Ford Focus RS from 2016 - Service Manual - Repair Manual

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FORD FOCUS RS (2016+) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for vehicles Ford Focus RS from 2016.


CONTENTS:

100-00 GENERAL INFORMATION
- Diagnostic Trouble Code Charts
- Diagnosis and Testing
- Symbols Glossary
- Description and Operation

100-01 IDENTIFICATION CODES
- Identification Codes - Description and Operation

100-04 NOISE, VIBRATION AND HARSHNESS
- Noise, Vibration and Harshness (NVH) - Description and Operation
- Noise, Vibration and Harshness (NVH) - Diagnosis and Testing

204-00 SUSPENSION SYSTEM - GENERAL INFORMATION
- Specifications
- Suspension System - Diagnosis and Testing
- Front Camber and Caster Adjustment - General Procedures
- Rear Camber Adjustment - General Procedures
- Rear Toe Adjustment - General Procedures
- Ride Height Measurement - General Procedures
- Front Toe Adjustment - General Procedures

204-01 FRONT SUSPENSION
- Front Suspension - Overview - Description and Operation
- Front Wheel Bearing - Removal and Installation
- Front Stabilizer Bar - Removal and Installation
- Front Strut and Spring Assembly - Removal and Installation
- Lower Arm LH - Removal and Installation
- Lower Arm RH - Removal and Installation
- Wheel Hub - Removal and Installation
- Wheel Knuckle - Removal and Installation
- Wheel Knuckle - RS - Removal and Installation
- Wheel Studs - Removal and Installation
- Lower Arm - RS - Removal and Installation
- Front Strut and Spring Assembly - RS - Removal and Installation
- Front Strut and Spring Assembly - RS - Disassembly and Assembly
- Front Strut and Spring Assembly - Disassembly and Assembly

204-02 REAR SUSPENSION
- Rear Suspension - Overview - Description and Operation
- Front Lower Arm - Removal and Installation
- Rear Shock Absorber - Removal and Installation
- Rear Stabilizer Bar - Removal and Installation
- Rear Stabilizer Bar Link - Vehicles With: Ball Joint Stabilizer Bar Link - Removal and Installation
- Trailing Arm - Removal and Installation
- Wheel Bearing and Wheel Hub - Removal and Installation
- Wheel Studs - Removal and Installation
- Trailing Arm - RS - Removal and Installation
- Spring - Removal and Installation
- Upper Arm - Removal and Installation
- Rear Stabilizer Bar - RS - Removal and Installation
- Wheel Bearing and Wheel Hub - RS - Removal and Installation
- Wheel Knuckle - RS - Removal and Installation
- Front Lower Arm - RS - Removal and Installation
- Rear Lower Arm - RS - Removal and Installation
- Rear Stabilizer Bar Link - RS - Removal and Installation
- Rear Shock Absorber - RS - Removal and Installation

204-04A WHEELS AND TIRES
- Specifications
- Wheels and Tires - Overview - Description and Operation
- Wheels and Tires - Diagnosis and Testing
- Wheel to Tire Runout Minimization - General Procedures
- Wheel and Tire - Removal and Installation
- Wheel and Tire - Disassembly and Assembly

204-04B TIRE PRESSURE MONITORING SYSTEM (TPMS)
- Tire Pressure Monitoring System (TPMS) - Component Location - Description and Operation
- Tire Pressure Monitoring System (TPMS) - System Operation and Component Description - Description
- and Operation
- Tire Pressure Monitoring System (TPMS) - Diagnosis and Testing

204-05 VEHICLE DYNAMIC SUSPENSION
- Vehicle Dynamic Suspension - Overview - Description and Operation
- Vehicle Dynamic Suspension - System Operation and Component Description - Description and
- Operation
- Vehicle Dynamic Suspension - Diagnosis and Testing

205-01 DRIVESHAFT
- Specifications
- Driveshaft - Diagnosis and Testing
- Driveshaft Runout and Balancing - General Procedures
- Driveshaft Angle Measurement - General Procedures
- Rear Driveshaft - Removal and Installation

205-02 REAR DRIVE AXLE/DIFFERENTIAL
- Specifications
- Rear Drive Axle and Differential - Diagnosis and Testing
- Differential Draining and Filling - General Procedures
- Differential Fluid Level Check - General Procedures
- Axle Assembly - Removal and Installation
- Drive Pinion Flange - Removal and Installation
- Drive Pinion Seal - Removal and Installation
- Rear Halfshaft Seal - Removal and Installation

205-04 FRONT DRIVE HALFSHAFTS
- Front Drive Halfshafts - Diagnosis and Testing
- Front Halfshaft LH - Removal and Installation
- Front Halfshaft RH - Removal and Installation
- Halfshaft Bearing - Removal and Installation
- Inner Constant Velocity (CV) Joint Boot - 2.0L EcoBoost (184kW/250PS) - MI4 - Removal and Installation
- Outer Constant Velocity (CV) Joint Boot - 2.0L EcoBoost (184kW/250PS) - MI4 - Removal and Installation
- Front Halfshaft LH - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation
- Front Halfshaft RH - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation

205-05 REAR DRIVE HALFSHAFTS
- Specifications
- Rear Drive Halfshafts - Diagnosis and Testing
- Rear Halfshaft - Removal and Installation

206-00 BRAKE SYSTEM - GENERAL INFORMATION
- Specifications
- Brake System - Diagnosis and Testing
- Brake System Pressure Bleeding - General Procedures
- Component Bleeding - General Procedures

206-03 FRONT DISC BRAKE
- Brake Caliper Anchor Plate - Removal and Installation
- Brake Disc - Removal and Installation
- Brake Disc Shield - Removal and Installation
- Brake Caliper - Removal and Installation
- Brake Pads - Removal and Installation
- Front Brake Flexible Hose - Removal and Installation
- Brake Caliper - RS - Removal and Installation
- Brake Disc - RS - Removal and Installation
- Brake Disc Shield - RS - Removal and Installation
- Brake Pads - RS - Removal and Installation
- Front Brake Flexible Hose - RS - Removal and Installation

206-04 REAR DISC BRAKE
- Brake Caliper Anchor Plate - Removal and Installation
- Brake Disc - Removal and Installation
- Brake Disc Shield - Removal and Installation
- Brake Caliper - Removal and Installation
- Brake Pads - Removal and Installation
- Rear Brake Flexible Hose - Removal and Installation
- Brake Pads - RS - Removal and Installation
- Brake Caliper - RS - Removal and Installation
- Brake Caliper Anchor Plate - RS - Removal and Installation
- Brake Disc - RS - Removal and Installation
- Brake Disc Shield - RS - Removal and Installation

206-05 PARKING BRAKE AND ACTUATION
- Parking Brake - Diagnosis and Testing
- Parking Brake Cable Adjustment - Vehicles With: Rear Disc Brakes - General Procedures
- Parking Brake Cable - Vehicles With: Rear Disc Brakes - Removal and Installation
- Parking Brake Cable - RS - Removal and Installation
- Parking Brake Control - RS - Removal and Installation

206-06 HYDRAULIC BRAKE ACTUATION
- Brake Fluid Reservoir - Removal and Installation
- Brake Master Cylinder - Removal and Installation
- Brake Pedal and Bracket - Removal and Installation

206-07 POWER BRAKE ACTUATION
- Brake Booster - Removal and Installation
- Brake Vacuum Pump - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation

206-09 ANTI-LOCK BRAKE SYSTEM (ABS) AND STABILITY CONTROL
- Anti-Lock Brake System (ABS) and Stability Control - Overview - Description and Operation
- Anti-Lock Brake System (ABS) and Stability Control - System Operation and Component Description -
- Description and Operation
- Anti-Lock Brake System (ABS) and Stability Control - Diagnosis and Testing
- Anti-Lock Brake System (ABS) Module - Removal and Installation
- Front Wheel Speed Sensor - Removal and Installation
- Hydraulic Control Unit (HCU) - Removal and Installation
- Rear Wheel Speed Sensor - RS - Removal and Installation

211-02 POWER STEERING
- Power Steering - Overview - Description and Operation
- Power Steering - System Operation and Component Description - Description and Operation
- Steering Gear - Removal and Installation
- Tie Rod - Removal and Installation

211-04 STEERING COLUMN
- Steering Column - Overview - Description and Operation
- Steering Wheel Cover Repair - General Procedures
- Steering Wheel - Removal and Installation
- Steering Column - Removal and Installation

211-05 STEERING WHEEL AND COLUMN ELECTRICAL COMPONENTS
- Steering Wheel and Column Electrical Components - Overview - Description and Operation
- Steering Wheel and Column Electrical Components - System Operation and Component Description -
- Description and Operation
- Steering Wheel and Column Electrical Components - Diagnosis and Testing
- Ignition Switch - Removal and Installation
- Ignition Switch - Vehicles With: Push Button Start - Removal and Installation
- Steering Angle Sensor Module (SASM) - Removal and Installation
- Steering Column Multifunction Switch LH - Removal and Installation

303-00 ENGINE SYSTEM - GENERAL INFORMATION
- Engine - Overview - Description and Operation
- Engine - Diagnosis and Testing
- Bearing Inspection - General Procedures
- Connecting Rod Bearing Journal Clearance - General Procedures
- Crankshaft Main Bearing Journal Clearance - General Procedures
- Cylinder Block Core Plug Replacement - General Procedures
- Cylinder Block Distortion - General Procedures
- Cylinder Bore Taper - General Procedures
- Cylinder Head Distortion - General Procedures
- Exhaust Manifold Cleaning and Inspection - General Procedures
- Piston Diameter - General Procedures
- Piston Inspection - General Procedures
- Piston Ring End Gap - General Procedures
- Piston Selection - General Procedures
- Powertrain/Drivetrain Mount Neutralizing - General Procedures
- RTV Sealing Surface Cleaning and Preparation - General Procedures
- Valve Stem Diameter - General Procedures
- Valve Guide Inner Diameter - General Procedures

303-01D ENGINE - 2.3L ECOBOOST (257KW/350PS) - MI4
- Specifications
- Engine - Component Location - Description and Operation
- Engine - Overview - Description and Operation
- Balance Shaft Backlash - General Procedures
- Valve Clearance Adjustment - General Procedures
- Camshafts - Removal and Installation
- Crankshaft Front Seal - Removal and Installation
- Crankshaft Pulley - Removal and Installation
- Crankshaft Rear Seal - Removal and Installation
- Cylinder Head - Removal and Installation
- Engine Front Cover - Removal and Installation
- Engine Mount - Removal and Installation
- Flywheel - Removal and Installation
- Intake Manifold - Removal and Installation
- Oil Cooler - Removal and Installation
- Oil Pan - Removal and Installation
- Oil Pressure Switch - Removal and Installation
- Oil Pump - Removal and Installation
- Timing Chain - Removal and Installation
- Variable Camshaft Timing (VCT) Unit - Removal and Installation
- Valve Cover - Removal and Installation
- Valve Stem Seals - Removal and Installation
- Engine - Removal
- Engine Accessories - Removal
- Engine - Disassembly
- Cylinder Head - Disassembly and Assembly of Subassemblies
- Piston - Disassembly and Assembly of Subassemblies
- Engine - Assembly
- Engine - Installation
- Engine Accessories - Installation

303-03D ENGINE COOLING - 2.3L ECOBOOST (257KW/350PS) - MI4
- Specifications
- Engine Cooling - Component Location - Description and Operation
- Engine Cooling - System Operation and Component Description - Description and Operation
- Engine Cooling - Diagnosis and Testing
- Cooling System Draining and Vacuum Filling - General Procedures
- Block Heater - Removal and Installation
- Coolant Pump - Removal and Installation
- Cooling Fan Motor and Shroud - Removal and Installation
- Radiator - Removal and Installation
- Thermostat - Removal and Installation

303-04D FUEL CHARGING AND CONTROLS - 2.3L ECOBOOST (257KW/350PS) - MI4
- Fuel Charging and Controls - Component Location - Description and Operation
- Fuel Charging and Controls - System Operation and Component Description - Description and Operation
- Fuel Charging and Controls - Diagnosis and Testing
- Fuel Injector - Removal and Installation
- Fuel Rail - Removal and Installation
- Fuel Pump Driver Module (FPDM) - Removal and Installation
- High-Pressure Fuel Pump - Removal and Installation
- High-Pressure Fuel Pump Drive Unit - Removal and Installation

303-04G FUEL CHARGING AND CONTROLS - TURBOCHARGER - 2.3L ECOBOOST (257KW/350PS) - MI4
- Turbocharger * Component Location - Description and Operation
- Turbocharger * Overview - Description and Operation
- Turbocharger * System Operation and Component Description - Description and Operation
- Turbocharger - Diagnosis and Testing
- Turbocharger - Removal and Installation
- Turbocharger Coolant Return Tube - Removal and Installation
- Turbocharger Coolant Supply Tube - Removal and Installation
- Turbocharger Oil Return Tube - Removal and Installation
- Turbocharger Oil Supply Tube - Removal and Installation

303-05D ACCESSORY DRIVE - 2.3L ECOBOOST (257KW/350PS) - MI4
- Accessory Drive - Component Location - Description and Operation
- Accessory Drive - Diagnosis and Testing
- Accessory Drive Belt - Removal and Installation
- Accessory Drive Belt Tensioner - Removal and Installation
- Air Conditioning (A/C) Compressor Belt - Removal and Installation

303-06D STARTING SYSTEM - 2.3L ECOBOOST (257KW/350PS) - MI4
- Specifications
- Starting System - Overview - Description and Operation
- Starting System - System Operation and Component Description - Description and Operation
- Starting System - Diagnosis and Testing
- Starter Motor Drive Gear and Flywheel Ring Gear Inspection - General Procedures
- Starter Motor - Removal and Installation

303-07D ENGINE IGNITION - 2.3L ECOBOOST (257KW/350PS) - MI4
- Specifications
- Engine Ignition - Component Location - Description and Operation
- Engine Ignition - System Operation and Component Description - Description and Operation
- Engine Ignition - Diagnosis and Testing
- Ignition Coil-On-Plug - Removal and Installation

303-08D ENGINE EMISSION CONTROL - 2.3L ECOBOOST (257KW/350PS) - MI4
- Engine Emission Control - Component Location - Description and Operation
- Engine Emission Control - System Operation and Component Description - Description and Operation
- Engine Emission Control - Diagnosis and Testing
- Crankcase Vent Oil Separator - Removal and Installation

303-12D INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L ECOBOOST (257KW/350PS) - MI4
- Intake Air Distribution and Filtering - Component Location - Description and Operation
- Intake Air Distribution and Filtering - Diagnosis and Testing
- Air Cleaner - Removal and Installation
- Charge Air Cooler (CAC) - Removal and Installation

303-13D EVAPORATIVE EMISSIONS - 2.3L ECOBOOST (257KW/350PS) - MI4
- Evaporative Emissions - Overview - Description and Operation
- Evaporative Emissions - System Operation and Component Description - Description and Operation
- Evaporative Emissions - Diagnosis and Testing
- Evaporative Emission Blocking Valve - Removal and Installation
- Evaporative Emission Canister - Removal and Installation
- Evaporative Emission Canister Purge Valve - Removal and Installation
- Evaporative Emission Canister Vent Solenoid - Removal and Installation

303-14D ELECTRONIC ENGINE CONTROLS - 2.3L ECOBOOST (257KW/350PS) - MI4
- Electronic Engine Controls - Component Location - Description and Operation
- Electronic Engine Controls - Overview - Description and Operation
- Electronic Engine Controls - System Operation and Component Description - Description and Operation
- Electronic Engine Controls - Diagnosis and Testing
- Camshaft Position (CMP) Sensor LH - Removal and Installation
- Camshaft Position (CMP) Sensor RH - Removal and Installation
- Catalyst Monitor Sensor - Removal and Installation
- Crankshaft Position (CKP) Sensor - Removal and Installation
- Cylinder Head Temperature (CHT) Sensor - Removal and Installation
- Engine Coolant Temperature (ECT) Sensor - Removal and Installation
- Front Knock Sensor (KS) - Removal and Installation
- Fuel Rail Pressure (FRP) Sensor - Removal and Installation
- Heated Oxygen Sensor (HO2S) - Removal and Installation
- Intake Air Temperature (IAT) Sensor - Removal and Installation
- Manifold Absolute Pressure (MAP) Sensor - Removal and Installation
- Manifold Absolute Pressure and Temperature (MAPT) Sensor - Removal and Installation
- Powertrain Control Module (PCM) - Removal and Installation
- Rear Knock Sensor (KS) - Removal and Installation
- Variable Camshaft Timing (VCT) Oil Control Solenoid - Removal and Installation
- Clutch Pedal Position (CPP) Sensor - Vehicles With: Auto-Start-Stop - Removal and Installation
- Clutch Pedal Position (CPP) Switch - Vehicles With: Auto-Start-Stop - Removal and Installation

308-01 CLUTCH
- Clutch - Overview - Description and Operation
- Clutch - System Operation and Component Description - Description and Operation
- Clutch - Diagnosis and Testing
- Clutch Disc and Pressure Plate - Removal and Installation
- Clutch Disc and Pressure Plate - 6-Speed Manual Transmission - MMT6 - Removal and Installation

308-02 CLUTCH CONTROLS
- Clutch Controls - Overview - Description and Operation
- Clutch Controls - Diagnosis and Testing
- Clutch System Bleeding - 6-Speed Manual Transmission - MMT6 - General Procedures
- Clutch Pedal - Removal and Installation
- Clutch Slave Cylinder - 6-Speed Manual Transmission - MMT6 - Removal and Installation

308-03C MANUAL TRANSMISSION - 6-SPEED MANUAL TRANSMISSION - MMT6
- Specifications
- Manual Transaxle - 2.3L EcoBoost (257kW/350PS) - MI4 - Overview - Description and Operation
- Manual Transaxle - 2.3L EcoBoost (257kW/350PS) - MI4 - System Operation and Component Description
-    Description and Operation
- Manual Transmission - Diagnosis and Testing
- Transmission Draining and Filling - 2.3L EcoBoost (257kW/350PS) - MI4 - General Procedures
- Transmission Fluid Level Check - 2.3L EcoBoost (257kW/350PS) - MI4 - General Procedures
- Halfshaft Seal LH - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation
- Halfshaft Seal RH - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation
- Roll Restrictor RH - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation
- Selector Mechanism - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation
- Transmission Support Insulator - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation
- Neutral Position Sensor - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal and Installation
- Transmission - 2.3L EcoBoost (257kW/350PS) - MI4 - Removal
- Transmission - 2.3L EcoBoost (257kW/350PS) - MI4 - Installation

308-06 MANUAL TRANSMISSION EXTERNAL CONTROLS
- External Controls - Overview - Description and Operation
- External Controls - Diagnosis and Testing
- Gearshift Cable Adjustment - 6-Speed Manual Transmission - MMT6 - General Procedures
- Gearshift Cables - 6-Speed Manual Transmission - MMT6 - Removal and Installation

308-07A FOUR-WHEEL DRIVE SYSTEMS
- Specifications
- Four-Wheel Drive Systems - Overview - Description and Operation
- Four-Wheel Drive Systems - System Operation and Component Description - Description and Operation
- Four-Wheel Drive Systems - Diagnosis and Testing
- Active Torque Coupling Configuration - General Procedures
- Rear Drive Unit (RDU) Oil Life Monitor Reset - General Procedures
- All-Wheel Drive (AWD) Module - Removal and Installation

308-07B POWER TRANSFER UNIT
- Power Transfer Unit - Overview - Description and Operation
- Power Transfer Unit - Diagnosis and Testing
- Power Transfer Unit Fluid Level Check - General Procedures
- Intermediate Shaft Seal - Removal and Installation
- Power Transfer Unit Input Shaft Seal - LHD - Removal and Installation
- Power Transfer Unit Rear Seal - Removal and Installation
- Power Transfer Unit - Removal
- Power Transfer Unit - Installation

309-00D EXHAUST SYSTEM - 2.3L ECOBOOST (257KW/350PS) - MI4
- Exhaust System - Component Location - Description and Operation
- Exhaust System - Overview - Description and Operation
- Exhaust System - Diagnosis and Testing
- Catalytic Converter - Removal and Installation
- Exhaust Flexible Pipe - Removal and Installation
- Muffler and Tailpipe - Removal and Installation

310-00D FUEL SYSTEM - GENERAL INFORMATION - 2.3L ECOBOOST (257KW/350PS) - MI4
- Specifications
- Fuel System - Overview - Description and Operation
- Fuel System - Diagnosis and Testing
- Fuel System Pressure Check - General Procedures
- Fuel System Pressure Release - General Procedures
- Fuel Tank Draining - General Procedures
- Quick Release Coupling - General Procedures
- Spring Lock Couplings - General Procedures

310-01D FUEL TANK AND LINES - 2.3L ECOBOOST (257KW/350PS) - MI4
- Fuel Tank and Lines - Component Location - Description and Operation
- Fuel Tank and Lines - Overview - Description and Operation
- Fuel Tank and Lines - Diagnosis and Testing
- Fuel Level Sender - Removal and Installation

AND MORE......