
The parking aid module carries out self-check
routines and when the parking aid system is active,
checks the parking aid sensor wiring for short or
open circuits. If a concern is detected, a diagnostic
trouble code (DTC) is stored in a memory in the
parking aid module and the front and rear parking
E92170
aid sensors will be disabled until the DTC is cleared
and the ignition cycled. The driver is made aware
For vehicles with four doors, the rear parking aid of any concern condition by a continuous warning
speaker is located behind the trim panel adjacent tone being emitted for 3 seconds when the parking
to the right-hand side of the rear seat backrest. For aid system is activated, in place of the normal short
vehicles with five doors, the rear parking aid tones when the parking aid system is functioning
speaker is located behind the parcel shelf normally. DTCs can be read using the Ford
right-hand support panel. approved diagnostic tool through the data link
connector (DLC).
For additional information, refer to: Parking Aid
Speaker (413-13 Parking Aid, Removal and
Installation). Front parking aid activate/deactivate
switch
Parking aid module
E92169
E92174 The front parking aid activate/deactivate switch is

located within the instrument panel, below the
The parking aid module has one electrical
climate control assembly.
connector which provides connection for power,
ground and CAN bus connections, front and rear The front parking aid activate/deactivate switch is
parking aid sensors, front parking aid a non-latching push switch which allows the driver
to select the front parking aid system on or off.
When pressed, the front parking aid
activate/deactivate switch momentarily connects
a ground to the parking aid module.
2007.50 Focus 3/2007 G964150en

413-13-6 Parking Aid 413-13-6
Front parking aid sensors
4-Door and 5-Door
E92178
Each parking aid sensor consists of the following:

Item Description
• a plastic housing
1 Front parking aid sensor(s).
• an aluminium membrane which contains a piezo
2 Front parking aid sensor holder(s). electric disc
• a decoupling ring which may be a separate
The parking aid sensor consists of a sensor and a
component from the sensor or over-moulded to
holder. The holder makes sure that each parking
the sensor membrane
aid sensor is correctly orientated in relation to its
location in the rear bumper. The disc resonates at a frequency of ca. 50kHz,
producing the ultrasonic output. The disc also
Each parking aid sensor has a three pin connector
receives the reflected echo signal from any objects
which connects with the rear bumper wiring
within range.
harness, which in turn is connected to the main
body wiring harness. Three pins provide for power
supply, ground and signal lines to and from the
parking aid module.
2007.50 Focus 3/2007 G964150en

413-13-7 Parking Aid 413-13-7
Rear parking aid sensors
4-Door and 5-Door
2 2
1 1
E92168
Item Description
1 Rear parking aid sensor(s).
2 Rear parking aid sensor holder(s).
Design and function principles of the rear parking
aid sensors are the same as on the front parking
aid sensors.
2007.50 Focus 3/2007 G964150en

413-13-8 Parking Aid 413-13-8
Parking Aid
Electrical
Inspection and Verification – Fuse(s)

– Wiring harness(s)
1. Verify the customer concern. – Electrical connector(s)
2. Visually inspect for obvious signs of electrical – Battery junction box (BJB)
damage. – Rear parking aid sensor(s)
– Rear parking aid speaker
– Parking aid module

Symptom Chart
• The front parking aid is inoper- • Fuse. • GO to Pinpoint Test A.
ative/does not operate correctly • Circuit(s).
• Parking aid speaker.
• Parking aid module.
• The rear parking aid is inoper- • Fuse. • GO to Pinpoint Test B.
ative/does not operate correctly • Circuit(s).
• Parking aid speaker.
• No communication with the • DLC. • GO to Pinpoint Test C.
parking aid module • Circuit(s).
• Front left parking aid sensor • Circuit(s). • GO to Pinpoint Test D.
signal circuit open or short to • Front left parking aid sensor.
ground • Parking aid module.
• Front right parking aid sensor • Circuit(s). • GO to Pinpoint Test E.
signal circuit open or short to • Front right parking aid sensor.
• Rear outer left parking aid • Circuit(s). • GO to Pinpoint Test F.
sensor signal circuit open or • Rear outer left parking aid
short to ground sensor.
• Rear outer right parking aid • Circuit(s). • GO to Pinpoint Test G.
sensor signal circuit open or • Rear outer right parking aid
short to ground sensor.
2007.50 Focus 3/2007 G964145en

413-13-9 Parking Aid 413-13-9

• Rear centre parking aid sensor • Circuit(s). • GO to Pinpoint Test H.
signal circuit open or short to • Rear centre parking aid sensor.
• Front Parking aid Sensor(s) • Circuit(s). • GO to Pinpoint Test I.
circuit to ground • Front parking aid sensor(s).
• Rear Parking aid Sensor(s) • Circuit(s). • GO to Pinpoint Test J.
circuit to ground • Rear parking aid sensor(s).
• Parking aid speaker circuit • Circuit(s). • GO to Pinpoint Test K.
short to ground • Parking aid speaker.
• Parking aid speaker circuit • Circuit(s). • GO to Pinpoint Test L.
short to battery • Parking aid speaker.
Pinpoint Tests
PINPOINT TEST A : THE FRONT PARKING AID IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
A1: CHECK FOR VOLTAGE TO THE PARKING AID MODULE
1 Disconnect Parking aid module C700.
3 Measure the voltage between the parking aid
module C700 pin 11, circuit 15-GN10 (GN/YE),
harness side and ground; and the parking aid
V module C700 pin 12, circuit 30-GN10 (RD),
• Are the voltage(s) greater than 10 volts?
→ Yes
GO to A2.
→ No
E91794 REPAIR the circuit(s) as necessary. TEST the
2007.50 Focus 3/2007 G964145en

413-13-10 Parking Aid 413-13-10

A2: CHECK THE PARKING AID MODULE GROUND CIRCUIT
1 Measure the resistance between the parking
aid module C700 pin 24, circuit 31-GN10 (BK),
→ Yes
GO to A3.
→ No
REPAIR the circuit 31-GN10 (BK/YE). TEST
E91795
A3: CHECK THE PARKING AID SPEAKER FOR CORRECT OPERATION

1 Remove the parking aid speaker.
REFER to: Parking Aid Speaker (413-13 Parking
Aid, Removal and Installation).
aid speaker C960 pin 2, and pin 3, component
side.
• Is the resistance 50 Ohms +/- 7.5 Ohms?
→ Yes
GO to A4.
→ No
INSTALL a new parking aid speaker. TEST
E92158
A4: CHECK THE CIRCUIT 15-GN25 AND 15-GN10A FOR OPEN

aid module C700 pin 11, circuit 15-GN10A
(GN/YE), harness side and the parking aid
speaker C960 pin 2, circuit 15-GN25 (GN/WH),
harness side.
→ Yes
GO to A5.
→ No
2007.50 Focus 3/2007 G964145en

413-13-11 Parking Aid 413-13-11

A5: CHECK THE CIRCUIT 10-GN25 FOR OPEN
aid module C700 pin 9, circuit 10-GN25
(GY/WH), harness side and the rear parking aid
speaker C960 pin 3, circuit 10-GN25 (GY/WH),
harness side.
→ Yes
GO to A6.
→ No
INSTALL a new parking aid speaker.
REFER to: Parking Aid Speaker (413-13
Parking Aid, Removal and Installation).
A6: CHECK THE CIRCUIT 91S-GN12 FOR OPEN
1 Disconnect Front Parking Aid Switch C451.
aid module C700 pin 10, circuit 91S-GN12
(BK/OG), harness side and the front parking aid
switch C451 pin 6, circuit 91S-GN12 (BK/OG),
harness side.
→ Yes
GO to A7.
→ No
normal operation.
A7: CHECK THE FRONT PARKING AID SWITCH GROUND CIRCUIT

parking aid switch C451 pin 2, circuit 91-GN12
→ Yes
GO to A8.
→ No
REPAIR the circuit 91-GN12 (BK/OG). TEST
E91922
2007.50 Focus 3/2007 G964145en

413-13-12 Parking Aid 413-13-12

A8: CHECK THE CIRCUIT 91S-GN12 FOR OPEN
parking aid switch C451 pin 6, and pin 2,
component side.
→ Yes
INSTALL a new parking aid module.
REFER to: Parking Aid Module (413-13
E91923
→ No
INSTALL a new front parking aid switch. TEST
PINPOINT TEST B : THE REAR PARKING AID IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
B1: CHECK FOR VOLTAGE TO THE PARKING AID MODULE
3 Measure the voltage between the parking aid
module C700 pin 11, circuit 15-GN10 (GN/YE),
harness side and ground; and the parking aid
V module C700 pin 12, circuit 30-GN10 (RD),
• Are the voltage(s) greater than 10 volts?
→ Yes
GO to B2.
→ No
2007.50 Focus 3/2007 G964145en

413-13-13 Parking Aid 413-13-13

B2: CHECK THE PARKING AID MODULE GROUND CIRCUIT
aid module C700 pin 24, circuit 31-GN10 (BK),
→ Yes
GO to B3.
→ No
REPAIR the circuit 31-GN10 (BK/YE). TEST
E91795
B3: CHECK THE REVERSE LAMP FOR CORRECT OPERATION

1 Select REVERSE.
2 Check the reverse lamps for correct operation.
• Do the reversing lamps illuminate?
→ Yes
GO to B4.
→ No
REFER to: Reversing Lamps (417-01 Exterior
Lighting, Diagnosis and Testing).
B4: CHECK THE PARKING AID SPEAKER FOR CORRECT OPERATION
side.
→ Yes
GO to B5.
→ No
E91796
B5: CHECK THE CIRCUIT 15-GN10 AND 15-GN10A FOR OPEN

2007.50 Focus 3/2007 G964145en

413-13-14 Parking Aid 413-13-14

(GN/YE), harness side and the rear parking aid
speaker C960 pin 1, circuit 15-GN10 (GN/YE),
harness side.
→ Yes
GO to B6.
→ No
B6: CHECK THE CIRCUIT 10-GN26 FOR OPEN

aid module C700 pin 21, circuit 10-GN26 (GY),
harness side and the rear parking aid speaker
C960 pin 4, circuit 10-GN26 (GY), harness side.
→ Yes
→ No
PINPOINT TEST C : NO COMMUNICATION WITH THE PARKING AID MODULE

C1: CHECK THAT THE FORD APPROVED DIAGNOSTIC TOOL IS COMMUNICATING THROUGH
THE DLC
1 Select an alternative system to check the DLC.
• Is the Ford approved diagnostic tool able to
communicate with the selected system.
→ Yes
GO to C2.
→ No
CHECK the DLC. For additional information,
refer the Wiring Diagrams.
2007.50 Focus 3/2007 G964145en

413-13-15 Parking Aid 413-13-15

C2: CHECK THE DLC CIRCUIT FOR OPEN
2 Measure the resistance between the DLC pin 3
and parking aid module C700 pin 1, harness
side.
• Is the resistance less the 5 Ohms?
→ Yes
GO to C3.
→ No
normal operation.
E91800
C3: CHECK THE DLC CIRCUIT FOR OPEN

1 Measure the resistance between the DLC pin
11 and parking aid module C700 pin 13, harness
side.
• Is the resistance less the 5 Ohms?
→ Yes
E91799
→ No
normal operation.
PINPOINT TEST D : FRONT LEFT PARKING AID SENSOR SIGNAL CIRCUIT OPEN OR SHORT TO
GROUND
D1: CHECK CIRCUIT 8-GN6 (WH) FOR OPEN
2 Disconnect Parking aid sensor C629.
2007.50 Focus 3/2007 G964145en

413-13-16 Parking Aid 413-13-16

aid module C700 pin 6, circuit 8-GN6 (WH),
harness side and parking aid sensor C629 pin
1, circuit 8-GN6 (WH), harness side.
→ Yes
GO to D2.
→ No
D2: CHECK CIRCUIT 8-GN22 (WH/GN) FOR SHORT TO GROUND

• Is the resistance greater than 10,000 Ohms?
→ Yes
INSTALL a new parking aid sensor. If the
concern persists, INSTALL a new parking aid
module.
E91917 Parking Aid, Removal and Installation).
→ No
REPAIR the short to ground. TEST the system
PINPOINT TEST E : FRONT RIGHT PARKING AID SENSOR SIGNAL CIRCUIT OPEN OR SHORT
TO GROUND
E1: CHECK CIRCUIT 8-GN9 (WH/GN) FOR OPEN
2007.50 Focus 3/2007 G964145en

413-13-17 Parking Aid 413-13-17

aid module C700 pin 5, circuit 8-GN9 (WH/GN),
1, circuit 8-GN9 (WH/GN), harness side.
→ Yes
GO to E2.
→ No
E2: CHECK CIRCUIT 8-GN9 (WH/GN) FOR SHORT TO GROUND

aid module C700 pin 5, circuit 8-GN9 (WH/GN),
→ Yes
module.
→ No
PINPOINT TEST F : REAR OUTER LEFT PARKING AID SENSOR SIGNAL CIRCUIT OPEN OR SHORT
TO GROUND
F1: CHECK CIRCUIT 8-GN22 (WH/GN) FOR OPEN
2007.50 Focus 3/2007 G964145en

413-13-18 Parking Aid 413-13-18

(WH/GN), harness side and parking aid sensor
C635 pin 1, circuit 8-GN22 (WH/GN), harness
side.
→ Yes
GO to F2.
→ No
normal operation.
F2: CHECK CIRCUIT 8-GN22 (WH/GN) FOR SHORT TO GROUND

→ Yes
module.
→ No
PINPOINT TEST G : REAR OUTER RIGHT PARKING AID SENSOR SIGNAL CIRCUIT OPEN OR
SHORT TO GROUND
G1: CHECK CIRCUIT 8-GN19 (WH) FOR OPEN
2007.50 Focus 3/2007 G964145en

413-13-19 Parking Aid 413-13-19

1, circuit 8-GN22 (WH), harness side.
→ Yes
GO to G2.
→ No
G2: CHECK CIRCUIT 8-GN19 (WH) FOR SHORT TO GROUND

→ Yes
module.
→ No
PINPOINT TEST H : REAR CENTRE PARKING AID SENSOR SIGNAL CIRCUIT OPEN OR SHORT
TO GROUND
H1: CHECK CIRCUIT 8-GN20 (WH/RD) FOR OPEN
2007.50 Focus 3/2007 G964145en

413-13-20 Parking Aid 413-13-20

(WH/RD), harness side and parking aid sensor
C633 pin 1, 8-GN20 (WH/RD), harness side.
→ Yes
GO to H2.
→ No
H2: CHECK CIRCUIT 8-GN20 (WH/RD) FOR SHORT TO GROUND

(WH/RD), harness side and ground.
→ Yes
module.
→ No
PINPOINT TEST I : FRONT PARKING AID SENSOR(S) CIRCUIT TO GROUND

I1: CHECK THE CIRCUIT 9-GN6 (BN) TO GROUND
1 Disconnect Parking aid sensors C629, C630.
aid module C700 pin 4, circuit 9-GN6 (BN),
→ Yes
GO to I2.
→ No
E92309
2007.50 Focus 3/2007 G964145en

413-13-21 Parking Aid 413-13-21

I2: CHECK EACH PARKING AID SENSOR(S) FOR SHORT BETWEEN PINS 1 AND 2
1 Measure the resistance of each parking aid
sensor between pins 1 and 2 component side.
→ Yes
INSTALL a new parking aid sensor(s). TEST
→ No
E91807
PINPOINT TEST J : REAR PARKING AID SENSOR(S) CIRCUIT TO GROUND

J1: CHECK THE CIRCUIT 9-GN19 (BN) TO GROUND
1 Disconnect Parking aid sensors C635, C633,
C632.
aid module C700 pin 16, circuit 9-GN19 (BN),
→ Yes
GO to J2.
→ No
E91806
2007.50 Focus 3/2007 G964145en

413-13-22 Parking Aid 413-13-22

J2: CHECK EACH PARKING AID SENSOR(S) FOR SHORT BETWEEN PINS 1 AND 2
1 Measure the resistance of each parking aid
sensor between pins 1 and 2 component side.
→ Yes
INSTALL a new parking aid sensor(s). TEST
→ No
E91807
PINPOINT TEST K : PARKING AID SPEAKER CIRCUIT SHORT TO GROUND

K1: CHECK THE (FRONT) PARKING AID SPEAKER FOR CORRECT OPERATION
side.
→ Yes
GO to K2.
→ No
E92158
2007.50 Focus 3/2007 G964145en

413-13-23 Parking Aid 413-13-23

K2: CHECK THE (REAR) PARKING AID SPEAKER FOR CORRECT OPERATION
side.
→ Yes
GO to K3.
→ No
E91796
K3: CHECK THE CIRCUIT 8-GN26 (WH) FOR SHORT TO GROUND
1 Disconnect Parking Aid Module C700.
→ Yes
the system for normal operation. If the concern
persists, INSTALL a new parking aid module.
→ No
GO to K4.
K4: CHECK THE CIRCUIT 10-GN26 (GY) FOR SHORT TO GROUND
→ Yes
GO to K5.
→ No
E91809
2007.50 Focus 3/2007 G964145en

413-13-24 Parking Aid 413-13-24

K5: CHECK THE CIRCUIT 10-GN25 (GY/WH) FOR SHORT TO GROUND
(GY/WH), harness side and ground.
→ Yes
E91916 → No
PINPOINT TEST L : PARKING AID SPEAKER CIRCUIT SHORT TO BATTERY

L1: CHECK THE (FRONT)_PARKING AID SPEAKER FOR CORRECT OPERATION
side.
→ Yes
GO to L2.
→ No
E92158
2007.50 Focus 3/2007 G964145en

413-13-25 Parking Aid 413-13-25

L2: CHECK THE (REAR) PARKING AID SPEAKER FOR CORRECT OPERATION
side.
→ Yes
GO to B5.
→ No
E91796
L3: CHECK THE CIRCUIT 15-GN25 AND 15-GN10A FOR OPEN
(GN/YE), harness side and the parking aid
speaker C960 pin 2, circuit 15-GN25 (GN/WH),
harness side.
→ Yes
GO to L4.
→ No
L4: CHECK THE CIRCUIT 10-GN25 FOR OPEN

(GY/WH), harness side and the rear parking aid
speaker C960 pin 3, circuit 10-GN25 (GY/WH),
harness side.
→ Yes
GO to L5.
→ No
2007.50 Focus 3/2007 G964145en

413-13-26 Parking Aid 413-13-26

L5: CHECK THE CIRCUIT 15-GN10 AND 15-GN10A FOR OPEN
(GN/YE), harness side and the rear parking aid
speaker C960 pin 1, circuit 15-GN10 (GN/YE),
harness side.
→ Yes
GO to L6.
→ No
L6: CHECK THE CIRCUIT 10-GN26 FOR OPEN

harness side and the rear parking aid speaker
C960 pin 4, circuit 10-GN26 (GY), harness side.
→ Yes
→ No
2007.50 Focus 3/2007 G964145en

413-13-27 Parking Aid 413-13-27
GENERAL PROCEDURES
Azimuth System Check

Rear Parking Aid Using a suitable pole, test the rear parking
1. NOTE: The rear parking aid system measures aid system for normal operation.
the distance to the closest obstacle when 2.
CAUTION: Do not clean the sensors with
manoeuvring and helps the driver to judge
abrasive or sharp objects. Failure to follow
distances correctly by audible signals.
this instruction may result in premature
NOTE: If a parking aid switch is fitted the system failure of the parking aid sensors.
will be de-activated and a light emitting diode (LED)
Make sure the rear parking aid sensors are
will indicate the state of the system. A lit LED will
free from ice, snow, dirt, scratches or grime.
indicate that the system is currently de-activated.
3. NOTE: The object used in this system check
NOTE: The rear parking aid system will be
can be fabricated from a tube approximately
de-activated when a Ford rear trailer tow module
7.5 cm in diameter and approximately 100
is attached to the vehicle.
cm in height.
NOTE: If the parking aid system is faulty, an error
NOTE: The following system check should be
tone approximately 3 seconds long will be issued
carried out with the vehicle on a flat dry surface.
at each ignition cycle or the first activation of the
system. If an LED is fitted and is lit, this will indicate NOTE: The parking aid system will switch on when
that a fault is present in the system. the ignition switch is turned to position II.
Turn the ignition switch to position II.
E40576
5. NOTE: The front parking aid will also operate

4. With the aid of another technician chock the
when reverse gear has been selected.
wheels with a suitable object, apply the
brakes and select reverse gear.
2007.50 Focus 3/2007 G295954en

413-13-28 Parking Aid 413-13-28
GENERAL PROCEDURES
NOTE: When checking the rear system make sure
that there are no other obstacle(s) to the front, rear
or side of the vehicle within the range shown.
Failure to follow this instruction may give a false
reading of the rear parking aid sensors.
Check the vehicle is clear from obstacles to
the front, rear and sides.
E41080
6. NOTE: Make sure the vehicle is not

overloaded and is on a flat surface. Failure
to follow this instruction may give a false
reading of the rear parking aid sensors.
The following system check should be
carried out with the vehicle on an
approximately 4.8 meters wide by 3.00
meters deep surface, free of all obstacle(s).
The area should also be free of noise,
especially from fans and pneumatic tools.
7. NOTE: Make sure the vehicle is not
overloaded and is on a flat dry surface.
Failure to follow this instruction may give a
false reading of the rear parking aid sensors.
Verify the parking aid system detects the
Tube by emitting an audible tone through
the rear speaker (approximately 7.5 cm in
diameter and 100 cm high) when placed in
the specified locations.
2007.50 Focus 3/2007 G295954en

413-13-29 Parking Aid 413-13-29
GENERAL PROCEDURES
Elevation System Check

Rear Parking Aid Check the vehicle is clear from obstacles to
the front, rear and sides.
1. NOTE: The rear parking aid system measures
the distance to the closest obstacle when
manoeuvring and helps the driver to judge
distances correctly by audible signals.
NOTE: If a parking aid switch is fitted the system
will be de-activated and a light emitting diode (LED)
will indicate the state of the system. A lit LED will
indicate that the system is currently de-activated.
NOTE: The rear parking aid system will be
de-activated when a Ford rear trailer tow module
is attached to the vehicle.
NOTE: If the parking aid system is faulty, an error E41080
tone approximately 3 seconds long will be issued
at each ignition cycle or the first activation of the 5. NOTE: The front parking aid will also operate
system. If an LED is fitted and is lit, this will indicate when reverse gear has been selected.
that a fault is present in the system.
NOTE: Make sure the vehicle is not overloaded
Ground reflection verification and sensor and is on a flat surface. Failure to follow this
coverage pattern. instruction may give a false reading of the rear
parking aid sensors.
The following system check should be
carried out with the vehicle on an
approximately 4.8 meters wide by 3.00
meters deep surface, free of all obstacle(s).
The area should also be free of noise,
especially from fans and pneumatic tools.
6. NOTE: The parking aid system will switch
on when the ignition switch is turned to
position II.
VUE0015826 Turn the ignition switch to position II.
7. With the aid of another technician chock the
2. wheels with a suitable object, apply the
CAUTION: Do not clean the sensors with
brakes and select reverse gear.
abrasive or sharp objects. Failure to follow
this instruction may result in premature 8. NOTE: If any audible alerts are heard, check
failure of the parking aid sensors. to make sure the bumper is properly installed
and is not tilted downward so the sensor is
Make sure the rear parking aid sensors are
pointing towards the ground.
free from ice, snow, dirt, scratches or grime.
3. The parking aid system must be checked to
make sure that the system does not see
signals from ground reflections.
4. NOTE: When checking the rear system make
sure that there are no other obstacle(s) to
the front, rear or side of the vehicle within
the range shown. Failure to follow this
instruction may give a false reading of the
rear parking aid sensors.
2007.50 Focus 3/2007 G295955en

413-13-30 Parking Aid 413-13-30
GENERAL PROCEDURES
Verify that no audible alert is heard from the
rear speaker.
18 18
E41084
2007.50 Focus 3/2007 G295955en

413-13-31 Parking Aid 413-13-31
Parking Aid Speaker

General Equipment
Flat-bladed screwdriver
Removal
contain installation details. 4-door
1.
1
2
E92300
2.
2007.50 Focus 3/2007 G964149en

413-13-32 Parking Aid 413-13-32
E92299
3.
E92301
2007.50 Focus 3/2007 G964149en

413-13-33 Parking Aid 413-13-33
4.
E92302
5-door
5.
2007.50 Focus 3/2007 G964149en

413-13-34 Parking Aid 413-13-34
E92173
6.
E92306
2007.50 Focus 3/2007 G964149en

413-13-35 Parking Aid 413-13-35
7. CAUTION: Take extra care not to
damage the wiring harnesses.
General Equipment: Flat-bladed screwdriver
E92308
8.
2007.50 Focus 3/2007 G964149en

413-13-36 Parking Aid 413-13-36
E92307
Installation
2007.50 Focus 3/2007 G964149en

413-13-37 Parking Aid 413-13-37
Parking Aid Module
Removal
contain installation details. 4-door
1.
1
2
E92300
2.
2007.50 Focus 3/2007 G964148en

413-13-38 Parking Aid 413-13-38
E92299
3.
E92301
2007.50 Focus 3/2007 G964148en

413-13-39 Parking Aid 413-13-39
4.
E92303
5.
2007.50 Focus 3/2007 G964148en

413-13-40 Parking Aid 413-13-40
E92298
5-door
7.
6. Remove the right-hand loadspace trim panel.
Refer to: Loadspace Trim Panel - 5-Door
(501-05 Interior Trim and Ornamentation,
2007.50 Focus 3/2007 G964148en

413-13-41 Parking Aid 413-13-41
E92176
Installation
2007.50 Focus 3/2007 G964148en

414-00-1 Charging System - General Information 414-00-1
.
SECTION 414-00 Charging System - General

Information
CONTENTS PAGE

Charging System................................................................................................................ 414-00-2
'Smart charge' generator control system - all except 2.5L Duratec-ST (VI5)..................... 414-00-2
'Smart charge' generator control system - 2.5L Duratec-ST (VI5)..................................... 414-00-4

Charging System................................................................................................................ 414-00-7
Symptom Chart................................................................................................................... 414-00-8
Pinpoint Tests..................................................................................................................... 414-00-10
Component Tests................................................................................................................ 414-00-16
GENERAL PROCEDURES
Battery Charging............................................................................................. (31 003 0) 414-00-20
General............................................................................................................................... 414-00-20
Health and Safety Precautions........................................................................................... 414-00-21
Checking the Battery Electrolyte Level............................................................................... 414-00-21
Automatic Battery Chargers (Recommended Best Practice)............................................. 414-00-22
Slow Charging (Recommended Best Practice).................................................................. 414-00-22
Constant Voltage Charging................................................................................................. 414-00-22
Multiple Battery Charging................................................................................................... 414-00-22
Fast (Boost) Charging (not recommended)........................................................................ 414-00-22
Connecting/Disconnecting the battery charger.................................................................. 414-00-23
Charging System
'Smart charge' generator control The smart charging system consists of the following
system - all except 2.5L Duratec-ST functions:
(VI5) • Battery temperature estimation and charging
voltage control
General • Generator load feed forward
• Generator deactivation during engine crank
The generator creates electrical current to supply • Idle speed increase under low voltage / high
the vehicle electrical system and maintain the electrical load conditions (to increase alternator
battery in a charged condition. The generator is output and reduce battery discharge)
driven by the accessory drive belt.
• Low voltage electrical load deactivation
For additional information, refer to: Accessory Drive • Over-voltage activation of electrical loads
- 1.8L Duratec-HE (MI4) (303-05 Accessory
Drive, Description and Operation) By continually calculating the battery temperature
/ Accessory Drive - 2.0L Duratorq-TDCi (DW) and controlling generator output voltage the battery
Diesel (303-05 Accessory Drive, Description and charging current is optimized. The generator load
Operation) feed forward function gives the PCM advance
/ Accessory Drive - 1.6L (Z6) (303-05 Accessory warning of impending electrical load, and hence
Drive, Description and Operation). impending changes in alternator torque. Using this
information, the PCM is able to achieve a greater
When the engine is started, the generator begins degree of idle stability. The PCM also controls the
to generate alternating current (AC) which it generator activation during crank, and the idle
converts to direct current (DC) internally. The DC speed increase functions. The passenger junction
current is supplied to the battery and vehicle box (PJB) controls the two remaining smart
electrical loads at a voltage controlled by the charging functions, low voltage electrical load
voltage regulator (located on the back of the deactivation and over-voltage activation of electrical
generator). The charging system voltage is loads. When the battery voltage drops below the
controlled by the powertrain control module (PCM). low voltage threshold, the PJB disables the
The battery is more efficiently charged with a higher following components in this order with a 5 second
voltage when the battery is cold and a lower delay between each load deactivation:
voltage when the battery is warm. The PCM is able
to adjust the charging voltage according to battery • Heated windshield
temperature, which it calculates based on intake • Heated rear window
air temperature (IAT) and engine coolant • Air conditioning
temperature (ECT).
The PJB re-enables all previously disabled
The PCM simultaneously monitors and controls electrical loads when the battery voltage is above
the voltage output of the generator. When the the low voltage threshold. The order for re-enabling
current consumption is high or the battery is loads is air conditioning, then the heated rear
excessively discharged, the system is able to window, then the heated windshield, with a 5
increase the idle speed. To minimize the engine second delay between each load reactivation.
drag when starting the engine, the PCM When re-enabled, the electrical loads are returned
deactivates the generator. When the engine has to normal mode, therefore the component is
started, the PCM then progressively increases the switched off awaiting a PJB input signal from the
output of the generator. switch. Over-voltage activation of electrical loads
The PCM controls the operation of the charging is enabled when the PJB recognizes the battery
system warning indicator which is located in the voltage is above the over-voltage threshold for a
instrument cluster. The PCM is therefore 20 second period, and the charging system warning
responsible for turning the warning indicator off indicator is on.
after the engine is started and illuminating it under When the threshold is reached the PJB activates
fault conditions, the warning indicator will also be the following components in this order with a 5
illuminated by the PCM at key–on, engin-off, and second delay between each load:
stall conditions.
2007.50 Focus 3/2007 G385147en

• Heated rear window may occur where loads are repeatedly activated
• Heated windshield and deactivated as the voltage levels increase and
decrease. This behavior is to be expected in a
The purpose of this is to reduce the voltage back continuous over-voltage fault condition, and serves
within specification, and reduce any overcharging to minimize both damage to the battery due to
damage to the battery. The PJB returns the overcharging, and the battery current drain due to
electrical loads to normal mode if the battery activation of the heated rear window and heated
voltage drops below the high voltage threshold for windshield. In normal mode, the electrical loads
a 20 second period. This is in order to prevent are switched off awaiting a PJB input signal from
excessive battery drain. The order for returning the switch. The low voltage threshold is
loads to normal mode is heated windshield then approximately 10.3 volts and the over-voltage
heated rear window, with a 5 second delay threshold is approximately 16 volts.
between each load reactivation. A cycling condition
Schematic of the 'Smart charge' generator control system
1 2 3 4 5 6 7
9 8
+
E83843
1 Generator 7 Instrument cluster
2 Battery voltage sensing line 8 Generator operation monitoring signal to

the PCM
3 3 Amp fuse
9 Battery
4 Battery junction box (BJB)
5 Generator required output signal from the
PCM
6 PCM
2007.50 Focus 3/2007 G385147en

Starting the generator during engine indicator to check that it operates. After the engine
starting starts the charging system warning indicator is
switched off again. During the engine run condition,
In the "smart charge" generator control system", the charging system warning indicator will only
the generator is deactivated during engine starting. illuminate if the PCM identifies that there is a fault
The generator is only switched on after the engine present for a 20 second period. (Voltage out of
has started. range, internal generator fault, or PCM to generator
Switching on is done electronically by the PCM. communication fault).
The generator power is then increased smoothly
to the value required. 'Smart charge' generator control
system - 2.5L Duratec-ST (VI5)
Increased idle speed
General
At idle with high generator load, the idle speed is
increased in order to increase the generator power. The charging system for this vehicle consists of a
The system can increase the idle speed in steps generator combined with a generator control
by up to 150 rev/min above the base idle speed. module.
The generators for some variants are equipped
with pulleys with built in reverse rotation clutches.
Diagnosis These pulleys allow the generator armature to
free-wheel during sudden engine deceleration so
There is a self-test facility for the Smart Charge smoothing the reduction in charge rate output. This
System, stored in the PCM and which can be also reduces the load changes on the accessory
accessed through the WDS. If a fault occurs in the drive belt.
system, the charging system warning indicator is
illuminated by the PCM. If voltage regulation fails, The generator creates electrical current to supply
the generator operates with a fixed charging the vehicle electrical system and maintain the
voltage of approximately 13.5 Volts. battery in a charged condition. The generator is
driven by the accessory drive belt.
With fixed charging voltage the generator operates
as usual and still delivers enough current for the For additional information, refer to: Accessory Drive
vehicle systems. After the ignition is switched on, (303-05 Accessory Drive - 2.5L Duratec-ST (VI5),
the PCM switches on the charging system warning Description and Operation).
2007.50 Focus 3/2007 G385147en

Charging Control
1 2 3 4 5 6
10
11
12
E71029
charging voltages in accordance with the

Item Description
requirements of the power supply systems. In turn
1 Generator the generator control module will inform the PCM
of the current output of the generator.
2 Generator control module
The generator control module monitors the
3 Local interconnect network (LIN) generator output. If a fault develops in the
communication generator control module, control circuits or the
4 Powertrain control module (PCM) generator, the PCM will be informed and a
diagnostic trouble code (DTC) will be set.
5 Control area network (CAN)
communication Using the information received by the PCM from
the generator control module, the PCM can
6 General electronic module (GEM) calculate the generator load. The generator load
information is transferred to the GEM using CAN
7 Heated windshield
communication. The GEM uses the load
8 Heated rear window information to calculate maximum allowable current
consumption of the climate related systems. The
9 Heated mirrors GEM also controls the initiation of fault warnings
10 Supplementary heater to the display information module. The battery
charge warning indicator is turned off by means of
11 Instrument cluster an instruction from the GEM using CAN
12 Battery communication.
To reduce the load on the generator to within its
Charging is controlled by the PCM and the GEM. working limits and assist with battery recovery after
The PCM communicates with the generator control start up, the GEM will switch non critical systems
module using a LIN connection. The PCM will off and on.
instruct the generator to increase or decrease
2007.50 Focus 3/2007 G385147en

The systems that are controlled by the GEM have
typical loads of:
• Heated windshield
– 70 amps
• Heated rear window
– 25 amps
• Heated mirrors
– 4 amps
• Supplementary heating
– 80 amps
The climate systems have been chosen because
they can be switched off for short periods of time
with barely detectable changes in their ultimate
function. During this control period, the function
indicators for the system being controlled will
remain illuminated. The total load reduction if all
controlled components where switched off would
be in the region of 180 amps.
Conversely, the GEM can switch the same
components on at any time thereby increasing
engine load. This function is used to assist with the
engine warm up process.
2007.50 Focus 3/2007 G385147en

Charging System
Refer to Wiring Diagrams Section 414-02, for battery, always shield your face and
schematic and connector information. protect your eyes. Always provide
General Equipment ventilation. Failure to follow these
Surface charge dissipation unit (SCD²)
Micro390 battery tester 2. Visually inspect for obvious signs of mechanical
Inspection and Verification Visual Inspection Chart
WARNINGS:
– Accessory drive belt – Fuse(s)
Batteries contain sulphuric acid. Avoid
contact with skin, eyes, or clothing. Also, – Generator – Wiring harness(es)
shield your eyes when working near – Generator
batteries to protect against possible – Electrical
splashing of the acid solution. In case of connector(s)
acid contact with skin or eyes, flush – Battery
immediately with water for a minimum of
15 minutes and get prompt medical – Battery cables
attention. If acid is swallowed, call a – Charging warning
physician immediately. Failure to follow indicator
injury. 3. If an obvious cause for an observed or reported
Batteries normally produce explosive concern is found, correct the cause (if possible)
gases which can cause personal injury. before proceeding to the next step.
Therefore, do not allow flames, sparks or 4. Check the operation of the charging system
lighted substances to come near the warning indicator lamp, located in the instrument
battery. When charging or working near a cluster. Normal operation is as follows:
Normal Charging System Voltages

Ignition Switch I Circuit Generator Battery Engine to Charging System
Position B+ Circuit battery ground Warning Indicator
Operation
Position 0 0V 10-12V 10-12V 0V OFF
Position II 0V 10-12V 10-12V 0V Illuminated
Position II with 13-15V 13-15V 13-15V 0V OFF
the engine
running
2007.50 Focus 3/2007 G167278en

Symptom Chart

• The charging system warning • Accessory drive belt. • CHECK the accessory drive
indicator is on with the engine belt condition,
running (The charging system REFER to: Accessory Drive
voltage does not increase) (303-05 Accessory Drive,
Diagnosis and Testing)
/ Accessory Drive (303-05
Accessory Drive, Diagnosis
and Testing).
• Generator decoupler (vehicles • CARRY out the Generator
with 1.8L diesel engine). Decoupler Component Test,
(303-05 Accessory Drive,
and Testing).
• Circuit. • GO to Pinpoint Test A.
• Generator.
• Voltage regulator.
• The charging system warning • Bulb. • INSTALL a new bulb.
indicator is off with the ignition
switch in the RUN position and
the engine off
• Ignition switch. • CHECK the ignition switch.
• Circuit. •
• Generator.
• Radio interference • Circuit. • GO to Pinpoint Test B.
• Generator.
• The generator is noisy • Accessory drive belt. • REFER to: Accessory Drive
and Testing).
• Generator decoupler (vehicles • CARRY out the Generator
with 1.8L diesel engine). Decoupler Component Test,
and Testing).
• Loose generator mounting • TIGHTEN the generator
bolts. mounting bolts.
2007.50 Focus 3/2007 G167278en


• Generator. • INSTALL a new generator.
REFER to: (414-02 Generator
and Regulator)
Generator - 1.4L Duratec-16V
(Sigma) (Removal and
Installation),
Generator - 2.0L Duratec-HE
Generator - 1.6L Duratorq-
Code: S, Vehicles With: Air
Conditioning (Removal and
Installation),
Code: K, Vehicles With: Air
Conditioning (Removal and
Installation),
Vehicles Without: Air Condi-
tioning (Removal and Installa-
tion),
Generator - 1.6L (Z6) (Removal
and Installation),
TDCi (Lynx) Diesel, Vehicles
With: Air Conditioning
TDCi (Lynx) Diesel, Vehicles
Without: Air Conditioning
TDCi (DW) Diesel, Vehicles
With: Water-in-Fuel Sensor
TDCi (DW) Diesel, Vehicles
ation),
Generator - 2.5L Duratec-ST
(VI5) (Removal and Installa-
tion).
• Vehicle electrical systems • Battery. • CARRY OUT the battery test,
inoperative REFER to the Battery Test in
Component Tests in this
section.
2007.50 Focus 3/2007 G167278en


• The engine cranks slowly • Battery. • CARRY OUT the battery test,
REFER to the Battery Test in
Component Tests in this
section.
• Battery cable(s). • REFER to: Starting System
• Starter motor. (303-06 Starting System,
Pinpoint Tests
measurements.
PINPOINT TEST A : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE
RUNNING
A1: CHECK THE BATTERY
1 CARRY OUT the battery test, REFER to the
Battery Test in Component Tests in this section.
• Is the battery OK?
→ Yes
GO to A2.
→ No
INSTALL a new battery. REFER to: (414-01
Battery, Mounting and Cables)
Battery - 2.0L Duratec-HE (MI4)/1.4L Duratec-
16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L
Duratec-HE (MI4)/1.6L (Z6) (Removal and
Installation),
Battery - 1.6L Duratorq-TDCi (DV) Diesel/2.0L
Duratorq-TDCi (DW) Diesel (Removal and
Installation),
Battery - 2.5L Duratec-ST (VI5) (Removal and
Installation).
2007.50 Focus 3/2007 G167278en


A2: CHECK THE CHARGING SYSTEM
1 CARRY OUT the generator tests, REFER to the
Generator On-Vehicle Tests in Component
Tests in this section.
• Is the generator output OK?
→ Yes
DIAGNOSE the charging system warning
indicator.
ment Cluster, Diagnosis and Testing).
→ No
GO to A3.
A3: CHECK FOR A GOOD GROUND
2 Measure the voltage between the generator
housing and the battery negative terminal.
→ Yes
GO to A4.
→ No
CLEAN and TIGHTEN the generator
mounting, engine to body ground strap, and
battery ground cable. TEST the system for
VUE0004619 normal operation. If the concern persists,
INSTALL a new battery ground cable.
A4: CHECK BATTERY CABLE

2 Measure the voltage between the generator B+
terminal and the battery positive terminal.
→ Yes
GO to A5.
→ No
CLEAN and TIGHTEN the battery positive
normal operation.
VUV9110224
2007.50 Focus 3/2007 G167278en


A5: CHECK BATTERY FEED TO THE GENERATOR
1 Measure the voltage between the generator B+
terminal, circuit 30-BA6 (RD), and ground.
V • Is the voltage equal to the battery voltage?
→ Yes
GO to A6.
→ No
REPAIR circuit 30-BA6 (RD) (starter motor to
generator) or circuit 30-BB10 (RD) (battery to
starter motor). TEST the system for normal
VUE0004620 operation.
A6: CHECK POWER TO THE VOLTAGE REGULATOR

2 Disconnect Generator C870.
3 Measure the voltage between the generator
C870 pin 3, circuit 30-BA10 (RD), harness side
and ground.
V → Yes
GO to A7.
→ No
REPAIR circuit 30-BA10. TEST the system
VUV9910080
A7: CHECK POWERTRAIN CONTROL MODULE AND COMMUNICATIONS LINK WITH GENERATOR
1 Connect Generator C870.
2 Connect the diagnostic tool.
2007.50 Focus 3/2007 G167278en


4 Retrieve PCM diagnostic trouble codes (DTCs).
• Are any DTCs retrieved?
→ Yes
Use the WDS to diagnose the PCM and
communications.
→ No
INSTALL a new generator. REFER to: (414-
02 Generator and Regulator)
Generator - 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma) (Removal and Installa-
tion),
Generator - 2.0L Duratec-HE (MI4)/1.8L Duratec-
HE (MI4) (Removal and Installation),
Generator - 1.6L Duratorq-TDCi (DV) Diesel (90
PS), VIN Plate Emission Level Code: S,
Vehicles With: Air Conditioning (Removal and
Installation),
PS), VIN Plate Emission Level Code: K,
Installation),
PS), Vehicles Without: Air Conditioning
Generator - 1.6L (Z6) (Removal and Installation),
Generator - 1.8L Duratorq-TDCi (Lynx) Diesel,
Installation),
Vehicles Without: Air Conditioning (Removal
and Installation),
Generator - 2.0L Duratorq-TDCi (DW) Diesel,
Vehicles With: Water-in-Fuel Sensor (Removal
and Installation),
Vehicles Without: Water-in-Fuel Sensor
Generator - 2.5L Duratec-ST (VI5) (Removal
and Installation).
2007.50 Focus 3/2007 G167278en

PINPOINT TEST B : RADIO INTERFERENCE
B1: ISOLATE THE GENERATOR
1 Remove the accessory drive belt. REFER to:
(303-05 Accessory Drive)
Accessory Drive Belt - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma), Vehicles
With: Air Conditioning (Removal and Installa-
tion),
Accessory Drive Belt - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma), Vehicles
Without: Air Conditioning (Removal and
Installation),
(MI4)/1.8L Duratec-HE (MI4) (Removal and
Installation),
Accessory Drive Belt - 1.6L Duratorq-TDCi (DV)
Diesel (Removal and Installation),
Accessory Drive Belt - 1.8L Duratorq-TDCi
(Lynx) Diesel (Removal and Installation),
Accessory Drive Belt - 2.0L Duratorq-TDCi (DW)
Diesel (Removal and Installation),
Accessory Drive Belt - 1.6L (Z6) (Removal and
Installation).
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec-ST (VI5),
2007.50 Focus 3/2007 G167278en


3 Run the engine for a few seconds with the radio
turned on.
• Is interference still present?
→ Yes
Vehicles with subwoofer,
REFER to: Audio System (415-00 Information
and Entertainment System - General
→ No
CLEAN and TIGHTEN all mounting points and
positive and ground cable connections. TEST
the system for normal operation. If interference
is still present, INSTALL a new generator.
REFER to: (414-02 Generator and Regulator)
Generator - 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma) (Removal and Installa-
tion),
Generator - 2.0L Duratec-HE (MI4)/1.8L Duratec-
HE (MI4) (Removal and Installation),
PS), VIN Plate Emission Level Code: S,
Installation),
PS), VIN Plate Emission Level Code: K,
Installation),
PS), Vehicles Without: Air Conditioning
Generator - 1.6L (Z6) (Removal and Installation),
Installation),
Vehicles Without: Air Conditioning (Removal
and Installation),
Vehicles With: Water-in-Fuel Sensor (Removal
and Installation),
Vehicles Without: Water-in-Fuel Sensor
Generator - 2.5L Duratec-ST (VI5) (Removal
and Installation).
2007.50 Focus 3/2007 G167278en

Component Tests voltage, carry out the Load Test. If the voltage
increase is greater than 2.5 volts, REFER to the
WDS.
Generator On-Vehicle Tests - No-Load Test
1. Turn off all electrical loads and the ignition Generator On-Vehicle Tests - Load Test
switch.
2. Switch the multimeter to the voltage function. 1. With the engine running, turn on the air
conditioning (if equipped), turn the blower motor
3. Connect the leads of the multimeter across the
to high speed and the headlamps to high beam.
battery terminals.
2. Increase the engine speed to 2000 rpm. The
4. Read the voltage (base voltage).
voltage should increase a minimum of 0.5 volts
5. Start the engine. above the base voltage. If the voltage does not
6. Run the engine at 1500 rpm with no electrical increase as specified, REFER to the WDS. If
load. the voltage increases as specified, the charging
7. Read the voltage. The voltage should be in the system is charging correctly. REFER to the
range of 14.1 volts to 15.1 volts. If the voltage Symptom Chart.
increase is less than 2.5 volts above the base
Battery Identification
Z0212058
1 Cold crank amp (CCA) rating 4 Ford Part number
2 Reserve capacity (RC) rating (minutes) 5 FINIS code
3 Battery voltage 6 EN number (European Norm)
2007.50 Focus 3/2007 G167278en


7 Battery type: Ca = Silver/Calcium; Sb = 8 Amp hour rating
Lead/Antimony
Battery Surface Charge Removal

Surface charge dissipation unit (SCD²)
7 8
1
5 6
E56846
disconnected from the vehicle. If the

Item Description
battery is holding a surface charge, the
1 Connect black lead to battery - Connect battery tester will give false readings.
red lead to battery + NOTE: The SCD² tool eliminates the need to
2 Red A indicator illuminates and green B dissipate the battery's surface charge via the
indicator flashes manual process of loading the battery via the
operation of the vehicles electrical systems. It also
3 Wait until green B indicator illuminates removes the variability in the process and makes
4 Disconnect from battery sure that the actual dissipation of the surface
charge is qualified prior to testing.
5 Max 18v
1. Connect the black lead to the battery negative
6 -20°C to +55°C terminal and the red lead to the battery positive
terminal.
7 Red indicator (A)
2. The red indicator (A) illuminates and the green
8 Green indicator (B) indicator (B) flashes.
CAUTION: Prior to testing any battery, the 3. Wait until the green indicator (B) fully
surface discharge must be dissipated. This illuminates, then disconnect from the battery.
includes batteries that are returned
2007.50 Focus 3/2007 G167278en

Alternative Method To Dissipate The • Connect the red clip to the battery positive
Battery Surface Charge (+) terminal and the black clip to the battery
negative (–) terminal.
1. Leave the battery to stand for a minimum of six
hours without charging or discharging or remove
the surface charge through partial loading as
follows:
• Turn the ignition key to position II and switch
on the headlamps (main beam), heated
windshield (if equipped), heated rear window
(if equipped) and the heater blower motor
(position II). Leave the vehicle in this
condition for a minimum of 60 seconds to
dissipate the battery surface charge.
• Turn the ignition key to position 0 and switch TIZ0212059
off the headlamps, heated windshield (if
equipped), heated rear window (if equipped) 2. NOTE: The label affixed to the top of
and the heater blower motor. Leave the batteries progressively from 06/1998
vehicle in this condition for a minimum of five identifies the battery CCA rating. Remove
minutes before testing battery condition. the battery if the label is obscured.
Use the ”Arrow” buttons on the battery tester to
scroll to the battery’s labelled CCA rating.
Battery Test
TIZ0212060
TIZ0212063
3. Press the ”Test” button that corresponds to the
correct battery temperature.
NOTE: Using the Micro390 Battery Tester: To fully
determine battery condition once the surface • If the battery temperature is above zero
charge has been dissipated, the Micro390 battery degrees centigrade: press the ”sun” button.
tester must be used. For the Micro390 battery If the battery temperature is below zero
tester to operate, it requires a minimum of 5.5 volts degrees centigrade: press the ”Ice-crystal”
charge to be present on the test battery. Therefore, button.
if the Micro390 does not operate when connected
to a test battery, then a charge of less than 5.5
volts is present. In this instance, the battery must 1
be charged in line with the battery charging
instructions prior to testing. In the event of a conflict
of results between the charge eye indicator and
the battery tester, the battery tester result must
always be used. The charge eye indicator is for 3
guidance only.
2
1. Connect the battery tester to the battery.
TIZ0212061
2007.50 Focus 3/2007 G167278en

4. Carry out the action based upon the test result
displayed and the following table.
1. Charge level bar graph.
2. Test result.
3. Battery voltage.
TIZ0212062
5. Press the "information" button and carefully note

the six-digit "Test Code" on the job card for
claim submission and audit purposes (graphic
shows an example of the code only).
Battery tester results and required actions

Tester Reading Action
GOOD BATTERY Return to service
GOOD RECHARGE Fully charge the battery and return to service*
CHARGE & RETEST Fully charge the battery and retest
REPLACE BATTERY or BAD CELL BATTERY WARNING: Do not recharge the battery.
Make sure that the surface charge was removed.
If so, disconnect the battery from the vehicle and
retest. If the result remains after surface charge
removal, install a new battery.
UNABLE TO TEST Disconnect the battery from the vehicle and retest.
*In addition, it is advisable to check the vehicle electrical system. Check that the generator is functioning correctly and that all
key-off loads (luggage compartment lamps, glove compartment lamp and interior lamps) are not staying on.
2007.50 Focus 3/2007 G167278en

GENERAL PROCEDURES
Battery Charging(31 003 0)

General Equipment last and that all electrical items are switched off.
Record the audio unit keycode and preset radio
Midtronics GR-590 Battery Management Center
frequencies before disconnecting the battery.
General Disconnect and Connect (414-01 Battery,
WARNINGS:
1. The Midtronics GR-590 Battery Management
Always observe the battery charger Center is available through the Ford Service
equipment manufacturer’s instructions. Equipment (FSE) Program and can effectively
Do not jump/slave start using a battery charge both lead antimony and silver calcium
charging system from another vehicle. type batteries. Once connected to the
battery, the battery charger detects the state
CAUTIONS: of battery charge and then applies the
Do not rely on the generator to recharge a appropriate charge rate and duration. When
discharged battery. It would take in excess the battery is fully charged, the battery
of eight hours of continuous driving with charger switches to stand-by, keeping the
no additional loads placed on the charging battery in a fully charged state preventing
system. excessive gassing and overcharging. This
battery charger also incorporates a software
Make sure that the battery electrolyte program that has the capability to assist in
reaches the indicated maximum mark (refer the recovery of deeply discharged
to Checking the Battery Electrolyte Level (sulphated) batteries.
in this procedure).
2. Charging methods and types of battery
Do not charge batteries installed in the chargers vary widely. Whichever method is
vehicle. utilized it must be carried out carefully to
Connect the battery charger cables to the avoid damage to the battery and possible
battery before switching the battery personal injury. Specific instructions
charger on. accompanying each battery charger and
must be followed exactly. Safeguards
Switch the battery charger off before provided by the equipment manufacturer
disconnecting the battery charger cables should not be disregarded by the operator.
from the battery.
3. A battery which has been stored in a highly
NOTE: When connecting and disconnecting the discharged state may be slow to accept a
battery from the vehicle, make sure that the battery charge at first. In such cases the initial
ground cable is disconnected first and connected charging rate may be so low that the
ammeter on some battery testers will not
show any indication of charge for 5 to 10
minutes.
2007.50 Focus 3/2007 G18345en

GENERAL PROCEDURES
Health and Safety Precautions
DTZ9722057
• Avoid splashes to the skin, eyes and clothing.

Item Description
Wear suitable protective impervious apron,
1 Explosive gases gloves and goggles. Do not breath mists.
• Make sure access to eye wash bottles,
2 Eye protection must be worn
shower and soap are readily available for
3 No smoking or naked flames splashing accidents. Seek prompt medical
attention.
4 Corrosive acid
• Display Eye Hazard sign.
5 Flush eyes immediately • Gases released during charging are
explosive. Never use naked flames or allow
6 Caution/Important notice
sparks near charging or recently charged
7 Read relevant instructions batteries.
• Make sure that there is adequate ventilation.
8 Keep away from children
9 Do not dispose of as household waste Checking the Battery Electrolyte Level
10 Recycle (through a recognized disposal WARNING: Do not overfill a battery as this
system) can cause acid leakage that will result in
damage to the vehicle and possible
1. Procedures associated with batteries involve personal injury.
physical hazards or other risks to health. The
following precautions must be taken to avoid NOTE: Ford batteries generally require no
these hazards: maintenance however, in certain conditions, it is
possible for the electrolyte in a battery to fall below
• Battery acid is an irritant and corrosive to the the minimum level.
skin, eyes, nose and throat. Battery acid can
cause burns and destroy ordinary protective
clothing.
2007.50 Focus 3/2007 G18345en

GENERAL PROCEDURES
1. Place the battery on a level surface. Slow Charging (Recommended Best
Practice)
1. The use of the Midtronics GR-590 Battery
Management Center that has been
specifically designed for use on silver
calcium type batteries is recommended.
Slow-charging will readily restore a battery
to a full state of charge and, since the
charging current is relatively low, the
possibility of overcharging a battery are
minimized. The charge rate used should be
approximately equal to 5% of the reserve
Z9622386 capacity of the battery being charged
(approximately three to six Amps depending
on battery size). The charging current should
2. NOTE: The maximum battery electrolyte level be adjusted 10 minutes after initial setting
is approximately 40 mm below the very top and again after 1 hour before being left to
of the battery casing. This corresponds to a charge the battery for between 8 and 12
point just below the lower rim of the battery hours.
casing.
Check that the battery electrolyte reaches Constant Voltage Charging
the indicated maximum level. Top up with
distilled/de-ionized water, as necessary. 1. A constant voltage battery charger will
charge a battery at a set maximum voltage.
The voltage used depends upon the design
and condition of the battery charger and the
age and temperature of the battery. This type
of battery charger initially charges at a high
40 mm rate of current that reduces as battery
voltage is restored. When using a constant
voltage battery charger, the charging current
should be recorded after five minutes and
the battery charger switched off when the
charging current falls to one–third of the
recorded value, or after eight hours
DTZ9722102 whichever occurs first.
Automatic Battery Chargers Multiple Battery Charging

(Recommended Best Practice) 1. Multiple battery chargers are designed to
1. The use of the Midtronics GR-590 Battery charge a number of batteries,
Management Center that has been simultaneously. Of the two different types of
specifically designed for use on silver multiple battery chargers available, only
calcium type batteries is recommended. those that charge batteries in series should
Once switched on, it will detect the state of be used and it is important that batteries are
battery charge and then apply the of the same or very similar ratings and
appropriate charge rate and duration. When voltages. Multiple battery chargers that
the battery is fully charged, the battery charge batteries in parallel are not
charger will switch to stand-by, keeping the recommended.
battery in a fully charged state preventing
excessive gassing and overcharging. Fast (Boost) Charging (not recommended)
Automatic battery chargers are also
protected against reverse polarity connection 1. The use of a fast (boost) battery charger is
and require no adjustment or monitoring. not recommended as it can cause damage
to a battery. Fast charging will only restore
a battery to a state of charge that will enable
2007.50 Focus 3/2007 G18345en

GENERAL PROCEDURES
it to carry out it’s critical function of cranking
the engine. Fast charging will not restore a
battery to a full state of charge and must
therefore be followed by a period of slow
charging. Excessively fast charging can
cause damage to a battery. For this reason,
charging times must be carefully controlled.
Fast battery chargers vary widely in design
so it is very important to strictly adhere to
the equipment manufacturer’s instructions.
A charge of 30 amps for up to 30 minutes is
the most common fast charging application.
If the battery is very discharged and requires
additional restoration, an additional charge
of 20 amps for a period up to one and a half
hours should be applied. Fast charging for
a period in excess of two hours significantly
increases the risk of causing damage to the
battery.
Connecting/Disconnecting the battery

charger
1. Remove the battery (Focus C-MAX 2003.75,
Focus 2004.75, S-MAX/Galaxy 2006.50,
Mondeo 2007.50 only).
2. Disconnect the battery ground cable (All,
except the vehicles mentioned in the
previous step).
3. Connect the positive red clamp from the
Midtronics GR-590 Battery Management
Center to the positive battery terminal.
4. Connect the negative black clamp from the
Center to the negative battery terminal.
5. Connect the AC power cable to the mains
outlet and switch on.
6. Follow the instructions supplied with the
Center to charge the battery.
7. To disconnect the Midtronics GR-590 Battery
Management Center, reverse the connection
procedure.
2007.50 Focus 3/2007 G18345en

414-01-1 Battery, Mounting and Cables 414-01-1
.
SECTION 414-01 Battery, Mounting and Cables

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 414-01-2

Battery................................................................................................................................ 414-01-5
GENERAL PROCEDURES
Battery Disconnect and Connect........................................................................................ 414-01-6

Battery — 2.0L Duratec-HE (MI4)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L
Duratec-HE (MI4)/1.6L (Z6).............................................................................................. 414-01-7
Battery Tray — 2.0L Duratec-HE (MI4)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma)/1.8L Duratec-HE (MI4)........................................................................................ 414-01-10
Battery Tray — 1.6L (Z6).................................................................................................... 414-01-12
Battery Cables — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)..................................... 414-01-15
Battery Cables — 1.6L (Z6)................................................................................................ 414-01-20
SPECIFICATIONS
Battery Specifications
Ah Rating Battery Type Build date that Ca battery can
be installed from
43 Silver Calcium (Ca) All
Torque Specifications - vehicles with 1.4L Duratec-16V (Sigma) engine/1.6L Duratec-16V (Sigma)
engine/1.6L Duratec-16V Ti-VCT (Sigma) engine
Battery terminal clamp retaining nuts 6 - 53
Battery retaining strap retaining nuts 6 - 53
Battery tray retaining bolts 12 9 -
Battery ground cable to body electrical 8 - 71
connector retaining bolt
Battery cable electrical connector to battery 12 9 -
positive terminal clamp retaining nut
Battery to starter motor solenoid cable 12 9 -
electrical connector retaining nut
Ignition switch to starter motor solenoid 7 - 62
cable electrical connector retaining nut
Battery cable to generator electrical 8 - 71
connector retaining nut
Battery to transaxle ground cable electrical 35 26 -

Battery to starter motor solenoid cable 10 - 89
Battery cable to generator electrical 13 10 -
Battery to transaxle ground cable electrical 10 - 89
2007.50 Focus 5/2007 G167282en

SPECIFICATIONS

Battery to engine ground cable electrical 10 - 89
Torque Specifications - vehicles with 1.6L Duratorq-TDCi (DV) diesel engine

Torque Specifications - vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine

Ignition switch to starter motor cable 7 5 -
retaining nut
Starter motor positive cable retaining nut 12 9 -
Starter motor retaining bolt 35 26 -
Torque Specifications - vehicles with 1.8L Duratec-HE (MI4) engine/2.0L Duratec-HE (MI4) engine
2007.50 Focus 5/2007 G167282en

SPECIFICATIONS

Torque Specifications - vehicles with 2.0L Duratorq-TDCi (DW) diesel engine

2007.50 Focus 5/2007 G167282en

Battery
REFER to: Charging System (414-00 Charging
System - General Information, Diagnosis and
Testing).
2007.50 Focus 5/2007 G167284en

GENERAL PROCEDURES
Battery Disconnect and Connect

Disconnect
Connect
WARNINGS:
WARNINGS:
Batteries normally produce explosive
gases which may cause personal injury, Batteries normally produce explosive
therefore do not allow flames, sparks or gases which may cause personal injury,
lighted substances to come near the therefore do not allow flames, sparks or
battery. When charging or working near lighted substances to come near the
the battery always shield your face and battery. When charging or working near
protect your eyes. Always provide the battery always shield your face and
adequate ventilation. Failure to follow protect your eyes. Always provide
these instructions may result in personal adequate ventilation. Failure to follow
injury. these instructions may result in personal
injury.
Batteries contain sulphuric acid, avoid
contact with skin, eyes or clothing. Shield Batteries contain sulphuric acid, avoid
your eyes when working near the battery contact with skin, eyes or clothing. Shield
to protect against possible splashing of your eyes when working near the battery
the acid solution. In case of acid contact to protect against possible splashing of
with the skin or eyes, flush immediately the acid solution. In case of acid contact
for a minimum of 15 minutes and seek with the skin or eyes, flush immediately
prompt medical attention. If swallowed, call for a minimum of 15 minutes and seek
a physician immediately. Failure to follow prompt medical attention. If swallowed, call
these instructions may result in personal a physician immediately. Failure to follow
injury. these instructions may result in personal
injury.
Audio unit key code saving devices must
not be used when working on CAUTION: Make sure all electrical systems
supplemental restraint or fuel systems. are switched OFF before connecting the
When using these devices the vehicle battery ground cable to avoid damage to
electrical system is still live but with a the vehicle electrical system.
reduced current flow. Failure to follow this 1. Connect the battery ground cable.
2. Enter the audio unit keycode and preset
CAUTION: Make sure the engine is not radio frequencies.
running before disconnecting the battery
ground cable to avoid damage to the 3. Reset the clock to the correct time.
vehicle electrical system. 4. NOTE: When the battery has been
NOTE: Before disconnecting the battery make sure disconnected and connected, the stored idle
that no data is required from the powertrain control and drive values contained within the
module (PCM), as battery cable disconnection will powertrain control module (PCM) will have
erase any fault codes and idle/drive values held in been erased. The following steps must be
the keep alive memory (KAM). It is not necessary carried out to allow the PCM to relearn its
to disconnect or remove electronic control modules. idle and drive values.
NOTE: This procedure should be used to Start and run the engine at idle for three
disconnect the battery while carrying out repairs minutes.
that refer to the battery being disconnected. 5. When the engine reaches normal operating
1. Obtain and record the audio unit keycode temperature, increase the engine speed to
and preset radio frequencies. 1200 rpm and maintain for approximately two
minutes.
6. Drive the vehicle for approximately five
miles/eight kilometers of varied driving.
2007.50 Focus 5/2007 G18350en

Battery — 2.0L Duratec-HE (MI4)/1.4L Duratec-16V (Sigma)/1.6L

Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/1.6L (Z6)
WARNING: Batteries contain sulphuric 1. Remove the air cleaner.
acid, avoid contact with skin, eyes or For additional information, refer to: Air
clothing. Shield your eyes when working Cleaner - 1.4L Duratec-16V (Sigma)/1.6L
near the battery to protect against possible Duratec-16V (Sigma) (303-12 Intake Air
splashing of the acid solution. In case of Distribution and Filtering, Removal and
acid contact with the skin or eyes, flush Installation)
immediately for a minimum of 15 minutes / Air Cleaner - 1.6L Duratec-16V Ti-VCT
and seek prompt medical attention. If (Sigma) (303-12 Intake Air Distribution and
swallowed, call a physician immediately. Filtering, Removal and Installation)
Failure to follow these instructions may / Air Cleaner - 2.0L Duratec-HE (MI4)/1.8L
result in personal injury. Duratec-HE (MI4) (303-12 Intake Air
Installation).
table(s).
2007.50 Focus 5/2007 G325379en

6 Nm
6 Nm 2
1
7
6 Nm 5
8
3
E41218
1 Battery cover 6 Battery tray extension panel

See Removal Detail
2 Battery ground cable terminal clamp
See Removal Detail 7 Battery retaining bracket
See Installation Detail 8 Battery
3 Battery positive cable terminal shield
See Removal Detail
CAUTION: If installing a new battery, only
4 Battery positive cable terminal clamp cover install the specified battery type.
5 Battery positive cable terminal clamp For additional information, refer to:
See Installation Detail Specifications (414-01, Specifications).
2007.50 Focus 5/2007 G325379en

Removal Details
Item 2 Battery ground cable terminal clamp
Item 3 Battery positive cable terminal shield
1. Release the battery positive cable terminal
For additional information, refer to: Battery shield locking tangs and remove the shield.
E39410
Item 6 Battery tray extension panel

1. Detach the battery cable retaining clips and
remove the battery tray extension panel.
Item 5 Battery positive cable terminal clamp
CAUTION: Make sure that the battery
positive cable terminal clamp is clean and
free of all foreign material to avoid
introducing starting and other electrical
concerns.
1. Connect the battery positive cable.

2007.50 Focus 5/2007 G325379en

Battery Tray — 2.0L Duratec-HE (MI4)/1.4L Duratec-16V

(Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)
2. Remove the powertrain control module
1. Remove the battery.
(PCM). For additional information, refer to
For additional information, refer to Battery - Section 303-14A [Electronic Engine
1.8L/2.0L/1.6L in this section. Controls] / 303-14B [Electronic Engine
Controls -- 2.5L Duratec-ST (VI5)].
table(s).
12 Nm
E41217
2007.50 Focus 5/2007 G325380en

Item Description
1 Battery tray
2007.50 Focus 5/2007 G325380en

Battery Tray — 1.6L (Z6)

Duratec-HE (MI4)/1.6L (Z6) (414-01 Battery,
Mounting and Cables, Removal and
For additional information, refer to: Battery Installation).
(Sigma)/1.6L Duratec-16V (Sigma)/1.8L
table(s).
4
12 Nm 5
1 6
E52681
1 Powertrain control module (PCM) upper 4 PCM electrical connectors

cover See Removal Detail
2 PCM lower cover 5 Battery tray retaining bolts

See Removal Detail 6 Battery tray
3 PCM wiring harness retaining bracket
retaining nut and bolt
2007.50 Focus 5/2007 G413465en

E52672

7 PCM retaining screws
8 PCM
Removal Details
2007.50 Focus 5/2007 G413465en

Item 2 PCM lower cover
1. Rotate the PCM lower shield away from the
battery tray.
E52908
Item 4 PCM electrical connectors

1. Disconnect the PCM wiring harness from the
PCM.
1. Rotate the PCM electrical connector locking
clips.
2. Disconnect the PCM electrical connectors.
1
E52909
2007.50 Focus 5/2007 G413465en

Battery Cables — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)

Special Tool(s) 3. Using the special tool, disconnect the
thermostat housing to coolant expansion
tank and heater core return coolant hose.
Hose Clamp
303-397
24003

Cables].
2. Drain the cooling system. For additional
E39414
[Engine Cooling -- 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma)] / 303-03B 4. Using the special tool, disconnect the
[Engine Cooling -- 1.6L Duratec-16V Ti-VCT radiator lower to thermostat housing coolant
(Sigma)] / 303-03C [Engine Cooling -- 2.0L hose.
Duratec-HE (MI4)/1.8L Duratec-HE (MI4)] /
303-03D [Engine Cooling -- 2.5L Duratec-ST
(VI5)] / 303-03E [Engine Cooling -- 1.6L
Cooling -- 1.8L Duratorq-TDCi (Lynx) Diesel]
/ 303-03G [Engine Cooling -- 2.0L
Duratorq-TDCi (DW) Diesel] / 303-03H
[Engine Cooling -- 1.6L (Z6)].
E40433

information, refer to Section 303-12A [Intake
Air Distribution and Filtering] / 303-12B
[Intake Air Distribution and Filtering -- 2.5L
Duratec-ST (VI5)].
table(s).
2007.50 Focus 5/2007 G325372en

12 Nm
E41435
1 Battery cover 4 Battery positive cable terminal clamp cover

See Removal Detail
2 Battery ground cable terminal clamp
See Removal Detail 5 Battery positive cable electrical connector
See Installation Detail 6 Battery positive and battery negative cable
3 Battery retaining bracket retaining nut retaining clip
See Removal Detail 7 Battery ground cable to body electrical
connector
2007.50 Focus 5/2007 G325372en

10
15 Nm
13 8
14
18 Nm
12
11
9
E41204
8 Battery to transaxle ground cable electrical 12 Battery cable retaining clip

connector 13 Generator battery cable electrical
9 Battery cable retaining clip connector
See Removal Detail
10 Starter motor solenoid electrical connector
14 Battery positive and negative cables
11 Starter motor solenoid cable electrical
connector(s) 7. To install, reverse the removal procedure.
See Removal Detail
2007.50 Focus 5/2007 G325372en

Removal Details
Item 2 Battery ground cable terminal clamp 2. Remove the engine undershield.
1. Detach the battery ground cable terminal • Rotate the locking tangs counterclockwise.
clamp.
For additional information, refer to Battery
Disconnect - in this section.
Item 3 Battery retaining bracket retaining nut

1. Remove the battery retaining bracket
retaining nut, to allow the battery ground
cable to be removed from under the battery
retaining bracket.
Item 4 Battery positive cable terminal clamp E40677

cover
3. Disconnect the ignition switch and battery
to starter motor solenoid cables.
E39410
1. Release the battery positive cable terminal

shield locking tangs and remove the shield. E41142
Item 11 Starter motor solenoid cable electrical

connector(s)
Item 13 Generator battery cable electrical
connector
information, refer to Section 100-02 [Jacking 1. Lower the vehicle.
and Lifting].
Item 11 Starter motor solenoid cable electrical
connector(s)
and Lifting].
2007.50 Focus 5/2007 G325372en

2. Connect the ignition switch and battery to
starter motor solenoid cables.
6 Nm
12 Nm
E41143

• Rotate the locking tangs clockwise.
E40677

For additional information, refer to Battery
Disconnect - in this section.
2007.50 Focus 5/2007 G325372en

Battery Cables — 1.6L (Z6)

Cables - 1.6L (Z6) (414-01 Battery, Mounting

table(s).
1 Battery junction box (BJB) cover 4 Battery cable electrical connector to

battery positive terminal clamp retaining
2 Battery cable harness to BJB electrical nut
connector
5 Powertrain control module (PCM) upper
3 Battery ground cable to vehicle body cover
electrical connector retaining bolt
2007.50 Focus 5/2007 G413466en


5 Powertrain control module (PCM) upper 6 PCM electrical connector
cover See Removal Detail
7 Battery cable harness to fuel charging
wiring harness electrical connector
8 22
19 13 Nm 21
12
8
14
14 11
9
18 10 Nm
16
20 10 Nm 13
17 10 Nm 15 14 14 10
E53006
8 Battery cable harness retaining clips 16 Ignition switch to starter motor solenoid
cable electrical connector
9 Reversing lamp switch electrical connector
17 Battery to starter motor solenoid cable
10 Battery cable harness reverse lamp switch electrical connector shield
electrical connector retaining clip See Removal Detail
11 Neutral position switch electrical connector 18 Battery to starter motor solenoid cable
12 Battery cable harness to vehicle speed electrical connector retaining nut
sensor (VSS) retaining clip 19 Battery cable to generator electrical
13 Battery cable harness ground connector connector retaining nut
retaining bolt 20 Oil pressure sensor electrical connector
14 Battery cable harness retaining clips 21 VSS electrical connector
15 Battery ground cable to engine block See Removal Detail
electrical connector retaining bolt 22 Battery cable harness
2007.50 Focus 5/2007 G413466en

Removal Details
Item 6 PCM electrical connector Item 21 VSS electrical connector
1. Disconnect the battery cable wiring harness 1. Disconnect the VSS electrical connector.
from the PCM.
1. Rotate the PCM electrical connector locking
clip.
2. Disconnect the PCM electrical connectors.
E53245
1
E52909
Item 17 Battery to starter motor solenoid cable

1. Unclip the battery to starter motor solenoid
electrical connector shield.
E51777
2007.50 Focus 5/2007 G413466en

414-02-1 Generator and Regulator 414-02-1
.
SECTION 414-02 Generator and Regulator

CONTENTS PAGE

Generator............................................................................................................................ 414-02-2

Generator — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)............................................ 414-02-3
Generator — 1.6L (Z6)....................................................................................................... 414-02-6
Generator
1. REFER to Section 414-00 [Charging System -
2007.50 Focus 5/2007 G328435en

Generator — 2.0L Duratec-HE (MI4)/1.8L Duratec-HE (MI4)

1. Disconnect the battery ground cable. For 5. Detach the air conditioning pipe and position
additional information, refer to it to one side (if equipped).
Cables]. • Release the locking tang.
2. Remove the left-hand side headlamp. For
Section 417-01 [Exterior Lighting].
3. Remove the accessory drive belt. For
(VI5)].
4. Remove the generator upper retaining bolt.
E43730

table(s).
E43729
2007.50 Focus 5/2007 G295974en

15 Nm
E39150
8. Install the generator upper retaining bolt.

Item Description
1 Battery to generator cable electrical
connector
3 Generator lower retaining bolts
4 Generator
See Removal Detail
E43729
2007.50 Focus 5/2007 G295974en

9. Tighten the generator retaining bolts in the • Apply the locking tang.
sequence shown (generator shown removed
for clarity).
25 Nm 1
2
3
E43730
E40753 12. Install the accessory drive belt. For

10. Raise and support the vehicle. For Section 303-05A [Accessory Drive] /
additional information, refer to 303-05B [Accessory Drive -- 2.5L
Section 100-02 [Jacking and Lifting]. Duratec-ST (VI5)].
11. Attach the air conditioning pipe. 13. Install the left-hand side headlamp. For
Section 417-01 [Exterior Lighting].
14. Connect the battery ground cable. For
Cables].
15. Initialize the door window motors. For
Mechanisms].
Removal Details
Item 4 Generator
1. Support the generator before removing the
last generator retaining bolt.
Item 3 Generator lower retaining bolts
1. Loosly install the generator lower retaining
bolts.
2007.50 Focus 5/2007 G295974en

Generator — 1.6L (Z6)

6. Detach the coolant expansion tank and
secure to one side.
7. Detach the power assisted steering (PAS)

reservoir and secure to one side.
5. Remove the coolant expansion tank coolant

hose retaining clips.
1. Detach the expansion tank coolant hoses
from the coolant hose retaining clips.
2. Remove the coolant hose retaining clips from
the hood slam panel. 8. Remove the barometric pressure sensor.
1. Disconnect the barometric pressure sensor
2. Release the barometric pressure sensor
retaining clip.
3. Pull the barometric pressure sensor upwards.
2007.50 Focus 5/2007 G413467en

9. Remove the components in the order table(s).
1 Generator electrical connector 6 Generator lower retaining bolt

See Removal Detail
2 Fuel charging wiring harness to generator
retaining clips 7 Generator
See Removal Detail
3 Battery cable to generator electrical
connector cover 10. To install, reverse the removal procedure.
4 Battery cable to generator electrical 11. Vehicles with global closing, initialize the
connector retaining nut door window motors.
5 Generator upper retaining bolt For additional information, refer to: Door
Removal Details
Item 6 Generator lower retaining bolt
Item 7 Generator
1. The generator lower retaining bolt cannot be
removed at this stage. The bolt must be CAUTION: Care must be taken not to place
pulled out until it is clear of the casting of excessive strain on the fuel charging
the engine generator mounting bracket. wiring harness and brake vacuum pipe
when removing the generator.
NOTE: The generator will require a rocking motion
to free the slide spacer during removal.
2007.50 Focus 5/2007 G413467en

Information and Entertainment System -
.
SECTION 415-00 Information and Entertainment

System - General Information
CONTENTS PAGE

Audio System...................................................................................................................... 415-00-2
Self-Diagnostic Mode - Low Series Audio Unit................................................................... 415-00-2
Self-Diagnostic Mode - High Series Audio Unit.................................................................. 415-00-2
Diagnostic Trouble Code (DTC) Index Chart...................................................................... 415-00-3
Symptom Chart................................................................................................................... 415-00-4
Pinpoint Tests..................................................................................................................... 415-00-5
Cellular Phone.................................................................................................................... 415-00-23
Diagnostic Trouble Code (DTC) Index Chart...................................................................... 415-00-24
Symptom Chart................................................................................................................... 415-00-26
Pinpoint Tests..................................................................................................................... 415-00-27
Audio System
Refer to Wiring Diagrams Section 415-01, for 2. Release the preset buttons 3 and 6 and the
schematic and connector information. audio unit will enter the Self-Diagnostic Mode.
Refer to Wiring Diagrams Section 415-03, for 3. To exit the Self-Diagnostic Mode, switch the
schematic and connector information. audio unit OFF.
General Equipment
Self-Diagnostic Mode
Message Displayed Circuit Tested
1. 4CH LF for four Left hand front speaker
Inspection and Verification channel system 2CH LF circuit.
for two channel system.
NOTE: If the code is entered incorrectly 3 times,
the system will lock out. The component can only 2. 4CH RF for four Right hand front
be unlocked by the manufacturer. channel system 2CH speaker circuit.
RF for two channel
1. Verify the customer concern. system.
or electrical damage. 3. 4CH LR for four Left hand rear speaker
channel system. circuit.
4. 4CH RR for four Right hand rear speaker
Mechanical Electrical channel system. circuit.
– Audio unit – Fuse(s)
4. If the cause is not evident after the
– Antenna – Wiring harness
Self-Diagnostic Mode, connect WDS to the data
– Foreign objects – Electrical link connector (DLC).
contacting speaker connector(s)
5. Retrieve the Diagnostic Trouble Code (DTC)s
– Trim poorly – Audio unit and refer to the DTC Index Chart.
fitted/resonance – Audio control switch
– Audio control switch (if equipped)
(if equipped) – Rear auxiliary audio
Self-Diagnostic Mode - High Series
– Rear auxiliary audio control (if equipped)
Audio Unit
control (if equipped) – CD changer NOTE: The audio unit must be in radio mode
– Compact disc (CD) – DVD player before entering the Self-Diagnostic Mode.
changer
– Central junction box 1. To enter the audio unit Self-Diagnostic Mode,
– Digital versatile disc (CJB) switch the audio unit ON. Within four seconds
(DVD) player
depress the preset button 4 and TA together.
2. Release the preset button 4 and TA and the
3. If an obvious cause for an observed or reported audio unit will enter the Self-Diagnostic Mode.
3. To exit the Self-Diagnostic Mode, switch the
audio unit OFF.
symptom and refer to the Self-Diagnostic Mode. Self-Diagnostic Mode
Message Displayed Circuit Tested
Self-Diagnostic Mode - Low Series 1. 4CH LF for four Left hand front speaker
Audio Unit channel system 2CH LF circuit.
for two channel system.
NOTE: The audio unit must be in radio mode
before entering the Self-Diagnostic Mode. 2. 4CH RF for four Right hand front
channel system 2CH speaker circuit.
1. To enter the audio unit Self-Diagnostic Mode, RF for two channel
switch the audio unit ON. Within four seconds system.
depress the preset buttons 3 and 6 together.
2007.50 Focus 3/2007 G167313en

Message Displayed Circuit Tested 4. If the cause is not evident after the
Self-Diagnostic Mode, connect WDS to the data
3. 4CH LR for four Left hand rear speaker link connector (DLC).
channel system. circuit. 5. Retrieve the Diagnostic Trouble Code (DTC)s
4. 4CH RR for four Right hand rear speaker and refer to the DTC Index Chart.
channel system. circuit.
5. FM frequency Antenna cable.
received.
Diagnostic Trouble Code (DTC) Index Chart

Diagnostic Trouble Code (DTC) Index Chart - Audio Unit
DTC Description/Condition Possible Source Action
B1342 Audio unit internal failure Audio unit INSTALL a new audio
unit.
REFER to: Audio Unit
(415-01 Audio Unit,
Removal and Installa-
tion).
B2401 Tape player failure Audio unit INSTALL a new audio
unit.
(415-01 Audio Unit,
tion).
B2403 CD player internal failure Audio unit INSTALL a new audio
unit.
(415-01 Audio Unit,
tion).
B2404 Audio control switch Audio control switch GO to Pinpoint Test E.
circuit failure
B2406 CD player internal failure Audio unit INSTALL a new audio
unit.
(415-01 Audio Unit,
tion).
B2408 Speaker line short circuit Speaker(s) GO to Pinpoint Test D.
B2409 AM receiving signal error Antenna cable GO to Pinpoint Test B.
B2410 FM receiving signal error Antenna cable GO to Pinpoint Test B.
B2477 Module configuration Audio unit and central REFER to WDS.
failure junction box (CJB)
P1628 Module ignition supply CJB REFER to WDS.
input
2007.50 Focus 3/2007 G167313en

Diagnostic Trouble Code (DTC) Index Chart - CD Changer
B1342 CD changer defective CD changer INSTALL a new CD
changer.
REFER to: Compact
Disc (CD) Changer
(415-01 Audio Unit,
tion).
B2403 CD changer internal CD changer INSTALL a new CD
failure changer.
REFER to: Compact
Disc (CD) Changer
(415-01 Audio Unit,
tion).
1. If the cause is still evident, refer to the Symptom

Chart.
Symptom Chart

• The audio unit is inoper- • Circuit. • GO to Pinpoint Test A.
ative/does not operate correctly • Audio unit.
• The display is blank - radio and • Audio unit. • INSTALL a new audio unit.
cassette player operate REFER to: Audio Unit (415-01
Audio Unit, Removal and
Installation).
operation.
• The display is blank - radio and • Audio unit. • INSTALL a new audio unit.
CD player operate REFER to: Audio Unit (415-01
Installation).
operation.
• Poor reception • Antenna. • GO to Pinpoint Test B.
• Antenna cable.
• Audio unit.
• Poor quality/distorted sound • Speaker(s). • GO to Pinpoint Test C.
from one or more speakers (not • Circuit.
all speakers) • Audio unit.
2007.50 Focus 3/2007 G167313en


• No sound from all speakers • Audio unit. • INSTALL a new audio unit.
REFER to: Audio Unit (415-01
Installation).
operation.
• No sound from one or more of • Speaker(s). • GO to Pinpoint Test D.
the speakers (not all speakers) • Circuit.
• Audio unit.
• The auxiliary audio control is • Circuit. • GO to Pinpoint Test E.
inoperative/does not operate • Auxiliary audio control switch.
correctly. • Rear auxiliary audio control.
• Audio unit.
• The CD changer is inoper- • Circuit(s). • GO to Pinpoint Test F.
ative/does not operate correctly • CD changer.
• Audio unit.
• The digital versatile disc (DVD) • Circuit(s). • GO to Pinpoint Test G.
player is inoperative/does not • DVD player.
operate correctly
• No sound from headphone(s) • Headphone(s). • Using a known good head-
• DVD player. phone, check the headphone
in the right-hand and left-hand
sockets. If sound is heard from
each headphone socket,
INSTALL a new headphone(s).
If no sound is heard from the
headphone socket(s), INSTALL
a new DVD player.
REFER to: Digital Versatile
Disc (DVD) Player (415-07
Video System, Removal and
Installation).
operation.
• The audio unit illumination is • Fuse(s). • REFER to: Instrument Cluster
inoperative • Circuit(s). and Panel Illumination (413-
• Audio unit. 00 Instrument Cluster and
• Genetic electronic module Panel Illumination, Diagnosis
(GEM). and Testing).
• The audio unit clock is not • Audio unit connector. • REFER to: Instrument Cluster
displayed • Audio unit. (413-01 Instrument Cluster,
• Instrument cluster. Diagnosis and Testing).
Pinpoint Tests
measurements.
2007.50 Focus 3/2007 G167313en

PINPOINT TEST A : THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
A1: CHECK FOR VOLTAGE TO AUDIO UNIT
2 Ignition switch in position I.
3 Measure the voltage between the audio unit
V C442 pin 15, circuit 29-MD15 (OG/BK), harness
side and ground, and between the audio unit
C442 pin 16, circuit 75-MD15 (YE/GN), harness
side and ground.
→ Yes
GO to A2.
→ No
E42130 REPAIR circuit 29-MD15 (OG/BK) or circuit
75-MD15 (YE/GN). TEST the system for
normal operation.
A2: CHECK THE AUDIO UNIT GROUND CIRCUITS FOR OPEN
C442 pin 11, circuit 91-MD5 (BK/BU), harness
side and ground, and between the audio unit
C442 pin 12, circuit 91-MD15 (BK/GN), harness
side and ground.
• Are the resistances less than 1 ohm?
→ Yes
GO to A3.
→ No
E42131 REPAIR circuit 91-MD5 (BK/BU) or 91-MD15
(BK/GN). TEST the system for normal opera-
tion.
A3: CHECK CIRCUIT 9-MD27 (BN/WH) TO GROUND
1 Connect Audio Unit C442.
2007.50 Focus 3/2007 G167313en


C448 pin 6, circuit 9-MD27 (BN/WH), harness
side and ground.
• Is the resistance less than 1 ohm?
→ Yes
E42132
→ No
REPAIR circuit 91-MD5 (BK/BU) . TEST the
PINPOINT TEST B : POOR RECEPTION

B1: CHECK THE ANTENNA CABLE SHIELD
2 Disconnect the antenna cable from the audio
unit.
3 Measure the resistance between the antenna
cable ground connector (shield), and ground.
→ Yes
GO to B2.
→ No
CLEAN and TIGHTEN the antenna base
connection to the body. If the concern persists,
INSTALL a new antenna cable.
TIW3801009
REFER to: Antenna Cable (415-02 Antenna,
B2: CHECK THE ANTENNA CENTER CONDUCTOR FOR OPEN
1 Remove the antenna mast.
2007.50 Focus 3/2007 G167313en


2 Measure the resistance of the center conductor
between the ends of the antenna cable.
→ Yes
GO to B3.
→ No
TIW3801010
B3: CHECK ANTENNA CABLE FOR SHORT

1 Measure the resistance between the antenna
center conductor and the antenna ground
(shield).
• Is the resistance greater than 10,000 ohms
(open circuit)?
→ Yes
CLEAN and TIGHTEN the ground connections
at the base of the antenna and battery
negative cable to the body. If concern the
persists, INSTALL a new audio unit.
V3801158
→ No
concern persists, INSTALL a new audio unit.
PINPOINT TEST C : POOR QUALITY/DISTORTED SOUND FROM ONE OR MORE SPEAKERS (NOT
ALL SPEAKERS)
C1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Affected Speaker.
2007.50 Focus 3/2007 G167313en


2 Measure the resistance between the affected
speaker pin 1 and pin 4, component side.
• Is the resistance approximately 4.0 ohms?
→ Yes
GO to C2.
→ No
INSTALL a new speaker. TEST the system
E42133
C2: CHECK SPEAKER INPUT FOR SHORT TO GROUND

speaker connector pin 1, harness side and
ground.
(open circuit)?
→ Yes
GO to C3.
→ No
REPAIR speaker input circuit. TEST the
E42134 system for normal operation.
C3: CHECK SPEAKER RETURN FOR SHORT TO GROUND

speaker connector pin 4, harness side and
ground.
(open circuit)?
→ Yes
for normal operation. If the concern persists,
E42135 REFER to: Audio Unit (415-01 Audio Unit,
→ No
REPAIR speaker return circuit. TEST the
2007.50 Focus 3/2007 G167313en

PINPOINT TEST D : NO SOUND FROM ONE OR MORE OF THE SPEAKERS (NOT ALL SPEAKERS)
D1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.
2 Measure the resistance between the inoperative
speaker pin 1 and pin 4, component side.
• Is the resistance approximately 4.0 ohms?
→ Yes
GO to D2.
→ No
INSTALL a new speaker(s). TEST the system
E42133
D2: CHECK THE INOPERATIVE SPEAKER(S) CONNECTOR PIN 1 CIRCUIT

2 Measure the resistance between the following
audio unit C442 pins, harness side and the
inoperative speaker(s) connector pin 1, harness
side:
– (Left front speaker) C937 pin 1, circuit 8-MD28
(WH) to C442 pin 3, circuit 8-MD10 (WH/BK).
– (Right front speaker) C938 pin 1, circuit 8-
MD28 (WH) to C442 pin 2, circuit 8-MD17
(WH/RD).
– (Left rear speaker) C939 pin 1, circuit 8-MD29
(WH/VT) to C442 pin 4, circuit 8-MD11
E42136 (WH/VT).
– (Right rear speaker) C940 pin 1, circuit 8-
MD29B (WH/VT) to C442 pin 1, circuit 8-MD18
(WH).
→ Yes
GO to D3.
→ No
REPAIR the circuit in question. TEST the
2007.50 Focus 3/2007 G167313en


D3: CHECK THE INOPERATIVE SPEAKER(S) CONNECTOR PIN 4 CIRCUIT
audio unit C442 pins, harness side and the
side:
– (Left front speaker) C937 pin 4, circuit 10-
MD28 (GY) to C442 pin 7, circuit 10-MD10
(GY/BK).
MD28 (GY) to C442 pin 6, circuit 10-MD17
(GY/RD).
– (Left rear speaker) C939 pin 4, circuit 10-
E42137 MD29 (GY/WH) to C442 pin 8, circuit 10-MD11
(GY/WH).
– (Right rear speaker) C940 pin 4, 10-MD29B
(GY/WH) to C442 pin 5, 10-MD18 (GY).
→ Yes
GO to D4.
→ No
D4: CHECK THE INOPERATIVE SPEAKER(S) CIRCUIT FOR SHORT TO GROUND
1 Disconnect Front Door Tweeter Speaker(s)
C941 (left-hand) C943 (right-hand).
2 Disconnect Rear Door Tweeter Speaker(s) C942
(left-hand) C944 (right-hand).
2007.50 Focus 3/2007 G167313en


side and ground:
– (Left front speaker) C937 pin 1, circuit 8-MD28
(WH), to ground.
MD28 (WH), to ground.
– (Left rear speaker) C939 pin 1, circuit 8-MD29
(WH/VT), to ground.
– (Right rear speaker) C940 pin 1, 8-MD29B
(WH/VT), to ground.
E42134
(open circuit)?
→ Yes
If the front door tweeter speaker(s) are inoper-
ative, GO to D5.
If the rear door tweeter speaker(s) are inoper-
ative, GO to D7.
→ No
D5: CHECK THE INOPERATIVE FRONT DOOR TWEETER SPEAKER(S) CIRCUIT FOR SHORT
TO GROUND
inoperative front door tweeter speaker(s)
connector pin 1, harness side and ground:
– (Left front door tweeter speaker) C941 pin 1,
circuit 8-MD28A (WH), to ground.
– (Right front door tweeter speaker) C943 pin
1, circuit 8-MD28A (WH), to ground.
(open circuit)?
→ Yes
E44211
INSTALL a new front door tweeter speaker.
REFER to: Front Door Tweeter Speaker (415-
03 Speakers, Removal and Installation).
→ No
GO to D6.
D6: CHECK THE FRONT SPEAKER(S) TO FRONT DOOR TWEETER SPEAKER(S) CIRCUIT(S)
FOR OPEN
2007.50 Focus 3/2007 G167313en


front speaker(s) and front door tweeter
speaker(s):
– left-hand front door tweeter speaker C941 pin
1, circuit 8-MD28A (WH), harness side and
front speaker C937 pin 2, circuit 8-MD28A
(WH), harness side.
– left-hand front door tweeter speaker C941 pin
3, circuit 10-MD28A (GY), harness side and
(GY), harness side.
E42138 – right-hand front door tweeter speaker C943
pin 1, circuit 8-MD28A (WH), harness side and
(WH), harness side.
– right-hand front door tweeter speaker C943
pin 3, circuit 10-MD28A (GY), harness side
and front speaker C938 pin 3, circuit 10-
MD28A (GY), harness side.
→ Yes
INSTALL a new front door tweeter speaker.
REFER to: Front Door Tweeter Speaker (415-
03 Speakers, Removal and Installation).
→ No
D7: CHECK THE INOPERATIVE REAR DOOR TWEETER SPEAKER(S) CIRCUIT FOR SHORT TO
GROUND
inoperative rear door tweeter speaker(s)
connector pin 1, harness side and ground:
– (Left rear door tweeter speaker) C942 pin 1,
circuit 8-MD29A (WH/VT), to ground.
– (Right rear door tweeter speaker) C943 pin 1,
circuit 8-MD29C (WH/VT), to ground.
(open circuit)?
→ Yes
E44211
INSTALL a new rear door tweeter speaker.
→ No
GO to D8.
2007.50 Focus 3/2007 G167313en


D8: CHECK THE REAR SPEAKER(S) TO REAR DOOR TWEETER SPEAKER(S) CIRCUIT(S) FOR
OPEN
rear speaker(s) and rear door tweeter
speaker(s):
– left-hand rear door tweeter speaker C942 pin
1, circuit 8-MD29A (WH/VT), harness side and
rear speaker C939 pin 2, circuit 8-MD29A
– left-hand rear door tweeter speaker C942 pin
3, circuit 10-MD29A (GY/WH), harness side
and rear speaker C939 pin 3, circuit 10-
MD29A (GY/WH), harness side.
E42138 – right-hand rear door tweeter speaker C944
pin 1, circuit 8-MD29C (WH/VT), harness side
and rear speaker C940 pin 2, circuit 8-MD29C
– right-hand rear door tweeter speaker C944
pin 3, circuit 10-MD29C (GY/WH), harness
side and rear speaker C940 pin 3, circuit 10-
MD29C (GY/WH), harness side.
→ Yes
INSTALL a new rear door tweeter speaker.
→ No
2007.50 Focus 3/2007 G167313en

PINPOINT TEST E : THE AUXILIARY AUDIO CONTROL SWITCH IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
E1: CHECK THE AUDIO UNIT OPERATES CORRECTLY USING THE AUDIO UNIT CONTROLS
1 Operate the audio unit using the audio unit
controls.
• Does the audio unit operate correctly using the
audio controls?
→ Yes
If the auxiliary audio control switch is inoper-
ative, GO to E2.
If the rear auxiliary audio control is inoperative,
GO to E4.
→ No
E2: CHECK THE CIRCUIT 8-MD26 (WH/BK) FOR OPEN
2 Disconnect Auxiliary Audio Control Switch C437.
C447 pin 6, circuit 8-MD26 (WH/BK) harness
side and the auxiliary audio control switch C437
pin 1, circuit 8-MD26 (WH/BK) harness side.
→ Yes
GO to E3.
→ No
2007.50 Focus 3/2007 G167313en


E3: CHECK CIRCUIT 9-MD26 (BN/YE) FOR OPEN
C447 pin 8, circuit 9-MD26 (BN/YE) harness
side and the auxiliary audio control switch C437
pin 2, circuit 9-MD26 (BN/YE) harness side.
→ Yes
INSTALL a new auxiliary audio control switch.
E42140 REFER to: Audio Unit (415-01 Audio Unit,
→ No
normal operation.
E4: CHECK CIRCUIT 29-MD16B (OG/GN) FOR VOLTAGE
1 Disconnect Rear Auxiliary Audio Control C451.
2 Measure the voltage between the rear auxiliary
audio control C451 pin 8, circuit 29-MD16B
(OG/GN), harness side and ground.
→ Yes
GO to E5.
→ No
normal operation.
E42141
E5: CHECK CIRCUIT 91-MD16 (BK/RD) FOR GROUND

→ Yes
GO to E6.
→ No
normal operation.
E42142
2007.50 Focus 3/2007 G167313en


E6: CHECK CIRCUIT 2-MD16 (GY/BK) FOR OPEN
(GY/BK), harness side and the audio unit C448
pin 8, circuit 2-MD16 (GY/BK), harness side.
→ Yes
GO to E7.
→ No
E7: CHECK CIRCUIT 1-MD16 (WH/BK) FOR OPEN

(WH/BK), harness side and the audio unit C448
pin 2, circuit 1-MD16 (WH/BK), harness side.
→ Yes
GO to E8.
→ No
E8: CHECK CIRCUIT 2-MD19 (GY/RD) FOR OPEN

(GY/RD), harness side and the audio unit C448
pin 7, circuit 2-MD19 (GY/RD), harness side.
→ Yes
GO to E9.
→ No
2007.50 Focus 3/2007 G167313en


E9: CHECK CIRCUIT 1-MD19 (WH/RD) FOR OPEN
(WH/RD), harness side and the audio unit C448
pin 1, circuit 1-MD19 (WH/RD), harness side.
→ Yes
INSTALL a new rear auxiliary audio control.
REFER to: Rear Auxiliary Audio Controls (415-
→ No
PINPOINT TEST F : CD CHANGER IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

F1: CHECK THE CD CHANGER FOR VOLTAGE
1 Disconnect CD Changer C440.
2 Measure the voltage between the CD changer
C440 pin 9, circuit 29-MD8 (OG), harness side
and ground.
→ Yes
GO to F2.
→ No
REPAIR circuit 29-MD8 (OG). TEST the
E42149
2007.50 Focus 3/2007 G167313en


F2: CHECK THE CD CHANGER FOR GROUND
1 Measure the resistance between the CD
changer C440 pin 3, circuit 91-MD8 (BK/OG),
→ Yes
GO to F3.
→ No
REPAIR the circuit 91-MD8 (BK/OG). TEST
E42148
F3: CHECK THE CD CHANGER TO AUDIO UNIT CIRCUIT(S) FOR OPEN

CD changer circuit(s) and the audio unit
circuit(s):
– CD changer C440 pin 5, circuit 1-MD49
(WH/GN), harness side and audio unit C447
pin 3, circuit 1-MD49 (WH/GN), harness side.
(GY/OG), harness side and audio unit C447
pin 9, circuit 2-MD49 (GY/OG), harness side.
(WH/BK), harness side and audio unit C447
E42147 pin 4, circuit 1-MD50 (WH/BK), harness side.
(GY/BK), harness side and audio unit C447
pin 10, circuit 2-MD50 (GY/BK), harness side.
→ Yes
INSTALL a new CD changer.
REFER to: Compact Disc (CD) Changer (415-
→ No
REPAIR the circuit(s) as necessary. TEST the
persists, INSTALL a new audio unit.
2007.50 Focus 3/2007 G167313en

PINPOINT TEST G : THE DIGITAL VERSATILE DISC (DVD) PLAYER IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
G1: CHECK THE DVD PLAYER FOR POWER
1 Disconnect DVD Player C437.
2 Measure the voltage between the DVD player
C437 pin 1, circuit 29-MD8 (OG), harness side
V and ground.
→ Yes
GO to G2.
→ No
REPAIR circuit 29-MD8 (OG). TEST the
E0037521 persists, install a new CJB. Test the system
G2: CHECK THE DVD PLAYER FOR SWITCHED POWER

E0037522

C437 pin 2, circuit 75-MD8 (YE/BU), harness
side and ground.
→ Yes
GO to G3.
→ No
REPAIR circuit 75-MD8 (YE/BU). Test the
G3: CHECK THE DVD PLAYER FOR GROUND
2007.50 Focus 3/2007 G167313en

E0037520
2 Measure the resistance between the DVD player

C437 pin 3, circuit 31-MD8 (BK), harness side
and ground.
→ Yes
GO to G4.
→ No
REPAIR circuit 31-MD8 (BK). Test the system
G4: CHECK THE DVD PLAYER ILLUMINATION CIRCUIT FOR POWER
1 Turn the multi-function switch to the on position.
E0037523

C437 pin 15, circuit 29S-LK17 (OG/BK), harness
side and ground.
→ Yes
GO to G5.
→ No
REPAIR circuit 29S-LK17 (OG-BK). Test the
2007.50 Focus 3/2007 G167313en


G5: CHECK THE DVD PLAYER ILLUMINATION CIRCUIT FOR GROUND
E0037524
1 Measure the resistance between the DVD player

C437 pin 16, 31-LK17 (BK), harness side and
ground.
→ Yes
INSTALL a new DVD player.
REFER to: Digital Versatile Disc (DVD) Player
(415-07 Video System, Removal and
Installation).
→ No
Repair the circuit(s) 31-LK17 (BK) or 31-MD8.
2007.50 Focus 3/2007 G167313en

Cellular Phone
Refer to Wiring Diagrams Section 415-00, for When selected as active the Bluetooth technology
schematic and connector information. is a wireless system that interacts with the relevant
General Equipment component modules through the PSE module. The
general operation of the Bluetooth is similar to the
voice control.
Bluetooth technology cannot transfer the cellular
Principles of Operation phone's PHONEBOOK or recent outgoing and
incoming call details to the audio unit or navigation
NOTE: Voice control will only operate with the system display module. If the cellular phone is
audio unit and components required switched ON. placed into the handset holder the PHONEBOOK
data and recent outgoing and incoming call
Voice Control information will be transferred to the audio unit or
The portable support electronics (PSE) module navigation system display module.
has a voice control system. The customer will be For additional information, REFER to the cellular
able to push the VOICE button on the audio control phone Owner's Guide.
switch located on the steering column lower
shroud, this will activate the PSE module and allow
voice control. An audible tone will be heard through Inspection and Verification
the audio unit speakers after which, a voice
command can then be spoken into the microphone NOTE: Make sure that the cellular phone is
located in the overhead console. featured on the list of recommended cellular
phones for the system.
The incoming calls and voice confirmation can be
heard through the audio system speakers. Make sure that the PSE module and cellular
phone are configured to each other before
When a voice command is spoken into the starting a system diagnosis. ENTER the
microphone it will be sent as a signal to the PSE following PIN number on the cellular phone to
module. The signal is then sent from the PSE configure the cellular phone to the PSE module:
module to the relevant components on the 0000.
medium-speed controller area network (CAN) bus
network. The component will then convert the Make sure that the MUTE symbol is not
signal back into the original voice command. displayed on the audio unit when trying to
operate the cellular phone system. If the MUTE
The components that the PSE module interacts symbol is displayed, this indicates that the PSE
with are as follows: module requires configuring to the vehicle and
• audio unit the cellular phone requires programming to the
• navigation system display module PSE module.GO to Pinpoint Test F.
• cellular phone 1. Verify the customer concern by operating the
system using the customers cellular phone.
For additional information on the cellular phone
system, REFER to the cellular phone Owner's 2. Visually inspect for obvious signs of electrical
Guide. damage.
Bluetooth
An input can be given through the cellular phone
with or without the cellular phone connected to the
handset holder. Providing that the cellular phone
is one of the recommended cellular phones for the
system, is supplied with the Bluetooth technology
and the cellular phone is programmed to the PSE
module.
2007.50 Focus 3/2007 G913439en

Visual Inspection Chart 3. If an obvious cause for an observed or reported
Electrical concern is found, correct the cause (if possible)
• Fuse(s) 4. If the cause is not visually evident, connect the
• Wiring harness WDS to the data link connector (DLC).
• Electrical connector(s) 5. SELECT the TOOLBOX menu.
• Cellular phone 6. SELECT the
• Microphone ENTERTAINMENT/COMMUNICATION menu.
• Handset holder 7. SELECT the SPEECH RECOGNITION
• PSE module MODULE option and follow the instructions on
the display.
• Audio unit
8. Retrieve the diagnostic trouble codes (DTC)s
and refer to the Diagnostic Trouble Code (DTC)
• Navigation system display module Index Chart.
9. If no DTCs are retrieved or there is no
communication with the module, proceed to the
Symptom Chart to continue diagnostics.
Diagnostic Trouble Code (DTC) Index Chart

B1038 Microphone input circuit Microphone defect or GO to Pinpoint Test C.
failure short to ground
B1317 Battery voltage high Battery voltage above 16 REFER to: Charging
volts System (414-00 Char-
ging System - General
Information, Diagnosis
and Testing).
B1318 Battery voltage low Battery voltage below 9 REFER to: Charging
volts System (414-00 Char-
ging System - General
Information, Diagnosis
and Testing).
B1342 PSE module failure PSE module INSTALL a new PSE
module.
REFER to: Portable
Support Electronics
(PSE) Module (419-08
Cellular Phone,
tion).
TEST the system for
normal operation.
B1899 Microphone input signal Microphone defect or not GO to Pinpoint Test C.
circuit open connected
B2272 Microphone bias circuit No supply to microphone GO to Pinpoint Test C.
failure
2007.50 Focus 3/2007 G913439en


B228A Voice recognition base- Wiring harness, GO to Pinpoint Test E.
plate detection connectors or cellular
phone handset holder
B2477 Faulty module configura- PSE module REFER to the WDS.
tion
P2503 Charging system voltage Short to ground GO to Pinpoint Test B.
low
U0074 Bluetooth communication PSE module or cellular CHECK the cellular
failure to cellular phone phone phone Bluetooth function
with another application
to determine if the
cellular phone is the
concern. If the Bluetooth
function operates
correctly with the other
application, INSTALL a
new PSE module.
REFER to: Portable
Support Electronics
Cellular Phone,
tion).
TEST the system for
normal operation. If the
Bluetooth function does
not operate with other
application, REFER to
the cellular phone
Owner's Guide.
U2050 No application present PSE module INSTALL a new PSE
module.
REFER to: Portable
Support Electronics
Cellular Phone,
tion).
TEST the system for
normal operation.

2007.50 Focus 3/2007 G913439en

Symptom Chart

• No communication with the • PSE module not configured to • GO to Pinpoint Test F.
portable support electronics the vehicle.
(PSE) module
• Fuse(s). • GO to Pinpoint Test A.
• Circuit(s).
• PSE module.
• DLC. • REFER to: Communications
Network (418-00 Module
Communications Network,
• The audio unit display does not • PSE module not configured to • GO to Pinpoint Test F.
display PHONE the vehicle.
• Audio unit. • CHECK all communication
• Navigation system display between the instrument cluster,
module. audio unit, navigation system
• PSE module. display module and PSE
• Instrument cluster. module. REFER to the WDS.
• The handset battery does not • Fuse(s). • GO to Pinpoint Test B.
charge • Circuit(s).
• PSE module.
• Handset holder.
• Cellular phone battery. • REFER to the cellular phone
Owner's Guide.
• The cellular phone microphone • Circuit(s). • GO to Pinpoint Test C.
is not operating correctly • Microphone.
• PSE module.
• Reduced sound or no sound • Audio unit. • CHECK all communication
through the speakers • PSE module. between the audio unit and
PSE module. REFER to the
WDS.
• Circuit(s). • GO to Pinpoint Test D.
• Audio unit.
• PSE module.
• The cellular phone information • Audio unit. • CHECK all communication
is not displayed • Navigation system display between the instrument cluster,
• The voice activated phone • Audio unit. • CHECK all communication
functions are inoperative • Navigation system display between the instrument cluster,
2007.50 Focus 3/2007 G913439en


• Circuit(s). • GO to Pinpoint Test E.
• Cellular Phone.
• Handset holder.
• PSE module.
• Cellular phone is not featured • CHECK the make and model
on the list of recommended of the cellular phone against
cellular phones for the system those on the list of recom-
mended cellular phones for the
system.
Pinpoint Tests NOTE: Use a digital multimeter for all electrical

measurements.
NOTE: ENTER the following PIN number on the
cellular phone to configure the cellular phone to
the PSE module: 0000.
PINPOINT TEST H : NO COMMUNICATION WITH THE PORTABLE SUPPORT ELECTRONICS (PSE)
MODULE
A1: CHECK FOR VOLTAGE AT THE PSE MODULE
1 Disconnect PSE Module C432.
2 Measure the voltage between the PSE module
C432 pin 17, circuit 29-MC12C (OG/YE),
harness side and ground; and the PSE module
C432 pin 18, circuit 29-MC12B (OG/YE),
V harness side and ground.
→ Yes
GO to A2.
→ No
E53363 REPAIR circuit 29-MC12C (OG/YE) or circuit
29-MC12B (OG/YE) as necessary. TEST the
2007.50 Focus 3/2007 G913439en


A2: CHECK THE PSE MODULE GROUND CIRCUIT(S)
1 Measure the resistance between the PSE
module C432 pin 33, circuit 91-MC12 (BK/YE),
C432 pin 34, circuit 91-MC12A (BK/YE),
→ Yes
INSTALL a new PSE module.
REFER to: Portable Support Electronics (PSE)
E53364 Module (419-08 Cellular Phone, Removal
and Installation).
→ No
REPAIR circuit 91-MC12 (BK/YE) or circuit
91-MC12A (BK/YE) as necessary. TEST the
PINPOINT TEST I : THE CELLULAR PHONE HANDSET BATTERY DOES NOT CHARGE
B1: CHECK THE CELLULAR PHONE DISPLAY WHEN BEING USED OUTSIDE OF THE VEHICLE
1 Operate the cellular phone outside of the
vehicle.
• Does the cellular phone display low battery?
→ Yes
CHECK the cellular phone battery. REFER to
the cellular phone Owner's Guide.
→ No
GO to B2.
B2: CHECK THE BATTERY SYMBOL ON THE CELLULAR PHONE
2 INSTALL the cellular phone into the handset
holder.
• Does the battery symbol flash?
→ Yes
The cellular phone battery is charging
correctly. WAIT for the cellular phone battery
to charge. TEST the system for normal opera-
tion.
→ No
GO to B3.
2007.50 Focus 3/2007 G913439en


B3: CHECK FOR VOLTAGE AT THE PSE MODULE
2 Measure the voltage between the PSE module
C432 pin 17, circuit 29-MC12C (OG/YE),
C432 pin 18, circuit 29-MC12B (OG/YE),
→ Yes
GO to B4.
→ No
E53363 REPAIR circuit 29-MC12C (OG/YE) or circuit
29-MC12B (OG/YE) as necessary. TEST the
B4: CHECK THE PSE MODULE GROUND CIRCUIT(S)
module C432 pin 33, circuit 91-MC12 (BK/YE),
C432 pin 34, circuit 91-MC12A (BK/YE),
→ Yes
GO to B5.
→ No
E53364 REPAIR circuit 91-MC12 (BK/YE) or circuit
91-MC12A (BK/YE) as necessary. TEST the
B5: CHECK FOR CHARGE VOLTAGE AT THE HANDSET HOLDER
1 Connect PSE Module C432.
2 Disconnect Handset Holder C131.
3 Measure the voltage between the handset
holder C131 pin 15, circuit 29-MC11 (OG/WH),
→ Yes
GO to B6.
→ No
NOTE: If the connector is damaged install a
new harness. REPAIR the circuit 29-MC11
E83444 (WH/OG). TEST the system for normal opera-
tion.
2007.50 Focus 3/2007 G913439en


B6: CHECK GROUND CIRCUIT 31-MC11 (BK)
1 Measure the resistance between the handset
holder C131 pin 8, circuit 31-MC11 (BK),
→ Yes
GO to B7.
→ No
normal operation.
E83445
B7: CHECK FOR VOLTAGE AT CIRCUIT 30-MC11 (RD)

1 Measure the voltage between the handset
holder C131 pin 7, circuit 30-MC11 (RD),
V
→ Yes
Module (419-08 Cellular Phone, Removal
and Installation).
→ No
INSTALL a new handset holder.
REFER to: Handset Holder (419-08 Cellular
Phone, Removal and Installation).
2007.50 Focus 3/2007 G913439en

PINPOINT TEST J : THE CELLULAR PHONE MICROPHONE IS NOT OPERATING CORRECTLY
C1: CHECK THAT THE VOICE IS BEING TRANSMITTED DURING A TELEPHONE CONVERSION
OUTSIDE OF THE VEHICLE
NOTE: Make sure that the Bluetooth functionality is disabled for this test.
1 Operate the cellular phone outside the vehicle.

• Does the cellular phone transmit the voice
during a telephone conversation outside of the
vehicle?
→ Yes
GO to C2.
→ No
REFER to the cellular phone Owner's Guide.
C2: CHECK CIRCUIT 8-MC8 (WH/RD) FOR OPEN
2 Disconnect Microphone C493.
module C432 pin 3, circuit 8-MC8 (WH/RD),
harness side and the microphone C493 pin 1,
circuit 8-MC8 (WH/RD), harness side.
→ Yes
GO to C3.
→ No
2007.50 Focus 3/2007 G913439en


C3: CHECK CIRCUIT 3-MC8 (BK) FOR OPEN
module C432 pin 4, circuit 3-MC8 (BK), harness
side and the microphone C493 pin 2, circuit 3-
MC8 (BK), harness side.
→ Yes
INSTALL a new microphone. TEST the system
→ No
and Installation).
PINPOINT TEST K : REDUCED SOUND OR NO SOUND THROUGH THE SPEAKERS

NOTE: Before carrying out the following tests make sure that the cellular phone system volume is not
set too low. Operate the cellular phone system and use the volume control on the audio unit to set the
cellular phone system volume.
D1: CHECK THE CELLULAR PHONE OPERATES CORRECTLY OUTSIDE THE VEHICLE
1 CARRY OUT an audio unit self-diagnostic
mode.
and Entertainment System - General Informa-
tion, Diagnosis and Testing).
2 Operate the cellular phone outside the vehicle.
• Does the cellular phone operate correctly
outside the vehicle?
→ Yes
GO to D2.
→ No
REFER to the cellular phone Owner's Guide.
D2: CHECK CIRCUIT 8-MC12 (WH) FOR OPEN
2007.50 Focus 3/2007 G913439en


module C432 pin 1, circuit 8-MC12 (WH),
harness side and the audio unit C447 pin 1,
circuit 8-MC12 (WH), harness side.
→ Yes
GO to D3.
→ No
D3: CHECK CIRCUIT 9-MC12 (BN) FOR OPEN

module C432 pin 2, circuit 9-MC12 (BN),
harness side and the audio unit C447 pin 7,
circuit 9-MC12 (BN), harness side.
→ Yes
→ No
and Entertainment System - General
PINPOINT TEST L : THE VOICE ACTIVATED PHONE FUNCTIONS ARE INOPERATIVE

E1: CHECK CIRCUIT 8-MC11 (WH/VT) FOR OPEN
2 Disconnect Handset Holder C131.
2007.50 Focus 3/2007 G913439en


module C432 pin 45, circuit 8-MC11 (WH/VT),
harness side and the handset holder C131 pin
4, circuit 8-MC11 (WH/VT), harness side.
→ Yes
GO to E2.
→ No
E2: CHECK CIRCUIT 4-MC16 (GY) FOR OPEN

module C432 pin 47, circuit 4-MC16 (GY),
1, circuit 8-MC16 (GY), harness side.
→ Yes
GO to E3.
→ No
E3: CHECK CIRCUIT 5-MC16 (BU) FOR OPEN

module C432 pin 48, circuit 5-MC16 (BU),
9, circuit 5-MC16 (BU), harness side.
→ Yes
GO to E4.
→ No
2007.50 Focus 3/2007 G913439en


E4: CHECK CIRCUIT 4-MC15 (GY/OG) FOR OPEN
module C432 pin 49, circuit 4-MC15 (GY/OG),
2, circuit 4-MC15 (GY/OG), harness side.
→ Yes
GO to E5.
→ No
E5: CHECK CIRCUIT 5-MC11 (BU/OG) FOR OPEN

module C432 pin 50, circuit 5-MC11 (BU/OG),
10, circuit 5-MC11 (BU/OG), harness side.
→ Yes
GO to E6.
→ No
E6: CHECK CIRCUIT 10-MC19 (GY/OG) FOR OPEN

module C432 pin 42, circuit 10-MC19 (GY/OG),
3, circuit 10-MC19 (GY/OG), harness side.
→ Yes
GO to E7.
→ No
2007.50 Focus 3/2007 G913439en


E7: CHECK CIRCUIT 8-MC19 (WH/GN) FOR OPEN
module C432 pin 41, circuit 8-MC19 (WH/GN),
11, circuit 8-MC19 (WH/GN), harness side.
→ Yes
GO to E8.
→ No
E8: CHECK CIRCUIT 9-MC19 (BN/GN) FOR OPEN

module C432 pin 51, circuit 9-MC19 (BN/GN),
12, circuit 9-MC19 (BN/GN), harness side.
→ Yes
GO to E9.
→ No
E9: CHECK CIRCUIT 1-MC13 (WH/RD) FOR OPEN

module C432 pin 37, circuit 1-MC13 (WH/RD),
5, circuit 1-MC13 (WH/RD), harness side.
→ Yes
GO to E10.
→ No
2007.50 Focus 3/2007 G913439en


E10: CHECK CIRCUIT 2-MC13 (GY/RD) FOR OPEN
module C432 pin 38, circuit 2-MC13 (GY/RD),
13, circuit 2-MC13 (GY/RD), harness side.
→ Yes
GO to E11.
→ No
E11: CHECK CIRCUIT 1-MC14 (WH/BU) FOR OPEN

module C432 pin 39, circuit 1-MC14 (WH/BU),
6, circuit 1-MC14 (WH/BU), harness side.
→ Yes
GO to E12.
→ No
E12: CHECK CIRCUIT 2-MC14 (GY/VT) FOR OPEN

module C432 pin 40, circuit 2-MC14 (GY/VT),
14, circuit 2-MC14 (GY/VT), harness side.
→ Yes
GO to E13.
→ No
2007.50 Focus 3/2007 G913439en


E13: CHECK CIRCUIT 30-MC11 (RD) FOR OPEN
module C432 pin 32, circuit 30-MC11 (RD),
7, circuit 30-MC11 (RD), harness side.
→ Yes
GO to E14.
→ No
E14: CHECK CIRCUIT 29-MC11 (OG/WH) FOR OPEN

module C432 pin 54, circuit 29-MC11 (OG/WH),
15, circuit 29-MC11 (OG/WH), harness side.
→ Yes
GO to E15.
→ No
E15: CHECK CIRCUIT 31-MC11 (BK) FOR OPEN

module C432 pin 53, circuit 31-MC11 (BK),
8, circuit 31-MC11 (BK), harness side.
→ Yes
→ No
INSTALL a new handset holder.
REFER to: Handset Holder (419-08 Cellular
Phone, Removal and Installation).
2007.50 Focus 3/2007 G913439en

PINPOINT TEST M : THE MUTE SYMBOL IS DISPLAYED ON THE AUDIO UNIT WHEN TRYING TO
OPERATE THE CELLULAR PHONE SYSTEM
F1: CONFIGURE THE PSE MODULE TO THE VEHICLE
2 Connect the WDS to the DLC.
3 Select the TOOLBOX menu.
4 Select the MODULE PROGRAMMING menu.
5 Select the MODULE REPROGRAMMING
menu.
6 Select the SPEECH RECOGNITION MODULE
option and follow the instructions on the display.
• Is the MUTE symbol displayed on the audio
unit when the cellular phone system is oper-
ated?
→ Yes
Carry out the PSE module configuration
procedure again. If the concern persists,
and Installation).
→ No
2007.50 Focus 3/2007 G913439en

415-01A-1 Audio Unit 415-01A-1
.
SECTION 415-01A Audio Unit

CONTENTS PAGE

Audio System...................................................................................................................... 415-01A-2
General............................................................................................................................... 415-01A-2
Different equipment levels.................................................................................................. 415-01A-2

Audio System...................................................................................................................... 415-01A-4

Audio Unit........................................................................................................................... 415-01A-5
Compact Disc (CD) Changer.............................................................................................. 415-01A-7
Rear Auxiliary Audio Controls............................................................................................. 415-01A-9
415-01A-2 Audio Unit 415-01A-2
Audio System
General • Change to a different preset radio station
("PRESET/DISC")
A multimedia system with RDS/EON and mobile • Change the CD ("PRESET/DISC" when playing
telephone compatibility is available. This includes a CD)
a radio, navigation system and an entertainment
system for the rear passengers. All systems have • Switch off traffic bulletins (quick press of
AVC, whereby the volume can be set by the user, "AM/FM")
and are equipped for voice control (Bluetooth). • Switch over to a different frequency band (press
and hold "AM/FM" slightly longer)
All units offer the performance and functionality of
earlier systems.
Every system is capable of performing a self-test; Different equipment levels
diagnosis is performed with WDS via the CAN bus.
The following units are available: Radio/cassette 5000C, basic version
• Audio, basic version
– Radio/cassette unit 5000 C, 10% more power output than previous units
– Radio/individual CD player 6000 CD, Electronic cassette player mechanism with
autoreverse and noise suppression
• Entertainment system for rear passengers, basic
version 4 x 17 watt loudspeakers
– Rear audio control unit (with display and Auxiliary audio stereo input
control elements)
Larger LCD display
• Audio, luxury version
– Sony radio/individual CD player Fittings for voice control
(MP3-capable), luxury version Speed-dependent volume control via CAN bus
– Sony 6 CD radio with integral 6-CD changer
• CDDJ external 6-CD changer (underneath the
seat or in the luggage compartment) Radio/individual CD player 6000 CD, basic
version
Navigation, luxury version - distributed system with:
• Navigation control module with maps stored on 10% more power output than previous units
DVD (in glove compartment) (Denso) 4 x 17 watt loudspeakers
• Display with a TFT screen and control keys
Auxiliary audio stereo input
(Denso)
• Navigation/audio unit, installed behind the Larger LCD display
display (Visteon) Fittings for voice control
• Air conditioning/navigation unit, installed behind Speed-dependent volume control via CAN bus
the display (Visteon)
Entertainment system for rear passengers,

Audio remote controls basic version - rear audio control unit (with
display and control elements)
Most current vehicles can be supplied with steering
wheel buttons for the audio remote controls. The The entertainment system for rear passengers,
steering wheel buttons control the following which is only available in conjunction with the
functions: luxury audio systems and the luxury navigation
• Volume adjustment ("VOL") system, includes a control unit and two headphone
• Station search ("SEEK") sockets.
• Track search ("SEEK" when playing a CD) This allows passengers in the rear to select a
different audio source to the driver.
2007.50 Focus 3/2007 G189026en

415-01A-3 Audio Unit 415-01A-3
Sony radio/individual CD player, luxury
version
CD/CDR/CDRW/MP3 playback
30% more power
4 x 20 watt loudspeakers
Digital sound processing with delay compensation
Entertainment system for rear passengers with
double playback device
Sony 6-CD changer in dashboard
30% more power

4 x 20 watt loudspeakers
CD/CDR playback
Digital sound processing with delay compensation
Entertainment system for rear passengers with
double playback device
2007.50 Focus 3/2007 G189026en

415-01A-4 Audio Unit 415-01A-4
Audio System
REFER to Section 415-00 [Information and
Entertainment System - General Information].
2007.50 Focus 3/2007 G18370en

415-01A-5 Audio Unit 415-01A-5
Audio Unit
General Equipment indicates the top of the tool, left-hand side of the
removal tool and TOP R (right-hand) indicates the
Audio unit removal tools (GV3301)
top of the tool, right-hand side of the removal tool.
NOTE: When installing the audio unit removal 1. Remove the components in the order
tools, make sure that the wording on the audio unit indicated in the following illustration(s) and
removal tools is followed, TOP L (left-hand) table(s).
4 3
1
E40456
Item Description NOTE: Remove the audio unit removal tools from
the audio unit before installing the original audio
1 Audio unit removal tools unit.
2 Audio unit NOTE: When installing a new audio unit, the
See Removal Detail audio unit must be configured by selecting the
See Installation Detail Programmable Module Installation Routine on
3 Audio unit electrical connector WDS.
4 Antenna cable
Removal Details
2007.50 Focus 3/2007 G323499en

415-01A-6 Audio Unit 415-01A-6
Item 2 Audio unit • Release the locking tangs.
1.
CAUTION: When detaching the audio unit,
do not place excessive strain on the wiring
harness.
Detach the audio unit from the instrument
panel.
Item 3 Audio unit electrical connector

1. Disconnect the audio unit electrical
connector.
E41000
Item 2 Audio unit
CAUTION: The audio unit wiring harness
and antenna cable must not become
trapped when installing the audio unit.
1. The audio unit rear support must engage
with the audio unit support bracket.
2007.50 Focus 3/2007 G323499en

415-01A-7 Audio Unit 415-01A-7
Compact Disc (CD) Changer

table(s).
1. Remove the passenger side front seat.
Seat (501-10 Seating, Removal and
Installation).
E39339
position. Failure to follow this instruction

Item Description
may result in internal damage to the CD
1 CD changer retaining screws changer.
2 CD changer electrical connector NOTE: Before installing a new CD changer,
See Removal Detail remove the CD changer transportation retaining
clips.
3 CD changer
NOTE: When installing a new CD changer, the
CAUTION: Make sure that the CD changer must be configured by selecting
horizontal/vertical orientation setting on the Programmable Module Installation Routine
the CD changer is in the horizontal on WDS.
Removal Details
2007.50 Focus 3/2007 G295980en

415-01A-8 Audio Unit 415-01A-8
Item 2 CD changer electrical connector
1. Disconnect the CD changer electrical
connector.
E39340
2007.50 Focus 3/2007 G295980en

415-01A-9 Audio Unit 415-01A-9
Rear Auxiliary Audio Controls

table(s).
6
2
E51600
1 Floor console compartment 3 Rear auxiliary audio controls wiring

See Removal Detail harness retaining clip
See Removal Detail
2 Rear auxiliary audio controls trim panel
See Removal Detail 4 Rear auxiliary audio controls electrical
connector
2007.50 Focus 3/2007 G413487en

415-01A-10 Audio Unit 415-01A-10

5 Rear auxiliary audio controls retaining clips
6 Rear auxiliary audio controls trim panel 2. To install, reverse the removal procedure.
Removal Details
Item 1 Floor console compartment
Item 5 Rear auxiliary audio controls
1. Open the floor console compartment.
1. Remove the rear auxiliary audio controls
from the rear auxiliary audio controls trim
Item 2 Rear auxiliary audio controls trim panel panel.
1. NOTE: Do not place excessive stress on the
• Release the locking tangs.
rear auxiliary audio controls wiring harness.
Detach the rear auxiliary audio controls trim
panel from the floor console.
Item 3 Rear auxiliary audio controls wiring

harness retaining clip
1. Detach the rear auxiliary audio controls
wiring harness retaining clip from the floor
console.
E51601
Item 6 Rear auxiliary audio controls trim panel
retaining clips
1. Install the rear auxiliary audio controls trim
panel retaining clips to the rear auxiliary
audio controls trim panel before installation.
2007.50 Focus 3/2007 G413487en

415-01B-1 Information and Entertainment System 415-01B-1
.
SECTION 415-01B Information and Entertainment

System
CONTENTS PAGE

Audio Unit — Vehicles With: Digital Versatile Disc (DVD) Player....................................... 415-01B-2
Audio Unit — Vehicles With: Digital Versatile Disc (DVD) Player

General Equipment General Equipment
Flat-bladed screwdriver Audio unit removal tools
Removal
NOTE: Make sure that any media is ejected from NOTE: Removal steps in this procedure may
the unit. contain installation details.
1. General Equipment: Flat-bladed screwdriver
E92247
2. CAUTION: Take extra care not to

damage the wiring harnesses.
General Equipment: Audio unit removal tools
2007.50 Focus 3/2007 G964871en

E92248
3.
E92249
Installation
2007.50 Focus 3/2007 G964871en

415-02-1 Antenna 415-02-1
.
SECTION 415-02 Antenna

CONTENTS PAGE

Antenna.............................................................................................................................. 415-02-2

Antenna Cable.................................................................................................................... 415-02-3
415-02-2 Antenna 415-02-2
Antenna
2007.50 Focus 3/2007 G18376en

415-02-3 Antenna 415-02-3
Antenna Cable
1. Remove the headliner. For additional 4. Remove the audio unit. For additional
information, refer to Section 501-05 [Interior information, refer to Section 415-01 [Audio
Trim and Ornamentation]. Unit].
2. Remove the steering column. For additional 5. Remove the components in the order
information, refer to Section 211-04 [Steering indicated in the following illustration(s) and
Column]. table(s).
3. Remove the side window trim panel.
E41015
2007.50 Focus 3/2007 G295981en

415-02-4 Antenna 415-02-4
NOTE: Instrument panel shown removed for clarity.
8
5 7
9
E41016
1 Antenna base and antenna 6 Antenna cable to instrument panel

See Removal Detail retaining clips
2 Antenna cable to windscreen header rail 7 Antenna cable to steering column support
retaining clips bracket retaining clips
3 Antenna cable to roof panel retaining clip 8 Antenna cable to audio unit support
bracket retaining clip
4 Antenna cable to A-pillar retaining clips
9 Antenna cable
5 Antenna cable electrical connectors See Removal Detail
2007.50 Focus 3/2007 G295981en

415-02-5 Antenna 415-02-5
Removal Details
Item 1 Antenna base and antenna Item 5 Antenna cable electrical connectors
1. Disconnect the antenna base electrical 1. Disconnect the antenna cable electrical
connector. connectors.
VUE0030812
E41017
Item 9 Antenna cable

NOTE: Make a note of the routing of the antenna
cable.
Item 9 Antenna cable
NOTE: The antenna cable must be installed to the
same routing as when removed.
2007.50 Focus 3/2007 G295981en

415-03-1 Speakers 415-03-1
.
SECTION 415-03 Speakers

CONTENTS PAGE

Speakers............................................................................................................................. 415-03-2

Front Door Tweeter Speaker.............................................................................................. 415-03-3
415-03-2 Speakers 415-03-2
Speakers
2007.50 Focus 3/2007 G18380en

415-03-3 Speakers 415-03-3
Front Door Tweeter Speaker

table(s).
2 1
E40765
2007.50 Focus 3/2007 G323497en

415-03-4 Speakers 415-03-4
Item Description CAUTIONS:
1 Exterior mirror interior trim panel. Care must be taken when installing the
See Removal Detail front door tweeter speaker to the exterior
mirror interior trim panel. Failure to follow
2 Front door tweeter speaker electrical this instruction may result in damage to
connector the front door tweeter speaker cone.
3 Front door tweeter speaker Make sure when installing the front door
See Removal Detail tweeter speaker, foreign matter is not
attached to the speaker magnet or cone.
2. To install, reverse the removal procedure. Failure to follow this instruction may result
in noise, vibration or harshness (NVH)
issues.
NOTE: When installing the front door tweeter
speaker to the exterior mirror interior trim panel an
audible click should be heard to indicate correct
installation.
Removal Details
Item 1 Exterior mirror interior trim panel.
1. Detach the exterior mirror electrical
connector from the exterior mirror interior
trim panel.
Item 3 Front door tweeter speaker

1. Release the locking tangs and remove the
front door tweeter speaker.
E40766
2007.50 Focus 3/2007 G323497en

417-01-1 Exterior Lighting 417-01-1
.
SECTION 417-01 Exterior Lighting

CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 417-01-3

Exterior Lighting.................................................................................................................. 417-01-4
Conventional headlamps.................................................................................................... 417-01-4
High intensity discharge headlamps................................................................................... 417-01-4
Headlamp leveling system.................................................................................................. 417-01-7
Autolamps........................................................................................................................... 417-01-7
Adaptive front lighting......................................................................................................... 417-01-8
Adaptive front lighting module............................................................................................ 417-01-10
Steering angle sensor......................................................................................................... 417-01-10
Rear lighting....................................................................................................................... 417-01-11
Peripheral lights.................................................................................................................. 417-01-11
Headlamp switch-off delay................................................................................................. 417-01-12

Stoplamps........................................................................................................................... 417-01-13
Symptom Chart................................................................................................................... 417-01-13
Pinpoint Tests..................................................................................................................... 417-01-13
Turn Signal and Hazard Lamps.......................................................................................... 417-01-23
Symptom Chart................................................................................................................... 417-01-23
Pinpoint Tests..................................................................................................................... 417-01-24
Parking, Rear and License Plate Lamps............................................................................ 417-01-44
Symptom Chart................................................................................................................... 417-01-44
Pinpoint Tests..................................................................................................................... 417-01-44
Fog Lamps.......................................................................................................................... 417-01-57
Symptom Chart................................................................................................................... 417-01-57
Pinpoint Tests..................................................................................................................... 417-01-57
Reversing Lamps................................................................................................................ 417-01-70
Symptom Chart................................................................................................................... 417-01-70
Pinpoint Tests..................................................................................................................... 417-01-70
Component Test:................................................................................................................ 417-01-82
Headlamps.......................................................................................................................... 417-01-84
Symptom Chart................................................................................................................... 417-01-84
Pinpoint Tests..................................................................................................................... 417-01-85
.
GENERAL PROCEDURES
Headlamp Adjustment.................................................................................... (32 113 0) 417-01-106
Headlamp Adjustment — Vehicles With: Adaptive Front Lighting.................. (32 113 0) 417-01-107
Front Fog Lamp Adjustment............................................................................................... 417-01-108

High Beam Headlamp Bulb — Vehicles With: High Intensity Discharge Headlamps......... 417-01-109
Low Beam Headlamp Bulb — Vehicles With: High Intensity Discharge Headlamps......... 417-01-110
Parking Lamp Bulb — Vehicles With: High Intensity Discharge Headlamps...................... 417-01-112
Headlamp Switch................................................................................................................ 417-01-113
Stoplamp Switch................................................................................................................. 417-01-115
Front Fog Lamp.................................................................................................................. 417-01-117
Headlamp Assembly........................................................................................................... 417-01-118
Rear Lamp Assembly......................................................................................................... 417-01-120
SPECIFICATIONS
Headlamp alignment
Item X value
Headlamp. X = 10 cm/10 m = 0°34' = 1.0%
Front fog lamps X = 22 cm/10 m = 1 degree 16 minutes = 2.2%
Bolt, headlamp 4 - 35
Rear lamp assembly screws 1 - 9
Bolt, front headlamp leveling sensor 8 - 35
Upper bolt, rear headlamp leveling sensor 8 - 71
Lower bolt, rear headlamp leveling sensor 48 35 -
2007.50 Focus 3/2007 G428575en

Exterior Lighting
Conventional headlamps The transparent plastic cover is made from
polycarbonate, which is coated for protection
against scratches and cracks.
In the event of damage to the cover the entire
headlamp unit needs to be replaced.
The turn signal lamps and side lights are also
integrated in the headlamp unit.
The manual headlamp leveling system operates
with an electric motor which is controlled via a
rotary control in the instrument cluster.
For conventional headlamps, adapting the vehicle
to conform to country-specific traffic situations
E40972
(left/right-hand side traffic) during travel is
The headlamp units are primarily made of plastic accomplished by affixing punched adhesive strips
and make use of free-form reflectors in order to to specific areas of the headlamp.
optimize light distribution. All conventional headlamps use 12 V bulbs with a
spiral-wound filament.
Lamp Bulb Current draw Bulb color

Low beam H7 55W clear
High beam H1 55W clear
Turn Signal Lamp Bayonet base 21W orange
Side Lamp Glass base 5W clear
High intensity discharge headlamps A single xenon high intensity discharge bulb in the
outer projector is used both for low and high
beams.
If the battery voltage drops below 7 volts during
engine start-up, the high intensity discharge
headlamps are switched off by the GEM. On
vehicles built from 03/2007, the headlamps are
switched on again 50ms after being switched off
by the GEM.
In order to prevent dazzling the oncoming traffic in
low beam mode, the light cone is modified by
means of a shutter. An additional reflector is
E40973
provided for the high beam, which is generated
using a conventional bulb with a spiral-wound
WARNING: High voltages of up to 30 kV filament. This bulb is switched on when the
are present in the system. Ensure that the headlamps are switched to high beam and when
headlamp assembly electrical connector the headlamp flasher is operated.
is disconnected if the headlamp assembly
is removed.
High intensity discharge headlamps are optionally
available.
2007.50 Focus 3/2007 G413415en

The headlamp flasher operates as follows: headlamp flasher function is provided by moving
• When the low beam is switched off the the masking screen away from the main reflector
headlamp flasher function is provided solely by and switching on the conventional bulb in the
means of the conventional bulb in the additional additional reflector.
reflector. The turn signal lamps and side lights are the same
• When the low beam is switched on the as in conventional headlamps.

Low beam High intensity discharge 35W clear
lamp
Turn signal lamp Bayonet base 21W orange
Side lamp Glass base 5W clear
2007.50 Focus 3/2007 G413415en

E43310
For high intensity discharge headlamps, adapting To prevent oncoming traffic from being dazzled,
the vehicle to conform to country-specific traffic the lever controls a second shutter which partially
situations (left/right-hand side traffic) during travel blocks the headlight beams in order to produce
is accomplished using a lever behind the headlamp symmetrically-shaped beams of light in low beam
cover, which is used to alter the headlamp beam. mode.
2007.50 Focus 3/2007 G413415en

Headlamp leveling system
E43230
An automatic headlamp leveling system is a legal The following components are part of the headlamp
requirement for vehicles with high intensity leveling system:
discharge headlamps. • Headlamp leveling sensors on the front and rear
The automatic headlamp leveling system is a axles
second-generation dynamic system which provides • Control module
additional benefits for the driver in terms of • Actuator motors for headlamp leveling
improved illumination of the road due to improved
control over the headlamp beam. Accordingly, the system needs to be set up with
WDS after any components are replaced or any
In a static system, the vehicle is only considered other repairs are carried out.
as a stationary object, whereas a dynamic system
also takes into account the dynamic changes to The front and rear sensors are Hall sensors, which
the inclination of the vehicle owing to load changes transmit an analog signal to the control module.
whilst driving.
The system is designed to respond to changes in Autolamps
the inclination of the vehicle caused by the
long-term effects of aerodynamic forces acting on CAUTIONS:
the vehicle (e.g. due to continuous driving at high On vehicles with autolamps, retrofitting
speeds). with daytime running lamps is not
In order to prevent unnecessary changes in the permissible, as otherwise, the engine
height of the headlamp beam, the system filters cannot be stopped when the lighting is
out surface irregularities and any pitching of the switched on.
vehicle under braking and acceleration. On vehicles with autolamps, the daytime
running lamp fuse must not be fitted, as
otherwise, the engine cannot be stopped
when the lighting is switched on.
2007.50 Focus 3/2007 G413415en

The ambient light sensor determines the general
light intensity. For this purpose, it records the light
over as wide an angle as possible, without taking
the direction of incidence into account.
The front light sensor determines the light intensity
directly in front of the vehicle.
If both the ambient light sensor and the front light
sensor detect a sudden reduction in light intensity
at the same time, then an algorithm-based
calculation is used to determine the fact that the
E43607
vehicle has entered a tunnel, a multi-storey car
park or a long underpass.
The low beams, side lamps, license plate lamps In this type of case a request to switch on the
as well as the instrument cluster and instrument exterior lights and the display lamps in the
panel illumination are switched on automatically if instrument cluster is transmitted to the GEM.
all the following conditions are met:
• Ignition switch in the "II" or "III" position If the vehicle is suddenly thrown into the shade by
a large truck, the two sensors will register different
• Light switch in the "AUTO" position light intensities. In this case, the algorithm-based
• Detected ambient light conditions below a stored calculation will not result in the lights being
threshold value switched on.
These are switched on and off by the Generic In vehicles built from 07/2004, a stepped switch-off
Electronic Module (GEM) in accordance with the of the low beams, side lamps, license plate lamps
input signals from the combined rain/light sensor. as well as the instrument cluster and instrument
panel illumination is implemented in the GEM. If
the ambient light changes from dark to bright, the
Combined rain sensor/light sensor
GEM first switches off the low beams. The side
lamps, license plate lamps, as well as the
instrument cluster and instrument panel illumination
1 are switched off approx. 6 seconds after the low
beams have been switched off.
Adaptive front lighting
3
E40968
Item Description
1 Lens
2 Front light sensor
3 Ambient light sensor
E52199
The combined rain sensor/light sensor is attached
to the windshield, near to the interior rear view
mirror.

Low beam H7 55W clear
2007.50 Focus 3/2007 G413415en


Turn signal lamp Bayonet base 21W orange
Side lamp Glass base 5W clear
7 5
3
8
6
1
4
2
E52198
The adaptive front lighting module must be

Item Description
configured for the various vehicle versions (wagon,
1 Adaptive front lighting actuator motor 3-door, 5-door, engine type, RHD/LHD etc.) using
the Worldwide Diagnostic System (WDS).
2 Headlamp leveling motor
During cornering, the dipped light projectors swivel
3 Low beam projector toward the inside of the curve, with a maximum
4 High beam reflector correction angle of 9° for the projector on the
outside of the curve and 14° for the projector on
5 Low beam lamp bulb the inside of the curve.
6 High beam lamp bulb When reverse gear is engaged, adaptive front
lighting is disabled. When reverse gear is
7 Turn signal lamp bulb
disengaged again and the vehicle moves at a
8 Parking lamp bulb speed above 3 km/h, the adaptive front lighting
follows the relevant steering movements.
Vehicles with conventional lighting (low beam with
projector) can optionally be equipped with the When performing parking maneuvers at a speed
newly developed adaptive front lighting. The below 3 km/h, the adaptive front lighting swivels,
system is not compatible with automatic headlamp in accordance with the country-specific
inclination and only works when the lights are configuration (LHD/RHD), to the relevant edge of
switched on. the road in order to avoid dazzling the oncoming
traffic when the steering wheel is turned in the
opposite direction.
2007.50 Focus 3/2007 G413415en

The straight ahead position of the steering should To prevent oncoming traffic from being dazzled,
be checked using WDS prior to headlamp the lever controls a shutter which partially blocks
adjustment. For this purpose, the headlamp the headlight beams in order to produce
leveling system must be in the "0" position and the symmetrically-shaped beams of light in low beam
steering wheel in the "0" (+/- 3°) position. mode.
The adaptive front lighting actuator motors are
stepper motors. Adaptive front lighting module
The headlamp leveling system motors are DC
motors. The adaptive front lighting module, which is
connected to the high-speed Controller Area
If there is a system fault with the adaptive front Network (CAN), processes the CAN reverse gear
lighting actuator motors, the fault code "Advance switch, vehicle speed, light switch position and
Front Light Failure (adaptive front lighting daytime running lamp signals as well as the
malfunction)" will be shown in the driver information steering angle sensor and headlamp leveling
display of the instrument cluster and the indicator signals and sends control commands to the
will flash. adaptive front lighting actuator motors and the
In the event of a headlamp leveling motor fault, headlamp leveling motors. The adaptive front
both headlamps are moved to the central position lighting module must be configured with the WDS
by means of the adaptive front lighting actuator after renewal.
motors and they remain in this position. When the ignition and lights are switched on, the
In the event of an adaptive front lighting actuator adaptive front lighting module performs calibration
motor fault, the headlamp leveling motor moves of the headlamps, during which both move inwards
the relevant headlamp to the lowest position where and then to the "0" position, independently of the
it remains. The intact headlamp is moved to the steering wheel position. The headlamps only turn
"0" position by the adaptive front lighting actuator in the direction of cornering when the steering
motor. wheel is turned by more than 4°. Calibration is
performed only once during an operating cycle
For adaptive front lighting headlamps, adapting the
(ignition key in position "2" and then in position "0").
vehicle to conform to country-specific traffic
situations (left/right-hand side traffic) during travel
is accomplished using a lever behind the headlamp
cover, which is used to alter the headlamp beam.
Steering angle sensor
E52402
2007.50 Focus 3/2007 G413415en

The steering angle sensor is located in the section The rear lamp assemblies need to be removed in
of the steering wheel below the steering column order to change a bulb.
stalk and is clipped to the clock spring. In vehicles The individual bulb holders and circuits are
with adaptive front lighting, a sensor with 6 integrated in the bulb holder assembly in wagon
connector contacts is used. Vehicles with ABS/ESP and 4-door vehicles. In 3-door and 5-door vehicles
without adaptive front lighting are equipped with a this function is performed by the wiring harness.
sensor with 4 connector contacts.
In wagon and 4-door vehicles, a compact connector
Before attaching it to the clock spring, the steering is used to connect the bulb holder with the wiring
angle sensor with 6 connector contacts must be harness. In 3-door and 5-door vehicles, the wiring
brought into the installation position (triangle harness is connected to the bulb holder by means
marking must align with the line in the alignment of two connectors.
window).
The high mounted stoplamp is installed in the
The steering angle sensor does not need to be centre of the liftgate in wagon vehicles. In 3-door
initialized following renewal. and 5-door vehicles it is installed in the rear spoiler
and in 4-door vehicles it is installed in the headliner
Rear lighting behind the rear window.
Peripheral lights
E51910
The purpose of peripheral lights is to illuminate the

ground in the immediate vicinity of the front doors.
The illumination is provided in the form of white
bulbs which are located on the underside of the
mirrors.
The peripheral lights are switched on when a door
or the liftgate are opened or an unlock command
is detected and the following conditions are fulfilled:
• The ignition key is in position "0" or "I".
E51951 • Reverse gear is not engaged.
• The vehicle speed is below 7 km/h.
The rear lamp assemblies of wagon vehicles
include all the rear lamp functions except the The peripheral lights are switched off when one of
license plate lamp and high mounted stoplamp. the following conditions is fulfilled:
In 3-door and 5-door vehicles, the rear fog lamp, • The ignition switch is turned to the position "II"
reversing lamp and reflectors are integrated in the or "III".
rear bumper. • Reverse gear is engaged.
The rear lamp assemblies are replaced as a • The vehicle speed exceeds 7 km/h.
complete unit during servicing.
2007.50 Focus 3/2007 G413415en

• More than 25 seconds have elapsed since the
liftgate was closed or a central locking command
was detected.
• The time set for the battery protection function
for the interior lighting has elapsed.
• More than 5 seconds have elapsed since the
doors and the liftgate were closed.
• More than 5 seconds have elapsed since a
central locking command was received and the
all doors and the liftgate were closed.
Headlamp switch-off delay

In vehicles with mid to high-end equipment, the
headlamp switch-off delay uses the low beams and
the peripheral lights (if equipped) for illuminating
the vehicle surroundings. The function is activated
by operating the high beam lever when the ignition
switch is in the "0" position.
After the last door has been closed, the function
remains active for a further 30 seconds and then
switches off automatically.
When a door or the liftgate is open, the switch-off
time is extended to 180 seconds. After the last door
has been closed, the switch-off time is reset to 30
seconds.
The headlamp switch-off delay can be deactivated
prematurely by operating the high beam lever again
or by switching on the ignition.
The s witch-off time is adjusted to set values at the
factory and cannot be re-programmed using WDS.
2007.50 Focus 3/2007 G413415en

Stoplamps
Refer to Wiring Diagrams Section 417-01, for 2. Visually check the following electrical causes
schematic and connector information. for the concern:
Special Tool(s)
Terminal Probe Kit
29-011A
• Stop lamp switch • Fuse(s)
adjustment • Lamp(s)
• Connection(s)
29011A
• Switches
• Wiring harness
Inspection and Verification 3. Resolve any obvious causes or concerns found

during the visual inspection before carrying out
NOTE: The generic electronic module (GEM) is any further tests.
part of the central junction box (CJB). 4. If the concern persists, check the symptoms
1. Verify the customer concern. and continue with the symptom chart.
Symptom Chart
Symptom Chart
• All stop lamps are inoperative • Fuse • GO to Pinpoint Test A.
• Circuit(s)
• Stop lamp switch
• One or more stop lamps inoper- • Circuit(s) • GO to Pinpoint Test B.
ative • Left/right-hand rear lamp
assembly
• Additional high-mounted stop
lamp
• Stop lamps continuously illumin- • Circuit(s) • GO to Pinpoint Test C.
ated • Stop lamp switch
• Transmission selector lever
assembly
(PCM)
Pinpoint Tests
measurements.
PINPOINT TEST A : ALL STOP LAMPS ARE INOPERATIVE
A1: CHECK FUSE F74 (CJB)
2007.50 Focus 3/2007 G425000en


2 Disconnect fuse F74 (15 A) (CJB).
3 CHECK fuse F74 (15 A) (CJB).
• Is the fuse OK?
→ Yes
GO to A2.
→ No
RENEW fuse F74 (15 A) and CHECK the
operation of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground using the Wiring Diagrams. CHECK
the operation of the system.
A2: CHECK VOLTAGE AT FUSE F74 (CJB)
1 Connect fuse F74 (15 A) (CJB).
and ground.
• Does the meter display battery voltage?
→ Yes
GO to A3.
→ No
LOCATE and RECTIFY the break in the power
supply of fuse F74 (CJB) using the Wiring
Diagrams, if necessary RENEW the CJB.
A3: CHECK VOLTAGE AT STOP LAMP SWITCH
2 Disconnect stop lamp switch from connector
C444.
4 Measure the voltage between stop lamp switch,
connector C444, pin 2, circuit 15-LG23
(GN/WH), wiring harness side and ground.
→ Yes
GO to A4.
→ No
LOCATE and RECTIFY the break in the circuit
between fuse F74 (CJB) and the stop lamp
VFE0038418 switch using the Wiring Diagrams. CHECK
2007.50 Focus 3/2007 G425000en


A4: CHECK STOP LAMP SWITCH
2 Connect a fused jumper wire (15 A) to the stop
lamp switch, connector C444, between pin 2,
circuit 15-LG23 (GN/WH) and pin 1, circuit 15S-
LG23 (GN/WH)/15S-LG14 (GN/RD), wiring
harness side.
VFE0038423

4 CHECK the operation of the stop lamps.
• Do the stop lamps illuminate?
→ Yes
RENEW the stop lamp switch. CHECK the
operation of the system.
→ No
between the stop lamp switch and soldered
connection S112 using the Wiring Diagrams.
PINPOINT TEST B : ONE OR MORE STOP LAMPS INOPERATIVE

B1: DETERMINE THE FAULT CONDITION
C444.
2007.50 Focus 3/2007 G425000en


3 Connect a fused jumper wire (15 A) to the stop
lamp switch, connector C444, between pin 2,
circuit 15-LG23 (GN/WH) and pin 1, circuit 15S-
LG23 (GN/WH)/15S-LG14 (GN/RD), wiring
harness side.
VFE0038423

5 Determine the fault condition.
6 CHECK the stop lamps.
• Is only the additional high-mounted stop lamp
inoperative?
→ Yes
GO to B6.
→ No
- Left-hand stop lamp is inoperative: GO to
B2.
- Right-hand stop lamp is inoperative: GO to
B4.
B2: CHECK VOLTAGE SUPPLY OF THE LEFT-HAND STOP LAMP
NOTE: The jumper lead used of the first step is still connected.

2 Disconnect left-hand rear lamp assembly from
connector.
– 5-door: C472
– 4-door: C476
2007.50 Focus 3/2007 G425000en


4 Measure the voltage between left-hand rear
lamp assembly:
– 5-door: connector C472, pin 2, circuit 15S-
LG14B (GN/RD), wiring harness side and
ground.
LG14A (GN/RD), wiring harness side and
ground.
VFE51988
→ Yes
GO to B3.
→ No
between soldered connection S112 and left-
hand rear lamp assembly using the Wiring
Diagrams. CHECK the operation of the
system.
B3: CHECK GROUND CONNECTION OF LEFT-HAND REAR LAMP ASSEMBLY
2 Measure the resistance between left-hand rear
lamp assembly:
– 5-door: connector C472, pin 3, circuit 31-
LF23B (BK), wiring harness side and ground.
– 4-door: connector C476, pin 3, circuit 31-LF23
(BK), wiring harness side and ground.
• Is less than 2 Ohm measured?
→ Yes
CHECK and if necessary RENEW the left-
VFE51983 hand rear lamp assembly. CHECK the opera-
tion of the system.
→ No
between left-hand rear lamp assembly and
ground connection G77 using the Wiring
system.
B4: CHECK VOLTAGE SUPPLY OF THE RIGHT-HAND STOP LAMP

2 Disconnect right-hand rear lamp assembly from
connector.
– 5-door: C473
– 4-door: C477
2007.50 Focus 3/2007 G425000en


4 Measure the voltage between right-hand rear
lamp assembly:
LG21A (GN/BK), wiring harness side and
ground.
LG21 (GN/BK), wiring harness side and
ground.
VFE51988
→ Yes
GO to B5.
→ No
between soldered connection S112 and the
rear lamp assembly using the Wiring
system.
B5: CHECK GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP ASSEMBLY
2 Measure the resistance between rear lamp
assembly right-hand side:
→ Yes
CHECK and if necessary RENEW the right-
tion of the system.
→ No
right-hand rear lamp assembly using the
Wiring Diagrams. CHECK the operation of the
system.
B6: CHECK VOLTAGE AT THE ADDITIONAL HIGH-MOUNTED STOP LAMP

2 Disconnect additional high-mounted stop lamp
from connector C107.
2007.50 Focus 3/2007 G425000en


4 Measure the voltage between additional high-
mounted stop lamp, connector C107, pin 1:
– 5-door: circuit 15S-LG6 (GN/YE), wiring
– 4-door: circuit 15S-LG6C (GN/YE), wiring
→ Yes
GO to B7.
VFE0003040
→ No
- 5-door: LOCATE and RECTIFY the break in
the circuit between soldered connection S112
and the additional high-mounted stop lamp
using the Wiring Diagrams. CHECK the oper-
ation of the system.
the circuit between stop lamp switch and the
additional high-mounted stop lamp using the
system.
B7: CHECK GROUND CONNECTION OF ADDITIONAL HIGH-MOUNTED STOP LAMP
2 Measure the resistance between additional high-
mounted stop lamp, connector C107, pin 2:
– 5-door: circuit 31-LG6 (BK), wiring harness
side and ground.
– 4-door: circuit 91-LG6 (BK/YE), wiring harness
side and ground.
→ Yes
CHECK and if necessary RENEW the addi-
VFE0003041
tional high-mounted stop lamp. CHECK the
→ No
the circuit between the additional high-
mounted stop lamp and soldered connection
S196 using the Wiring Diagrams. CHECK the
the circuit between the additional high-
mounted stop lamp and soldered connection
2007.50 Focus 3/2007 G425000en

PINPOINT TEST C : STOP LAMPS CONTINUOUSLY ILLUMINATED
C1: CHECK STOP LAMP SWITCH
C444.
• Are the stop lamps continuously illuminated?
→ Yes
- Vehicles without automatic transmission: GO
to C4.
- Vehicles with automatic transmission: GO to
C2.
→ No
RENEW the stop lamp switch. CHECK the
C2: RULE OUT TRANSMISSION SELECTOR LEVER ASSEMBLY AS POSSIBLE CAUSE FOR A
SHORT TO BATTERY VOLTAGE
→ Yes
GO to C3.
→ No
RENEW the transmission selector lever
assembly. CHECK the operation of the
system.
C3: NARROW DOWN THE CAUSE FOR THE SHORT TO BATTERY VOLTAGE
3 Disconnect CJB from connector C102.
2007.50 Focus 3/2007 G425000en


→ Yes
GO to C4.
→ No
LOCATE and RECTIFY the short to battery
voltage in the circuits connected with CJB,
connector C102, pin 17, using the Wiring
system.
C4: RULE OUT PCM MODULE AS POSSIBLE CAUSE FOR A SHORT TO BATTERY VOLTAGE
2 Disconnect fuse F34 (10 A) (BJB).
– 1,6l (Z6) engine
– 2,0l Duratorq TDCi engine
– 1,8l/2,0l Duratec-HE engine
→ Yes
GO to C5.
→ No
CHECK the PCM module using WDS,
RENEW if necessary. CHECK the operation
of the system.
2 Connect fuse F34 (10 A) (BJB).
2007.50 Focus 3/2007 G425000en


– 1,6l (Z6) engine
– 1,8/2,0l Duratec-HE engine
→ Yes
GO to C6.
→ No
voltage in the circuits connected with CJB,
connector C96, pin 31, using the Wiring
system.
→ Yes
voltage in the circuits connected to soldered
→ No
CHECK and if necessary RENEW the CJB.
2007.50 Focus 3/2007 G425000en

Turn Signal and Hazard Lamps

Special Tool(s)
Terminal Probe Kit
Electrical
29-011A
• Fuse(s)
• Lamp(s)
• Connector(s).
29011A
• Switches
• Wiring harness

NOTE: The generic electronic module (GEM) is a any further tests.
component of the central junction box (CJB). 4. If the concern persists, check the symptoms
Symptom Chart
Symptom Chart
• All turn signal lamps inoper- • Fuse(s) • GO to Pinpoint Test A.
ative • Circuit(s)
• Multifunction switch
(GEM)
• All turn signal lamps illuminate • Central junction box (CJB) • CHECK the generic electronic
continuously • Generic electronic module module (GEM) using WDS and
(GEM) RENEW it if necessary.
CHECK the operation of the
system.
• One/several turn signal lamps • Circuit(s) • GO to Pinpoint Test B.
are inoperative • Headlamp
• Turn signal side lamp
• Rear lamp assembly/ies
(GEM)
• Left-hand or right-hand turn • Circuit(s) • GO to Pinpoint Test C.
signal lamps flash continuously • Multifunction switch
(GEM)
2007.50 Focus 3/2007 G425001en


• Left-hand or right-hand turn • Circuit(s) • GO to Pinpoint Test D.
signal lamps illuminate • Headlamp
continuously • Turn signal side lamp
(GEM)
• The hazard warning lights are • Fuse(s) • GO to Pinpoint Test E.
inoperative • Circuit(s)
• Hazard warning switch
(GEM)
• The hazard warning lights flash • Circuit(s) • GO to Pinpoint Test F.
continuously • Hazard warning switch
(GEM)
Pinpoint Tests
measurements.
PINPOINT TEST D : ALL TURN SIGNAL LAMPS INOPERATIVE
A1: CHECK GROUND CONNECTION OF THE MULTIFUNCTION SWITCH
2 Disconnect multifunction switch from connector
C459.
3 Measure the resistance between the multifunc-
tion switch, connector C459, pin 10, circuit 91-
LG27 (BK/GN), wiring harness side and ground.
• Is the resistance less than 2 Ohm?
→ Yes
GO to A2.
→ No
between the multifunction switch and soldered
VFE0038452 connection S12 using the Wiring Diagrams.
2007.50 Focus 3/2007 G425001en


A2: CHECK THE MULTIFUNCTION SWITCH
1 Connect a fused jumper lead (10 A) to the
multifunction switch, connector C459, between
pin 6, circuit 91S-LG1 (BK/YE) and pin 10,
circuit 91-LG27 (BK/GN), wiring harness side.
VFE0038506

3 CHECK left-hand turn signal lamp operation.
• Do the left-hand turn signal lamps flash?
→ Yes
RENEW the multifunction switch. CHECK the
→ No
CHECK the operation of the system. If the
concern persists, CHECK the GEM using
WDS and RENEW if necessary. CHECK the
PINPOINT TEST E : ONE/SEVERAL TURN SIGNAL LAMPS ARE INOPERATIVE

2 SWITCH ON left-hand turn signal.
3 SWITCH ON right-hand turn signal.
2007.50 Focus 3/2007 G425001en


4 Determine which turn signal lamp(s) are inoper-
ative.
• Is one left-hand turn signal lamp inoperative?
→ Yes
- All left-hand turn signal lamps are inoper-
ative: GO to B2.
- Left-hand front turn signal lamp and left-hand
turn signal side lamp are inoperative: GO to
B5.
- Left-hand rear turn signal lamp is inoperative:
GO to B7.
- Left-hand front turn signal lamp is inoper-
ative:GO to B10.
- Left-hand turn signal side lamp is inoperative:
GO to B12.
→ No
- All right-hand turn signal lamps are inoper-
ative: GO to B2.
- Right-hand front turn signal lamp and right-
hand turn signal side lamp are inoperative:
GO to B14.
- Right-hand rear turn signal lamp is inoper-
ative: GO to B16.
- Right-hand front turn signal lamp is inoper-
ative: GO to B19.
- Right-hand turn signal side lamp is inoper-
ative: GO to B21.
B2: CHECK MULTIFUNCTION SWITCH
C459.
pin 10, circuit 91-LG27 (BK/GN), wiring harness
side and:
– left-hand turn signal lamps are inoperative:
pin 6, circuit 91S-LG1 (BK/YE), wiring harness
side.
– right-hand turn signal lamps are inoperative:
pin 7, circuit 91S-LG2 (BK/BU), wiring harness
side.
VFE49886
2007.50 Focus 3/2007 G425001en


5 CHECK turn signal lamp operation.
• Do the turn signal lamps flash?
→ Yes
→ No
- Left-hand turn signal lamps are inoper-
ative:GO to B3.
- Right-hand turn signal lamps are inoperative:
GO to B4.
B3: CHECK CONTROL CIRCUIT OF THE LEFT-HAND TURN SIGNAL FOR OPEN
3 Measure the resistance between the CJB,
connector C103, pin 32, circuit 91S-LG1
(BK/YE), wiring harness side and multifunction
switch, connector C459, pin 6, circuit 91S-LG1
(BK/YE), wiring harness side and ground.
→ Yes
→ No
between the CJB and the multifunction switch
B4: CHECK CONTROL CIRCUIT OF THE RIGHT-HAND TURN SIGNAL FOR OPEN
2007.50 Focus 3/2007 G425001en


(BK/BU), wiring harness side and multifunction
switch, connector C459, pin 7, circuit 91S-LG2
(BK/BU), wiring harness side and ground.
→ Yes
→ No
B5: CHECK COMMON GROUND CONNECTION OF LEFT-HAND TURN SIGNAL LAMPS FOR OPEN
2 OPERATE the horn.
• Does the horn work?
→ Yes
GO to B6.
→ No
LOCATE and RECTIFY the break in circuit
31-DA3 (BK) between soldered connection
S121 and ground G37 using the Wiring
system.
B6: CHECK COMMON POWER SUPPLY OF LEFT-HAND TURN SIGNAL LAMPS FOR OPEN
3 Disconnect left-hand headlamp from connector
C836 .
2007.50 Focus 3/2007 G425001en


connector C96, pin 37, circuit 49S-LG11A
(BU/OG), wiring harness side and left-hand
headlamp, connector C836, pin 3, circuit 49S-
LG11 (BU/OG), wiring harness side.
→ Yes
→ No
49S-LG11A (BU/OG) between the CJB and
soldered connection S125 using the Wiring
system.
B7: CHECK THE GROUND SUPPLY OF THE LEFT-HAND REAR LAMP ASSEMBLY/TURN SIGNAL
LAMP FOR OPEN
2 Disconnect component.
– 5-door: left-hand rear turn signal lamp from
connector C461
– 4-door: left-hand rear lamp assembly from
connector C476
3 Measure the resistance between:
– 5-door: left-hand rear turn signal lamp,
connector C461, pin 2, circuit 31-LG12A (BK),
wiring harness side and ground.
– 4-door: left-hand rear lamp assembly,
connector C476, pin 3, circuit 31-LF23 (BK),
→ Yes
VFE51986 GO to B8.
→ No
the circuit 31-LG12A (BK) between the rear
turn signal lamp and ground connection G77
the circuit 31-LF23 (BK) between the rear
lamp assembly and ground connection G77
2007.50 Focus 3/2007 G425001en


B8: CHECK THE LEFT-HAND REAR LAMP ASSEMBLY/TURN SIGNAL LAMP
3 Measure the voltage between:
– 5-door: left-hand rear turn signal lamp,
connector C461, pin 1, circuit 49S-LG12 (BU),
– 4-door: left-hand rear lamp assembly,
• Does the meter display fluctuating battery
voltage?
VFE51987 → Yes
- 5-door: CHECK and if necessary RENEW
the rear turn signal lamp. CHECK the opera-
tion of the system.
the rear lamp assembly. CHECK the operation
of the system.
→ No
GO to B9.
B9: CHECK THE POWER SUPPLY OF THE LEFT-HAND REAR LAMP ASSEMBLY/TURN SIGNAL
LAMP FOR OPEN
2007.50 Focus 3/2007 G425001en


– 5-door: CJB, connector C100, pin 32, circuit
49S-LG12 (BU), wiring harness side and left-
hand rear turn signal lamp, connector C461,
pin 1, circuit 49S-LG12 (BU), wiring harness
side.
49S-LG12 (BU), wiring harness side and left-
hand rear lamp assembly, connector C476,
pin 5, circuit 49S-LG12 (BU), wiring harness
side.
→ Yes
→ No
the circuit between the CJB and the turn signal
lamp using the Wiring Diagrams. CHECK the
the circuit between the CJB and the rear lamp
assembly using the Wiring Diagrams. CHECK
B10: CHECK THE POWER SUPPLY OF THE LEFT-HAND HEADLAMP FOR OPEN
C836.
5 Measure the voltage between left-hand head-
lamp, connector C836, pin 3, circuit 49S-LG11
(BU/OG), wiring harness side and ground.
voltage?
→ Yes
GO to B11.
→ No
headlamp using the Wiring Diagrams. CHECK
2007.50 Focus 3/2007 G425001en


B11: CHECK THE GROUND SUPPLY OF THE LEFT-HAND HEADLAMP FOR OPEN
2 Measure the resistance between the left-hand
headlamp, connector C836, pin 6, circuit 31-
LE31 (BK), wiring harness side and ground.
→ Yes
CHECK and if necessary RENEW the head-
lamps. CHECK the operation of the system.
→ No
between headlamp and soldered connection
B12: CHECK THE POWER SUPPLY OF THE LEFT-HAND TURN SIGNAL SIDE LAMP FOR OPEN
2 Disconnect left-hand turn signal side lamp from
connector C753.
5 Measure the voltage between left-hand turn
signal side lamp, connector C753, pin 2, circuit
49S-LG13 (BU/RD), wiring harness side and
ground.
voltage?
→ Yes
GO to B13.
→ No
VFE0016137 LOCATE and RECTIFY the break in the circuit
between soldered connection S125 and turn
signal side lamp using the Wiring Diagrams.
B13: CHECK THE GROUND SUPPLY OF THE LEFT-HAND TURN SIGNAL SIDE LAMP FOR OPEN
2007.50 Focus 3/2007 G425001en


2 Measure the resistance between left-hand turn
31-LG13 (BK), wiring harness side and ground.
→ Yes
hand turn signal side lamp. CHECK the oper-
→ No
between turn signal side lamp and soldered
B14: CHECK THE COMMON GROUND SUPPLY OF THE RIGHT-HAND TURN SIGNAL LAMPS
FOR OPEN
2 SWITCH ON windshield wipers.
• Do the wipers operate?
→ Yes
GO to B15.
→ No
S109 and ground connection G56 using the
system.
B15: CHECK THE COMMON POWER SUPPLY OF THE RIGHT-HAND TURN SIGNAL LAMPS FOR
OPEN
3 Disconnect right-hand headlamp from connector
C837 .
2007.50 Focus 3/2007 G425001en


4 Measure the resistance between, CJB,
connector C96, pin 36, circuit 49S-LG18A (BU),
wiring harness side and right-hand headlamp,
wiring harness side.
→ Yes
→ No
49S-LG18A (BU) between CJB and soldered
B16: CHECK THE GROUND SUPPLY OF THE RIGHT-HAND REAR LAMP ASSEMBLY/TURN
SIGNAL LAMP FOR OPEN
– 5-door: right-hand rear turn signal lamp from
connector C462
– 4-door: right-hand rear lamp assembly from
connector C477
– 5-door: right-hand rear turn signal lamp,
connector C462, pin 2, circuit 31-LG19 (BK),
– 4-door: right-hand rear lamp assembly,
connector C477, pin 3, circuit 31-LF24 (BK),
→ Yes
VFE51986 GO to B17.
→ No
the circuit 31-LG19 (BK) between the rear turn
signal lamp and soldered connection S199
the circuit 31-LF24 (BK) between the rear
lamp assembly and ground connection G70
2007.50 Focus 3/2007 G425001en


B17: CHECK THE RIGHT-HAND REAR LAMP ASSEMBLY/TURN SIGNAL LAMP
– 5-door: right-hand rear turn signal lamp,
(BU/RD), wiring harness side and ground.
– 4-door: right-hand rear lamp assembly,
(BU/RD), wiring harness side and ground.
voltage?
VFE51987 → Yes
the rear turn signal lamp. CHECK the opera-
tion of the system.
the rear lamp assembly. CHECK the operation
of the system.
→ No
GO to B18.
B18: CHECK THE POWER SUPPLY OF THE RIGHT-HAND REAR LAMP ASSEMBLY/TURN SIGNAL
LAMP FOR OPEN
2007.50 Focus 3/2007 G425001en


right-hand rear turn signal lamp, connector
C462, pin 1, circuit 49S-LG19 (BU/RD), wiring
harness side.
right-hand rear lamp assembly, connector
C477, pin 5, circuit 49S-LG19 (BU/RD), wiring
harness side.
→ Yes
→ No
the circuit between the CJB and the turn signal
lamp using the Wiring Diagrams. CHECK the
the circuit between the CJB and the rear lamp
B19: CHECK THE POWER SUPPLY OF THE RIGHT-HAND FRONT TURN SIGNAL LAMP
C837.
2007.50 Focus 3/2007 G425001en


5 Measure the voltage between, right-hand
LG18 (BU), wiring harness side and ground.
voltage?
→ Yes
GO to B20.
→ No
49S-LG18 (BU) between soldered connection
S126 and the headlamp using the Wiring
system.
B20: CHECK THE GROUND SUPPLY OF THE RIGHT-HAND HEADLAMP
2 Measure the resistance between the right-hand
→ Yes
lamp. CHECK the operation of the system.
→ No
between headlamp and soldered connection
B21: CHECK THE POWER SUPPLY OF THE RIGHT-HAND TURN SIGNAL SIDE LAMP FOR OPEN
2 Disconnect right-hand turn signal side lamp from
connector C754.
2007.50 Focus 3/2007 G425001en


5 Measure the voltage between right-hand turn
49S-LG20 (BU/WH), wiring harness side and
ground.
voltage?
→ Yes
GO to B22.
→ No
between soldered connection S126 and turn
signal side lamp using the Wiring Diagrams.
B22: CHECK THE GROUND SUPPLY OF THE RIGHT-HAND TURN SIGNAL SIDE LAMP FOR OPEN
2 Measure the resistance between right-hand turn
31-LG20 (BK), wiring harness side and ground.
→ Yes
CHECK and if necessary RENEW the turn
signal side lamp. CHECK the operation of the
system.
→ No
between turn signal side lamp and soldered
PINPOINT TEST F : LEFT-HAND OR RIGHT-HAND TURN SIGNAL LAMPS FLASH CONTINUOUSLY

C1: CHECK MULTIFUNCTION SWITCH
C459.
2007.50 Focus 3/2007 G425001en


• Do all turn signal lamps on one side flash
continuously?
→ Yes
GO to C2.
→ No
CHECK and if necessary RENEW the multi-
function switch. CHECK the operation of the
system.
C2: NARROW DOWN THE CAUSE FOR CONTINUOUS FLASHING
• Do all turn signal lamps on one side flash
continuously?
→ Yes
→ No
- Concern is the left-hand side turn signal
lamps are flashing: LOCATE and RECTIFY
the short to ground in the control circuit 91S-
LG1 (BK/YE) between the CJB and the multi-
function switch using the Wiring Diagrams.
- Concern is the right-hand side turn signal
lamps are flashing: LOCATE and RECTIFY
the short to ground in the control circuit 91S-
LG2 (BK/BU) between the CJB and the multi-
function switch using the Wiring Diagrams.
PINPOINT TEST G : LEFT-HAND OR RIGHT-HAND TURN SIGNAL LAMPS ILLUMINATE

CONTINUOUSLY
D1: DETERMINE THE FAULT CONDITION
2007.50 Focus 3/2007 G425001en


2 CHECK the turn signal lamps.
• Is at least one of the left-hand turn signal lamps
illuminate continuously?
→ Yes
- Front turn signal lamp and turn signal side
lamp are continuously illuminated: GO to D2.
- Rear turn signal lamp is continuously illumin-
ated: GO to D3.
→ No
- Right-hand front turn signal lamp and right-
hand turn signal side lamp are continuously
illuminated:GO to D2.
- Rear turn signal lamp is continuously illumin-
ated: GO to D3.
D2: CHECK THE POWER SUPPLY CIRCUITS OF THE FRONT TURN SIGNAL LAMPS FOR SHORT
TO POWER
• Do the turn signal lamps illuminate continu-
ously?
→ Yes
- Left-hand front turn signal lamps: LOCATE
and RECTIFY the short to battery in the
circuits connected with the soldered connec-
tion S125 using the Wiring Diagrams. CHECK
- Right-hand front turn signal lamps: LOCATE
and RECTIFY the short to battery in the
circuits connected with the soldered connec-
→ No
D3: CHECK THE POWER SUPPLY CIRCUITS OF THE REAR TURN SIGNAL LAMPS FOR SHORT
TO POWER
2007.50 Focus 3/2007 G425001en


• Do the turn signal lamps illuminate continu-
ously?
→ Yes
- Left-hand rear turn signal lamps: LOCATE
and RECTIFY the short to battery in the circuit
49S-LG12 (BU) connected with the CJB,
connector C100, pin 32 using the Wiring
system.
- Right-hand rear turn signal lamps: LOCATE
and RECTIFY the short to battery in the circuit
49S-LG19 (BU/RD) connected with the CJB,
system.
→ No
PINPOINT TEST H : THE HAZARD WARNING LIGHTS ARE INOPERATIVE

E1: CHECK HAZARD WARNING SWITCH
2 Disconnect hazard warning switch from
connector C454.
3 Measure the resistance between the hazard
warning switch, connector C454, pin 2, circuit
91-LG8 (BK/OG), wiring harness side and
ground.
→ Yes
GO to E2.
→ No
VFE49893
between the hazard warning switch and
system.
2007.50 Focus 3/2007 G425001en


E2: CHECK HAZARD WARNING SWITCH
hazard warning switch, connector C454,
between pin 4, circuit 91S-LG8 (BK/OG) and
pin 2, circuit 91-LG8 (BK/OG), wiring harness
side.
VFE49894

3 CHECK hazard warning lamps.
• Do the hazard warning lights operate?
→ Yes
RENEW the hazard warning switch. CHECK
→ No
GO to E3.
E3: CHECK CONTROL CIRCUIT OF THE HAZARD WARNING SWITCH FOR OPEN
(BK/OG), wiring harness side and hazard
warning switch, connector C454, pin 4, circuit
91S-LG8 (BK/OG), wiring harness side.
→ Yes
→ No
between the CJB and the hazard warning
switch using the Wiring Diagrams. CHECK
2007.50 Focus 3/2007 G425001en

PINPOINT TEST I : THE HAZARD WARNING LIGHTS FLASH CONTINUOUSLY
F1: CHECK HAZARD WARNING SWITCH
2 Disconnect hazard warning switch from
connector C454.
• Do the hazard warning lamps flash continu-
ously?
→ Yes
GO to F2.
→ No
RENEW the hazard warning switch. CHECK
F2: CHECK THE CONTROL CIRCUIT OF THE HAZARD WARNING SWITCH FOR SHORT TO
GROUND
• Do the hazard warning lamps operate?
→ Yes
→ No
LOCATE and RECTIFY the short to ground
in the circuit 91S-LG8 (BK/OG) between the
CJB and the hazard warning switch using the
system.
2007.50 Focus 3/2007 G425001en

Parking, Rear and License Plate Lamps

Special Tool(s)
Terminal Probe Kit
Electrical
29-011A
• Fuse(s)
• Lamp(s)
• Connector(s).
29011A
• Switches
• Wiring harness

Symptom Chart
Symptom Chart
• Parking lamps, rear lamps and • Fuse(s) • GO to Pinpoint Test A.
license plate lamps are inoper- • Circuit(s)
ative when the side lights are • Light switch
switched on • Central junction box (CJB)
• Parking lamps and rear lamps • Circuit(s) • GO to Pinpoint Test B.
are inoperative when the • Ignition switch
parking lights are switched on • Light switch
• One or more parking lamps, • Fuse(s) • GO to Pinpoint Test C.
rear lamps or license plate • Circuit(s)
lamps are inoperative • Left/right-hand headlamp
• Left/right-hand rear lamp
assembly
• Left/right-hand license plate
lamp
• Parking lamps, rear lamps and • circuit(e) • GO to Pinpoint Test D.
license plate lamps illuminate • Light switch
continuously • Central junction box (CJB)
Pinpoint Tests
measurements.
2007.50 Focus 3/2007 G425002en

PINPOINT TEST J : PARKING LAMPS, REAR LAMPS AND LICENSE PLATE LAMPS ARE
INOPERATIVE WHEN THE SIDE LIGHTS ARE SWITCHED ON
• Is the fuse OK?
→ Yes
GO to A2.
→ No
A2: CHECK THE VOLTAGE AT FUSE F49 (CJB)
and ground.
→ Yes
GO to A3.
→ No
LOCATE and RECTIFY the break in the power
supply of fuse F49 (CJB) using the Wiring
Diagrams, if necessary RENEW the CJB.
A3: CHECK VOLTAGE SUPPLY AT LIGHT SWITCH FOR OPEN
1 Disconnect light switch from connector C320.
2 Measure the voltage between the light switch,
connector C320, pin 11, circuit 29-LE29
(OG/BK), wiring harness side and ground.
→ Yes
RENEW the light switch. CHECK the operation
of the system.
→ No
VFE0016145 between fuse F49 (CJB) and the light switch
2007.50 Focus 3/2007 G425002en

PINPOINT TEST K : PARKING LAMPS AND REAR LAMPS ARE INOPERATIVE WHEN THE PARKING
LIGHTS ARE SWITCHED ON
B1: CHECK VOLTAGE SUPPLY AT LIGHT SWITCH FOR OPEN
connector C320, pin 12, circuit 30S-LE29
(RD/GN), wiring harness side and ground.
→ Yes
GO to B2.
→ No
between the ignition switch and the light switch
VFE0003169 using the Wiring Diagrams. CHECK the oper-
ation of the system. If the concern persists,
RENEW the new ignition switch. CHECK the
B2: CHECK THE LIGHT SWITCH
1 Connect a fused jumper wire (20 A) to the light
switch, connector C320, between pin 12, circuit
30S-LE29 (RD/GN) and pin 13, circuit 29S-LF1
(OG/YE), wiring harness side.
• Do the parking lamps and rear lamps illu-
minate?
→ Yes
of the system.
E0036118 → No
29S-LF1 (OG/YE), between the light switch
and fuses F53 (CJB) and F54 (CJB), using
the Wiring Diagrams. CHECK the operation
of the system.
PINPOINT TEST L : ONE OR MORE PARKING LAMPS, REAR LAMPS OR LICENSE PLATE LAMPS
ARE INOPERATIVE
C1: DETERMINE THE FAULT CONDITION
2007.50 Focus 3/2007 G425002en


2 SWITCH ON the side lights.
• Is a left-hand parking lamp or license plate
lamp inoperative?
→ Yes
- Front left-hand parking lamp and left-hand
rear lamp inoperative (all other lamps OK):
GO to C2.
- Front left-hand parking lamp inoperative (all
other lamps OK): GO to C3.
- Left-hand rear lamp inoperative (all other
lamps OK):GO to C5.
- Philipines, vehicles built as of 08/2005, left-
hand license plate lamp inoperative (all other
lamps OK): LOCATE and RECTIFY the break
in circuit 31-LF21 (BK), between the license
plate lamp and soldered connection S200
- All other vehicles, left-hand license plate
lamp inoperative (all other lamps OK):
31-LF21 (BK), between the license plate lamp
and soldered connection S196 using the
system.
- Both license plate lamps inoperative (all
other lamps OK): GO to C14.
- Front parking lamps and left and right-hand
rear lamps inoperative (both license plate
lamps OK). GO to C17.
→ No
- Front right-hand parking lamp and right-hand
rear lamp inoperative (all other lamps OK):
GO to C7.
- Front right-hand parking lamp inoperative
(all other lamps OK): GO to C8.
- Right-hand rear lamp assembly inoperative
- Right-hand license plate lamp inoperative
C2: CHECK FUSE F53 (CJB)
1 Disconnect fuse F53 (7.5 A) (CJB).
2007.50 Focus 3/2007 G425002en


2 CHECK fuse F53 (7.5 A) (CJB).
• Is the fuse OK?
→ Yes
RENEW the CJB. CHECK the operation of
the system.
→ No
RENEW fuse F53 (7.5 A) (CJB). If the fuse
blows again, LOCATE and RECTIFY the short
to ground using the Wiring Diagrams. CHECK
C3: CHECK VOLTAGE SUPPLY AT THE FRONT LEFT-HAND PARKING LAMP FOR OPEN
C836.
3 Measure the voltage between the left-hand
LF7 (OG/BU), wiring harness side and ground.
→ Yes
GO to C4.
→ No
between fuse F53 (CJB) and the headlamp
C4: CHECK GROUND SUPPLY AT LEFT-HAND HEADLAMP FOR OPEN
→ Yes
→ No
between the headlamp and soldered connec-
2007.50 Focus 3/2007 G425002en


C5: CHECK VOLTAGE SUPPLY AT LEFT-HAND REAR LAMP ASSEMBLY FOR OPEN
connector.
– 5-door: C472
– 4-door: C476
3 Measure the voltage between the left-hand rear
lamp assembly:
LF11A (OG/WH), wiring harness side and
ground.
LF11 (OG/WH), wiring harness side and
ground.
VFE51982
→ Yes
GO to C6.
→ No
between fuse F53 (CJB) and the rear lamp
the operation of the system. If the concern
persists, CHECK the CJB and RENEW if
necessary. CHECK the operation of the
system.
C6: CHECK GROUND SUPPLY AT LEFT-HAND REAR LAMP ASSEMBLY FOR OPEN
1 Measure the resistance between the rear lamp
assembly:
LF23B (BK), wiring harness side and ground.
→ Yes
tion of the system.
→ No
between the rear lamp assembly and ground
connection G77 using the Wiring Diagrams.
2007.50 Focus 3/2007 G425002en


• Is the fuse OK?
→ Yes
the system.
→ No
RENEW fuse F54 (7.5 A) (CJB). If the fuse
blows again, LOCATE and RECTIFY the short
to ground using the Wiring Diagrams. CHECK
C8: CHECK VOLTAGE SUPPLY AT THE FRONT RIGHT-HAND PARKING LAMP FOR OPEN
C837.
3 Measure the voltage between right-hand head-
lamp, connector C837, pin 4, circuit 29S-LF16
(OG/GN), wiring harness side and ground.
→ Yes
GO to C9.
→ No
ation of the system. If the concern persists,
CHECK the CJB and RENEW if necessary.
C9: CHECK GROUND SUPPLY AT RIGHT-HAND HEADLAMP FOR OPEN
1 Measure the resistance between right-hand
→ Yes
→ No
2007.50 Focus 3/2007 G425002en


C10: CHECK VOLTAGE SUPPLY TO RIGHT-HAND REAR LAMP ASSEMBLY FOR OPEN
connector.
– 5-door: C473
– 4-door: C477
3 Measure the voltage between the rear lamp
assembly:
LF20A (OG), wiring harness side and ground.
LF20 (OG), wiring harness side and ground.
→ Yes
GO to C11.
VFE51982
→ No
between fuse F54 (CJB) and the rear lamp
the operation of the system. If the concern
persists, CHECK the CJB and RENEW if
system.
C11: CHECK GROUND SUPPLY AT THE RIGHT-HAND REAR LAMP ASSEMBLY FOR OPEN
1 Measure the resistance between the rear lamp
assembly:
LF24A (BK), wiring harness side and ground.
→ Yes
tion of the system.
→ No
between the rear lamp assembly and soldered
C12: CHECK VOLTAGE SUPPLY TO RIGHT-HAND LICENCE PLATE LAMP
1 Disconnect right-hand license plate lamp from
connector C497.
2007.50 Focus 3/2007 G425002en


3 Measure the voltage between right-hand license
plate lamp, connector C497, pin 1, circuit 29S-
LF22 (OG/BK), wiring harness side and ground.
→ Yes
GO to C13.
→ No
between the right-hand license plate lamp and
VFE0007844 the left-hand license plate lamp using the
system.
C13: CHECK GROUND SUPPLY AT RIGHT-HAND LICENCE PLATE LAMP FOR OPEN
1 SWITCH OFF the side lights.
2 Disconnect right-hand license plate lamp from
connector C496.
license plate lamp, connector C496, pin 1, circuit
31-LF22 (BK), wiring harness side and ground.
→ Yes
CHECK and if necessary RENEW the license
plate lamp. CHECK the operation of the
system.
→ No
E0011541 - Philipines, vehicles built as of 08/2005,
between the right-hand license plate lamp and
system.
- All other vehicles, LOCATE and RECTIFY
the break in the circuit between the right-hand
license plate lamp and soldered connection
2007.50 Focus 3/2007 G425002en


• Is the fuse OK?
→ Yes
GO to C15.
→ No
RENEW fuse F73 (7.5 A) (CJB). CHECK the
C15: CHECK THE VOLTAGE AT FUSE F73 (CJB)
1 Connect fuse F73 (7.5 A) (CJB).
3 Measure the voltage between fuse F73 (7.5 A)
and ground.
→ Yes
29S-LF21 (OG/BK) or 29S-LF21 (BK),
between fuse F73 (CJB) and the left-hand
license plate lamp using the Wiring Diagrams.
→ No
GO to C16.
C16: CHECK THE LIGHT SWITCH
1 SWITCH OFF the side lights.
(OG/BU), wiring harness side.
minate?
→ Yes
of the system.
VFE51984
→ No
29S-LF5 (OG/BU), between the light switch
and fuse F73 (CJB) using the Wiring
system.
2007.50 Focus 3/2007 G425002en


C17: CHECK THE LIGHT SWITCH
(OG/YE), wiring harness side.
minate?
→ Yes
of the system.
E0036118 → No
29S-LF1 (OG/YE), between the light switch
and fuses F53 (CJB) and F54 (CJB), using
of the system.
PINPOINT TEST M : PARKING LAMPS, REAR LAMPS AND LICENSE PLATE LAMPS ILLUMINATE
CONTINUOUSLY
2007.50 Focus 3/2007 G425002en


5 CHECK parking lamps, rear lamps and license
plate lamps.
• Do the left-hand parking lamps illuminate
continuously?
→ Yes
LOCATE AND RECTIFY the short to battery
voltage in the circuits connected to fuse F53
(CJB), output side, using the Wiring Diagrams.
→ No
- Right-hand parking lamps illuminate
continuously: LOCATE and RECTIFY the
short to battery voltage in the circuits
connected to fuse F54 (CJB), output side,
- License plate lamps illuminate continuously:
voltage in the circuits connected to fuse F73
(CJB), output side, using the Wiring Diagrams.
- No malfunction detected: GO to D2.
D2: CHECK THE LIGHT SWITCH
7 CHECK parking lamps, rear lamps and license
plate lamps.
• Do the parking lamps and rear lamps illuminate
continuously?
→ Yes
GO to D3.
→ No
- The license plate lamps illuminate continu-
ously: GO to D4.
- No malfunction detected: RENEW light
switch. CHECK the operation of the system.
2007.50 Focus 3/2007 G425002en


D3: RULE OUT CENTRAL JUNCTION BOX AS POSSIBLE CAUSE FOR SHORT TO BATTERY
VOLTAGE
connector C320, pin 13, circuit 29S-LF1
(OG/YE), wiring harness side and ground.
→ Yes
voltage in circuit 29S-LF1 (OG/YE), between
the light switch and the CJB using the Wiring
VFE0034861
system.
→ No
D4: RULE OUT CENTRAL JUNCTION BOX AS POSSIBLE CAUSE FOR SHORT TO BATTERY
VOLTAGE
connector C320, pin 16, circuit 29S-LF5
(OG/BU), wiring harness side and ground.
→ Yes
voltage in circuit between the light switch and
the CJB using the Wiring Diagrams. CHECK
VFE0034837 → No
2007.50 Focus 3/2007 G425002en

Fog Lamps
Special Tool(s)
Terminal Probe Kit
Electrical
29-011A
• Fuse(s)
• Lamp(s)
• Connector(s)
29011A
• Switches
• Wiring harness

Symptom Chart
Symptom Chart
• Fog lamps are inoperative • Fuse • GO to Pinpoint Test A.
• Circuit(s)
• Light switch
• One fog lamp is inoperative • Circuit(s) • GO to Pinpoint Test B.
• Left/right-hand front fog lamp
• Left/right-hand rear fog lamp,
4-door
• Front fog lamps or rear fog • Circuit(s) • GO to Pinpoint Test C.
lamps illuminate continuously • Light switch
• indicator lamp (fog lamps) is • Circuit(s) • GO to Pinpoint Test D.
inoperative • Instrument cluster
Pinpoint Tests
measurements.
PINPOINT TEST N : FOG LAMPS ARE INOPERATIVE
A1: DETERMINE THE FAULT CONDITION
2 SWITCH ON the dipped beam.
2007.50 Focus 3/2007 G425003en


3 SWITCH ON the front and rear fog lamps.
4 CHECK fog lamps.
• Are all fog lamps inoperative?
→ Yes
GO to A2.
→ No
- Front fog lamps inoperative:GO to A5.
- Rear fog lamps inoperative: GO to A7.
• Is the fuse OK?
→ Yes
GO to A3.
→ No
and ground.
→ Yes
GO to A4.
→ No
LOCATE and RECTIFY the break in the
voltage supply to fuse F69 (CJB) using the
Wiring Diagrams, if necessary RENEW the
CJB. CHECK the operation of the system.
A4: CHECK VOLTAGE AT LIGHT SWITCH
2007.50 Focus 3/2007 G425003en


connector C320, pin 7, circuit 15-LD16 (GN/RD),
→ Yes
of the system.
→ No
VFE0003184 between fuse F69 (CJB) and the light switch
and using the Wiring Diagrams, if necessary
the system.
A5: CHECK LIGHT SWITCH
15-LD16 (GN/RD) and pin 3, circuit 15S-LD7A
(GN/BU), wiring harness side.
E0024111

5 CHECK the front fog lamps.
• Do the front fog lamps illuminate?
→ Yes
of the system.
→ No
GO to A6.
A6: CHECK THE COMMON GROUND SUPPLY OF THE FRONT FOG LAMPS FOR OPEN
2 Disconnect left-hand front fog lamp from
connector C302.
2007.50 Focus 3/2007 G425003en


3 Measure the resistance between left-hand front
fog lamp, connector C302, pin 2, circuit 31-LD11
→ Yes
circuits 15S-LD7A (GN/BU) or 15S-LD1
(GN/YE) between light switch and soldered
VFE49875 CHECK the operation of the system.
→ No
S121 and ground connection G37 using the
system.
15-LD16 (GN/RD) and pin 2, circuit 15S-LD13A
(GN/OG), wiring harness side.
E0024110

5 Check the rear fog lamps.
• Do the rear fog lamps illuminate?
→ Yes
of the system.
→ No
- 5-door: GO to A8.
circuit between the light switch and the left-
hand rear lamp assembly using the Wiring
system.
2007.50 Focus 3/2007 G425003en


A8: CHECK THE POWER SUPPLY AT THE REAR FOG LAMP FOR OPEN (5-DOOR)
NOTE: The jumper lead used in the previous step is still connected.

– LHD: left-hand, rear fog lamp from connector
C434
– RHD: right-hand, rear fog lamp from connector
C430
VFE0016230

– Except China vehicles as of 11/2004, LHD:
left-hand, rear fog lamp, connector C434, pin
1, circuit 15S-LD6 (GN/YE), wiring harness
side and ground.
– All other vehicles, LHD: left-hand, rear fog
lamp, connector C434, pin 1, circuit 15S-LD6A
(GN/YE), wiring harness side and ground.
– Vehicles built as of 11/2004, RHD: right-hand,
rear fog lamp, connector C430, pin 1, circuit
15S-LG16 (GN/OG), wiring harness side and
ground.
– All other vehicles, RHD: right-hand, rear fog
lamp, connector C430, pin 1, circuit 15S-
LG16A (GN/OG), wiring harness side and
ground.
→ Yes
GO to A9.
→ No
circuit(s) between the light switch and the rear
fog lamp using the Wiring Diagrams. CHECK
2007.50 Focus 3/2007 G425003en


A9: CHECK THE GROUND SUPPLY AT THE REAR FOG LAMP FOR OPEN (5-DOOR)
VFE49878

– LHD: left-hand, rear fog lamp, connector
C434, pin 2, circuit 31-LD6 (BK), wiring
– RHD: right-hand, rear fog lamp, connector
C430, pin 2, circuit 31-LG16 (BK), wiring
→ Yes
RENEW the rear fog lamp. CHECK the oper-
→ No
between the rear fog lamp and ground
CHECK the operation of the system. CHECK
PINPOINT TEST O : ONE FOG LAMP IS INOPERATIVE

2 SWITCH ON the fog lamps.
2007.50 Focus 3/2007 G425003en


• Is one of the front fog lamps inoperative?
→ Yes
- Left-hand front fog lamp inoperative: GO to
B2.
- Right-hand front fog lamp inoperative:GO to
B4.
→ No
- Left-hand rear fog lamp inoperative, 4-door:
GO to B6.
- Right-hand rear fog lamp inoperative, 4-door:
GO to B7.
B2: CHECK THE POWER SUPPLY OF THE LEFT-HAND FRONT FOG LAMP FOR OPEN
2 Disconnect left-hand front fog lamp from
connector C302.
5 Measure the voltage between, left-hand front
fog lamp, connector C302, pin 1, circuit 15S-
LD11 (GN/WH), wiring harness side and ground.
→ Yes
GO to B3.
→ No
VFE49879
front fog lamp using the Wiring Diagrams.
B3: CHECK THE GROUND SUPPLY OF THE LEFT-HAND FRONT FOG LAMP FOR OPEN
2007.50 Focus 3/2007 G425003en


front fog lamp, connector C302, pin 2, circuit
31-LD11 (BK), wiring harness side and ground.
→ Yes
CHECK and RENEW the front fog lamp.
→ No
VFE49875
between the left-hand front fog lamp and
system.
B4: CHECK THE POWER SUPPLY OF THE RIGHT-HAND FRONT FOG LAMP FOR OPEN
2 Disconnect right-hand front fog lamp from
connector C304.
5 Measure the voltage between right-hand front
fog lamp, connector C304, pin 1, circuit 15S-
LD17 (GN/WH), wiring harness side and ground.
→ Yes
GO to B5.
→ No
between soldered connection S108 and front
VFE49879
fog lamp using the Wiring Diagrams. CHECK
B5: CHECK THE GROUND SUPPLY OF THE RIGHT-HAND FRONT FOG LAMP FOR OPEN
2007.50 Focus 3/2007 G425003en


front fog lamp, connector C304, pin 2, circuit
31-LD17 (BK), wiring harness side and ground.
→ Yes
CHECK and if necessary RENEW the front
fog lamp. CHECK the operation of the system.
→ No
VFE49875
between the front fog lamp and soldered
B6: CHECK THE GROUND SUPPLY OF THE LEFT-HAND REAR LAMP ASSEMBL FOR OPEN (4-
DOOR)
connector C476.
rear lamp assembly, connector C476, pin 3,
circuit 31-LF23 (BK), wiring harness side and
ground.
→ Yes
CHECK and if necessary RENEW the rear
lamp assembly. CHECK the operation of the
system.
VFE49877
→ No
between rear lamp assembly and ground
B7: CHECK THE POWER SUPPLY OF THE RIGHT-HAND REAR LAMP ASSEMBLY FOR OPEN
(4-DOOR)
connector C477.
4 SWITCH ON the rear fog lamps.
2007.50 Focus 3/2007 G425003en


5 Measure the voltage between right-hand rear
lamp assembly, connector C477, pin 7, circuit
15S-LD12 (GN/YE), wiring harness side and
ground.
→ Yes
GO to B8.
→ No
E0031100 between the right-hand rear lamp assembly
and the left-hand rear lamp assembly using
of the system.
B8: CHECK THE GROUND SUPPLY OF THE RIGHT-HAND REAR LAMP ASSEMBLY FOR OPEN
(4-DOOR)
rear lamp assembly, connector C477, pin 3,
circuit 31-LF24 (BK), wiring harness side and
ground.
→ Yes
hand rear lamp assembly. CHECK the opera-
tion of the system.
VFE49877
→ No
between the right-hand rear lamp assembly
and ground connection G70 using the Wiring
system.
PINPOINT TEST P : FRONT FOG LAMPS OR REAR FOG LAMPS ILLUMINATE CONTINUOUSLY
C1: CHECK LIGHT SWITCH
2007.50 Focus 3/2007 G425003en


4 CHECK fog lamps.
• Do the fog lamps illuminate continuously?
→ Yes
GO to C2.
→ No
of the system.
C2: RULE OUT INSTRUMENT CLUSTER AS POSSIBLE CAUSE FOR A SHORT TO BATTERY
VOLTAGE
5 CHECK fog lamps.
• Do the fog lamps illuminate continuously?
→ Yes
- Front fog lamps illuminate continuously:
- Rear fog lamp(s) illuminate continuously:
→ No
CHECK the instrument cluster using WDS,
of the system.
PINPOINT TEST Q : INDICATOR LAMP (FOG LAMPS) IS INOPERATIVE

2 SWITCH ON the front fog lamps.
3 SWITCH ON the rear fog lamps.
2007.50 Focus 3/2007 G425003en


4 CHECK the indicator lamps for both switch
settings.
• Are both indicator lamps inoperative ?
→ Yes
of the system.
→ No
- Indicator lamp for front fog lamps is inoper-
ative: GO to D2.
- Indicator lamp for rear fog lamp(s) is inoper-
ative: GO to D3.
D2: CHECK THE CONTROL CIRCUIT OF THE INDICATOR LAMP FRONT FOG LAMPS FOR OPEN
3 Disconnect instrument cluster from connector
C809.
4 Measure the resistance between the light switch,
connector C320, pin 3, circuit 15S-LD7A
(GN/BU), wiring harness side and instrument
cluster, connector C809, pin 16, circuit 15S-LD7
(GN/BU), wiring harness side.
→ Yes
VFE49882 of the system.
→ No
between the soldered connection S71 and
instrument cluster using the Wiring Diagrams.
D3: CHECK THE CONTROL CIRCUIT OF THE INDICATOR LAMP REAR FOG LAMPS FOR OPEN
3 Disconnect instrument cluster from connector
C809.
2007.50 Focus 3/2007 G425003en


4 Measure the resistance between the light switch,
connector C320, pin 2, circuit 15S-LD13A
(GN/OG), wiring harness side and instrument
cluster, connector C809, pin 1, circuit 15S-LD13
(GN/OG), wiring harness side.
→ Yes
VFE49881 of the system.
→ No
between the soldered connection S72 and
instrument cluster using the Wiring Diagrams.
2007.50 Focus 3/2007 G425003en

Reversing Lamps
Special Tool(s)
Visual Inspection
Terminal Probe Kit
Electrical
29-011A
• Fuse(s)
• Lamp(s)
• Connector(s)
29011A
• Switches
• Wiring harness

Symptom Chart
Symptom Chart
• Reversing lamps are inoper- • Fuse • GO to Pinpoint Test A.
• In-gear switch
• Gearshift lever unit
• Reversing lamp relay
• One reversing lamp is inoper- • Circuit(s) • GO to Pinpoint Test B.
ative (4-door) • Bulb
• Rear lamp assembly
• The reversing lamps illuminate • Circuit(s) • GO to Pinpoint Test C.
continuously • In-gear switch
• Reversing lamp relay
• Interior mirror with automatic
glare adjustment
Pinpoint Tests
measurements.
2007.50 Focus 3/2007 G425004en

PINPOINT TEST R : REVERSING LAMPS ARE INOPERATIVE
• Is the fuse OK?
→ Yes
GO to A2.
→ No
1 Connect fuse F84 (10 A).
and ground.
→ Yes
GO to A3.
→ No
Wiring Diagrams, if necessary RENEW the
CJB. CHECK the operation of the system.
A3: DETERMINE MODEL VERSION
1 Determine the model version.
• Is the vehicle equipped with the automatic
transmission and Duratec-HE engine?
→ Yes
GO to A6.
→ No
GO to A4.
A4: CHECK THE VOLTAGE AT THE IN-GEAR SWITCH OR GEARSHIFT LEVER UNIT
2007.50 Focus 3/2007 G425004en


2 Disconnect the component concerned.
– MTX transmission: Reversing lamps switch
from connector C864
– MMT6 transmission: Reversing lamps switch
from connector C864
– F5M transmission: Reversing lamps switch
from connector C866
– Automatic transmission with 1,6L (Z6) engine:
Gearshift lever unit from connector C182
4 Measure the voltage between the in-gear switch
or gearshift lever unit:
– MTX transmission: connector C864, pin 2,
circuit 15-LG28 (GN/WH), wiring harness side
and ground.
– MMT6 transmission: connector C864, pin 2,
circuit 15-LG28 (GN/WH), wiring harness side
and ground.
– F5M transmission: connector C866, pin B,
circuit 15-LG28A (GN/WH), wiring harness
side and ground.
connector C182, pin E, circuit 15-LG28
→ Yes
GO to A5.
→ No
between fuse F84 (CJB) and the in-gear
switch or gearshift lever unit using the Wiring
system.
A5: CHECK THE IN-GEAR SWITCH OR GEARSHIFT LEVER UNIT
2007.50 Focus 3/2007 G425004en


2 Connect a fused jumper wire (10 A) to the in-
gear switch or gearshift lever unit:
– MTX transmission: connector C864, between
pin 2, circuit 15-LG28 (GN/WH) and pin 1,
circuit 15S-LG9 (GN/BK), wiring harness side.
– MMT6 transmission: connector C864, between
pin 2, circuit 15-LG28 (GN/WH) and pin 1,
circuit 15S-LG9 (GN/BK), wiring harness side.
– F5M transmission: connector C866, between
pin B, circuit 15-LG28A (GN/WH) and pin A,
circuit 15S-LG9A (GN/BK), wiring harness
side.
connector C182, pin E, circuit 15-LG28
(GN/WH) and pin D, circuit 15S-LG9 (GN/BK),
4 CHECK the operation of the reversing lamps.
→ Yes
RENEW the in-gear switch or gearshift lever
unit. CHECK the operation of the system.
→ No
GO to A10.
A6: CHECK THE VOLTAGE AT THE POWER CIRCUIT OF THE REVERSING LAMP RELAY
2 Disconnect reversing lamp relay from socket
C1003.
4 Measure the voltage between the reversing
lamp relay, socket C1003, pin 3, circuit 15-LG46
(GN/OG), wiring harness side and ground.
→ Yes
GO to A7.
→ No
between fuse F84 (CJB) and the reversing
lamp relay using the Wiring Diagrams. CHECK
2007.50 Focus 3/2007 G425004en


A7: CHECK THE VOLTAGE AT THE CONTROL CIRCUIT OF THE REVERSING LAMP RELAY
1 Measure the voltage between the reversing
lamp relay, socket C1003, pin 1, circuit 15-LG45
(GN/BK), wiring harness side and ground.
→ Yes
GO to A8.
→ No
reversing lamp relay using the Wiring
system.
A8: CHECK REVERSING LAMP RELAY
reversing lamp relay, socket C1003, between
pin 3, circuit 15-LG46 (GN/OG) and pin 5, circuit
15S-LG9 (GN/BK), wiring harness side.
2 CHECK the operation of the reversing lamps.
→ Yes
GO to A9.
→ No
GO to A10.
A9: CHECK THE CONTROL CIRCUIT 91S-LG45 (BK/GN) OF THE REVERSING LAMP RELAY FOR
OPEN CIRCUIT
2 Disconnect transmission control unit (TCU) from
connector C414.
2007.50 Focus 3/2007 G425004en


3 Measure the resistance between the reversing
lamp relay, socket C1003, pin 2, circuit 91S-
LG45 (BK/GN), BJB side and transmission
control unit (TCU), connector C414, pin 67,
wiring harness side.
→ Yes
CHECK the reversing lamp relay according to
the component test at the end of this section,
RENEW as necessary. CHECK the operation
of the system. If the relay is OK:
REFER to: Diagnosis By Symptom (307-
→ No
between the reversing lamp relay and trans-
mission control unit (TCU) using the Wiring
system.
A10: CHECK FOR OPEN CIRCUIT IN 15S-LG9(A) (GN/BK), OR 15S-LG46 (GN/OG)
2007.50 Focus 3/2007 G425004en


– MTX transmission: in-gear switch, connector
C864, between pin 1, circuit 15S-LG9 (GN/BK)
and CJB, connector C96, pin 25, circuit 15S-
LG9A (GN/BK), wiring harness side.
– MMT6 transmission: in-gear switch, connector
C864, between pin 1, circuit 15-LG9 (GN/BK)
– F5M transmission: in-gear switch, connector
C866, between pin 1, circuit 15-LG9A (GN/BK)
Gearshift lever unit, connector C182, between
pin D, circuit 15S-LG9 (GN/BK) and CJB,
connector C96, pin 25, circuit 15-LG9A
(GN/BK), wiring harness side.
– Automatic transmission with Duratec-HE
engine: reversing lamp relay, socket C1003,
between pin 5, circuit 15S-LG9 (GN/BK) and
CJB, connector C96, pin 25, circuit 15-LG9
→ Yes
GO to A11.
→ No
- Vehicles without automatic transmission:
between the in-gear switch or reversing lamp
relay and CJB using the Wiring Diagrams.
- Vehicles with automatic transmission with
1,6L (Z6) engine: LOCATE and RECTIFY the
break in the circuit between the gearshift lever
unit or reversing lamp relay and CJB using
of the system.
- Vehicles with automatic transmission with
Duratec-HE engine: LOCATE and RECTIFY
the break in the circuit between the reversing
lamp relay and CJB using the Wiring
system.
A11: CHECK FOR OPEN CIRCUIT IN THE CJB
2 Connect CJB to connector C96.
2007.50 Focus 3/2007 G425004en


3 Connect the component concerned.
– MTX transmission: Reversing lamps switch to
connector C864
to connector C864
– F5M transmission: Reversing lamps switch to
connector C866
Gearshift lever unit to connector C182
– Automatic transmission with Duratec-HE
engine: reversing lamp relay to socket C1003
5 ENGAGE reverse gear.
6 Measure the voltage between CJB, C100, pin
1, CJB side and ground.
→ Yes
- 5-door: GO to A12.
circuit, between the rear lamp assembly and
CJB using the Wiring Diagrams. CHECK the
→ No
the system.
A12: CHECK THE POWER SUPPLY OF THE REVERSING LAMP (5-DOOR)
2 Disconnect reversing lamp from connector.
– LHD: C430
– RHD: C434
2007.50 Focus 3/2007 G425004en


4 Measure the voltage between reversing lamp:
– LHD: right-hand side, connector C430, pin 1,
circuit 15S-LG16 (GN/OG), harness side and
ground.
– RHD: right-hand side, connector C430, pin 1,
circuit 15S-LD6 (GN/YE), harness side and
ground.
→ Yes
E0024112
GO to A13.
→ No
between the reversing lamp and CJB using
of the system.
A13: CHECK GROUND SUPPLY AT THE REVERSING LAMP FOR OPEN (5-DOOR)
2 Measure the resistance between reversing lamp:
– LHD: right-hand side, connector C430, pin 2,
circuit 31-LG16 (BK), harness side and
ground.
– RHD: right-hand side, connector C434, pin 2,
circuit 31-LG6 (BK) harness side and ground.
→ Yes
CHECK and if necessary RENEW the
VFE49878 reversing lamp. CHECK the operation of the
system.
→ No
between reversing lamp and soldered
PINPOINT TEST S : ONE REVERSING LAMP IS INOPERATIVE (4-DOOR)

B1: DETERMINE INOPERATIVE HEADLAMP
2 ENGAGE reverse gear.
2007.50 Focus 3/2007 G425004en


3 Determine which reversing lamp is inoperative.
• Is the left-hand reversing lamp inoperative?
→ Yes
GO to B2.
→ No
Right-hand reversing lamp inoperative: GO to
B3.
B2: CHECK GROUND SUPPLY AT LEFT-HAND REAR LAMP ASSEMBLY FOR OPEN
• Do the rear lamps left-hand side illuminate?
→ Yes
tion of the system.
→ No
31-LF23 (BK), between rear lamp assembly,
left-hand side and ground connection G77
B3: CHECK GROUND SUPPLY AT RIGHT-HAND REAR LAMP ASSEMBLY FOR OPEN
• Do the rear lamps right-hand side illuminate?
→ Yes
GO to B4.
→ No
31-LF24 (BK), between rear lamp assembly,
right-hand side and soldered connection S199
B4: CHECK FOR OPEN CIRCUIT IN 15S-LG16A (GN/OG)
NOTE: Reverse gear is still engaged.

connector C477.
2007.50 Focus 3/2007 G425004en


4 Measure the voltage between the rear lamp
assembly right-hand side, connector C477, pin
6, circuit 15S-LG16A (GN/OG), wiring harness
side and ground.
→ Yes
tion of the system.
VFE51985
→ No
between the left-hand rear lamp assembly and
the right-hand rear lamp assembly using the
system.
PINPOINT TEST T : THE REVERSING LAMPS ILLUMINATE CONTINUOUSLY

C1: DETERMINE MODEL VERSION
1 Determine the model version.
• Is the vehicle equipped with the automatic
transmission and Duratec-HE engine?
→ Yes
GO to C3.
→ No
GO to C2.
C2: CHECK THE IN-GEAR SWITCH OR GEARSHIFT LEVER UNIT
1 Disconnect the component concerned.
– MTX transmission: Reversing lamps switch
from connector C864
from connector C864
– F5M transmission: Reversing lamps switch
from connector C866
Gearshift lever unit from connector C182
2007.50 Focus 3/2007 G425004en


3 CHECK the reversing lamps.
• Do the reversing lamps illuminate continu-
ously?
→ Yes
GO to C5.
→ No
RENEW the in-gear switch. CHECK the
C3: CHECK REVERSING LAMP RELAY
1 Disconnect reversing lamp relay from socket
C1003.
ously?
→ Yes
GO to C5.
→ No
GO to C4.
C4: CHECK THE CONTROL CIRCUIT 91S-LG45 (BK/GN) OF THE REVERSING LAMP RELAY FOR
SHORT TO GROUND
2 Disconnect transmission control unit (TCU) from
connector C414.
3 Measure the resistance between the reversing
lamp relay, socket C1003, pin 2, circuit 91S-
LG45 (BK/GN), BJB side and ground.
→ Yes
CHECK the reversing lamp relay according to
the component test at the end of this section,
RENEW as necessary. CHECK the operation
of the system. If the relay is OK:
REFER to: Diagnosis By Symptom (307-
→ No
LOCATE and RECTIFY the short to ground
between the reversing lamp relay and trans-
mission control unit (TCU) using the Wiring
system.
2007.50 Focus 3/2007 G425004en


C5: CHECK CIRCUIT 15S-LG9(A) (GN/BK) FOR SHORT TO BATTERY VOLTAGE
ously?
→ Yes
GO to C6.
→ No
voltage in the circuits connected to the CJB,
system.
C6: RULE OUT CJB AS POSSIBLE CAUSE FOR SHORT TO BATTERY VOLTAGE
4 CHECK the reversing lamps.
ously?
→ Yes
voltage in the circuits connected to the CJB,
system.
→ No
the system.
Component Test: • If not, RENEW the reversing lamp relay.

state:
REVERSING LAMP RELAY
• Using a fused test cable (3 A), connect pin
1 of the reversing lamp relay, component
1. Check the normally open contact in the
side, to the battery positive terminal.
unswitched state:
• Using a test cable, connect pin 2 of the
• Measure the resistance at the reversing lamp reversing lamp relay, component side, to the
relay, between pin 3 and pin 5, component battery negative terminal.
side.
• Measure the resistance at the reversing lamp
• Is the resistance greater than 10,000 Ohms? relay, between pin 3 and pin 5, component
• If yes, go to 2. side.
2007.50 Focus 3/2007 G425004en

• If yes, then the reversing lamp relay is OK.
• If not, RENEW the reversing lamp relay.
2007.50 Focus 3/2007 G425004en

Headlamps
Special Tool(s)
Terminal Probe Kit
Electrical
29-011A
• Fuse(s)
• Lamp(s)
• Connection(s)
29011A
• Switches
• Wiring harness

NOTE: The generic electronic module (GEM) is any further tests.
part of the central junction box (CJB). 4. If the concern persists, check the symptoms
Symptom Chart
Symptom Chart
• Dipped beam and main beam • Fuse • GO to Pinpoint Test A.
are inoperative • Circuit(s)
• Light switch
(GEM)
• Dipped beam is inoperative • Fuse • GO to Pinpoint Test B.
• Circuit(s)
(GEM)
• Main beam is inoperative • Circuit(s) • GO to Pinpoint Test C.
(GEM)
• One dipped beam is inoper- • Fuse • GO to Pinpoint Test D.
• Left/right-hand headlamp
• One main beam is inoperative • Fuse • GO to Pinpoint Test E.
• Circuit(s)
• Left/right-hand headlamp
(GEM)
2007.50 Focus 3/2007 G425005en


• Headlamps illuminate continu- • Circuit(s) • GO to Pinpoint Test F.
ously • Light switch
(GEM)
• Flash-to-pass feature is inoper- • Circuit(s) • GO to Pinpoint Test G.
ative • Multifunction switch
(GEM)
• Main beam warning lamp is • Circuit(s) • REFER to: Instrument Cluster
inoperative • Instrument cluster (413-01 Instrument Cluster,
• Central junction box (CJB) Diagnosis and Testing).
(GEM)
Pinpoint Tests
measurements.
PINPOINT TEST U : DIPPED BEAM AND MAIN BEAM ARE INOPERATIVE
2 Disconnect fuse F66 (7.5A) (CJB).
• Is the fuse OK?
→ Yes
GO to A2.
→ No
RENEW fuse F66 (7.5 A) and CHECK the
A2: CHECK VOLTAGE AT FUSE F66 (CJB)
2007.50 Focus 3/2007 G425005en


3 Measure the voltage between fuse F66 (7.5 A)
and ground.
→ Yes
GO to A3.
→ No
Wiring Diagrams, if necessary CHECK and
the system.
A3: CHECK VOLTAGE SUPPLY TO LIGHT SWITCH
connector C320, pin 8, circuit 15-LE29 (GN/BK),
→ Yes
GO to A4.
→ No
between fuse F66 (CJB) and the light switch
VFE0001471 using the Wiring Diagrams. CHECK the oper-

1 Connect a fused jumper wire (7.5 A) to the light
15-LE29 (GN/BK) and pin 6, circuit 15S-LE21
VFE0016100
2007.50 Focus 3/2007 G425005en


3 CHECK the operation of the dipped beam.
• Does the dipped beam illuminate?
→ Yes
of the system.
→ No
GO to A5.
A5: CHECK CIRCUIT 15S-LE21 (GN/BK) FOR OPEN
3 Measure the resistance between CJB, connector
C102, pin 44, circuit 15S-LE21 (GN/BK), wiring
harness side and light switch, connector C320,
pin 6, circuit 15S-LE21 (GN/BK), wiring harness
side.
→ Yes
CHECK the GEM using WDS and RENEW if
system.
→ No
between CJB and the light switch using the
system.
PINPOINT TEST V : DIPPED BEAM IS INOPERATIVE

B1: DETERMINE THE MODEL
1 Determine the model.
• Is the vehicle equipped with gas discharge
headlamps?
→ Yes
GO to B3.
→ No
Vehicles with conventional headlamps: GO to
B2.
B2: CHECK THE POWER SUPPLY OF THE DIPPED BEAM RELAY FOR OPEN
2007.50 Focus 3/2007 G425005en


connector C102, pin 19, circuit 31-DA1 (BK),
→ Yes
CHECK CJB and if necessary RENEW.
→ No
between CJB and soldered connection S6
B3: CHECK FUSE F48(CJB)
• Is the fuse OK?
→ Yes
GO to B4.
→ No
B4: CHECK VOLTAGE AT FUSE F66 (CJB)
and ground.
→ Yes
system.
→ No
CHECK the CJB and if necessary RENEW.
2007.50 Focus 3/2007 G425005en

PINPOINT TEST W : MAIN BEAM IS INOPERATIVE
C1: DETERMINE THE FAULT CONDITION
2 SWITCH ON dipped beam.
3 SWITCH ON main beam.
4 SWITCH OFF main beam.
5 OPERATE headlamp flasher.
• Are both vehicle systems inoperative?
→ Yes
GO to C2.
→ No
- Only the high beam feature is inoperative:
GO to C2.
- Only the flash to pass feature is inoperative:
GO to Pinpoint Test G.
C2: CHECK MULTIFUNCTION SWITCH
C459.
3 Connect a fused jumper wire (7.5 A) at the
pin 8, circuit 91S-LE14 (BK/OG) and pin 10,
VFE0038456

2007.50 Focus 3/2007 G425005en


6 CHECK the operation of the main beam.
• Does the main beam illuminate?
→ Yes
→ No
- Both vehicle systems were inoperative: GO
to C3.
- Main beam was inoperative: GO to C4.
C3: CHECK GROUND CONNECTION OF THE MULTIFUNCTION SWITCH
2 Measure the resistance between the multifunc-
tion switch, connector C459, pin 10, circuit 91-
LG27 (BK/GN) and ground.
→ Yes
system.
→ No
between the multifunction switch and soldered
C4: CHECK CONTROL CIRCUIT 91S-LE14 (BK/OG) FOR OPEN
2007.50 Focus 3/2007 G425005en


(BK/OG), wiring harness side and the multifunc-
tion switch, connector C459, pin 8, circuit 91S-
LE14 (BK/OG), wiring harness side.
→ Yes
CHECK the GEM using WDS, RENEW if
system. If the concern persists, CHECK the
CJB, RENEW if necessary. CHECK the oper-
→ No
PINPOINT TEST X : ONE DIPPED BEAM IS INOPERATIVE

• Is the left-hand dipped beam inoperative?
→ Yes
GO to D2.
→ No
The right-hand dipped beam is inoperative:
GO to D7.
D2: CHECK FUSE F61 (CJB)
2007.50 Focus 3/2007 G425005en


• Is the fuse OK?
→ Yes
GO to D3.
→ No
RENEW fuse F61 (15 A). If the fuse blows
D3: CHECK VOLTAGE AT FUSE F61 (CJB)
(CJB) and ground.
→ Yes
GO to D4.
→ No
system. If necessary CHECK and RENEW
the CJB. CHECK the operation of the system.
D4: CHECK VOLTAGE SUPPLY OF LEFT-HAND HEADLAMP
C836.
2007.50 Focus 3/2007 G425005en


lamp, connector C836, pin 2, circuit 15S-LE16
→ Yes
GO to D5.
→ No
ation of the system. If necessary CHECK and
the system.
D5: CHECK GROUND CONNECTION OF THE LEFT-HAND HEADLAMP
2 Measure the resistance between left-hand
→ Yes
- Vehicles with conventional headlamps:
CHECK the left-hand headlamp if necessary
RENEW. CHECK the operation of the system.
- Vehicles with gas discharge headlamp: GO
to D6.
→ No
D6: CHECK GROUND CONNECTION OF THE LEFT-HAND HEADLAMP
LE45 (BK/YE), wiring harness side and ground.
→ Yes
CHECK the left-hand headlamp if necessary
RENEW. CHECK the operation of the system.
→ No
2007.50 Focus 3/2007 G425005en


D7: CHECK FUSE F60 (CJB)
• Is the fuse OK?
→ Yes
GO to D8.
→ No
D8: CHECK VOLTAGE AT FUSE F60 (CJB)
(CJB) and ground.
→ Yes
GO to D9.
→ No
D9: CHECK VOLTAGE SUPPLY OF RIGHT-HAND HEADLAMP
C837.
2007.50 Focus 3/2007 G425005en


→ Yes
GO to D10.
→ No
circuit(s) between fuse F60 (CJB) and the
the operation of the system. If necessary
CHECK and RENEW the CJB. CHECK the
D10: CHECK GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
→ Yes
hand headlamp. CHECK the operation of the
system.
- Vehicles with gas discharge headlamps:GO
to D11.
→ No
2007.50 Focus 3/2007 G425005en


D11: CHECK GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
LE46 (BK/BU), wiring harness side and ground.
→ Yes
system.
→ No
PINPOINT TEST Y : ONE MAIN BEAM IS INOPERATIVE

E1: DETERMINE THE FAULT CONDITION
• Is the left-hand main beam inoperative?
→ Yes
GO to E2.
→ No
The right-hand main beam is inoperative: GO
to E7.
E2: CHECK FUSE F37 (CJB)
• Is the fuse OK?
→ Yes
GO to E3.
→ No
2007.50 Focus 3/2007 G425005en


E3: CHECK VOLTAGE AT FUSE F37 (CJB)
(CJB) and ground.
→ Yes
GO to E4.
→ No
system. If necessary CHECK the CJB and
of the system.
E4: CHECK VOLTAGE SUPPLY OF LEFT-HAND HEADLAMP
C836.
(GN/BK), wiring harness side and ground.
→ Yes
GO to E5.
→ No
CHECK the CJB and RENEW if necessary.
E5: CHECK GROUND CONNECTION OF THE LEFT-HAND HEADLAMP
2007.50 Focus 3/2007 G425005en


→ Yes
system.
- Vehicles with gas discharge lamps: GO to
E6.
→ No
E6: CHECK GROUND CONNECTION OF THE LEFT-HAND HEADLAMP
LE45 (BK/YE), wiring harness side and ground.
→ Yes
system.
→ No
E7: CHECK FUSE F38 (CJB)
• Is the fuse OK?
→ Yes
GO to E8.
→ No
2007.50 Focus 3/2007 G425005en


E8: CHECK VOLTAGE AT FUSE F38 (CJB)
(CJB) and ground.
→ Yes
GO to E9.
→ No
E9: CHECK VOLTAGE SUPPLY OF RIGHT-HAND HEADLAMP
C837.
→ Yes
GO to E10.
→ No
CHECK and RENEW the CJB. CHECK the
E10: CHECK GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
2007.50 Focus 3/2007 G425005en


→ Yes
system.
- Vehicles with gas discharge lamps: GO to
E11.
→ No
E11: CHECK GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
LE46 (BK/BU), wiring harness side and ground.
→ Yes
system.
→ No
PINPOINT TEST Z : HEADLAMPS ILLUMINATE CONTINUOUSLY

F1: DETERMINE THE FAULT CONDITION
• Does the main beam illuminate continuously?
→ Yes
GO to F5.
→ No
Dipped beam illuminates continuously:GO to
F2.
2007.50 Focus 3/2007 G425005en


F2: NARROW DOWN THE CAUSE OF THE SHORT TO BATTERY VOLTAGE
4 CHECK the dipped beam.
• Does the dipped beam illuminate continuously?
→ Yes
GO to F3.
→ No
of the system.
F3: CHECK CIRCUIT 15S-LE21 (GN/BK) FOR SHORT TO BATTERY VOLTAGE
• Does the dipped beam illuminate continuously?
→ Yes
GO to F4.
→ No
LOCATE and RECTIFY short to battery
voltage in circuit 15S-LE21 (GN/BK) between
light switch and CJB using the Wiring
GEM using WDS, RENEW if necessary.
2007.50 Focus 3/2007 G425005en


• Does the dipped beam illuminate on one side
continuously?
→ Yes
- Left-hand dipped beam illuminates: LOCATE
and RECTIFY the short to battery voltage in
circuit 15S-LE16 (GN/OG) between fuse F61
(CJB) and the left-hand headlamp using the
- Right-hand dipped beam illuminates:
voltage in circuit 15S-LE23 (GN/WH) between
fuse F60 (CJB) and the right-hand headlamp
ation of the system. If necessary CHECK and
the system.
→ No
F5: RULE OUT MULTIFUNCTION SWITCH AS POSSIBLE CAUSE FOR A SHORT TO BATTERY
VOLTAGE
C459.
5 CHECK the main beam.
→ Yes
GO to F6.
→ No
F6: NARROW DOWN THE CAUSE OF THE SHORT TO GROUND
2007.50 Focus 3/2007 G425005en


→ Yes
GO to F7.
→ No
LOCATE and RECTIFY short to ground in
circuit 91S-LE14 (BK/OG) or 91S-LE25
(BK/BU) between the CJB and the multifunc-
tion switch using the Wiring Diagrams. CHECK
• Does main beam illuminate on one side
continuously?
→ Yes
- Left-hand main beam illuminates: LOCATE
circuit 15S-LE15 (GN/BK) between fuse F37
(CJB) and the headlamp using the Wiring
- Right-hand main beam illuminates: LOCATE
circuit 15S-LE22 (GN/OG), between fuse F38
(CJB) and the headlamp using the Wiring
→ No
2007.50 Focus 3/2007 G425005en

PINPOINT TEST AA : FLASH-TO-PASS FEATURE IS INOPERATIVE
G1: DETERMINE THE FAULT CONDITION
→ Yes
GO to G2.
→ No
GO to Pinpoint Test C.
G2: CHECK MULTIFUNCTION SWITCH
C459.
3 Connect a fused jumper wire (10 A) to the
pin 9, circuit 91S-LE25 (BK/BU) and pin 10,
VFE0038457

→ Yes
→ No
GO to G3.
G3: CHECK CONTROL CIRCUIT 91S-LE25 (BK/BU) FOR OPEN
2007.50 Focus 3/2007 G425005en


(BK/BU), wiring harness side and the multifunc-
tion switch, connector C459, pin 9, circuit 91S-
LE25 (BK/BU), wiring harness side.
→ Yes
→ No
between CJB and the multifunction switch
2007.50 Focus 3/2007 G425005en

GENERAL PROCEDURES
Headlamp Adjustment(32 113 0)

General Equipment Adjust the dipped beam so that the rising
line of the light/dark boundary lies at the
Headlamp beam setting equipment
point of intersection of the horizontal line
1. Park the vehicle on a level surface. and the 15° line.
2. Ensure that the tire pressures are to
specification and that the vehicle is not
overloaded.
3. Switch on the dipped beam.
4. Repeatedly actuate the headlamp levelling
switch and then set it to "0".
5. Set the measuring screen of the headlamp
beam setting equipment to the correct
headlamp alignment setting.
6. Adjust the dipped beam so that the light/dark
boundary touches the horizontal line.
15
VFE0035163
15
VFE0035162
7. NOTE: Scattered light from the dipped beam

may cross the 15 degree line.
2007.50 Focus 3/2007 G167350en

GENERAL PROCEDURES
Headlamp Adjustment — Vehicles With: Adaptive Front

Lighting(32 113 0)
General Equipment Adjust the dipped beam so that the rising
line of the light/dark boundary lies in the
Beam setting equipment
intersection point of the horizontal line and
1. Stand the vehicle on a level surface. the 15 degree line.
2. Make sure that the tire pressures are to
abnormally laden.
3. Switch the headlamps on and to dipped
beam.
4. Repeatedly operate the headlamp levelling
switch through its range, then set it to "0".
5. Use WDS to make certain that the front
wheels are in the straight ahead position.
6. Set up the measuring screen of the beam
setting device to the correct headlamp
setting value.
7. Adjust the headlamps so that the boundary
line touches the horizontal line.
15
VFE0035163
15
VFE0035162
8. NOTE: A stray portion of the dipped beam

may cross the 15 degree line.
2007.50 Focus 3/2007 G427337en

GENERAL PROCEDURES
Front Fog Lamp Adjustment

General Equipment
Headlamp beam setting equipment
1. Park the vehicle on a level surface.
2. Ensure that the tire pressures are to
overloaded.
3. Switch on the front fog lamps.
4. Set the measuring screen of the headlamp
beam setting equipment to the correct front
fog lamp al

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No part of this publication may be reproduced,

Service training programs D-F/GT-1

Printed in Germany - rewi druckhaus, Wissen

Printed on environmentally friendly

Climate Control System

Body and Paint 5

Body and Paint

SECTION 100-00 General Information

DESCRIPTION AND OPERATION

About This Manual

Warnings, Cautions and Notes in This

Item Designation Description

2007.50 Focus 3/2007 G935689en

Item Designation Description

2007.50 Focus 3/2007 G935689en

Health and Safety symbols recommend the use of

2007.50 Focus 3/2007 G935689en

Warning symbols are used to indicate potential

2007.50 Focus 3/2007 G935689en

Location symbols are used to show the location of

2007.50 Focus 3/2007 G935689en

Gearshift lever or selector lever position symbols

2007.50 Focus 3/2007 G935689en

2007.50 Focus 3/2007 G935689en

Movement arrows are used to show three

2007.50 Focus 3/2007 G935689en

The following graphic illustrates a set of symbols

2007.50 Focus 3/2007 G935689en

Measurement symbols provide detailed information

2007.50 Focus 3/2007 G935689en

Special Tools and Torque Figure(s) If components need to be removed or

2007.50 Focus 3/2007 G935689en

2007.50 Focus 3/2007 G935689en

Health and Safety Precautions

2007.50 Focus 3/2007 G17372en

Mixing should be carried out in well ventilated

Many are irritant, sensitizing or harmful to the skin

Follow manufacturers instructions.

2007.50 Focus 3/2007 G17372en

2007.50 Focus 3/2007 G17372en

2007.50 Focus 3/2007 G17372en

Dusts Exhaust Fumes

Electric Shock There may not be adequate warning of odor or of

2007.50 Focus 3/2007 G17372en

Fluoroelastomer Highly flammable - observe No Smoking policy.

2007.50 Focus 3/2007 G17372en

Kerosene (Paraffin) Gas Cylinders

2007.50 Focus 3/2007 G17372en

Workplace risk assessments made under national

2007.50 Focus 3/2007 G17372en

2007.50 Focus 3/2007 G17372en

2007.50 Focus 3/2007 G17372en

See Corrosion Protection.

If Viton or any other fluoroelastomers have been

2007.50 Focus 3/2007 G17372en

Warning Symbols on Vehicles

1. Components or assemblies displaying the 4. Components or assemblies displaying this

2007.50 Focus 3/2007 G17372en

5. Displaying the caution circle with a deleted

6. Displaying this symbol (normally in conjunction

7. Displaying this symbol warn that children should

2007.50 Focus 3/2007 G17372en