CONTENT
1: General Information
Service Information
General Information
– Description and Operation
– About This Manual
– Application and Use of Specifications
– General Service Information
– Health and Safety Precautions
– How To Use This Manual
– Important Safety Instructions
– Road/Roller Testing
– Solvents, Sealants and Adhesives
– Standard Workshop Practices
Identification Codes
– Description and Operation
– Identification Codes
Jacking and Lifting
– Description and Operation
– Jacking
– Lifting
Noise, Vibration and Harshness
– Description and Operation
– Noise, Vibration and Harshness (NVH)
– Diagnosis and Testing
– Noise, Vibration and Harshness (NVH)
– General Procedures
– Exhaust System Neutralizing
2: Chassis
Suspension
Suspension System – General Information
– Specification
– Description and Operation
– Wheel Alignment Angles
– Diagnosis and Testing
– Suspension System
– General Procedures
– Front Toe Adjustment (57.65.01)
– Rear Toe Adjustment (57.65.08)
– Wheel Bearing Inspection
Front Suspension
– Specification
– Description and Operation
– Front Suspension
– Diagnosis and Testing
– Front Suspension
– Removal and Installation
– Lower Arm (60.35.02)
– Shock Absorber and Spring Assembly (60.30.02)
– Front Stabilizer Bar (60.10.01)
– Front Stabilizer Bar Bushing (60.10.04)
– Front Wheel Bearing and Wheel Hub (60.25.03)
– Wheel Knuckle (60.25.23)
– Disassembly and Assembly
– Shock Absorber and Spring Assembly (60.30.21)
Rear Suspension
– Specification
– Description and Operation
– Rear Suspension
– Diagnosis and Testing
– Rear Suspension
– Removal and Installation
– Damper
– Front Lower Arm (64.35.51) – 4-Door
– Front Lower Arm (64.35.51) – Wagon
– Rear Lower Arm (64.35.52)
– Spring (64.20.01)
– Rear Stabilizer Bar (64.35.08)
– Rear Stabilizer Bar Link (64.35.24)
– Upper Arm (64.25.31)
– Wheel Hub (64.15.14)
– Wheel Knuckle (64.15.22)
– Wheel Knuckle Front Bushing (64.15.28)
– Wheel Knuckle Rear Bushing (64.15.30)
Wheels and Tires
– Specification
– Description and Operation
– Safety Precautions
– Wheels and Tires
– Diagnosis and Testing
– Wheels and Tires
– Removal and Installation
– Tire Low Pressure Sensor – VIN Range: J28493->V99999
– Tire Pressure Monitoring System (TPMS) Front Antenna – VIN Range: J28493- >V99999
Tire Pressure Monitoring System (TPMS) Main Antenna – VIN Range: J28493- >V99999
– Tire Pressure Monitoring System (TPMS) Module – VIN Range: J28493->V99999
– Tire Pressure Monitoring System (TPMS) Rear Antenna – VIN Range: J28493- >V99999
– Wheel and Tire (74.20.05)
Driveline
Driveline System – General Information
– Description and Operation
– Driveline System
– Diagnosis and Testing
– Driveline System
Driveshaft
– Specification
– Description and Operation
– Driveshaft
– Diagnosis and Testing
– Driveshaft
– General Procedures
– Driveshaft Runout and Balancing
– Removal and Installation
– Driveshaft (47.15.01)
Rear Drive Axle/Differential
– Specification
– Description and Operation
– Rear Drive Axle and Differential
– Diagnosis and Testing
– Rear Drive Axle and Differential
– In-Vehicle Repair
– Axle Shaft Seal (51.20.04) (51.20.36)
– Drive Pinion Flange
– Drive Pinion Seal (51.20.01)
– Removal and Installation
– Axle Assembly (51.25.13)
Front Drive Halfshafts
– Specification
– Description and Operation
– Front Drive Halfshafts
– Diagnosis and Testing
– Front Drive Halfshafts
– Removal and Installation
– Front Halfshaft LH (47.10.15)
– Front Halfshaft RH (47.10.16) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Front Halfshaft RH (47.10.16) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Inner Constant Velocity (CV) Joint Boot (47.10.18)
– Intermediate Shaft
– Outer Constant Velocity (CV) Joint Boot (47.10.19)
Rear Drive Halfshafts
– Specification
– Description and Operation
– Rear Drive Halfshafts
– Diagnosis and Testing
– Rear Drive Halfshafts
– Removal and Installation
– Rear Halfshaft (47.10.13)
– Outer Constant Velocity (CV) Joint Boot (47.10.32)
Brake System
Brake System – General Information
– Specification
– Description and Operation
– Brake System
– Diagnosis and Testing
– Brake System
– General Procedures
– Brake Disc Runout Check
– Brake System Bleeding (70.25.03)
Front Disc Brake
– Specification
– Description and Operation
– Front Disc Brake
– Diagnosis and Testing
– Front Disc Brake
– Removal and Installation
– Brake Caliper (70.55.02)
– Brake Disc (70.10.10)
– Brake Pads (70.40.02)
Rear Disc Brake
– Specification
– Description and Operation
– Rear Disc Brake
– Diagnosis and Testing
– Rear Disc Brake
– Removal and Installation
– Brake Caliper (70.55.03) (70.55.25)
– Brake Disc (70.10.11)
– Brake Disc Shield (70.10.19)
– Brake Pads (70.40.03)
Parking Brake and Actuation
– Specification
– Description and Operation
– Parking Brake
– Diagnosis and Testing
– Parking Brake
– General Procedures
– Removal and Installation
– Parking Brake Cable (70.35.29) – Vehicles With: Manually Adjusted Parking Brake
– Parking Brake Cable (70.35.29) – Vehicles With: Self-Adjusting Parking Brake
– Parking Brake Control (70.35.08) – Vehicles With: Manually Adjusted Parking
– Brake
– Parking Brake Control (70.35.08) – Vehicles With: Self-Adjusting Parking Brake
Hydraulic Brake Actuation
– Specification
– Description and Operation
– Hydraulic Brake Actuation
– Diagnosis and Testing
– Hydraulic Brake Actuation
– Removal and Installation
– Brake Fluid Reservoir (70.30.16)
– Brake Master Cylinder (70.30.08)
– Brake Pedal and Bracket (70.35.03)
– Brake Pedal Cross-Shaft
Power Brake Actuation
– Specification
– Description and Operation
– Brake Booster
– Diagnosis and Testing
– Power Brake System
– Removal and Installation
– Brake Booster (70.50.17) – LHD AWD/LHD FWD
– Brake Booster (70.50.17) – RHD AWD/RHD FWD
– Brake Vacuum Pump – 2.0L NA V6 – AJV6
– Brake Vacuum Pump – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
Anti-Lock Control – Stability Assist
– Specification
– Description and Operation
– Anti-Lock Control – Stability Assist
– Diagnosis and Testing
– Anti-Lock Control – Stability Assist – VIN Range: C00344->J12991
– Anti-Lock Control – Stability Assist – VIN Range: J12992->V99999
– Removal and Installation
– Anti-Lock Brake System (ABS) Module (70.60.02) – VIN Range: C00001->J12991
– Front Wheel Speed Sensor (70.60.03)
– Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) – VIN Range: C00001->J12991
– Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) – VIN Range: J12992->V99999
– Rear Wheel Speed Sensor (70.60.04)
– Stability Assist Module
– Steering Wheel Rotation Sensor (86.56.58)
– Yaw Rate Sensor (86.56.57) – 2.0L Duratorq-TDCi/2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Yaw Rate Sensor (86.56.57) – 2.2L Duratorq-TDCi (110kW/150PS) – Puma
Steering System
Steering System – General Information
– Specification
– Description and Operation
– Steering System
– Diagnosis and Testing
– Steering System
– General Procedures
– Power Steering System Filling
– Power Steering System Flushing (57.15.08)
Power Steering
– Specification
– Description and Operation
– Power Steering
– Diagnosis and Testing
– Power Steering
– General Procedures
– Start Up Procedure After Power Steering Pump/Gear Overhaul
– Removal and Installation
– Power Steering Control Valve Actuator (57.10.32) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Power Steering Fluid Cooler (57.15.11) – 2.0L Duratorq-TDCi
– Power Steering Fluid Cooler (57.15.11) – 2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Power Steering Fluid Reservoir (57.15.08)
– Power Steering Pump (57.20.14) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Power Steering Pump (57.20.14) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Steering Gear (57.10.01) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Steering Gear (57.10.01) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Steering Linkage
– Specification
– Description and Operation
– Steering Linkage
– Diagnosis and Testing
– Steering Linkage
– Removal and Installation
– Steering Gear Boot (57.10.29)
– Tie Rod End (57.55.02)
Steering Column
– Specification
– Description and Operation
– Steering Column
– Diagnosis and Testing
– Steering Column
– Removal and Installation
– Ignition Switch Lock Cylinder (57.40.29)
– Steering Column (57.40.01)
– Steering Column Coupling
– Steering Wheel (57.60.01)
Steering Column Switches
– Description and Operation
– Steering Column Switches
– Diagnosis and Testing
– Steering Column Switches
– Removal and Installation
– Steering Column Multifunction Switch LH (86.65.78)
– Steering Column Multifunction Switch RH (86.65.41)
3: Powertrain
Engine
Engine System – General Information
– Specification
– Description and Operation
– Engine
– Diagnosis and Testing
– Engine
– General Procedures
– Bearing Inspection
– Camshaft Bearing Journal Clearance
– Camshaft Bearing Journal Diameter
– Camshaft End Play
– Camshaft Lobe Lift
– Camshaft Surface Inspection
– Connecting Rod Cleaning
– Connecting Rod Large End Bore
– Crankshaft End Play
– Crankshaft Main Bearing Journal Clearance
– Crankshaft Main Bearing Journal Diameter
– Cylinder Block Distortion
– Cylinder Bore Out-of-Round
– Cylinder Head Distortion
– Exhaust Manifold Cleaning and Inspection
– Flywheel Inspection
– Piston Diameter
– Piston Inspection
– Piston Pin Diameter
– Piston Pin to Bore Diameter
– Piston Ring End Gap
– Piston Ring-to-Groove Clearance
– Valve Seat Inspection
– Valve Spring Free Length
– Valve Stem Diameter
– Leakage Test Using Smoke Test Equipment
Engine – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Specification
– Description and Operation
– Engine
– Diagnosis and Testing
– Engine
– General Procedures
– Valve Clearance Adjustment (12.29.48)
– Valve Clearance Check (12.29.47)
– In-Vehicle Repair
– Camshafts LH (12.13.19)
– Crankshaft Front Seal (12.21.14)
– Crankshaft Pulley (12.21.09)
– Crankshaft Rear Seal (12.21.20)
– Cylinder Head LH (12.29.02)
– Engine Front Cover (12.65.01)
– Engine Front Mount (12.45.01)
– Exhaust Manifold LH (30.15.55)
– Flexplate (12.53.13)
– Exhaust Manifold RH (30.15.56)
– Flywheel (12.53.07)
– Intake Manifold (30.15.01)
– Lower Intake Manifold (30.15.61)
– Oil Cooler (12.60.68)
– Oil Pan (12.60.44)
– Oil Pressure Sender
– Oil Pump (12.60.26)
– Timing Drive Components (12.65.13)
– Valve Cover LH (12.29.43)
– Valve Cover RH (12.29.44)
– Removal
– Engine (12.41.01) – Vehicles With: 5-Speed Manual Transmission – MT75/6-
– Speed Manual Transaxle – MMT6
– Engine (12.41.01) – Vehicles With: 5-Speed Automatic Transaxle – JATCO/6-Speed
– Automatic Transaxle – AWF21
– Disassembly
– Engine
– Disassembly and Assembly of Subassemblies
– Cylinder Head (12.29.22)
– Piston (12.17.02)
– Assembly
– Engine
– Installation
– Engine (12.41.01) – Vehicles With: 5-Speed Manual Transmission – MT75/6-
– Speed Manual Transaxle – MMT6
– Engine (12.41.01) – Vehicles With: 5-Speed Automatic Transaxle – JATCO/6-Speed
– Automatic Transaxle – AWF21
Engine – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Specification
– Description and Operation
– Engine
– In-Vehicle Repair
– Crankshaft Front Seal (12.21.14)
– Crankshaft Rear Seal (12.21.20)
– Engine Front Cover (12.65.01)
– Engine Front Mount (12.45.01)
– Flexplate (12.53.13)
– Flywheel (12.53.07)
– Intake Manifold (30.15.01)
– Oil Pan (12.60.44)
– Timing Chain
– Valve Cover
– Removal
– Engine (12.41.01) – 2.0L Duratorq-TDCi
– Engine (12.41.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Disassembly
– Engine
– Assembly
– Engine
– Installation
– Engine (12.41.01) – 2.0L Duratorq-TDCi
– Engine (12.41.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Puma
Engine Cooling – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Specification
– Description and Operation
– Engine Cooling
– Diagnosis and Testing
– Engine Cooling
– General Procedures
– Cooling System Backflushing
– Cooling System Draining, Filling and Bleeding
– Cooling System Flushing
– Removal and Installation
– Block Heater (86.62.18)
– Coolant Expansion Tank (26.15.01)
– Cooling Fan Module (26.25.38)
– Cooling Fan Motor (26.25.24)
– Cooling Fan Motor and Shroud (26.25.25)
– Cooling Module (26.40.16)
– Radiator (26.40.01)
– Thermostat (26.45.07)
– Water Pump (26.50.01)
– Water Pump Housing (26.50.07)
Engine Cooling – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Specification
– Description and Operation
– Engine Cooling
– General Procedures
– Cooling System Draining, Filling and Bleeding
– Cooling System Draining and Vacuum Filling
– Removal and Installation
– Cooling Fan Motor and Shroud (26.25.25)
– Cooling Module (26.40.16)
– Radiator (26.40.01)
– Water Pump (26.50.01)
Fuel Charging and Controls – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Specification
– Description and Operation
– Fuel Charging and Controls
– Diagnosis and Testing
– Fuel Charging and Controls – 2.0L NA V6 – AJV6
– Fuel Charging and Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27, VIN Range: E96603->J28492
– Fuel Charging and Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27, VIN Range: J28493->V99999
– Removal and Installation
– Fuel Charging Wiring Harness (86.70.22)
– Fuel Injection Supply Manifold (19.60.13)
– Fuel Injectors (18.10.02)
– Fuel Pulse Damper (18.30.98) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Throttle Body (19.70.04)
Fuel Charging and Controls – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Specification
– Description and Operation
– Fuel Charging and Controls
– Diagnosis and Testing
– Fuel Charging and Controls
– General Procedures
– Fuel Injection Component Cleaning
– Removal and Installation
– Fuel Injection Pump
– Fuel Injection Supply Manifold (19.60.13)
– Fuel Injector (18.10.01)
– Fuel Metering Valve
– Fuel Return Line Venturi
Fuel Charging and Controls – Turbocharger
– Specification
– Description and Operation
– Turbocharger
– Diagnosis and Testing
– Turbocharger
– Removal and Installation
– Turbocharger
Accessory Drive
– Specification
– Description and Operation
– Accessory Drive
– Diagnosis and Testing
– Accessory Drive
– Removal and Installation
– Accessory Drive Belt (12.10.40) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Accessory Drive Belt (12.10.40) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Accessory Drive Belt Tensioner (12.10.41) – 2.0L Duratorq-TDCi/2.2L Duratorq- TDCi (110kW/150PS) – Puma
– Accessory Drive Belt Tensioner (12.10.41) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Power Steering Pump Belt – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Power Steering Pump Belt Tensioner – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Water Pump Belt (12.10.44) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Water Pump Belt Tensioner (12.10.45) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Starting System
– Specification
– Description and Operation
– Starting System
– Diagnosis and Testing
– Starting System – 2.0L NA V6 – AJV6
– Starting System – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Removal and Installation
– Starter Motor (86.60.01) – 2.0L Duratorq-TDCi
– Starter Motor (86.60.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Starter Motor (86.60.01) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Engine Ignition – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Specification
– Description and Operation
– Engine Ignition
– Diagnosis and Testing
– Engine Ignition – 2.0L NA V6 – AJV6
– Engine Ignition – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Removal and Installation
– Ignition Coil-On-Plug LH (18.20.44)
– Ignition Coil-On-Plug RH (18.20.43)
Glow Plug System
– Specification
– Description and Operation
– Glow Plug System
– Diagnosis and Testing
– Glow Plug System
– Removal and Installation
– Glow Plugs
Engine Emission Control – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Puma
– Specification
– Description and Operation
– Engine Emission Control
– Diagnosis and Testing
– Engine Emission Control
– Removal and Installation
– Exhaust Gas Recirculation (EGR) Cooler
– Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube
– Exhaust Gas Recirculation (EGR) Valve (17.45.01)
Intake Air Distribution and Filtering – 2.0L NA V6 – AJV6/2.5L NA V6 –AJV6/3.0L NA V6 – AJ27
– Description and Operation
– Intake Air Distribution and Filtering
– Diagnosis and Testing
– Intake Air Distribution and Filtering
– Removal and Installation
– Air Cleaner (19.10.05)
– Air Cleaner Element (19.10.08)
– Air Cleaner Outlet Pipe (19.10.31)
Intake Air Distribution and Filtering – 2.0L Duratorq-TDCi/2.2L Duratorq- TDCi (110kW/150PS) – Puma
– Specification
– Description and Operation
– Intake Air Distribution and Filtering
– Diagnosis and Testing
– Intake Air Distribution and Filtering
– Removal and Installation
– Air Cleaner (19.10.05)
– Air Cleaner Element (19.10.08)
– Air Cleaner Outlet Pipe (19.10.31)
– Charge Air Cooler – 2.0L Duratorq-TDCi
– Charge Air Cooler – 2.2L Duratorq-TDCi (110kW/150PS) – Puma
Evaporative Emissions
– Specification
– Description and Operation
– Evaporative Emissions
– Diagnosis and Testing
– Evaporative Emissions – 2.0L NA V6 – AJV6
– Evaporative Emissions – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Removal and Installation
– Evaporative Emission Canister (17.15.13) – 2.0L NA V6 – AJV6
– Evaporative Emission Canister (17.15.13) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Evaporative Emission Canister Purge Valve (17.15.30)
Electronic Engine Controls – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Specification
– Description and Operation
– Electronic Engine Controls
– Diagnosis and Testing
– Electronic Engine Controls – 2.0L NA V6 – AJV6
– Electronic Engine Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27, VIN Range: E96603->J28492
– Electronic Engine Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27, VIN Range: J28493->V99999
– General Procedures
– Powertrain Control Module (PCM) Long Drive Cycle Self-Test
– Powertrain Control Module (PCM) Short Drive Cycle Self-Test
– Removal and Installation
– Camshaft Position (CMP) Sensor (18.30.63)
– Catalyst Monitor Sensor LH (18.30.81)
– Catalyst Monitor Sensor RH (18.30.80)
– Crankshaft Position (CKP) Sensor (18.30.12)
– Engine Control Module (ECM) (18.30.01)
– Fuel Temperature Sensor (18.30.99) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Heated Oxygen Sensor (HO2S) LH (18.30.79)
– Heated Oxygen Sensor (HO2S) RH (18.30.78)
– Knock Sensor (KS) (18.30.69)
– Mass Air Flow (MAF) Sensor (18.30.15)
– Oil Temperature Sensor (18.31.01)
– Throttle Position (TP) Sensor (18.30.17)
– Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
Electronic Engine Controls – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) – Puma
– Specification
– Description and Operation
– Electronic Engine Controls
– Diagnosis and Testing
– Electronic Engine Controls
– Removal and Installation
– Camshaft Position (CMP) Sensor (18.30.63)
– Catalytic Converter Temperature Sensor
– Crankshaft Position (CKP) Sensor (18.30.12)
– Cylinder Head Temperature (CHT) Sensor (18.30.97)
– Diesel Particulate Filter (DPF) Temperature Sensor
– Engine Control Module (ECM) (18.30.01)
– Engine Oil Pressure (EOP) Sensor
– Fuel Temperature Sensor (18.30.99)
– Knock Sensor (KS) (18.30.69)
– Manifold Absolute Pressure and Temperature (MAPT) Sensor
– Manifold Absolute Pressure (MAP) Sensor (18.30.86)
– Mass Air Flow (MAF) Sensor (18.30.15)
Automatic Transmission/Transaxle
Automatic Transmission/Transaxle – Vehicles With: 5-Speed Automatic Transaxle – JATCO
– Specification
– Description and Operation
– Transmission Description – Vehicles With: 5-Speed Automatic Transaxle – JATCO
– Diagnosis and Testing
– Diagnostic Strategy – Vehicles With: 5-Speed Automatic Transaxle – JATCO
– General Procedures
– Transmission Fluid Drain and Refill (44.24.02)
– Transmission Fluid Level Check
– Transmission Range (TR) Sensor Adjustment (44.15.37)
– In-Vehicle Repair
– Halfshaft Seal LH (37.23.10)
– Halfshaft Seal RH
– Main Control Valve Body (44.40.01)
– Shift Solenoids (SS) (44.15.50)
– Transaxle Support Insulator (37.16.42)
– Transmission Control Module (TCM) (44.15.32)
– Transmission Range (TR) Sensor
– Removal
– Transaxle (44.20.01)
– Disassembly and Assembly of Subassemblies
– Input Shaft Seal (44.32.07)
– Installation
– Transaxle (44.20.01)
Automatic Transmission/Transaxle – Vehicles With: 6-Speed Automatic Transaxle – AWF21
– Specification
– Description and Operation
– Transmission Description – Vehicles With: 6-Speed Automatic Transaxle – AWF21
– Transmission Electronic Control System – Vehicles With: 6-Speed Automatic
– Transaxle – AWF21
– Diagnosis and Testing
– Diagnostic Strategy – Vehicles With: 6-Speed Automatic Transaxle – AWF21
– General Procedures
– Transmission Fluid Drain and Refill (44.24.02)
– Transmission Fluid Level Check
– In-Vehicle Repair
– Main Control Valve Body (44.40.01)
– Selector Shaft Seal
– Transmission Control Module (TCM) (44.15.32)
– Transmission Internal Wiring Harness (44.15.35)
– Transmission Fluid Pan (44.24.04)
– Removal and Installation
– Torque Converter
– Torque Converter Seal
– Turbine Shaft Speed (TSS) Sensor
– Removal
– Transmission (44.20.01)
– Installation
– Transmission (44.20.01)
Transmission/Transaxle Cooling – Vehicles With: 5-Speed Automatic Transaxle – JATCO
– Specification
– Description and Operation
– Transmission Cooling – Vehicles With: 5-Speed Automatic Transaxle – JATCO
– Diagnosis and Testing
– Transmission Cooling
– Removal and Installation
– Transmission Fluid Cooler (44.24.10)
– Transmission Fluid Cooler Tubes (44.24.19)
Transmission/Transaxle Cooling – Vehicles With: 6-Speed Automatic Transaxle – AWF21
– Specification
– Description and Operation
– Transmission Cooling – Vehicles With: 6-Speed Automatic Transaxle – AWF21
– Diagnosis and Testing
– Transmission Cooling
– Removal and Installation
– Transmission Fluid Cooler (44.24.10)
– Transmission Fluid Cooler Return Tube (44.24.13) (44.24.29)
– Transmission Fluid Cooler Supply Tube (44.24.14) (44.24.28)
Automatic Transmission/Transaxle External Controls – Vehicles With: 5-Speed Automatic Transaxle – JATCO
– Specification
– Description and Operation
– External Controls – Vehicles With: 5-Speed Automatic Transaxle – JATCO
– Diagnosis and Testing
– External Controls
– General Procedures
– Selector Lever Cable Adjustment (44.15.07)
– Removal and Installation
– Selector Lever Cable and Bracket (44.15.08)
– Selector Lever Assembly (44.15.04)
Automatic Transmission/Transaxle External Controls – Vehicles With: 6-Speed Automatic Transaxle – AWF21
– Specification
– Description and Operation
– External Controls – Vehicles With: 6-Speed Automatic Transaxle – AWF21
– Diagnosis and Testing
– External Controls
– General Procedures
– Selector Lever Cable Adjustment (44.15.07)
– Removal and Installation
– Selector Lever Assembly (44.15.04)
– Selector Lever Knob (44.15.06)
Manual Transmission/Transaxle, Clutch and Transfer Case
Manual Transmission/Transaxle and Clutch – General Information
– Specification
– Description and Operation
– Manual Transmission and Clutch
– Diagnosis and Testing
– Manual Transmission and Clutch
– General Procedures
– Clutch System Bleeding (33.15.01) – Vehicles With: 5-Speed Manual Transmission – MT75
– Clutch System Bleeding (33.15.01) – Vehicles With: 6-Speed Manual Transaxle – MMT6
– Gearshift Cable Adjustment (37.16.47)
– Release Hub and Bearing Check
Clutch
– Specification
– Description and Operation
– Clutch
– Diagnosis and Testing
– Clutch
– Removal and Installation
– Clutch Disc and Pressure Plate (12.53.13) (33.10.01)
Clutch Controls
– Specification
– Description and Operation
– Clutch Controls
– Diagnosis and Testing
– Clutch Controls
– Removal and Installation
– Clutch Master Cylinder (33.20.01)
– Clutch Slave Cylinder (33.35.01) – Vehicles With: 5-Speed Manual Transmission – MT75
– Clutch Slave Cylinder (33.35.01) – Vehicles With: 6-Speed Manual Transaxle – MMT6
Manual Transmission/Transaxle
– Specification
– Description and Operation
– Manual Transaxle – Vehicles With: 5-Speed Manual Transmission – MT75
– Manual Transaxle – Vehicles With: 6-Speed Manual Transaxle – MMT6
– Diagnosis and Testing
– Manual Transaxle
– General Procedures
– Transaxle Draining and Filling (44.24.02) – Vehicles With: 5-Speed Manual
– Transmission – MT75
– Transaxle Draining and Filling (44.24.02) – Vehicles With: 6-Speed Manual
– Transaxle – MMT6
– In-Vehicle Repair
– Halfshaft Seal LH
– Halfshaft Seal RH
– Input Shaft Seal (37.23.09)
– Selector Mechanism – Vehicles With: 5-Speed Manual Transmission – MT75
– Selector Mechanism – Vehicles With: 6-Speed Manual Transaxle – MMT6
– Support Insulator (37.16.42)
– Removal
– Transaxle (37.20.01) – 2.0L Duratorq-TDCi
– Transaxle (37.20.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Transaxle (37.20.01) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Installation
– Transaxle (37.20.01) – 2.0L Duratorq-TDCi
– Transaxle (37.20.01) – 2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Transaxle (37.20.01) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Manual Transmission/Transaxle External Controls
– Specification
– Description and Operation
– External Controls
– Diagnosis and Testing
– External Controls
– Removal and Installation
– Gearshift Cables (37.16.45) – Vehicles With: 5-Speed Manual Transmission – MT75
– Gearshift Cables (37.16.45) – Vehicles With: 6-Speed Manual Transaxle – MMT6
– Gearshift Lever (37.16.04) – Vehicles With: 5-Speed Manual Transmission – MT75
– Gearshift Lever (37.16.04) – Vehicles With: 6-Speed Manual Transaxle – MMT6
Transfer Case
– Specification
– Description and Operation
– Transfer Case
– General Procedures
– Transfer Case Draining and Filling
– In-Vehicle Repair
– Halfshaft Seal RH (46.10.03)
– Transfer Case Rear Output Shaft Seal (46.10.04)
– Removal
– Transfer Case (46.10.01)
– Installation
– Transfer Case (46.10.01)
Exhaust System
Exhaust System
– Specification
– Description and Operation
– Exhaust System
– Diagnosis and Testing
– Exhaust System
– Removal and Installation
– Catalytic Converter (17.50.05) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Catalytic Converter LH (17.50.15) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Catalytic Converter RH (17.50.16) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Diesel Particulate Filter (DPF)
– Diesel Particulate Filter (DPF) Differential Pressure Sensor
– Exhaust Flexible Pipe (30.10.57) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Front Muffler (30.10.18) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Front Muffler (30.10.18) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Muffler and Tailpipe (30.10.52) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma, 2.0L
– Muffler and Tailpipe (30.10.52) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Muffler Inlet Pipe (30.10.06) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Muffler Inlet Pipe (30.10.06) – Vehicles With: Diesel Particulate Filter (DPF)
Fuel System
Fuel System – General Information
– Specification
– Description and Operation
– Fuel System
– Diagnosis and Testing
– Fuel System
– General Procedures
– Fuel System Pressure Check
– Fuel System Pressure Release (19.50.02)
– Fuel Tank Draining – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Fuel Tank Draining – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Quick Release Coupling – Push Connect
– Spring Lock Couplings
Fuel Tank and Lines
– Specification
– Description and Operation
– Fuel Tank and Lines
– Diagnosis and Testing
– Fuel Tank and Lines
– Removal and Installation
– Fuel Filter (19.25.02) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Fuel Filter (19.25.02) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Fuel Level Sender – 2.0L NA V6 – AJV6
– Fuel Level Sender – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Fuel Level Sender LH – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Fuel Level Sender RH – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Fuel Level Sensor (88.25.32) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Fuel Pump Module (19.45.08) – 2.0L NA V6 – AJV6
– Fuel Pump Module (19.45.08) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Fuel Tank (19.55.01) – 2.0L NA V6 – AJV6
– Fuel Tank (19.55.01) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Fuel Tank (19.55.01) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Fuel Tank Filler Pipe (19.55.33)
– Gas Fuel Tank Pressure Sensor (19.55.31)
– Fuel Transfer Pump (19.45.21)
– Inertia Fuel Shutoff (IFS) Switch (18.30.35)
– Fuel Tank Filler Pipe Hose
Acceleration Control
– Specification
– Description and Operation
– Acceleration Control
– Diagnosis and Testing
– Acceleration Control
– General Procedures
– Accelerator Cable Adjustment (12.20.05) – 2.0L NA V6 – AJV6
– Removal and Installation
– Accelerator Cable (19.20.06) – 2.0L NA V6 – AJV6
– Accelerator Pedal (19.20.01)
Speed Control
– Specification
– Description and Operation
– Speed Control
– Diagnosis and Testing
– Speed Control – 2.0L NA V6 – AJV6
– Speed Control – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Removal and Installation
– Speed Control Deactivator Switch (19.75.20)
– Speed Control Module (19.75.26)
– Speed Control Switch (19.75.25)
Electrical
Climate Control System
Climate Control System – General Information
– Specification
– Description and Operation
– Climate Control System
– Diagnosis and Testing
– Climate Control System
– General Procedures
– Air Conditioning (A/C) Compressor Leak Detection
– Air Conditioning (A/C) System Flushing
– Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)
– Contaminated Refrigerant Handling
– Discharging and Recovery (82.30.30)
– Electronic Leak Detection
– Inspection and Assembly Requirements
– Leak Detection
– Refrigerant Oil Adding
– Refrigerant System Tests
Air Distribution and Filtering
– Description and Operation
– Air Distribution and Filtering
– Diagnosis and Testing
– Air Distribution and Filtering
– Removal and Installation
– Center Registers (82.20.38)
– Driver Side Register (82.20.39)
– Front Footwell Duct LH (82.20.91)
– Front Footwell Duct RH (82.20.92)
– Passenger Side Register (82.20.40)
– Pollen Filter (76.10.09)
Heating and Ventilation
– Specification
– Description and Operation
– Heating and Ventilation
– Diagnosis and Testing
– Heating and Ventilation
– Removal and Installation
– Blower Motor (82.25.66)
– Evaporator Core Housing (80.20.01)
– Heater Core (80.20.29)
– Disassembly and Assembly
– Evaporator Core Housing
Auxiliary Heating
– Specification
– Description and Operation
– Electric Booster Heater
– Fuel Fired Booster Heater
– Diagnosis and Testing
– Auxiliary Heater
– Fuel Fired Booster Heater
– Removal and Installation
– Electric Booster Heater
– Fuel Fired Booster Heater
Air Conditioning
– Specification
– Description and Operation
– Air Conditioning
– Diagnosis and Testing
– Air Conditioning
– Removal and Installation
– Air Conditioning (A/C) Compressor (82.10.20) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Air Conditioning (A/C) Compressor (82.10.20) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Air Conditioning (A/C) Pressure Transducer (82.10.47)
– Clutch and Clutch Field Coil (82.10.25) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Condenser Core (82.15.07)
– Evaporator Core (82.25.20)
– Evaporator Core Orifice (82.25.67)
– Suction Accumulator (82.17.02)
Control Components
– Description and Operation
– Control Components
– Diagnosis and Testing
– Control Components
– Removal and Installation
– Air Discharge Temperature Sensor (82.20.64)
– Ambient Air Temperature Sensor (82.20.02)
– Climate Control Assembly (82.20.07)
– Defrost Vent/Register Blend Door Actuator (82.20.84)
– Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85)
– Sunload Sensor (82.20.70)
– Temperature Blend Door Actuator (82.20.86)
Instrumentation and Warning Systems
Instrument Cluster and Panel Illumination
– Diagnosis and Testing
– Instrument Cluster and Panel Illumination
Instrument Cluster
– Description and Operation
– Instrument Cluster
– Diagnosis and Testing
– Instrument Cluster
– Removal and Installation
– Instrument Cluster (88.20.01)
Horn
– Description and Operation
– Horn
– Diagnosis and Testing
– Horn
– Removal and Installation
– Horn (86.30.02) (86.30.10)
– Horn Switch (86.30.01)
Information and Message Center
– Description and Operation
– Information and Message Center
– Diagnosis and Testing
– Information and Message Center
– Removal and Installation
– Message Center
– Message Center Switch (86.66.11)
Warning Devices
– Description and Operation
– Warning Devices
– Diagnosis and Testing
– Warning Devices
– General Procedures
– Oil Change Indicator Reset
– Removal and Installation
– Low Washer Fluid Warning Indicator Switch (84.10.17)
Parking Aid
– Description and Operation
– Parking Aid
– Diagnosis and Testing
– Parking Aid
– Removal and Installation
– Front Parking Aid Sensor (86.62.33)
– Front Parking Aid Speaker (86.54.18) (86.62.34)
– Parking Aid Module (86.80.39) – 4-Door
– Parking Aid Module (86.80.39) – Wagon
– Rear Parking Aid Sensor (86.54.14) (86.62.01)
– Rear Parking Aid Speaker (86.54.19) (86.62.02) – 4-Door
– Rear Parking Aid Speaker (86.54.19) (86.62.02) – Wagon, VIN Range: D86655- >E43419
– Rear Parking Aid Speaker (86.54.19) (86.62.02) – Wagon, VIN Range: E43420- >V99999
Battery and Charging System
Battery and Charging System – General Information
– Description and Operation
– Charging System
– Battery Care
– Quiescent Drain
– Diagnosis and Testing
– Charging System – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Charging System – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –
– Puma
– General Procedures
Battery Charging
Battery, Mounting and Cables
– Specification
– Description and Operation
– Battery and Cables
– Diagnosis and Testing
– Battery
– General Procedures
– Battery Connect (86.15.15)
– Battery Disconnect and Connect
– Removal and Installation
– Battery (86.15.01)
– Battery Cables (86.15.32) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Battery Cables (86.15.32) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Battery Tray (86.15.11)
Generator and Regulator
– Specification
– Description and Operation
– Generator
– Diagnosis and Testing
– Generator
– Removal and Installation
– Generator (86.10.02) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Generator (86.10.02) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
Information and Entertainment Systems
Information and Entertainment System – General Information
– Diagnosis and Testing
– Audio System
Audio Unit
– Description and Operation
– Audio System
– Diagnosis and Testing
– Audio System
– Removal and Installation
– Audio Unit (86.50.03)
– Audio Unit Amplifier (86.50.10) (86.50.36) – 4-Door
– Audio Unit Amplifier (86.50.10) (86.50.36) – Wagon
– Compact Disc (CD) Changer (86.50.06) – 4-Door
– Compact Disc (CD) Changer (86.50.06) – Wagon
– Steering Wheel Audio Controls (86.50.42)
Antenna
– Specification
– Description and Operation
– Antenna
– Diagnosis and Testing
– Antenna
– Removal and Installation
– Antenna (86.51.17.60) – Wagon
– Module
Speakers
– Description and Operation
– Speakers
– Diagnosis and Testing
– Speakers
– Removal and Installation
– Front Door Speaker (86.50.13)
– Front Door Tweeter Speaker (86.50.63)
– Parcel Shelf Speaker (86.51.06)
– Rear Door Speaker (86.50.14)
– Rear Door Tweeter Speaker (86.50.62)
Lighting
Exterior Lighting
– Specification
– Description and Operation
– Exterior Lighting
– Diagnosis and Testing
– Headlamps
– General Procedures
– Headlamp Adjustment (86.40.18)
– Removal and Installation
– Ballast (86.41.52)
– Front Fog Lamp (86.40.96)
– Headlamp Assembly (86.41.33)
– Headlamp Bulb (86.42.14) – Vehicles With: High Intensity Discharge Headlamps
– Headlamp Leveling Module
– Headlamp Leveling Sensor (86.42.15)
– Headlamp Switch (86.65.26)
– High Mounted Stoplamp (86.41.01) (86.41.32) – 4-Door
– High Mounted Stoplamp (86.41.01) (86.41.32) – Wagon
– Rear Lamp Assembly (86.40.70) – 4-Door
– Rear Lamp Assembly (86.40.70) – Wagon
Interior Lighting
– Description and Operation
– Interior Lighting
– Diagnosis and Testing
– Interior Lighting
– Removal and Installation
– Front Interior Lamp (86.45.12)
– Rear Interior Lamp (86.46.03)
Daytime Running Lamps (DRL)
– Description and Operation
– Daytime Running Lamps (DRL)
– Diagnosis and Testing
– Daytime Running Lamps (DRL)
Electrical Distribution
Module Communications Network
– Description and Operation
– Communications Network
– Diagnosis and Testing
– Communications Network – VIN Range: E96603->J28492
– Communications Network – VIN Range: J28493->V99999
Module Configuration
– Diagnosis and Testing
– Module Configuration
– General Procedures
– Module Configuration
Wiring Harnesses
– Description and Operation
– Wiring Harness
– General Procedures
– Wiring Harness Repair
Electronic Feature Group
Anti-Theft – Active
– Description and Operation
– Anti-Theft – Active
– Diagnosis and Testing
– Anti-Theft – Active
– Removal and Installation
– Anti-Theft Alarm Horn (86.52.03)
Anti-Theft – Passive
– Description and Operation
– Anti-Theft – Passive
– Diagnosis and Testing
– Anti-Theft – Passive
– General Procedures
– Anti-Theft Security Access
– Key Programming Using Diagnostic Equipment
– Removal and Installation
– Passive Anti-Theft System (PATS) Transceiver (86.52.30)
Remote Convenience
– Description and Operation
– Universal Transmitter
– Diagnosis and Testing
– Universal Transmitter
– General Procedures
– Universal Transmitter Programming
Navigation System
– Description and Operation
– Navigation System
– Diagnosis and Testing
– Navigation System
– Removal and Installation
– Navigation System Antenna (86.62.06) – 4-Door, VIN Range: E96603->J39905
– Navigation System Antenna (86.62.06) – 4-Door, VIN Range: J39906->V99999
– Navigation System Antenna (86.62.06) – Wagon
– Navigation System Display Module (86.62.07)
– Navigation System Module (86.62.05) – 4-Door
– Navigation System Module (86.62.05) – Wagon
Cellular Phone
– Specification
– Description and Operation
– Cellular Phone
– Diagnosis and Testing
– Cellular Phone
– Cellular Phone – Vehicles With: Bluetooth
– Removal and Installation
– Bluetooth Module
– Handset Holder (86.51.12)
– Module – 4-Door
– Module – Wagon
Multifunction Electronic Modules
– Specification
– Description and Operation
– Module Controlled Functions
– Diagnosis and Testing
– Multifunction Electronic Module
– Removal and Installation
– Generic Electronic Module (GEM) (86.55.75) (86.80.38)
– Multifunction Voice Activated Module (86.53.13) (86.80.40) – 4-Door
– Multifunction Voice Activated Module (86.53.13) (86.80.40) – Wagon
Body and Paint
Front End Body Panels
– Description and Operation
– Front End Body Panels
– Removal and Installation
– Air Deflector (76.11.41) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Cowl Vent Screen (76.10.01)
– Fender Splash Shield (76.10.90)
– Radiator Splash Shield (76.22.90)
Body Closures
– Specification
– Description and Operation
– Body Closures
– General Procedures
– Door Alignment
– Hood Alignment (76.16.02)
– Liftgate Alignment (76.19.54.60)
– Luggage Compartment Lid Alignment (76.19.03)
– Removal and Installation
– Weatherstrip
Interior Trim and Ornamentation
– Specification
– Description and Operation
– Interior Trim
– Removal and Installation
– A-Pillar Trim Panel (76.13.31)
– B-Pillar Lower Trim Panel (76.13.29)
– B-Pillar Upper Trim Panel (76.13.28)
– Cowl Side Trim Panel (76.13.30)
– C-Pillar Trim Panel (76.13.73) – 4-Door
– C-Pillar Trim Panel (76.13.73) – Wagon
– D-Pillar Trim Panel (76.13.73.60)
– Front Door Trim Panel (76.34.01)
– Front Scuff Plate Trim Panel (76.13.81)
– Headliner (76.64.01) – 4-Door
– Headliner (76.64.01) – Wagon
– Liftgate Trim Panel (76.19.65.60)
– Loadspace Scuff Plate Trim Panel (76.19.90.60)
– Loadspace Trim Panel (76.13.73.60)
– Parcel Shelf (76.67.06)
– Rear Door Trim Panel (76.34.04)
– Rear Scuff Plate Trim Panel (76.13.82)
– Rear Window Blind (76.14.04)
– Sun Visor (76.10.48)
Exterior Trim and Ornamentation
– Specification
– Description and Operation
– Exterior Trim
– Removal and Installation
– Door Moulding (76.43.72)
– Liftgate Moulding (76.43.79)
– Radiator Grille (76.55.03)
– Rear Spoiler (76.19.86.60) – Wagon
– Rocker Panel Moulding (76.11.36)
– Roof Rail (76.43.86.60)
– Window Moulding (76.43.20)
Rear View Mirrors
– Specification
– Description and Operation
– Rear View Mirrors
– Diagnosis and Testing
– Rear View Mirrors
– Removal and Installation
– Auto-Dimming Interior Mirror (76.10.56)
– Exterior Mirror (76.10.52)
– Exterior Mirror Control Switch (86.65.75)
– Exterior Mirror Cover (76.10.55)
– Exterior Mirror Glass (76.10.53)
– Exterior Mirror Motor (76.10.57) (76.11.09)
– Interior Mirror (76.10.51)
Seating
– Specification
– Description and Operation
– Seats
– Diagnosis and Testing
– Seats
– Removal and Installation
– Front Seat (76.70.01)
– Front Seat Backrest (76.70.06)
– Front Seat Cushion (76.70.11)
– Front Seat Front Height Adjustment Motor (86.75.31)
– Front Seat Rear Height Adjustment Motor (86.75.32)
– Front Seat Recliner Motor (86.75.04)
– Front Seat Track Motor (86.75.33)
– Lumbar Assembly (86.75.12)
– Rear Seat Backrest (76.70.38) – 4-Door
– Rear Seat Backrest (76.70.38) – 4-Door, Vehicles With: 70/30 Split Seat
– Rear Seat Backrest (76.70.38) – Wagon, Vehicles With: 70/30 Split Seat
– Rear Seat Backrest Latch (76.70.62.60) – Wagon
– Rear Seat Bolster (76.70.67) – 4-Door
– Rear Seat Bolster (76.70.67) – Wagon
– Rear Seat Cushion (76.70.37)
– Seat Base (76.70.08)
– Seat Control Switch (86.75.23)
– Disassembly and Assembly
– Front Seat Backrest (76.70.23)
– Front Seat Cushion (76.70.34)
– Rear Seat Backrest (76.70.48) – 4-Door, Vehicles With: 70/30 Split Seat
– Rear Seat Backrest (76.70.48) – Wagon, Vehicles With: 70/30 Split Seat
– Rear Seat Backrest (76.70.48)
– Rear Seat Bolster
– Rear Seat Cushion (76.70.47)
Glass, Frames and Mechanisms
– Specification
– Description and Operation
– Glass, Frames and Mechanisms
– Diagnosis and Testing
– Glass, Frames and Mechanisms
– General Procedures
– Door Window Motor Initialization
– Liftgate Window Glass Adjustment
– Removal and Installation
– Front Door Window Glass (76.31.01)
– Front Door Window Regulator and Motor (76.31.45)
– Liftgate Window Glass (76.31.22) (76.81.11.60)
– Rear Door Fixed Window Glass
– Rear Door Window Glass (76.31.02)
– Rear Door Window Regulator (76.31.46)
– Rear Door Window Regulator and Motor (86.25.09)
– Rear Quarter Window Glass (76.31.31)
– Rear Window Glass Using Cheese Wire (76.81.41)
– Rear Window Glass Using Cutting Tool
– Window Control Switch (86.25.08)
– Windshield Glass Using Cheese Wire (76.81.40)
– Windshield Glass Using Cutting Tool (76.81.01)
Instrument Panel and Console
– Description and Operation
– Instrument Panel
– Removal and Installation
– Floor Console (76.25.01)
– Instrument Panel (76.46.01)
– Overhead Console (76.13.69)
– Overhead Console Switch Moulding
Handles, Locks, Latches and Entry Systems
– Specification
– Description and Operation
– Handles, Locks, Latches and Entry Systems
– Diagnosis and Testing
– Locks, Latches and Entry Systems
– General Procedures
– Remote Transmitter Programming
– Removal and Installation
– Exterior Front Door Handle (76.58.01)
– Front Door Lock Actuator (76.37.74)
– Front Door Lock Cylinder (76.37.71)
– Fuel Filler Door Release Handle and Cable (76.11.39) – 4-Door
– Fuel Filler Door Release Handle and Cable (76.11.39) – Wagon
– Liftgate Latch Actuator (86.25.65.60)
– Liftgate Window Glass Release Switch (76.19.59.60)
– Luggage Compartment Lid Latch Actuator (76.19.25)
– Rear Door Lock Actuator (76.37.09)
Wipers and Washers
– Specification
– Description and Operation
– Wipers and Washers
– Diagnosis and Testing
– Wipers and Washers
– Removal and Installation
– Headlamp Washer Pump (84.20.21)
– Rain Sensor (84.12.10) (86.56.62)
– Rain Sensor Module (86.56.60)
– Rear Window Wiper Motor (84.15.48.60) (84.35.12)
– Windshield and Rear Window Washer Pump (84.10.21.60)
– Windshield Washer Pump (84.10.21)
– Windshield Washer Reservoir (84.10.01) (84.10.03)
– Windshield Wiper Motor (84.15.13)
– Wiper Mounting Arm and Pivot Shaft (84.15.24)
– Wiper Pivot Arm (84.15.03)
Roof Opening Panel
– Specification
– Description and Operation
– Roof Opening Panel
– Diagnosis and Testing
– Roof Opening Panel
– General Procedures
– Motor Synchronization (76.82.48)
– Roof Opening Panel Alignment
– Removal and Installation
– Air Deflector (76.82.07)
– Lifter Arms (76.82.57)
– Roof Opening Panel Control Switch (86.76.05)
– Roof Opening Panel Drain Hose (76.82.26)
– Roof Opening Panel Frame (76.82.01)
– Roof Opening Panel Glass (76.82.05)
– Roof Opening Panel Motor (86.76.01)
– Roof Opening Panel Shield (76.82.06)
– Roof Opening Panel Weatherstrip (76.82.15)
Bumpers
– Specification
– Description and Operation
– Bumpers
– Removal and Installation
– Front Bumper Cover (76.22.78)
– Front Bumper Cover Insert (76.22.73)
– Rear Bumper (76.22.27) (76.22.52) – 4-Door
– Rear Bumper (76.22.27) (76.22.52) – Wagon
– Rear Bumper Cover (76.22.74) (76.22.77) – 4-Door
– Rear Bumper Cover (76.22.74) (76.22.77) – Wagon
– Rear Bumper Cover Insert (76.22.75) – 4-Door
– Rear Bumper Cover Insert (76.22.75) – Wagon
Safety Belt System
– Specification
– Description and Operation
– Safety Belt System
– Diagnosis and Testing
– Safety Belt System
– Removal and Installation
– Front Safety Belt Retractor (76.73.10)
– Front Safety Belt Shoulder Height Adjuster (76.73.12)
– Rear Center Safety Belt Retractor (76.73.20) – 4-Door
– Rear Center Safety Belt Retractor (76.73.20) – Wagon
– Rear Safety Belt Buckle (76.73.50)
– Rear Safety Belt Retractor (76.73.18) – 4-Door
– Rear Safety Belt Retractor (76.73.18) – Wagon
– Safety Belt Buckle and Pretensioner (76.73.49)
Supplemental Restraint System
– Specification
– Description and Operation
– Air Bag Supplemental Restraint System (SRS)
– Diagnosis and Testing
– Air Bag Supplemental Restraint System (SRS)
– General Procedures
– Air Bag Disposal
– Removal and Installation
– Clockspring (86.65.92)
– Crash Sensor (76.73.55)
– Driver Air Bag Module (76.73.39)
– Driver Lower Air Bag Module (76.73.75)
– Occupant Classification Sensor (76.73.60)
– Passenger Air Bag Deactivation (PAD) Indicator (76.73.58)
– Passenger Air Bag Module (76.73.37)
– Restraints Control Module (RCM) (76.73.48)
– Seat Position Sensor (76.73.62)
– Side Air Curtain Module (76.73.64) – 4-Door
– Side Air Curtain Module (76.73.64) – Wagon
– Side Impact Sensor (76.73.53)
Frame and Mounting
Uni-Body, Subframe and Mounting System
– Specification
– Description and Operation
– Frame Assembly
– General Procedures
– Underbody Misalignment Check (57.65.20)
– Removal and Installation
– Front Subframe (76.10.05) – 2.0L NA V6 – AJV6/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
– Front Subframe (76.10.05) – 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) – Puma
– Front Subframe Front Bushing (60.35.51)
– Front Subframe Rear Bushing (60.35.26)
– Rear Axle Crossmember Bushing (64.25.02)
– Rear Subframe (64.25.01)
– Rear Subframe Bushing (64.25.04)
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