Page 1
Factory Workshop Manual
Ford
Focus Rs 2003 09.2002
(09.2002-)
Anonymous
1st January 2018
Make
Model
Engine and year
This manual was submitted by
Date
Page 2
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > About This Manual
Introduction This manual has been written in a format that is designed to meet the needs of
technicians worldwide. The objective is to use common formats and include similar content in each
manual. This manual provides general descriptions for accomplishing diagnosis and testing,
service and repair work with tested, effective techniques. Following them will help assure reliability.
Special Tools The special tool(s) table provided at the beginning 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 required. Important Safety Instructions Appropriate service methods and
correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well
as the personal safety of the individual carrying out the work. This manual cannot possibly
anticipate all such variations and provide advice or cautions as to each. Anyone who departs from
the instructions provided in this manual must first establish that he compromises neither his
personal safety nor the vehicle integrity by his choice of methods, tools or components. Warnings,
Cautions and Notes in This Manual As you read through this manual, you will come 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 steps. If the warning, caution or note only applies to one step,
it is placed at the beginning of the specific step (after the step number). How to Use This Manual
This manual covers diagnosis and testing, service and repair procedures. This manual is structured
into groups and sections, with specific system sections collected together under their relevant
group. A group covers a specific portion of the vehicle. The manual is divided into five groups,
General Information, Chassis, Powertrain, Electrical and Body and Paint. The number of the group
is the first number of a section number. Pages at the start of the manual list all sections available.
Each section has a contents list detailing Specifications, Description and Operation, Diagnosis and
Testing, In Vehicle Repairs, Disassembly and Assembly, Removal and Installation. If components
need to be removed or disassembled in sequence, the sequence will be identified numerically in a
graphic and the corresponding text will be numbered accordingly. All left and right-hand references
to the vehicle are taken from a position sitting in the driver seat looking forward. All left and
right-hand references to the engine are taken from a position at the flywheel looking towards the
front camshaft pulley. Where appropriate, instructions will be given for the use of the diagnostic
tool. Overview Procedures Overview procedures contain an exploded view illustration(s). The
numbered sequence within the illustration(s) indicate the order to be followed when
removing/disassembling or when installing/assembling a component. Additional information,
symbol(s) or a torque figure, may also be shown alongside the component. There are ten symbols
used to give additional information when removing/disassembling or when installing/assembling a
component. Inspection and Verification Visual Inspection Charts, Symptom Charts and other
information charts (such as diagnostic routines) or supplement test procedures with technical
specifications will navigate the user to a specific test procedure. Symptom Chart The symptom
chart indicates symptoms, sources and actions to address a condition. 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.
Page 3
Special Tools and Torque Figures Any requirement for special tools will picture the tool, showing it
in use and with its tool number shown. Torque settings will be given at the relevant point in the
procedure.
Page 4
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > Standard Workshop Practices
Vehicle in Workshop When working on a vehicle in the workshop always make sure that:
Alternative Fuel If the odor of liquefied petroleum gas (LPG) or compressed natural gas (CNG) is
present in the air in the workshop, warn all persons in the area to: Alternative Fuel — Do's
Alternative Fuel — Do Nots Be aware of situations that may cause the LPG or CNG fuel system to
vent off fuel, such as: Only fully trained personnel, who are conversant with local standards, are to
work on alternative fuel vehicles. Towing the Vehicle 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 the ground. Alternatively the vehicle can be transported on a low
loader or a trailer. Connecting a Slave Battery Using Jumper Cables Always connect the jumper
cables in the following sequence: Always reduce the engine speed to idle before disconnecting the
jumper cables. Before removing the jumper cables from the vehicle that had the discharged
battery, switch on the heater blower (high) or the heated rear window, to reduce the voltage peak
when the cables are removed. Always disconnect the jumper cables in the reverse order to the
connecting sequence and do not short the ends of the cables. Do not rely on the generator to
restore a discharged battery. For a generator to recharge a battery, it would take in excess of eight
hours continuous driving with no additional loads placed on the battery. Component Cleaning To
prevent the ingress of dirt, accumulations of loose dirt and greasy deposits should be removed
before disconnecting or dismantling components or assemblies. Components should be thoroughly
cleaned before inspection prior to reassembly. Cleaning Methods: Various solvents are available
which are suitable for component cleaning. Some components, such as brake hydraulic parts and
electrical assemblies should be cleaned only with recommended solvents — refer to Solvents,
Sealers and Adhesives or to the section of the manual relevant to the component. Calibration of
Essential Measuring Equipment It is of fundamental importance that certain essential equipment,
for example torque wrenches, multimeters, exhaust gas analyzers or rolling roads, are regularly
calibrated in accordance with the manufacturers instructions.
Page 5
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-01 Identification
Codes > Description and Operation > Identification Codes
The VIN for registration purposes is stamped onto the body on the right-hand side floor panel. The
vehicle identification number is also located on the VIN plate. The VIN plate is positioned within the
engine compartment on the front body crossmember in front of the air intake duct. The visible VIN
(label) is fastened to the instrument panel. It is positioned close to the windshield glass on the
left-hand side of the vehicle and is visible from the outside. Vehicle Identification Number (VIN) VIN
Positions 1, 2 and 3 — World Manufacturer Identifier VIN Positions 4 and 10 — Body Type VIN
Positions 5 and 6 — Constant X VIN Position 7 — Product Source Company and Assembly Plant
VIN Position 8 — Assembly Plant VIN Position 9 — Model VIN Position 11 — Year of Manufacture
VIN Position 12 — Month of Manufacture VIN Position 13 to 17 — Vehicle serial number Vehicle
serial number Vehicle Certification Label (Typical) or VIN Plate Item 1 to 6: Vehicle Certification
Label Item 7: Smoke Value (Diesel only) Item 8 and 9: Variants Item 10: Emission Level Codes
Item 11: Body Color Codes Item 12: Interior Trim Codes Item 13: Transaxle Final Drive Ratio Item
14: Transaxle Codes Item 15: Engine Codes Item 16: Hand of Drive
Page 6
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Bearing - 2.0L Duratec-RS (Zetec)
Collet for 205-295 204-158 (14-038) Adaptor for 204-158 (Thrust Pad) 204-158-01 (14-038-01)
Installer, Front Wheel Bearing 204-160 (14-040) Adapter for 205-074 205-074-01 (15-036) Installer,
Rear Hub Oil Seal 205-075 (15-036) Remover, Bearing (Main tool) 205-295 (15-050-A) Remover,
Bearing/Gear 205-310 (15-091) Installer/Aligner, Crankshaft Rear Oil Seal 303-171-03 (21-102-03)
Removal Installation
Page 7
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 8
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Stabilizer Bar - 2.0L Duratec-RS (Zetec)
Alignment Pins, Subframe 205-316 (15-097A) Separator, Ball Joint 211-020 (13-006) Removal
Installation
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Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Knuckle - 2.0L Duratec-RS (Zetec)
Lever, Wheel Knuckle 204-159 (14-039) Installer, Halfshaft 204-161 (14-041) Separator, Ball Joint
211-020 (13-006) Removal Installation
Page 10
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Strut and Spring
Assembly
Compressor, Coil Spring 204-167 (14-042) Adapter for 204-167 205-318 (15-103) Disassembly
Assembly
Page 11
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Hub - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 12
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Bearing - 2.0L Duratec-RS (Zetec)
Installer, Differential Bearing 205-062 (15-025A) Installer, Input Shaft Seal 307-210 (17-041)
Removal Installation
Page 13
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Lower Arm - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 14
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Rear Lower Arm - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 15
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Stabilizer Bar - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 16
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Upper Arm - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 17
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Knuckle - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 18
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Spindle - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 19
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Shock Absorber - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 20
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Crossmember - 2.0L Duratec-RS (Zetec)
Compressor, Coil Spring 204-167 (14-042) Adapters for 204-167 204-215 (15-111) Removal
Installation
Page 21
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Halfshaft LH - 2.0L Duratec-RS (Zetec)
Installer, Drive Halfshaft 204-161 (14-041) Remove, Drive Halfshaft 204-226 (16-092) Adapter for
204-226 204-226-01 (16-092-01) Slide Hammer 205-047 (15-011) Separator, Ball Joint 211-020
(13-006) Removal Installation
Page 22
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Halfshaft RH - 2.0L Duratec-RS (Zetec)
Installer, Drive Halfshaft 204-161 (14-041) Remover, Drive Halfshaft 204-226 (16-092) Adapter for
16-092/204-226 204-226-01 (16-092-01) Slide Hammer 205-047 (15-011) Removal Installation
Page 23
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Intermediate Shaft - 2.0L Duratec-RS (Zetec)
Remover, Drive Halfshaft 204-226 (16-092) Adapter for 204-226/16-092 204-226-01 (16-092-01)
Slide Hammer 205-047 (15-011) Removal Installation
Page 24
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Constant Velocity (CV) Joint Boot - 2.0L Duratec-RS
(Zetec)
Clamping Tool, Boot Retaining Clamp 204-169 (14-044) Remover, Bearing/Gear 205-310 (15-091)
Remover, Bearing/Gear 205-311 (15-092) Installer, Extension Housing Bushing/Oil Seal 308-046
(16-016) Removal Installation
Page 25
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Halfshaft LH
Gaiter clamp tightening tool 204-169 (14-044) Separating tool, Bearing/Gear 205-310 (15-091)
Remover, Bearing/Gear 205-311 (15-092) Installer, Extension Housing Bushing/Oil Seal 308-046
(16-016) Disassembly Assembly
Page 26
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-00 Brake System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Brake Disc Runout Check
Dial Indicator Gauge (Metric) 205-069 (15-046) Holding Fixture, Dial Indicator Gauge 205-070
(15-022A) Holding Fixture, Dial Indicator Gauge (Disc Brake) 206-003 (12-003) Check
Page 27
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Pads - 2.0L Duratec-RS (Zetec)
Retractor, Caliper Piston. 206-005 (12-014) Removal Installation
Page 28
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Disc - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 29
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-04 Rear Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Caliper - 2.0L Duratec-RS (Zetec)
Retractor, Rear Caliper piston setting 206 - 012 (12 - 006) Removal Installation
Page 30
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05 Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Parking Brake Cable Adjustment - 2.0L
Duratec-RS (Zetec)
Page 31
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05 Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake
Control - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 32
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05 Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake
Cable - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 33
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Pedal - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 34
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Fluid Reservoir - 2.0L Duratec-RS
(Zetec)
Removal Installation
Page 35
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Booster - 2.0L Duratec-RS (Zetec)
LHD
Removal Installation
Page 36
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Booster - 2.0L Duratec-RS (Zetec)
RHD
Disconnect Tool, Spring-Lock Coupling 5/8 inch (black) 412-038 (34-003) Lifting Bracket, Engine
303-122 (21-068A) Removal Installation
Page 37
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09A Anti-Lock Control > Description
and Operation > Diagnosis and Testing > Removal and Installation > Anti-Lock Brake System (ABS) Module - 2.0L
Duratec-RS (Zetec) RHD
Removal Installation
Page 38
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09A Anti-Lock Control > Description
and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Speed Sensor
Removal Installation
Page 39
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09A Anti-Lock Control > Description
and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Speed Sensor Ring - 2.0L Duratec-RS
(Zetec)
Removal Installation
Page 40
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Power Steering System Flushing
- 1.4L-1.6L-1.8L-2.0L-2.0L Duratec-RS (Zetec)
Page 41
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump to Steering Gear Pressure Line
- 2.0L Duratec-RS (Zetec)
Expander, Teflon Seal 211-188 (13-015) Removal Installation
Page 42
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Fluid Cooler - 2.0L Duratec-RS (Zetec)
Remover, Oil Cooling Pipe 307-242 (17-049) Removal Installation
Page 43
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear
Alignment Pins, Subframe 205 - 316 (15 - 097A) Separator, Ball Joint 211 - 020 (13 - 006)
Removal Installation
Page 44
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear Bushing
Remover/Installer, Pivot Bushing 205 - 297 (15 - 086) Installer, Wheel Hub 204 - 148 (14 - 037)
Removal Installation
Page 45
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear Boot
Removal Installation
Page 46
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Tie Rod End
Separator, Ball Joint 211 - 020 (13 - 006) Removal Installation
Page 47
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Wheel
Removal Installation
Page 48
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Column - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 49
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Steering Column - 2.0L
Duratec-RS (Zetec)
Disassembly Assembly
Page 50
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-05 Steering Column Switches >
Diagnosis and Testing > Removal and Installation > Ignition Switch - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 51
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Bearing Journal Diameter
Page 52
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Bearing Journal Clearance
Page 53
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft End Play
1. End play = maximum value minus minimum value
Page 54
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Surface Inspection
Page 55
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Crankshaft Main Bearing Journal Diameter
Page 56
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Lobe Lift
Page 57
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Crankshaft End Play
Page 58
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Inspection
Page 59
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Pin to Bore Diameter
Page 60
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Diameter
Page 61
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Ring End Gap
Page 62
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Ring-to-Groove Clearance
Page 63
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Pin Diameter
Page 64
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Connecting Rod Large End Bore
Page 65
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Flywheel Inspection
Page 66
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Valve Stem Diameter
Page 67
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Cylinder Block Distortion
Page 68
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Cylinder Head Distortion
Page 69
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Valve Seat Inspection
Page 70
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Crankshaft Front Seal
Remover, Crankshaft Oil Seal 303-293 (21-143) Installer, Crankshaft Oil Seal 303-395 (21-171)
Installer, Crankshaft Oil Seal 303-684 (21-243) Removal Installation
Page 71
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Valve Springs
Compressor, Valve Spring 303-361 (21155) Adapter for 21-155 303-361-02 (2115502) Adapter, Air
Supply (Cylinder Head) 303-363 (21157) Remover, Valve Stem Oil Seal 303-374 (21160) Removal
Installation
Page 72
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Camshaft Seal
Installer, Oil Seal 303-039 (21009B) Removal Installation
Page 73
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Exhaust Manifold
Removal Installation
Page 74
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Oil Pan
Slide Hammer 205-047 (15-011) Adapter for 205-047 303-633 (21-227) Removal Installation
Page 75
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Oil Cooler
Remover/Installer Cooling Hose Clamp 303-397 (24-003) Removal Installation
Page 76
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Oil Pump
Removal Installation
Page 77
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Crankshaft Rear Seal
Centring tool, clutch disc 308 - 204 (16067) Locking tool, flywheel 303 - 254 (21135) Puller, oil seal
303 - 291 (21141) Remover, oil seal 303 - 293 (21143) Removal Installation
Page 78
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal > Disassembly >
Engine
Slide Hammer 205-047 (15-011) Flange Holding Wrench, Universal 205-072 (15-030A) Mounting
Bracket for 303-435 303-435-04 (21-064) Locking Tool, Flywheel 303-254 (21-135) Mounting Plate
for 303-435-04 303-435-12 (21-150A) Adapter for 205-047 303-633 (21-227) Socket, Cylinder
Head Bolt 303-392 (21-167) Disassembly
Page 79
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal > Disassembly >
Assembly > Engine
Flange Holding Wrench, Universal 205-072 (15-030 A) Installer, Timing Cover Oil Seal 303-039
(21-009 B) Locking Tool, Flywheel 303-254 (21-135) Installer, Crankshaft Rear Oil Seal 303-291
(21-141) Timing Plate, Camshaft Alignment 303-376 (21-162 B) Socket, Cylinder Head Bolt
303-392 (21-167) Installer, Crankshaft Seal 303-395 (21-171) Mounting Stand 303-435 (21-187)
Mounting Plate for 303-435 303-435-04 (21-064) Timing Peg, Crankshaft TDC 303-574 (21-163)
Installer, Crankshaft Front Seal 303-684 (21-243) Assembly
Page 80
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01F Engine - 2.0L Duratec-RS (Zetec) >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal > Disassembly >
Assembly > Installation > Engine
Lifting Bracket, Engine 303-122 (21-068A) Remover/Installer Cooling Hose Clamp 303-397
(24-003)
Page 81
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Cooling System Draining, Filling and Bleeding - 2.0L
Duratec-RS (Zetec)
Drain Refill
Page 82
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat - 2.0L Duratec-RS
(Zetec)
Remover/Installer, Cooling Hose Clamp 303-397 Removal Installation
Page 83
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Cooling Fan Motor and Shroud -
2.0L Duratec-RS (Zetec)
Removal Installation
Page 84
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Coolant Expansion Tank
Removal Installation
Page 85
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04I Fuel Charging and Controls - 2.0L
Duratec-RS (Zetec) > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Charging
Wiring Harness
Removal Installation
Page 86
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04J Fuel Charging and Controls Turbocharger - 2.0L Duratec-RS (Zetec) > Description and Operation > Diagnosis and Testing > Removal and Installation >
Turbocharger
Removal Installation
Page 87
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt
Removal Installation
Page 88
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt Tensioner
Removal Installation
Page 89
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt Idler Pulley
Support Bar, Engine 303-290 (21-140) Adapter for 303-290 303-290-01 (21-140-01) Adapter for
303-290 303-290-02 (21-140-02) Adapter for 303-290 303-290-03 (21-140-03) Removal Installation
Page 90
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-06 Starting System > Description and
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 91
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07F Engine Ignition - 2.0L Duratec-RS
(Zetec) > Description and Operation > Diagnosis and Testing > Removal and Installation > Ignition Coil Pack
Removal Installation
Page 92
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08E Engine Emission Control - 2.0L
Duratec-RS (Zetec) > Description and Operation > Diagnosis and Testing > Removal and Installation > Positive Crankcase
Ventilation (PCV) Hose
Removal Installation
Page 93
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08E Engine Emission Control - 2.0L
Duratec-RS (Zetec) > Description and Operation > Diagnosis and Testing > Removal and Installation > Valve Cover Vent
Oil Separator
Removal Installation
Page 94
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Air Cleaner - 2.0L
Duratec-RS (Zetec)
Removal Installation
Page 95
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Charge Air Cooler -
2.0L Duratec-RS (Zetec)
Removal Installation
Page 96
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Charge Air Cooler
Radiator - 2.0L Duratec-RS (Zetec)
Removal Installation
Page 97
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Charge Air Cooler
Water Pump - 2.0L Duratec-RS (Zetec)
Remover/Installer, Cooling Hose Clamp 303-397 Removal Installation
Page 98
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Camshaft Position (CMP) Sensor - 1.6L
Zetec-E (Zetec)-1.8L-2.0L
Removal Installation
Page 99
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Crankshaft Position (CKP) Sensor - 1.6L
Zetec-E (Zetec)-1.8L-2.0L
Removal Installation
Page 100
Ford Focus Rs 2003 09.2002 Workshop Manual ((09.2002-))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pressure (PSP) Switch -
1.6L Zetec-E (Zetec)-1.8L-2.0L
Removal Installation
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