2003 Ford Focus Service & Repair Manual

SECTION 100-01: Identification Codes 2003 Focus Workshop Manual DESCRIPTION AND OPERATION Identification Codes The vehicle identification number is stamped on the vehicle certification label. It is positioned on the left-hand B-pillar, above the latch. 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. Visible VIN (label) Vehicle Identification Number (VIN) Item Part Number Description 1 - World manufacturer identifier 2 - Manufacturer specification 3 - Line, series, body type 4 - Check digit 5 - Vehicle model year 6 - Production sequence number 7 - Assembly plant Unfiled Notes Page 1

7 - Assembly plant 8 - Engine type 9 - Restraint system type Vin Position 1, 2, and 3 Codes Manufacturer Make Type 1FA Ford Motor Company, USA Ford Passenger vehicle 1FM Ford Motor Company, USA Ford MPV 1FT Ford Motor Company, USA Ford Truck (complete vehicle) 1FD Ford Motor Company, USA Ford Incomplete vehicle 1FC Ford Motor Company, USA Ford Basic (stripped) Chassis 1FB Ford Motor Company, USA Ford Bus 1FF Ford Motor Company, USA Ford Motor vehicle equipment W/O Engine/Powertrain (glider) 1ME Ford Motor Company, USA Mercury Passenger vehicle 1MH Ford Motor Company, USA Mercury Incomplete vehicle 1LN Ford Motor Company, USA Lincoln Passenger vehicle 1LJ Ford Motor Company, USA Lincoln Incomplete vehicle 1ZV Auto Alliance International, Inc Ford Passenger vehicle 1ZW Ford Motor Company, USA Mercury Passenger vehicle 2FA Ford Motor Company of Canada, Ltd. Ford Passenger vehicle 2FM Ford Motor Company of Canada, Ltd. Ford MPV 2FT Ford Motor Company of Canada, Ltd. Ford Truck (complete vehicle) 2FD Ford Motor Company of Canada, Ltd. Ford Incomplete vehicle 2FC Ford Motor Company of Canada, Ltd. Ford Basic (stripped) chassis 2FB Ford Motor Company of Canada, Ltd. Ford Bus 2FF Ford Motor Company of Canada, Ltd. Ford Motor vehicle equipment (W/O Engine/ Powertrain (Glider) 2ME Ford Motor Company of Canada, Ltd. Mercury Passenger vehicle 2MH Ford Motor Company of Canada, Ltd. Mercury Incomplete vehicle 3FA Ford Motor Company (Mexico) Ford Passenger vehicle 3FB Ford Motor Company (Mexico) Ford Bus 3FC Ford Motor Company (Mexico) Ford Basic (stripped) chassis 3FE Ford Motor Company (Mexico) Ford Incomplete vehicle 3FM Ford Motor Company (Mexico) Ford MPV 3FT Ford Motor Company (Mexico) Ford Truck (complete vehicle) 3ME Ford Motor Company (Mexico) Mercury Passenger vehicle 4F2 Ford Motor Company, USA Mazda MPV 4F3 Ford Motor Company, USA Mazda Incomplete vehicle 4F4 Ford Motor Company, USA Mazda Truck (complete vehicle) 4M2 Ford Motor Company, USA Mercury MPV 4M3 Ford Motor Company, USA Mercury Incomplete vehicle 4M4 Ford Motor Company, USA Mercury Truck (complete vehicle) 4N2 Ford Motor Company, USA Nissan MPV Unfiled Notes Page 2

4N2 Ford Motor Company, USA Nissan MPV 4N3 Ford Motor Company, USA Nissan Incomplete vehicle 4N4 Ford Motor Company, USA Nissan Truck complete vehicle KNJ Kia Motors Inc. Korea Ford Passenger vehicle (imported aspire) World Manufacturer Identifier VIN Position 4 Code Description B Active belts (all positions) F Active belts (all positions) and front air bags (driver and passenger) H Active belts (all positions) and front and side air bags (driver and passenger) Restraint System Type VIN Position 5 Code Vehicle M Passenger vehicle Lincoln, Mercury, North American Vehicles P Passenger vehicle Ford North American vehicles T Passenger vehicle All passenger vehicles imported from outside North America or non-Ford built passenger vehicle marketed by Ford in North America Manufacturer Specification VIN Position 6 and 7 Code Line Series Additional Optional Exterior Nameplate Body Type Body Code 30 Focus ECO - 3-door ECO 31 Focus ZX3 - 3-door ZX3 33 Focus LX - 4-door LX4 34 Focus SE - 4-door SE4 36 Focus ZTS - 4-door LTS 38 Focus SE - wagon SEW Line, Series and Body Type VIN Position 8 Code Displacement Liters Displacement CID Cylinders Fuel Manufacturer P 2.0 SPI 121 4 Gasoline Ford 3 2.0 Zetec 121 4 Gasoline Ford Engine Type VIN Position 9 VIN position 9 is a check digit VIN Position 10 Code Year of Manufacture Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 Year of Manufacture VIN Position 11 Code Assembly Plant Unfiled Notes Page 3

A Atlanta: Hapeville, Georgia B Oakville: Oakville, Ontario D Ohio: Avon Lake, Ohio F Dearborn: Dearborn, Michigan G Chicago: Chicago, Illinois H Lorain: Lorain, Ohio J IMMSA: Monterrey, Mexico K Kansas City: Claycomo, Missouri N Norfolk: Norfolk, Virginia P Twin Cities: St. Paul, Minnesota R Hermosillo: Hermosillo, Mexico T Edison: Edison, New Jersey U Louisville: Louisville, Kentucky W Wayne: Wayne, Michigan X St. Thomas: Talbotville, Ontario Y Wixom: Wixom, Michigan Z St. Louis: Hazelwood, Missouri 5 AAI: Flat Rock, Michigan 6 Mazda-Kia: Kyrung Ki-Do Korea Assembly Plant VIN Position 12 through 17 Sequence Number 100,001 through 599,999 - Ford Division Vehicles 600,001 through 999,999 - Lincoln and Mercury Division vehicles Production Sequence Number Vehicle Certification (VC) Label (Typical) The vehicle certification label also contains the 17 character vehicle identification number. This number is used for warranty identification of the vehicle. Vehicle Certification Label Item Part Number Description 1 - Name and location of manufacturer Unfiled Notes Page 4

2 - Gross vehicle weight ratings in pounds (LB) and Kilograms (KG) 3 - Accessory reserve load codes 4 - District/special order codes 5 - Sales region codes 6 - Suspension identification 7 - Transmission/transaxle codes 8 - Axle ratio codes 9 - Radio type codes 10 - Tape stripe/paint stripe codes 11 - Interior trim codes (first code letter = fabric and seat type, second code letter = color 12 - Brake type codes 13 - Exterior paint codes 14 - Vehicle identification number 15 - Rear gross axle weight ratings in pounds (LB) and Kilograms (KG) 16 - Front gross axle weight ratings in pounds (LB) and Kilograms (KG) 17 - Build date Exterior Paint Color Codes Code Color TS Silver Frost BL Harvest Gold FL Toreador Red K6 Atlantic Blue SU Amazon Green BG Bright Amber LV Light Sapphire Blue YZ Performance White E4 Vermillion Solid UA Ebony Solid MK Twilight Blue K7 Bright Atlantic Blue Interior Trim (Fabric) Codes Code Trim Scheme Fabric Seat Type Trim Color DA Shadow/Oasis Sport seat Medium dark graphite DW Shadow/Oasis Sport seat Midnight black EA Finnesse/Oasis Individual Medium dark graphite EW Finnesse/Oasis Individual Midnight black EH Finnesse/Oasis Individual Medium parchment CA Kirk/Oasis Individual Medium dark graphite CH Kirk/Oasis Individual Medium parchment 8A Leather/Leather Individual Medium dark graphite 8H Leather/Leather Individual Medium parchment Brake Type Codes Code Brake Type 2 Anti-lock brakes (ABS) Non-ABS, FR disk/RR drum Unfiled Notes Page 5

2 Anti-lock brakes (ABS) Non-ABS, FR disk/RR drum Interior Color Code Trim Color A Medium Dark Graphite W Midnight Black H Medium Parchment Axle Ratio Codes Code Axle Ratio II 3:61 SPI Manual NN 3:693 SPI Automatic UU 3:820 SPI Manual WW 3:904 SPI Automatic Transaxle Codes Code Axle Ratio 5 iB5 Manual A FN Automatic M MTX75 Manual Unfiled Notes Page 6

SECTION 100-00: General Information 2003 Focus Workshop Manual DESCRIPTION AND OPERATION About This Manual Introduction This manual has been written in a format that is designed to meet the needs of Ford technicians worldwide. The objective is to use common formats and include similar content in each manual worldwide. This manual provides general descriptions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. Replacement Parts Ford and Motorcraft parts are made to the same exacting standards as the original factory fitted components. For this reason, it is recommended that only genuine Ford or Motorcraft parts are installed during service or repair. 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. Special tools may be ordered from Loewener OTC GmbH, Rotunda Equipment, or their agents/distributors. Europe North America Loewener OTC GmbH Rotunda Equipment Industriestrasse 67 PO Box 1450 D40764 Langenfeld Kenosha W1 53141-1450 Germany Phone 1-800-ROTUNDA Tel: +49 (0) 2173 928-0 FAX 1-800-762-6181 Fax: +49 (0) 2173 928-199 WWW.FORDROTUNDA.COM 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 parts. Warnings, Cautions and Notes in This Manual WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury. CAUTION: Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the vehicle or equipment being used. NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory repair. 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 Unfiled Notes Page 1

How to Use This Manual This manual covers 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 General Specifications, Description and Operation and Service Adjustment and Checks. 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 (refer to `Samples'). 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 WDS, FDS2000 or New Generation STAR Tester diagnostic equipment. Inspection and Verification Visual Inspection Charts, Symptom Charts and other information charts (such as diagnostic routines), supplement test procedures with technical specifications, or navigate the user to a specific test procedure. Sympton 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 labelled with the pin number. Samples 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. Unfiled Notes Page 2

SECTION 100-00: General Information 2003 Focus Workshop Manual DESCRIPTION AND OPERATION Health and Safety Precautions Introduction Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This subsection lists, alphabetically, some of these hazardous operations and the materials and equipment associated with them. Precautions necessary to avoid these hazards are identified. The list is not exhaustive and all operations and procedures, and the handling of materials, should be carried out with health and safety in mind. Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be consulted. Acids and Alkalis See also Battery Acids. For example caustic soda, sulphuric acid. Used in batteries and cleaning materials. Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary protective clothing. Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists. Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents. Display Eye Hazard sign. Air Bags See also Fire, Chemical Materials Highly flammable, explosive – observe No Smoking policy. Used as a safety restraint system mounted in the steering wheel and passenger side of the instrument panel. The inflator contains a high-energetic propellant which, when ignited, produces a VERY HOT GAS (2500°C). The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be worn when dealing with the spillage. After normal deployment, gloves and safety goggles should be worn during the handling process. Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste site. • wash affected areas thoroughly with water. • seek medical assistance if necessary. Following any direct contact with gas generant. • do store modules in an upright position. • do keep modules dry. • do carry modules with the cover side pointing away from the body. • do place modules with their cover side upwards. • do carefully inspect modules for damage. • do stand to one side when connecting modules. • do make sure all test equipment is properly calibrated and maintained. • do wash hands after handling deployed air bags. Air Bags - Do's • do not store highly flammable material together with modules or gas generators. • do not store gas generators at temperatures exceeding 80°C. • do not store modules upside down. • do not attempt to open a gas generator housing. • do not expose gas generators to open flame or sources of heat. • do not place anything on top of a module cover. Air Bags - Do Nots Unfiled Notes Page 1

• do not place anything on top of a module cover. • do not use damaged modules. • do not touch a fired module or gas generator for at least 10 minutes. • do not use any electrical probes on the wiring circuit. Air Conditioning Refrigerant See also Chlorofluorocarbon, Chemical Materials Highly flammable, combustible – observe No Smoking policy. Skin contact may result in frostbite. Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles. If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should also be rinsed with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY. • do not expose refrigerant bottles to sunlight or heat. • do not stand refrigerant bottles upright; when filling, hold them with the valve downwards. • do not expose refrigerant bottles to frost. • do not drop refrigerant bottles. • do not vent refrigerant to atmosphere under any circumstance. • do not mix refrigerants, for example R12 (Freon) and R134a. Air Conditioning Refrigerant - Do Nots Adhesives and Sealers See also Fire, Chemical Materials Highly flammable, flammable, combustible – observe No Smoking policy. Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be observed, for example disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled appropriately. Solvent-based Adhesives/Sealers - See Solvents Follow manufacturers instructions. Water-based Adhesives/Sealers Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use. Hot Melt Adhesives In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation of toxic fumes. Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate extraction. Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact. Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants. Skin and eye contact should be avoided and the manufacturers instructions followed. Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull tissue apart. Use in well ventilated areas as vapours can cause irritation to the nose and eyes. For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers. Isocyanate (Polyurethane) Adhesives/Sealers See also Resin-based Adhesives Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur. Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapour concentrations may result in adverse health effects. Prolonged contact with the skin may have a defatting effect which may lead to skin irritation and in some cases, dermatitis. Splashes entering the eye will cause discomfort and possible damage. Any spraying should preferably be carried out in exhaust ventilated booths, removing vapours and spray droplets from the breathing zone. Wear appropriate gloves, eye and respiratory protection. Antifreeze See also Fire, Solvents. Unfiled Notes Page 2

2003 Ford Focus Service & Repair Manual

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