Focus Rs 2016

FORD TRAINING
Technical Service Training
FORD Focus
New Model Introduction - Supplement
E223796
P346 R010 01
CGAPA/S en
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Copyright ©2015
Ford-Werke GmbH
Service training programs D-F/GT1 (GB)

Preface
The 2016 Focus RS is the latest in a line of iconic cars developed by Ford. Experts in small-car engineering, the
Ford Performance Team has consistently pioneered innovative performance technologies.
Featuring the new Ford performance All-Wheel Drive with Dynamic Torque Vectoring, the RS offers the next level
in handling capability.
The RS has taken the 2.3L engine to another level with its unique turbo charger, cooling and exhaust. With well in
excess of 257 kW and 440 Nm of torque, with the ability to over boost to an output of 470 Nm of torque.
Configuration of the RS drive options will enable street or on track performance:
Select Normal, Sport, Track, or the special Drift mode control that lets you achieve controlled oversteer drifts under
track conditions
With enhanced aerodynamic redesigns of the front grille and the rear diffuser and the unique spoiler addition, Focus
RS creates zero lift overall for optimum high-speed handling
The high-performance character also comes through with its sleek interior design.
The details are simply impressive with a new flat-bottomed steering wheel that has a soft-feel leather covered rim,
RECARO® sport seats, alloy pedals and unique instrument graphics.
Course Objectives
At the conclusion of the course, the technician will be able to identify the unique vehicle features and systems on
the 2016 Focus RS.
Course Outcomes
At the conclusion of this course the Technician will be able to:
• Identify the 2.3 EcoBoost engine features and operation
• Identify the front and rear suspension
• Identify the dynamic suspension system
• Identify the wheel and tire options
• Identify the braking system
• Identify the manual transmission
• Identify the all wheel drive system
• Identify the exhaust system
• Identify the instrument panel
• Identify the adaptive exterior lighting
• Identify the front seats
• Identify the instrument panel and console
• Identify changes to the body structure
Course Materials
In order to participate in this New Model Training course you will require the following material:
• Integrated Study Guide (ISG)
• Pen and/or highlighter
Service Training (G1821216) 1

Preface
This ISG contains information for the training course and for future reference, however, some of the information
contained in this publication may not be covered in the training. In time, the information contained in this ISG may
also become superseded and therefore inaccurate and/or obsolete. Always refer to the current Workshop Manual
(WSM) and Owner Guide along with the latest Technical Service publications to obtain the most accurate and up
to date information.
• Always read the ISG again soon after completing the training course
• Arrive early and be prepared to participate in the training
• Always refer to current Service Publications for further information
2 (G1821216) Service Training

Table of Contents
PAGE
Preface............................................................................................................................... 1
Introduction...................................................................................................................... 6
Opening the Hood and Closing the Hood......................................................................................................................... 7
Data Link Connector......................................................................................................................................................... 8
Engine Compartment Fuse Box........................................................................................................................................ 8
Passenger Compartment Fuse Box ................................................................................................................................... 8
Load Compartment Fuse Box ........................................................................................................................................... 9
Capless Fuel Filler............................................................................................................................................................. 10
Keyless Remote Control Battery Replacement................................................................................................................. 10
Tire Repair Kit................................................................................................................................................................... 11
Lesson 1 – General Information

Towing............................................................................................................................................................ 12
........................................................................................................................................................................................... 12
Service Points................................................................................................................................................ 13
2.3L EcoBoost................................................................................................................................................................... 13
Transport Mode............................................................................................................................................ 13
Transport Mode Deactivation ........................................................................................................................................... 13
Jacking and Lifting....................................................................................................................................... 14

........................................................................................................................................................................................... 14
Lesson 2 – Chassis
Front Suspension.......................................................................................................................................... 16
........................................................................................................................................................................................... 16
Rear Suspension............................................................................................................................................ 18
........................................................................................................................................................................................... 19
Wheels and Tires........................................................................................................................................... 20

........................................................................................................................................................................................... 20
Vehicle Dynamic Suspension........................................................................................................................ 21

Dual Mode Damper System.............................................................................................................................................. 21
Brake System................................................................................................................................................. 22
........................................................................................................................................................................................... 22
Power Steering.............................................................................................................................................. 24
Lesson 3 – Powertrain
Engine............................................................................................................................................................ 25
Service Training 3
Table of Contents
Powertrain.......................................................................................................................................................................... 25
2.3L EcoBoost Engine....................................................................................................................................................... 26
Lubrication System................................................................................................................................................................................... 30
Engine Cooling.............................................................................................................................................. 34
Radiator............................................................................................................................................................................. 34
Fuel Charging and Controls........................................................................................................................ 35

High-Pressure Fuel System............................................................................................................................................... 35
Direct Fuel Injection System............................................................................................................................................. 36
Operating Modes............................................................................................................................................................... 36
Throttle Body.................................................................................................................................................................... 36
High Pressure Fuel Rail..................................................................................................................................................... 37
High Pressure Fuel Pump.................................................................................................................................................. 37
Fuel Injectors..................................................................................................................................................................... 38
Turbocharger................................................................................................................................................ 39
........................................................................................................................................................................................... 39
Twin-Scroll Turbocharger................................................................................................................................................. 40
Integrated Exhaust Manifold (IEM).................................................................................................................................. 42
Charge Air Cooler (CAC).................................................................................................................................................. 43
Accessory Drive............................................................................................................................................. 44
Engine Ignition.............................................................................................................................................. 45
........................................................................................................................................................................................... 45
Intake Air Distribution and Filtering......................................................................................................... 46
Electronic Engine Controls.......................................................................................................................... 48

2.3L EcoBoost Electronic Engine Controls...................................................................................................................... 48
Clutch............................................................................................................................................................. 48
........................................................................................................................................................................................... 48
Manual Transmission................................................................................................................................... 51
MMT6 Manual Transmission with AWD (all-wheel drive).............................................................................................. 51
Four-Wheel Drive Systems........................................................................................................................... 52

AWD (all-wheel drive) with Dynamic Torque Vectoring.................................................................................................. 52
Dynamic Torque Vectoring................................................................................................................................................ 54
Transfer Case .................................................................................................................................................................... 55
TWINSTER® Rear Drive Unit......................................................................................................................................... 57
Exhaust System............................................................................................................................................. 61
........................................................................................................................................................................................... 61
Fuel System................................................................................................................................................... 62
Low Pressure Fuel System................................................................................................................................................ 62
4 Service Training
Table of Contents
Lesson 4 – Electrical
Instrument Panel Cluster (IPC).................................................................................................................. 67
........................................................................................................................................................................................... 67
Exterior Lighting.......................................................................................................................................... 70
........................................................................................................................................................................................... 70
Communications Network........................................................................................................................... 75
........................................................................................................................................................................................... 75
Lesson 5 – Body and Paint

Front Seats..................................................................................................................................................... 78
........................................................................................................................................................................................... 78
Instrument Panel.......................................................................................................................................... 79
........................................................................................................................................................................................... 79
Vehicle Specific Body Construction............................................................................................................ 80

........................................................................................................................................................................................... 80
List of Abbreviations........................................................................................................ 81
Service Training 5
Introduction
Introduction • Manual transmission MMT6

• AWD (all-wheel drive)
Key Vehicle Features • Exhaust System
Chassis Electrical
• Front and rear suspension • Instrument panel
• Wheels and tires • Adaptive exterior lighting
• Dynamic Suspension Body
• Braking - Brembo • Instrument panel and console
• Power steering EPAS • Vehicle body strengthening
Powertrain
• Engine
– 2.3L EcoBoost 257 Kw
Vehicle Exterior
1 2
E215866
1 Front fog lamps

2 Trapezoid grille
3 Bi - Xenon head lamps

Introduction
4 3
E215868
1 Twin exhaust system 3 Rear diffuser

2 Rear spoiler with RS branding 4 Rear LED fog light
NOTE: Rear LED fog light market dependant
Opening the Hood and Closing the Hood
E73698
E133239
• Pull the handle to unlatch the bonnet
• Move the yellow catch to the right

Introduction
• To close the hood and allow it to drop under its own

weight from the last 20 – 30 centimetres
Data Link Connector
E87786 E223798
• Support the hood using the prop rod Engine Compartment Fuse Box
WARNING: Make sure that the bonnet is closed NOTE: Only additional fuses and relays which are fitted
properly. to the RS are listed below.
E129925
F17 30A Rear drive unit control R1 Pump electronic module 2 feed
F30 20A Pump electronic module 2 feed R3 Cooling fan control 5
F36 7.5A Exhaust valve R5 Cooling fan control 4
Passenger Compartment Fuse Box

The passenger compartment fuse box is located behind
the glove box. The fuse box is incorporated int the BCM
(body control module).

Introduction
E224054
Load Compartment Fuse Box

NOTE: Only additional fuses and relays which are fitted
to the RS are listed below.
E224216
F21 15A Fuel control relay. Damper control relay

F22 10A Active noise cancellation. Electronic sound
enhancement
R4 Fuel control module. Damper control module

Introduction
Capless Fuel Filler
E105362
• Twist the screwdriver in the position shown (3) to

separate the two halves of the remote control
E135935
WARNING: If you use a high pressure spray

to wash your vehicle, only spray the fuel filler
flap briefly from a distance not less than 20
centimetres.
4
NOTE: When you insert the fuel nozzle, a spring loaded
inhibitor will open if the correct size nozzle is detected. E119190
This helps to avoid filling up with the wrong fuel.
• Carefully insert the screwdriver in the position shown
Press the flap to open it. Open the flap fully until it to open the remote control
engages
Keyless Remote Control Battery 5

Replacement
1
E125860
NOTE: Do not touch the battery contacts or the printed

circuit board with the screwdriver.
E87964 1 • Carefully prise out the battery with the screwdriver
• Press and hold the buttons on the key edges (1) to • Install a new battery (3V CR 2032) with the + facing
release the cover. Carefully remove the cover downwards
• Remove the key blade (2) • Assemble the two halves of the remote control
• Install the key blade and cover

Introduction
Tire Repair Kit
E134613
This vehicle is equipped with a tire repair kit as standard.

The tire repair kit is stowed in the spare wheel well.
The tire repair kit consists of:
• Compressor with a pressure gauge
• Power supply cable which plugs into the cigarette
lighter
• Air hose
• Tire sealant
A tire filled with sealant must be replaced with a new
tire after 200 km (approx).
NOTE: Instructions on using the tire repair kit can be
found in a separate manual that is enclosed with the tire
repair kit.

Towing Vehicles CANNOT be flat-towed (all wheels on the

ground) as vehicle or transmission damage may occur.
Tow the vehicle using flatbed towing equipment only.
E203788

Service Points
2.3L EcoBoost
2 3 4 5
1
9 7
E215066
1 Coolant reservoir 6 BJB (battery junction box)

2 Oil dipstick 7 Air cleaner housing
3 Oil filler cap 8 Air conditioning connection
4 Brake fluid reservoir 9 Windshield washer reservoir
5 Battery
Various systems may be altered or are disabled when

in the transport mode. The vehicle automatically reverts
Transport Mode to normal operation mode after being driven for more
than 201 km .
Transport Mode Deactivation The vehicle can be manually taken out of Transport
mode using the following procedure.
After vehicle build, some vehicle modules are set in
Transport mode including the IPC and the BCM. Deactivation Using Passive Key
Transport mode reduces battery drain during longer 1. Place the ignition in the OFF position
periods where the vehicle is not used.
2. On vehicles with Push-Button Start, place a
While in transport mode, the IPC displays TRANSPORT programmed passive key in the PATS backup
MODE CONTACT DEALER in the message center. starting location. Place the ignition in the ON
position

Jacking and Lifting Lesson 1 – General Information
3. Press and release the brake pedal 5 times NOTE: When exiting Transport mode, the IPC message
4. Press and release the hazard switch 2 times center will indicate NORMAL MODE when the
procedure has been successfully completed.
5. Place the ignition in the OFF position
6. Start the engine
Jacking and Lifting
E223756
Only the specified jacking points may be used for Never get underneath a vehicle that is supported
jacking and supporting the vehicle. only by a jack. The jack could unintentionally
lower. Always support vehicle with floor stands.
WARNINGS:
Identify the correct jacking points by locating
Position the hoist lift arms on the lift points that
the triangle stamped on the sill panel. Place the
sre shown on the above diagram. Incorrect
hoist pads on the point shown on the vehicle.
positioning could result in vehicle slipping or
(The triangles are a guide to indicate the
falling causing significant damage to the vehicle.
position of the jacking points that are under the
vehicle) .

Lesson 1 – General Information Jacking and Lifting
Only raise the vehicle when positioned on a

hard, level surface. Attempting to raise the
vehicle on an uneven or soft surface may result
in vehicle slipping or falling from the jack or
jackstand..
When jacking or lifting the vehicle use a block
to all wheels remaining on the ground activate
the parking brake. These actions help prevent
unintended vehicle movement.
NOTICE:
The jack provided with the vehicle is intended
to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle,
never use the jack to lift the vehicle for any
other purpose.
Place blocks underneath the lifting points if a
two-post hoist is used.
Damage to the suspension, exhaust or steering
linkage components will occur if care is not
exercised when positioning the hoist adapters
prior to lifting the vehicle.
To prevent possible damage to the underbody,
do not drive the vehicle onto a four post hoist
without first checking for possible interference.
When raising a vehicle on a two-post hoist, use
care when positioning the vehicle so that the
hoist arms do not interfere with underbody
components.

Front Suspension Lesson 2 – Chassis
Front Suspension
6 2
4
9
E224055
1 Modified springs with firmer spring rate 5 Shorter lower arm and reinforced mounts
2 Front strut and spring assembly - with 6 Larger front stabilizer bar links
electronic shock absorbers 7 Front stabilizer bar
3 Torsion-resistant steering knuckle 8 Front hub
4 Front suspension brace 9 Ball joint
The front suspension uses a MacPherson strut system.

This suspension system incorporates a strut assembly
The front suspension consists of the following
that takes the place of the upper arm and ball joint. The
components:
strut performs the function of a shock absorber and is
• Lower arms encompassed by a coil spring. The strut and spring
• Stabilizer bar, bushings and links assembly carries the sprung weight of the vehicle and
is also the pivot point for the steering knuckle.
• Strut and spring assemblies
This system uses a lower control arm and ball joint for
• Wheel bearings the lower (unloaded) pivot point of the steering knuckle.
• Wheel hubs The Focus RS has an improved front suspension system
• Wheel knuckles with spring rates, bushes and anti-roll-bars all of which
are stiffer than those found in the Focus ST. Featured
• Wheel studs
front suspension system changes are listed below:

Lesson 2 – Chassis Front Suspension
• Modified springs with firmer spring rate Front Suspension Alignment and Adjustment
• Electronic front shock absorbers - Two-mode shock Front Toe Adjustment
absorbers with normal and a firmer setting for track
driving
• Torsion-resistant steering knuckles
• Shorter wishbones and reinforced mounts 2
• Larger front anti-roll bar
E67410
1 Outer tie-rod locknut

2 Inner tie-rod adjustment rotate either clockwise
or counterclockwise

Rear Suspension Lesson 2 – Chassis
Rear Suspension
2 2
2
2
1 1
E224060
1 Upper arm 3 Reinforced lower connecting rods

2 Reinforced areas 4 Wheel knuckle
5 Wheel bearing and hub (AWD )
18 Service Training
Lesson 2 – Chassis Rear Suspension
4 5
6
7
E224096
1 Rear shock absorbers - electronic 4 Rear lower trailing arms

2 Rear stabilizer bar 5 Rear front lower arms
3 Rear stabilizer bar links 6 Rear lower arms
7 Rear Upper arms
• Modified side members

The rear suspension uses 3 parallel arms (one upper and • Reinforced subframe areas
2 lower). Each arm has a mounting position to the • Reinforced lower connecting rods
chassis and an attachment at the wheel knuckle. This
suspension allows the wheels to react to road • Electronic rear shock absorbers
imperfections independent of each other. The shock • Larger rear anti-roll bar
absorber mounts to the wheel knuckle and along with
• Provision in the subframe to mount the rear drive
the spring, controls vertical movement. The stabilizer unit
bar and links control suspension lean/sway.
• Wheel knuckles to support drive shafts
One of the main objectives is to make the new Focus
RS more resistant to torsion, which has been achieved
by strengthening and adding reinforced components to
the rear suspension system. The following rear
suspension system changes have been made:

Wheels and Tires Lesson 2 – Chassis
Wheels and Tires
1 2
E215833
1 'Ronal' light alloy rim, available in silver or

matte magnetized (standard 8 x 19 RO50
2 'Dicastal' forged light alloy rim, available in
black (optional) 8 x 19 RO50
The vehicle is fitted with tires designed to optimize the The Dicastal forged wheels are much lighter than cast
performance. wheels. They also have a better mass ratio (unsprung
Due to their lower profile they can be are more masses). This optimizes the vehicle's suspension,
performance, and road holding, especially when
susceptible to damage due to poor road conditions.
cornering and driving on poor road surfaces. The forged
The following tires are available rim has a lower rotational torque and therefore lower
• 235/35 R19 91Y Michelin Pilot Super Sport inertia, which means that less power is absorbed during
acceleration and better performance is achieved during
• 235/35 R19 91Y Michelin Pilot Sport Cup 2 (only braking. The structural strength of the light alloy rims
in combination with the Dicastal forged rim)
gives them a weight advantage of 600 grams.
Instead of an emergency spare wheel. The vehicle is
equipped with a tire repair kit.

Lesson 2 – Chassis Vehicle Dynamic Suspension
Vehicle Dynamic Suspension

Dual Mode Damper System
1 2 3
4
E224181
1 Electronic shock absorbers front 3 Electrical connection rear shock absorber

2 Electronic shock absorbers rear 4 Electronic shock absorber switch
5 Shock absorber control module
Selecting Damping Modes Inside the shock absorber is an electromagnetic,

infinitely variable bypass valve. Control is performed
The Focus RS is equipped with a dual mode damper
via the magnitude of the control current to the shock
suspension system that allows the driver to choose
absorber bypass valve as supplied by the shock absorber
between a comfort and sport ride.
control module.
The suspension mode selection is made via a switch on
A low control current results in soft damping, a high
the steering column control stalk. The driver can select
adjusted current results in hard damping.
between a normal setting and a sport setting as listed
below:
• Normal - Default setting each time the vehicle starts.
Vehicle damping is tuned for street driving delivering
sporty, comfortable handling on ordinary roads
• Sport - For spirited and aggressive driving where
damping is tuned for performance. Sport mode gives
firmer damper characteristics optimizing the
feedback to the driver and the handling on race tracks
Service Training 21
Brake System Lesson 2 – Chassis
To select Normal or Sport damping, do the following:

• Press the button on the end of the direction indicator
lever
– The current setting appears in the information
display (Normal/Sport)
E219514
Brake System
1 2
6
7
E224097
1 Left side bleeder valve 4 Caliper pistons

2 Right side bleeder valve 5 Anti rattle plate holding pin
3 Brake pad 6 Anti rattle plate
7 Brake fluid crossover pipe
Brembo® front brakes are fitted with four-piston painted

calipers with performance pads and 350 mm brake
The Focus RS is fitted with Brembo® four-piston
rotors.
monoblock brake calipers at the front axle. The housing
is made from a single piece. There is a steel pin in the Rear brakes are fitted with single-piston sliding calipers
center of the brake caliper to reinforce it. and 302 mm rear brake rotors.

Lesson 2 – Chassis Brake System
Front Brake Cooling Air Ducts front bumper to the inner wheel well. The inlet to the
air duct is located in the front bumper fascia next to the
front fog lamp.
There is also an air deflector which is used to diverted
additional air to the brake system from under the vehicle.
Anti-Lock Brake System (ABS) Module
E223894
E223891
The MK100 module is 20 percent smaller than the unit
1 Air duct fitted to the Focus ST and integrates sensor clusters such
as yaw rate and acceleration sensors.
2 Air deflector
The MK100 ABS (anti-lock brake system) may be
An air duct has been developed to provide additional disconnected from the HCU (hydraulic control unit)
cooling to the front brakes, by directing fresh air onto during servicing. Diagnosis is performed using the IDS
the brake caliper and rotor. The air duct runs from the (Integrated Diagnostic System)

Power Steering Lesson 2 – Chassis
Power Steering
3
4
2
7 5
E224217
1 Torque shaft 4 Housing steering assistance drive

2 EPS module 5 Torsional shaft with steering torque sensor
3 EPS motor 6 Securing bolts steering gear
A tuned electric power-assisted steering system works

in combination with a more rigid front suspension
knuckle design and shorter-link arms to deliver
connected and responsive steering with outstanding feel.
The steering gear is mounted lower due to the AWD
(all-wheel drive). The torsion shaft with steering gear
pinion has been extended by 2 cm.
This extension of the torque shaft is to compensate for
the lowering of the EPAS to a lower position on the sub
frame.

Lesson 3 – Powertrain Engine
Engine
Powertrain
1 3
E224295
1 2.3L EcoBoost engine

2 MMT6 transmission
3 Rear drive unit
The 2015 Focus RS is available with the following • MMT6, 6 speed manual transmission (incorporating
powertrain components. transfer case)
Engine: AWD System:
• 2.3L EcoBoost four cylinder engine • Electronically controlled AWD system incorporating
TWINSTER® rear drive unit
Transmission:

Engine Lesson 3 – Powertrain
2.3L EcoBoost Engine
E178752
The new Ford Focus RS engine shares its fundamental The 2.3L Gasoline Turbocharged Direct Injection
structure with the all-aluminium four-cylinder 2.3-litre 4-cylinder engine has the following features:
engine in the all-new Mustang.
• Dual overhead camshafts
This engine has, however, been significantly upgraded
• Four valves per cylinder
through a comprehensive package of design changes.
Increased output is generated by a new low-inertia • Composite intake manifold
twin-scroll turbocharger with larger compressor that • Aluminum cylinder head
delivers significantly greater air flow, along with a much
• Aluminum engine block
bigger intercooler to maximise charge density.
• Direct fuel injection
Engine breathing also is enhanced through a less
restrictive intake system design and a large-bore high • Twin-scroll turbocharger with internal wastegate
performance exhaust system. • Twin Independent Variable Camshaft Timing
(Ti-VCT)
26 Service Training
E221208
The engine has a maximum power output of 257 kW at

The cylinder head is produced from an upgraded alloy
a torque value of 440 Nm, with the ability to increase
material capable of withstanding higher temperatures
engine torque to 470 Nm using the overboost function.
and is mounted on a more robust head gasket with
improved thermal capability.
The cylinder block employs stronger high-tensile cast
iron liners.
Meticulous calibration work has ensured that the power
unit delivers excellent low-end responsiveness with a
powerful mid-range pull, climbing to a free-revving
top-end up to a maximum rev limit of 6,800 rpm.
With its high-efficiency EcoBoost design featuring
direct fuel injection, twin independent variable camshaft
1
timing, advanced turbocharging and Auto-Start-Stop
fitted as standard the engine also delivers significantly
improved fuel consumption.
2 The 2.3L EcoBoost engine delivers a spontaneous
response in the lower engine speed range, develops a
E224359
high torque of 440 Nm at medium engine speeds and
makes it constantly available between 2000 and 4500
1 Cylinder Head
rpm, and peaks at 6800 rpm.
2 Turbocharger
The overboost control increases the maximum torque
to 470 Nm for 15 seconds under full acceleration.
The 2.3L EcoBoost engine requires a full synthetic
0W-40 engine oil.
Service Training 27
Engine Structural Changes
2 3 4
1
5
9
7 6
E223818
1 High tensile engine block to reduce wear under 5 PCV (positive crankcase ventilation) flow
high temperature and load increased from 17 liters per minute to 45 liters
per minute
2 Dual mass flywheel
6 New wiring loom with increased plug security
3 Crankshaft pulley specially adapted to the RS
engine 7 Cylinder head with new aluminum alloy to
improve heat dissipation
4 Turbocharger with larger compressor wheel
(from 60 mm to 63 mm) and new turbine wheel 8 Cylinder head gasket with higher heat tolerance
9 Higher strength exhaust valve springs
28 Service Training
Cylinder Head Cylinder head made of cast aluminum with integrated

exhaust manifold with 16 valve 4 valves per cylinder.
N0152419
The valve are actuated using Direct Acting Mechanical

Buckets (DAMB). The camshaft lobes are positioned
directly above mechanical buckets which are on top of
the valves.
Valve clearance adjustment is carried out by measuring
the clearance of each valve base using a feeler gauge,
with the lobe pointed away from the tappet. If a
clearance is out of specification a new DAMB with the
appropriate thickness will need to be installed.
E210524
Service Training 29
Lubrication System
15
11 12
13
10
14
16
8
17
7
18
6 19
5 20
21
4
3 22
2
24
23
1
25
26
N0152464
1 Oil pump screen and pickup tube 10 Camshaft front bearing cap
2 Oil pump 11 Exhaust VCT oil control solenoid
3 Turbocharger oil return tube 12 Intake VCT oil control solenoid
4 Timing chain tensioner 13 Exhaust camshaft
5 Turbocharger oil filter 14 Intake camshaft
6 Turbocharger oil supply tube 15 Fuel pump housing
7 Turbocharger 16 Vacuum pump
8 Intake VCT (variable camshaft timing) unit 17 Cylinder head
9 Exhaust VCT unit 18 Head gasket
30 Service Training
19 Cylinder block 23 Oil filter

20 Crankcase vent oil separator 24 Crankshaft assembly
21 Oil Filter Adapter 25 Balance shaft assembly
22 Oil pressure switch 26 Oil pan
The engine lubrication system is of the force-feed type Generically, this design is known as a gear rotor pump,
in which oil is supplied under full pressure to the which operates as follows:
crankshaft, connecting rod bearings, timing chain
• The oil pump is chain driven off of the crankshaft
tensioners, camshaft bearing caps and VCT solenoids.
The flow of oil to the valve tappets and valve train is • System pressure is limited by an integral,
controlled by a restricting orifice located in the cylinder internally-vented relief valve which directs the
head gasket. bypassed oil back to the inlet side of the oil pump
The lubrication system is designed to provide optimum • Oil pump displacement has been selected to provide
oil flow to critical components of the engine through adequate volume to make sure of correct oil pressure
its entire operating range. The 2.3L RS engine uses a both at hot idle and maximum speed
new synthetic oil for greater lubrication and improved • The relief valve calibration protects the system from
durability. excessive pressure during high-viscosity conditions
The heart of the system is a positive displacement • The relief valve is designed to provide adequate
internal gear oil pump. connecting rod bearing lubrication under high
temperature and high-speed conditions
Service Training 31
Twin Independent Variable Cam Timing (TI-VCT)
E178753
1 Friction washers 3 Crankshaft pulley bolt

2 Friction washers 4 Camshaft chain wheel bolts
The Ti-VCT system allows variable independent control all operating ranges and ambient conditions which also
of both the intake and exhaust camshafts by adjusting improves fuel economy, exhaust emissions, and engine
their rotational position. This alters the valves opening performance.
and closing timing with relation to the crankshaft
The camshaft adjustment units are controlled via two
position. Improved power from low to high engine
VCT solenoids. The VCT solenoids for the intake and
speeds (broadening of the torque curve) is achieved by exhaust camshafts differ only in terms of the position
varying the valve overlap and camshaft timing to match
of the fastening point by which they are fixed to the
VCT bearing cap.
32 Service Training
NOTE: The camshaft adjustment units can only be • 303-507 Crankshaft locking tool
changed as a complete set during servicing. They cannot
• 303-1565 Camshaft alignment tool
be repaired.
• 303-1521 CKP alignment tool
This system uses electro-hydraulically regulated
camshaft adjustment. The timing of the intake and
exhaust valves can be controlled independently of one
another using a pressurized engine oil supply which is
controlled by solenoids.
NOTE: When repairing parts of the timing gear which
operate under engine oil pressure, extreme cleanliness
is vital. Particles larger than 0.2 mm in diameter can
303-507
cause the valve adjustment to fail.
Upon starting the engine and during idling, both
camshafts are mechanically locked in their starting
positions. The exhaust camshaft is in the advanced
position and the intake camshaft is in the retarded
position.
The camshaft adjuster on the exhaust side has a torsion
spring which compensates the camshaft drive torque. E182334
This ensures, under all operating conditions and when

the engine is turned off, that the assembly can return to
the starting position.
Internal exhaust gas recirculation can be realized through
continuous adjustment of the timings. The resulting
de-throttling of the engine results in better fuel
consumption and more favourable combustion
temperatures at which fewer pollutants are generated.
VCT can also optimise the camshaft timing to maximize
engine performance at wide open throttle.
The camshaft timing must be performed whenever either E202225 303-1565
the front camshaft bolts or the crankshaft pulley bolts
have been loosened. This must be done as the camshafts
and the crankshaft don’t have keyways for chain wheel
or pulley location. The friction washers must be replaced
whenever a camshaft chain wheel or crankshaft pulley
bolt has been loosened.
2
NOTE: If the crankshaft pulley or VCT unit bolts are
loosened, the camshaft timing procedure needs to be
performed.
When replacing the timing chain there are a number of
special tools which are required to ensure correct engine x2 3
timing:
If the crankshaft pulley or VCT unit bolts are loosened, 1 303-1521
the camshaft timing procedure needs to be performed.
When replacing the timing chain there are a number of
E137263
special tools which are required to ensure correct
camshaft timing:
Service Training 33
Engine Cooling Lesson 3 – Powertrain
NOTE: For further information regarding camshaft Workshop Manual.

timing procedures and tightening torques refer to the
Engine Cooling
Radiator
E221408
Engine cooling has been given the highest priority on Two cooling fans provide additional airflow through
the Focus RS, with engineers creating additional space the radiator when the vehicle is at low speed, stationary
within the front of the vehicle to house a significantly or during high engine temperatures.
larger radiator pack, the biggest ever fitted to a Focus.
The radiator was designed to provide the level of cooling
demanded for hard circuit use.

Lesson 3 – Powertrain Fuel Charging and Controls
Fuel Charging and Controls

High-Pressure Fuel System
2 4
1
E179607
1 Throttle Body (TB) 3 Fuel injector

2 Fuel rail 4 High-pressure fuel pump drive unit
5 High-pressure fuel pump
The high pressure fuel system consists of the following

components:
• Mechanical high pressure fuel pump with
incorporated fuel metering valve
• High pressure fuel line
• High pressure fuel rail
• FRP (fuel rail pressure) sensor
Service Training 35
Fuel Charging and Controls Lesson 3 – Powertrain
The high pressure fuel system receives low pressure fuel is metered precisely to the fresh air at the
fuel from the fuel pump assembly and delivers fuel at stoichiometric air to fuel ratio for petrol of 14.7:1
high pressure to the fuel injectors. (Lambda 1.00).
The fuel is injected during the intake stroke here so that
System Operation enough time remains to homogenise the entire mixture.
In homogenous operating mode, the fuel charging and
combustion are similar to manifold injection.
Direct Fuel Injection System
Heat Catalytic Converter Operating Mode
2 The heat catalytic converter operating mode serves to
3 quickly heat up the three-way catalytic converter when
4 the engine is cold and is possible by means of twin
1 injection.
The first injection, as in homogeneous operating mode,
5 is initiated during the intake stroke. The second injection
takes place during the compression stroke, immediately
after the intake valves close. This produces a rich core
of fuel around the spark plug.
The ignition timing is retarded so that maximum
combustion heat can enter the exhaust tract to heat the
three-way catalytic converter.
NOTE: If the fuel rail pressure is too low on engine
E210638 warm up then it will not be possible to initiate the heat
catalytic converter operating mode. The injection will
1 Injector nozzle outlet be in homogenous mode and a DTC code will be set.
2 Inlet valve
3 Spark Plug Component Description
4 Piston
Throttle Body
5 Fuel Injector
Direct petrol fuel injection systems feature a
high-pressure fuel system which injects fuel directly
into the combustion chamber. The fuel/air mixture is
generated inside the combustion chamber.
Operating Modes
The direct fuel injection system fitted to 2.3L EcoBoost
engines has two different operating modes:
E219730
• Homogeneous operating mode
• Heat catalytic converter operating mode The throttle body system meters air to the engine during
idle, part throttle, and wide open throttle (WOT)
Homogeneous Operating Mode conditions. The throttle body system consists of single
When the engine is at operating temperature, mixture bore with butterfly valve throttle plates and a throttle
formation takes place exclusively in homogeneous position (TP) sensor.
operating mode. In this mode, the injected quantity of

Lesson 3 – Powertrain Fuel Charging and Controls
The major components of the throttle body assembly assembly.

include the TP sensor and the throttle body housing
High Pressure Fuel Rail
2
4
1
E219399
1 FRP sensor 3 High pressure fuel rail removed

2 High pressure fuel rail 4 Fuel injector
The high pressure fuel pump supplies fuel to the fuel

High Pressure Fuel Pump
rail which distributes fuel to the fuel injectors. When
the fuel injectors are opened by a signal from the PCM
the fuel is injected into the cylinder.
The FRP sensor is a diaphragm strain gauge device
which measures the pressure difference between the
fuel rail and atmospheric pressure.
The FRP sensor nominal output varies between 0.5 and
4.5 volts, with 0.5 volts. The sensor can read vacuum
and may lower the output voltage to slightly below 0.5
volts.
This condition is normal and is usually the case after
several hours of cold soak before the vehicle dome light x2
is turned ON.
The FRP sensor is located on the fuel rail and provides
a feedback signal to indicate the fuel rail pressure to the
E217867
PCM. The PCM uses the FRP signal to command the
correct injector timing and pulse width for correct fuel
The high pressure fuel pump is located at the rear of the
delivery at all speed and load conditions. The FRP
engine and is driven by a four sided cam on the exhaust
sensor, along with the fuel volume regulator (part of the
camshaft. The high pressure fuel pump increases fuel
fuel injection pump), form a closed loop fuel pressure
rail pressure to the desired level to support fuel injection
control system.
requirements.
Service Training 37
Fuel Charging and Controls Lesson 3 – Powertrain
Unlike conventional gasoline port fuel injection systems, The primary function of the FRP sensor is to provide
the desired fuel rail pressure for the direct injection fuel rail pressure feedback to the PCM. The PCM
system ranges widely over various engine operating monitors FRP sensor as the engine is operating to
conditions. The high pressure fuel pump receives fuel control fuel pressure.
from the fuel pump assembly (in tank), and increases
This is a closed loop function which means the PCM
the fuel pressure delivering it to the fuel rail.
continuously monitors and adjusts for ideal fuel rail
NOTE: When the high pressure fuel pump is removed pressure determined by conditions such as engine load,
the retaining bolts must discarded and a new bolts speed and temperature. The fuel rail pressure can be
installed, refer to the WSM for more information. monitored using IDS.
Fuel Injectors
1
4
2
3
E217869
1 High pressure fuel pump

2 Fuel volume control valve (integral to the high
pressure fuel pump)
3 Fuel rail pipe connection (outlet)
4 Fuel line to fuel tank connection (inlet)
The fuel volume control valve is a solenoid valve
permanently mounted to the pump assembly. The PCM E217868
commands the fuel volume control valve to meter in a
specified fuel volume with each pump stroke. The PCM The direct fuel injection fuel injector delivers fuel
regulates the fuel volume into the rail to achieve the directly into the cylinder under high pressure. Each
desired fuel rail pressure. injector is controlled by 2 circuits from the PCM.
The fuel volume control valve is synchronised to the A boosted voltage supply, up to 65 volts, is generated
cam position on which the pump is mounted. The PCM in the PCM and used to initially open the injector. The
takes into account that camshaft phasing which varies injector driver controls three transistor switches that
during engine operation. apply the boost voltage to open the injector and then
The fuel pressure sensor is a 3 wire variable capacitance modulates the current to hold the injector open.
sensor located at the end of the fuel rail. The PCM The PCM contains a smart driver that monitors and
supplies a 5 volt reference (VREF) signal which the compares high side and low side injector currents to
FRP sensor uses to produce a linear analog voltage diagnose numerous concerns. Each fuel injector high
indicating fuel pressure. side circuit is paired inside the PCM with another fuel
injector high side circuit.
38 Service Training
Lesson 3 – Powertrain Turbocharger
NOTE: When replacing fuel injector(s) the fuel injector NOTE: When replacing fuel injector(s) the following
O-ring, injector support ring and lower fuel injector special tools must be used, 310-205 Brush, 310-206
Teflon® seal must be removed and discarded and new Remover, 310-207 Seal Installer, 303-1567 Teflon®
components must be installed. Seal Sizer and 307-005 (T59L-100-B) or equivalent
Slide Hammer.
Turbocharger
E224442
1 Turbocharger assembly 4 Air inlet from air cleaner

2 Direct mount to cylinder head 5 Turbo charger by pass valve
3 Turbocharge wastegate actuator 6 Air outlet (CAC)
7 Exhaust system
NOTICE: Whenever turbocharger air intake The Focus RS 2.3 Litre EcoBoost engine is fitted with
system components are removed, always cover a NEW twin-scroll turbocharger. The turbocharger
open ports to protect from debris. It is incorporates an internal bypass valve.
important that no foreign material enter the The turbocharger is an exhaust-driven centrifugal air
system. The turbocharger compressor vanes compressor. Its purpose is to increase power output by
are susceptible to damage from even small supplying compressed air to the engine. The internal
particles. All components should be inspected components are cooled by engine oil, engine coolant
and cleaned, if necessary, prior to installation and air. Engine oil and coolant are circulated through
or reassembly. the center housing which acts as a heat barrier between
the "hot" turbine and the "cold" compressor. Bearings
are sleeve type and lubricated by engine oil. Oil is

Turbocharger Lesson 3 – Powertrain
circulated to the turbocharger center housing and The turbocharger is mounted to the cylinder head. This
returned to the sump through an oil drain in the center configuration improves engine responsiveness (turbo
housing. lag) due to the close proximity of the exhaust turbine
to the cylinder head. This also leads to an improved
Expanding exhaust gases drive the turbine shaft
turbocharger package and better utilization of heat
assembly to speeds up to 200,000 rpm. Filtered air
energy from the compact cylinder head to turbocharger
entering the compressor side of the turbocharger is
flange. The compact design of the system allows the
compressed and delivered through a Charge Air Cooler
(CAC). The very hot compressed air is cooled by the catalysts to be located very close to the turbocharger
outlet for improved emissions.
CAC, and then continues on to fill the intake manifold
at a higher pressure than atmospheric pressure. Because A bypass valve is fitted to the TC (turbocharger) outlet
considerably more air is forced into the intake manifold, pipe. The bypass valve maintains impeller shaft speed
the results are increased power, fuel efficiency and the when the throttle is closed quickly. The bypass valve is
ability to maintain power at higher altitudes. a pneumatic valve which is actuated by the PCM
The turbocharger wastegate is designed to be in the (powertrain control module).
closed position. The wastegate is normally closed at the
onset of engine run.
System Operation
Twin-Scroll Turbocharger
2
1
8 5
E187368
7 6
1 Turbine housing volute, cylinders 1 and 4 3 Compressor wheel

combined 4 Turbine wheel
2 Turbine housing volute, cylinders 2 and 3 5 Exhaust cylinder 1
combined

6 Exhaust cylinder 2 8 Exhaust cylinder 4

7 Exhaust cylinder 3 9 Turbine housing exhaust outlet
Unlike a traditional mono-scroll turbo, a twin-scroll Conventional mono-scroll turbochargers route those
turbo has two separate chambers in the turbo housing irregular pulses of exhaust into the turbine with a single
along with two separate exhaust runners that flow into runner (think of a 4-into-1 exhaust). This design causes
the turbo, one runner for cylinders 1 and 4 and another the exhaust gases to collide and interfere with one
runner for cylinders 2 and 3. Since the cylinders fire in another, reducing the strength of the flow.
sequence (not all at once), the exhaust exits the
In contrast, a twin-scroll turbocharger gathers exhaust
combustion chamber in irregular pulses.
from pairs of cylinders in alternating sequence. This
design maximizes pulse energy to the turbine wheel.
The result is a quicker torque delivery (reduced lag).
E203664
1 Compressor wheel 3 Turbine wheel

2 Twin scrolls 4 Housing
The Focus RS twin scroll turbocharger is equipped with The system allows a maximum of 20 seconds of engine
a new turbine and larger compressor wheel (60 mm to overboost. After 20 seconds the system automatically
63 mm). This permits a higher boost pressure and ramps down the turbo boost to a predetermined max
ensures improved airflow. limit.
The engine also has an overboost feature increasing Once the turbo boost drops below the predetermined
boost above its normal max boost pressure to allow limit the system resets and a further 20 seconds of
temporary torque delivery. This feature widens the RPM engine overboost is permitted.
range of the peak torque curve, giving maximum NOTE: The engine management system automatically
performance while passing another vehicle or launching controls overboost.
from a standing start.
Component Description
Service Training 41
Turbocharger Lesson 3 – Powertrain
Integrated Exhaust Manifold (IEM)
2
3
E203665
1 Exhaust passage 3 Integrated Exhaust manifold (IEM)

2 Coolant passage 4 Cylinder head
The turbocharger is mounted to an Integrated Exhaust reach the turbine wheel minimizes the backflow into
Manifold (IEM) positioning it closer to the cylinder the next pulse, which provides a more efficient delivery
head exhaust ports for better response. The exhaust that of exhaust gas energy to the turbine wheel.
flows from the inner and outer pairs of cylinders are The result is quicker response, improved efficiency and
kept separate as they flow into the two scrolls of the
better scavenging through valve overlap. The IEM is
turbocharger. Separating the exhaust pulses until they
cooled by engine coolant flowing throught it.
42 Service Training
Charge Air Cooler (CAC)
1
E221230
1 Charge Air Cooler (CAC)
A larger charge air cooler is used in combination with

the TC to increase the air density in the combustion
chamber.

Accessory Drive Lesson 3 – Powertrain
Accessory Drive
8
3
6
5
E155977
1 Accessory drive belt tensioner 5 Belt - A/C compressor

2 Accessory drive belt 6 Pulley - A/C compressor
3 Drive belt idler pulley assembly 7 Generator pulley
4 Crankshaft belt pulley 8 Coolant pump pulley

Lesson 3 – Powertrain Engine Ignition
Engine Ignition
E176727
1 Ignition coil-on-plug(s)
2 Spark plug(s)
The ignition system fitted to this engine is referred to a

COP (coil on plug) type, where each spark plug has its
own ignition coil. COP ignition coils eliminate the need
for secondary spark plug wires which improves ignition
spark reliability.
The ignition system uses a 3 wire COP type ignition
coil. This means the coil driver is integrated in the COP
assembly. This configuration eliminates the need for
high current circuits from the PCM to the COP.
NOTE: Electronic ignition engine timing is controlled
by the PCM and is not adjustable. Do not attempt to
E220120 check base timing as a false reading will be obtained.
The ignition system ignites the compressed air and fuel The integrated electronic ignition system consists of a
mixture in the engine's combustion chamber using a Crankshaft Position (CKP) sensor, Camshaft Position
high voltage spark delivered from an ignition coil. The (CMP) sensor, COP, connecting wiring, and PCM.
ignition coil is controlled by the PCM.

Intake Air Distribution and Filtering Lesson 3 – Powertrain
The PCM uses the CKP sensor signal to calculate a

spark target and then fires the COP. The PCM uses the
CMP sensor signal to identify the compression stroke
of cylinder 1.
The PCM controls the ignition coils after it calculates
the spark target. The COP coils fire the spark plug after
receiving the fire signal from the PCM.
The current flow or dwell through the primary ignition
coil is controlled by the COP electronics.
x2
When the ignition coil driver is switched ON, current
rapidly builds up to a maximum value, determined by
the coil inductance and resistance. When the current is
switched OFF, the magnetic field collapses which
induces a secondary high voltage surge and the spark
N0152495 plug is fired.
Intake Air Distribution and Filtering
1 2
3
4
E224363
1 Turbocharger 3 CAC (charge air cooler)

2 Inlet manifold 4 Boost pressure sensor
5 Throttle body

Lesson 3 – Powertrain Intake Air Distribution and Filtering
Air Filter Element Replacement
1 x4
E224362
1 Remove the screws that secure the air filter 4 Install a new air filter element
housing cover 5 Install the air filter housing cover
2 Remove the air filter housing cover 6 Install the screws to secure the air filter housing
3 Remove the air filter element from the air filter cover to the air filter housing
housing
Comments:
Wipe any dirt or debris from the air filter
housing and cover to make sure no dirt gets
in the engine and that you have a good seal

Electronic Engine Controls Lesson 3 – Powertrain
Electronic Engine Controls

2.3L EcoBoost Electronic Engine Controls
E131654
The EEC system provides optimum control of the engine The software strategy controls the basic operation of
through the enhanced capability of the powertrain the engine, provides the OBD strategy, controls the
control module (PCM). The EEC system also has an on malfunction indicator lamp (MIL), communicates to the
board diagnostic (OBD) monitoring system with features scan tool over the data link connector (DLC), allows
and functions to meet federal regulations on exhaust for flash electrically erasable programmable read only
emissions. memory (EEPROM), provides idle air and fuel trim,
and controls failure mode effects management (FMEM).
The EEC system has two major divisions: hardware and
software. The hardware includes the PCM, sensors,
switches, actuators, solenoids, and interconnecting
terminals. The software in the PCM provides the
Clutch
strategy control for outputs (engine hardware) based on
the values of the inputs to the PCM. The Focus RS is equipped with a modified PW10F
The PCM receives information from a variety of sensor clutch to handle the additional engine torque.
and switch inputs. Based on the strategy and calibration The clutch utilises a 'TAC' (Travel Adjusted Clutch)
stored within the PCM, the PCM generates the technology enabling higher overboost torques and is
appropriate output. The system is designed to minimize automatically adapted to the wear.
emissions and optimize fuel economy and driveability.

Lesson 3 – Powertrain Clutch
1 2
2 4
1 3
E224437
1 Clutch plate 3 Clutch wear

2 Ramp ring 4 Ramp ring movement
The system provides a way of compensating clutch The lining wear is compensated by turning the ramp
lining wear. This is accomplished with the aid of a ring. The installation position of the Belleville washer
pinion/spindle drive and a ramp ring between the and the actuation forces remain constant.
Belleville washer and pressure plate
The ramp ring is driven by the pinion/spindle drive via
a positive connection. The pinion is not driven if there
is no wear.
Service Training 49
Clutch Lesson 3 – Powertrain
E224435
1 Pinion Spindle drive

2 Drive pawl
The drive pawl engages in the next tooth and drives the A redesigned dual-mass flywheel is also installed to
pinion, which compensates for wear. A mechanical minimize undesired noise, vibration and harshness.
freewheel locks the position of the pinion.

Lesson 3 – Powertrain Manual Transmission
Manual Transmission
MMT6 Manual Transmission with AWD (all-wheel drive)
E217553
The six-speed manual transmission has been optimised The sporty gearshift feel comes about through the
for the enthusiast driver with a shorter gear lever to shorter gearshift lever.
deliver faster and more accurate shifts. Both the
transmission and the clutch have been upgraded with Ratios
stronger components to cope with the engine’s increased 2.3L
torque output. EcoBoost Transmis- Final Drive Overall
257Kw sion Ratio Ratio Ratio
The Focus RS is equipped with a modified MMT6
1st Gear. 3,231 4,063 13,128
manual transmission featuring carbon synchronizer
rings, modified mounts at the halfshaft and a reinforced 2nd. Gear 1,952 4,063 7,931
hub for greater load-carrying capacity. 3rd. Gear 1,321 4,063 5,367
The transmission bell housing has been adapted to suit 4th. Gear 1,029 4,063 4,181
the 2.3L EcoBoost RS engine. A neutral position sensor 5th. Gear 1,129 2,955 3,336
is installed for the Auto Start Stop functionality. This 6th. Gear 0,943 2,955 2,787
minimizes the fuel consumption and enables the CO² Reverse 1,423 2,955 13,586
targets to be reached. Gear
To meet the vehicle requirements, the torque of first
gear has been increased to 350 Nm, the torque of second
gear to 440 Nm, and the overall on demand torque to
470 Nm.

Four-Wheel Drive Systems Lesson 3 – Powertrain
Four-Wheel Drive Systems
E215177
1 Transfer case (power transfer unit) 3 TWINSTER® rear drive unit

2 Hydraulically actuated clutches 4 AWD electronic control unit
5 3-piece drive shaft
• Torque vectoring control - Automatically applies

brake torque on the inner wheel in a curve to increase
AWD (all-wheel drive) with Dynamic traction and decrease understeer
Torque Vectoring
• Cornering understeer control - Automatically
The Focus RS is offers a new level of handling controls the traction response of the vehicle under
capability and driver enjoyment with Dynamic Torque braking and acceleration on high and low friction
Vectoring, which combines outstanding traction and surfaces
grip with exciting agility and cornering speed.
Unlike electronic stability control, enhanced torque
Dynamic torque vectoring use all four wheels to power vectoring control does not slow the vehicle. The system
the vehicle and independently control the torque to each limits excessive wheel slip giving greater cornering
wheel. agility.
The system also has the ability to over speed the outside NOTE: The system does not disable enhanced torque
rear wheel while cornering, this increases traction and vectoring control if the stability control system or
handling performance giving the vehicle handling traction control system are switched off.
capabilities that are superior to conventional two-wheel
The AWD system uses two electro-hydraulically
drive and four-wheel drive vehicles. The system is active
controlled clutch packs on each side of the rear drive
all the time and requires no input from the driver.
unit to apply torque to the rear wheels.
The system comprises of two elements:

Lesson 3 – Powertrain Four-Wheel Drive Systems
The clutch packs connect each rear halfshaft to the rear A wide range of sensor signals is processed at 100 times
drive unit when engaged. The clutch packs manage the a second by the AWD system to adapt the torque
car’s front/rear torque split and control the side-to-side distribution to the respective driving situation.
torque distribution on the rear axle, delivering torque
This includes the following data:
vectoring capability that has a dramatic impact on
handling and cornering stability. • Steering input
A maximum of 70% of the drive torque can be diverted • Mixture control
to the rear axle, with up to 100% of available torque at • Engine power output/engine speed
the rear that can be sent to each rear wheel. This ensures
• Yaw rate
optimum vehicle stability, counteracting 'Understeer'
and initiating controlled 'oversteer'. • Lateral and longitudinal acceleration
The rear drive unit does not require any normal • Brake system data
scheduled maintenance. The system is electronically • Wheel speed
monitored and any required service messages appear in
the information display. • Temperature
The rear drive unit lubricants may require changing if AWD System Messages
the vehicle is subject to extended periods of high speed
driving, for example race circuit use. When a AWD system fault is present, a message appears
in the information display and the system defaults to
front-wheel drive. If a warning displays, the vehicle
must be checked as soon as possible.
Messages Action and Description

AWD OFF Appears in the information display if the all-wheel drive system overheats and
defaults to front-wheel drive. This may be caused by operating the vehicle with an
incorrect wheel or tire installed or excessive wheel slip and the system is over-
heating. The system resumes normal function and the message clears after the
correct wheel or tire fitted or after the system has cooled. To resume normal all-
wheel drive function as soon as possible, stop the vehicle in a safe location and
switch the engine off for at least 10 minutes.
Check AWD Appears in the information display along with the powertrain malfunction warning
lamp when the system is not operating correctly. Have your vehicle checked as
soon as possible.
Driveline Oil Minder Appears in the information display when the power transfer unit or rear drive unit
lubrication requires changing. The power transfer unit or rear drive unit lubricants
may require changing if you use your vehicle for extended periods of high speed
driving, for example race circuit use.
Operating With Mismatched Tires or Wheels The system may automatically enter front-wheel drive
only mode to protect driveline components if a
NOTE: Only use replacement tires and wheels that are
mismatched tire or spare wheel is installed and a
of the same size, load index, speed rating.
message displays in the information display. The
NOTE: Using a tire or wheel that is not recommended message turns off after the correct wheel and is installed
could cause steering, suspension, axle, power transfer and the ignition is cycled.
unit or rear drive unit failure.
Major mismatched tire or wheel sizes between the front
The Focus RS does not have a spare tire. It is not and rear axles, for example 18 inch low profile tires on
recommend using a mismatched tire or spare wheel, the front axle and 20 inch low profile tires on the rear
however in an emergency, the system can tolerate a axle causes the system to default to front-wheel drive
mismatched tire or spare wheel of a different size to the only mode.
original for a short journey.
Service Training 53
The system can tolerate any combination of new and using 3 worn tires and 1 new tire.
worn tires of the same original tire size. For example,
System Operation
Dynamic Torque Vectoring
E220850
1 55% of the torque to the rear axle

2 90% of the rear-wheel torque to the outside
wheel
3 10% of the rear-wheel torque to the inside
wheel
Dynamic torque vectoring is used to actively influencing With the conventional traction control system, wheelspin
the yaw angle of vehicle. The AWD system can provide on the inside wheel is prevented by reducing engine
targeted steering assistance by distributing drive torque torque. Therefore the vehicle is only able to drive as
to an individual rear wheel. fast as permitted by the traction on the inside wheel.
The vehicle tires may loose grip with the road surface During cornering on vehicles with dynamic torque
when cornering in the conditions listed below: vectoring, the inside wheel is braked and the rear drive
unit pre-emptively diverts torque to the outer rear wheel
• High speed
immediately, based on inputs from steering wheel angle,
• Wet road surface lateral acceleration, yaw and speed. The vehicle gains
• Uneven road surface agility, has improved driving behaviour and increased
steering precision.
• Narrow curve radius

Component Description
Transfer Case
E217955
1 Transfer case (power transfer unit)
The main purpose of the transfer case is to transmit

engine torque to the RH front halfshaft as well as to the
TWINSTER® rear drive unit via the 3-piece drive shaft.
Service Training 55
3 4
2
5
E220840
1 Input shaft 4 Water-cooled heat exchanger

2 Temperature sensors 5 Pinion
3 Ring gear 6 Output flange
To enable greater heat dissipation at the transfer case The transfer case ring gear has been reinforced in order
and support high torque input, a water-cooled heat to withstand higher torques values of up to 1150 Nm.
exchanger and a temperature sensor have been installed The ring gear is welded onto the input shaft and drives
into the transfer case.
the output pinion. The gear ratio is 2.58333 (31 ring
The AWD system monitors temperature sensor and gear teeth to 12 pinion teeth).
when the temperature limits are exceeded the AWD
The capacity of the transfer case is 0.75 l (Motorcraft
functionality is deactivated.
SAE 75W-140 synthetic oil – WSL-M2C192-A).
56 Service Training
TWINSTER® Rear Drive Unit
E217956
1 TWINSTER® rear drive unit
The TWINSTER® rear drive unit is a disconnect The independent rear drive unit continuously adapts the
all-wheel drive system that disengages the rear wheels torque to each rear wheel depending on the driving
when it is not needed. situation.
The rear drive unit contains two multi-plate clutches
which are able to transmit engine torque to the rear
wheels. The two clutches can be actuated on a
wheel-specific basis using an electro-hydraulic servo
drive and two control valves.
Service Training 57
E220578
The rear drive unit stores fluid in three separate NOTE: The clutch pack hydraulic fluid can not be
chambers. replaced.
• Rear drive unit differential housing The clutches are wet-running multi-plate clutches with
a carbon lining and are immersed in Pentison CMF11S
• Left clutch pack housing
275 ml hydraulic fluid. Carbon is used on the clutches
• Right clutch pack housing as it has the best properties in terms of power density
The rear drive unit differential housing is filled with and NVH (noise, vibration and harshness) performance.
Hypoid oil Ford 75W 85 plus 5% Lubrizol FM6179 to Modulation of the multi-plate clutch locking torque is
lubricate the differential and to actuate the multi plate performed by means of a hydraulic pressure that acts
clutch packs. directly on the plate assembly via a piston.
58 Service Training
Multi-Plate Clutch Actuation
1
3
E220579
1 Electro-hydraulic servo drive

2 Control valves
3 Hydraulically actuated clutches
The hydraulic actuation system consists of an electronic The two control valves are used to pressurize the
control unit and an electro-hydraulic servo drive clutches and transmit engine torque to the rear wheels.
mounted on the rear drive unit. The control valves are actuated using a PWM (pulse
The electro-hydraulic servo drive uses a 3-phase, width modulation) signal voltage.
brushless electronically controlled DC (direct current)
motor. The motor is connected to a pump that provides
the line pressure for two control valves.
Service Training 59
E221058
1 Label for clutch correction data

2 AWD electronic control unit
The AWD electronic control unit is mounted to rear NOTE: The AWD electronic control unit can be
drive unit. The AWD control unit specifications are replaced using the familiar inhale/exhale method.
listed below:
NOTE: During normal operation the rear drive unit
• Splash-proof fluid will not need to be changed or checked.
• Operating temperature range: -40 °C – 105 °C The rear drive unit fill plug is located on the back of the
rear drive unit (under the electro-hydraulic servo drive)
• Operating voltage range: 9 – 16 V
and the drain plug is on the underside of the rear drive
• Nominal voltage at 13 V unit.
The capacity of the rear drive unit is 890 ml.

Lesson 3 – Powertrain Exhaust System
Exhaust System
E215856
The Focus RS is fitted with a large-bore high • Minimal exhaust restriction and sporty sound during
performance exhaust system. The right tailpipe is performance driving conditions - Valve open
equipped with an electronically controlled valve. The • Sufficient back pressure and muffled exhaust noise
electronically controlled valve ensures a balance during highway cruise or low speed/low load
between sufficient back pressure and a sporty sound. conditions - Valve closed
The electronically controlled valve enables:

Fuel System Lesson 3 – Powertrain
Fuel System
E223271
1 Fuel pump and sender unit

2 Fuel level sender
3 External fuel filter
fuel is stored in two separate chambers and therefore

two fuel level sensors (one for each chamber) are
Low Pressure Fuel System required to measure the fuel level.
The Focus RS is equipped with a saddle shaped fuel
tank to accommodate the AWD systems 3-piece drive
shaft and exhaust system. Due to the design of the tank

Lesson 3 – Powertrain Fuel System
E224103
A Fuel pump and sender unit 1 Two electric fuel pumps

B Fuel level sender unit 2 Suction line
The Focus RS requires two electric fuel pumps to

achieve its impressive performance. These pumps ensure
a higher flow rate and pressure in the low pressure fuel
system. The two Delfi electric pumps can supply 160
l/h of fuel to the direct injection fuel pump at pressures
ranging between 3.5 and 5.2 bar.
The two electric pumps are located in the fuel pump
and sender unit. A metal protective bracket is installed
above the fuel pump and sender unit.
Fuel is pumped from the fuel pump and sender unit (one
side of the tank) to the high pressure fuel system. Fuel
from the other side of the tank is drawn into the fuel
pump and sender unit using a suction jet pump. The
suction jet pump is connected to the fuel level sender
unit pickup using a suction line.
Service Training 63
1 Fuel pump and sender unit

1 2 Fuel level sender unit
When replacing the fuel pump and sender unit or fuel
level sender unit, care must be taken to align the units
correctly to ensure the correct operation if the fuel level
sensors and fuel delivery system. The tab on the units
must be positioned next to the "locator" marking on the
fuel tank.
E224105
Fuel Pump Operation
2 3
4 8
5
11 10 6
7
9
E222031
64 Service Training
Lesson 3 – Powertrain Fuel System
1 Fuel tank 7 Two suction jet pumps

2 Electric pump 1 8 Reservoir
3 Pressure control valve 9 Line connection to the passive side
4 Electric pump 2 10 Screen
5 Filter 11 Valve
6 One-way valve
Electric pump 2 (primary pump) drives two suction jet The two electric pumps supply the required fuel to the
pumps (passive). One of the suction jet pumps fills the high-pressure pump via a pressure control valve. There
reservoir with fuel from the fuel tank, which holds fuel is a pre-filter in the reservoir and a main filter outside
to supply the electric fuel pumps. the fuel tank.
The other suction jet pump draws in the fuel from the The pre-filter is not subject to change intervals. The
fuel level sender unit via a suction pipe. Electric pump valve on the underside of the reservoir ensures sufficient
1 (secondary pump) has a cooling flow opening for a filling of the reservoir.
low fuel requirement.
The valve opens when it is surrounded by sufficient fuel
in the fuel tank. It closes if there is just a residual
amount of fuel in the tank. This means that no air can
form in the reservoir and the lines remain filled.
2 4
7 5
E224104
1 Fuel pump relays 5 High-pressure fuel pump

2 FPDM (fuel pump driver module) 6 Low-pressure fuel system sensor
3 PCM 7 Fuel level sensor 1 (fuel pump and sender unit)
4 Fuel level sensor 2 (fuel level sender unit)
Service Training 65
8 Electric fuel pumps 9 Pressure control valve

Lesson 4 – Electrical Instrument Panel Cluster (IPC)
Instrument Panel Cluster (IPC)
E224148
The Focus RS has unique instrument cluster graphics To achieve maximum acceleration through the gears, a
incorporating the 'RS' logo as a welcome animation in small 'RS' indicator illuminates in the IPC when the
the message center. powertrain reaches the optimum upshift point. The 'RS'
indicator flashes when the engine is close to reaching
the RPM limiter and when 6900 RPM is exceeded.
Auxiliary Gauges
1 2 3
E224149
1 Oil temperature gauge

2 Turbo boost gauge
3 Oil pressure gauge

Instrument Panel Cluster (IPC) Lesson 4 – Electrical
The Focus RS has also has three auxiliary gauges located • Oil temperature gauge - Displays engine
on top of the instrument panel to display additional temperature
engine information: • Turbo boost gauge - Displays the added intake
system pressure provided by the turbocharger
• Oil pressure gauge - Displays engine oil pressure
– If the needle enters the red section a warning lamp
illuminates and a message appears in the
information display
Drive Modes
1 2
E224150
1 Drive mode switch

2 Drive mode information in information display
The Focus RS has four drive modes that can deliver When the desired mode appears in the message center,
driving experiences through a suite of sophisticated pressing the OK button on the steering wheel selects it.
electronic systems. Each mode has preset vehicle The four drive modes and their features are listed below:
management settings to optimize:
• Normal - Default setting each time the vehicle is
• Steering started. Vehicle response tuned for street driving,
where the Electronic Stability Control and Traction
• All Wheel Drive (AWD)
Control systems are fully enabled
• Torque vectoring
• Sport - Vehicle response tuned for performance
• Powertrain response street driving, where the Traction Control system is
• Suspension and. disabled while the Electronic Stability Control
system remains fully enabled
• Traction and electronic stability control
• NOTE: This mode is for track use only.
There is a drive mode switch located beside the gearshift
lever, which is used to select the desired drive mode. Track - For aggressive driving while at race circuits,
Pressing the button repeatedly will enable the driver to where the system allows greater wheel spin and
scroll through all available modes which are displayed limited drift limits. Electronic Stability Control and
in the message center. Traction Control systems are disabled
• NOTE: This mode is for track use only.
68 Service Training
Lesson 4 – Electrical Instrument Panel Cluster (IPC)
Drift - For spirited and aggressive driving, where The launch control feature configures the chassis and
the system allows controlled oversteer drifts. powertrain systems to deliver the fastest possible
Electronic Stability Control and Traction Control acceleration when launching from a standing start. The
systems are reduced while the system disables engine following must be carried out to switch the feature on:
stability control intervention, allowing more vehicle
NOTE: The vehicle must be completely stationary.
drift
1. Fully depress the clutch pedal and shift the gearshift
Drive lever to first gear
Mode Normal Sport Track Drift
2. NOTE: When the feature is switched on, it is only
Engine Normal Sport Sport Sport active for one launch. The feature must be switched
controls on each time it is required.
Exhaust Normal Sport Sport Sport
Access the following menu using the information
sound
display control "Settings/Driver Assist/Launch
Twinster Normal Sport Sport Drift Control" and check the box to switch the feature on
controls
3. Within a few seconds, fully depress the accelerator
Damper Normal Sport Sport Normal
pedal
controls
Brake Normal Normal Sport Sport 4. Release the clutch pedal when ready to launch
controls NOTE: The system does not operate in any of the
Steering Normal Sport Sport Normal following conditions:
controls • Transmission is in reverse gear
Launch Control • Engine has not reached normal operating temperature
E224336

Exterior Lighting Lesson 4 – Electrical
Exterior Lighting
E224156
The Focus RS is equipped with Bi-Xenon HID

headlamps and Adaptive Front Lighting. The adaptive
front lighting system adjusts the intensity and angle of
the headlamp beams according to vehicle speed, steering
angle and distance to objects, for optimal illumination.
The Focus RS also has unique vertical front fog lamps
located in the flanks of the front bumper.
E224158
The rear lamps have been carried over from the Focus
MCA.
70 Service Training
Lesson 4 – Electrical Exterior Lighting
The vehicle is fitted with a unique rear fog lamp which

contains 6 LEDs (light emitting diodes). The LED fog
lamp has an approximate current consumption of 0.2
amps/2.4 watts.
E224157
Adaptive Front Lighting
2
3
E197692
1 Multifunction unit incorporating: 3 Lens

Comments: 4 Stepper motor for adaptive front light
Free-form drum
Deflection mechanism
Stepper motor for multifunction unit
2 Reflector
The Bi-Xenon HID headlamp assembly has an integrated assembly. The headlamp assembly is provided power
solenoid activated shutter which changes the headlamp on independent circuits for the low beams and the high
beam pattern when activated. The solenoid and shutter beams.
are not serviceable separately from the headlamp
Service Training 71
The Bi-Xenon HID headlamp also contains LEDs that Depending on the inputs received (steering wheel angle
are signature lights when used as DRL (daytime running and vehicle speed for example), the HCM can command
lamps) and are illuminated at their highest intensity or the angle at which the headlamps are aimed (left or
parking lamps and are illuminated at a reduced intensity right) to improve nighttime visibility around curves.
when the parking lamps or headlamps are activated.
Additional functions have been added to the existing
adaptive front lighting system enabling it to adapt the
light beam to the respective driving situation.
Different light distributions e.g. for city or country
roads, adverse weather or freeway light, can be
generated using the free-form drum based on internal
vehicle data. A projection module with a rotating
free-form drum between the light source and lens is
required for this.
The drum has different contours and can swivel around
E197679 its own longitudinal axis. The drum is swivelled into
the required position within milliseconds using a stepper
NOTE: Adaptive front lighting is only activated when motor and in this way adapts the cut-off line to the
the headlamp switch is in the AUTOLAMPS position. respective light mode.
Adaptive front lighting uses a HCM (headlamp control The following light modes are used depending on the
module) to command the left/right aiming of the vehicle speed and lighting conditions.
headlamps through the LIN (local interconnect network) NOTE: The indicated speeds are approximate values.
to the headlamp assemblies. The loop must include hysteresis in order to avoid
The headlamp assemblies contain a module that receives control oscillations due to constant fluctuations above
the messages through the LIN from the HCM. and below the speed limits resulting in continuous
cycling between the light modes. The result is that the
higher light mode in each case is maintained.
Pedestrian Area Light Mode
E197661
72 Service Training
Lesson 4 – Electrical Exterior Lighting
Town Light Mode
E197662
This light mode is used at speeds <30 km/h. Cornering Light Mode
This light mode is used at speeds from 31 to 50 km/h.
E197678
This light is used to illuminate tight bends, intersections

or entryways at low speed.
Service Training 73
Driving Light Mode
E197663
NOTE: The light distribution for mode is the same as This light mode is used at speeds from 51 to 100 km/h.
for the conventional driving light.
Freeway Light Mode
E197664
This light mode is used at speeds >110 km/h until top

speed is reached.
It is activated when speeds of 110 km/h are exceeded
for more than 30 seconds.
The auto high bean feature activates the main (high)
beam using lighting information from the IPMA (image
processing module A) (front camera).
The system is able to detect oncoming traffic in
combination with the IPMA and adapts the high beam
if any are detected.
74 Service Training
Lesson 4 – Electrical Communications Network
Adverse Weather Light Mode This light mode is used at speeds from 0 to 50 km/h if
the wipers have been on for more than two minutes and
the front fog lamps are not switched on.
E197954
Failsafe Light Mode
E197663
Failsafe mode is automatically activated if the HCM The private HS-CAN is used for rapid, interference-free
diagnoses a fault in the system during the self-test. The data exchange.
light distribution is the same in this case as for driving
The HS-CAN bus, the HS-CAN multimedia bus and
light mode. the private HS-CAN bus have a speed of 500 kBit/s.
The MS-CAN bus and the private MS-CAN bus have
Communications Network a speed of 125 kBit/s.
The keyless vehicle module is connected with the radio
There are a total of Six data bus systems used on the frequency receiver over an ISO bus.
communication network: A total of 8 terminating resistors are installed.
• HS-CAN (controller area network) bus The two terminating resistors of the HS-CAN data bus,
• HS-CAN multimedia bus 120 ohms each, are integrated into the PCM (powertrain
control module) and the BCM (body control module).
• Private HS-CAN bus Since both 120 ohm resistors are connected in parallel,
• MS-CAN bus the total resistance is 60 ohms (measured at the DLC
(data link connector)). If a control unit is disconnected
• LIN (local interconnect network) bus
from the network, 120 ohms must be present between
• ISO bus pin 6 and 14 at the DLC.

Communications Network Lesson 4 – Electrical
The terminating resistors of the HS-CAN multimedia The RCM (restraints control module) is connected to
system are located in the IPC (instrument panel cluster) the CAN module via a private HS-ABS (anti-lock brake
and in the ACM (audio front control module). system) bus. Two separate termination resistors are
installed here.
The HS-CAN multimedia bus signals can be picked off
via pins 1 and 8 The MS CAN bus terminating resistors are located in
the IPC and the BCM. The total resistance can be
measured at the DLC between pins 3 and 11 and should
be 60 ohms.
E224838
Two modules are designed as gateways: • GPSM (global positioning system module)
• The BCM between the HS-CAN and MS-CAN • RFA (remote function actuator)
• The IPC between the MS-CAN and HS-CAN • RFR - RF receiver (radio receiver for keyless locking
multimedia system)
Module acronyms: • BCM (body control module
• ACM (audio front control module) • FDSM (front distance sensing module)
• DSP (audio digital signal processing module) • PAM (parking assist control module)
• EFP (electronic (finisher panel) • PSCM (power steering control module)
• APIM (SYNC module) • ICM (information center module)
• IPC (instrument panel cluster) • SASM (steering angle sensor module)
• PDM (passenger door module) • HCM (headlamp control module)
• DDM (driver door module) • PCM (powertrain control module
• HVAC (heating, ventilation and air conditioning) • RCM (restraints control module)
76 Service Training
Lesson 4 – Electrical Communications Network
• ABS (anti lock braking system) module

• FLCM (fuel level control module)
• RDU ( rear drive unit)

Front Seats Lesson 5 – Body and Paint
Front Seats
1 2
E224221
1 Partial-leather Recaro sports seat

2 Signature RS Recaro shell seats (manually
adjusted)
The high-performance character of the RS is reflected Signature RS Recaro shell seats, with authentic
inside the car with heavily-bolstered partial-leather motorsport microfibre fabric panels, are an optional on
Recaro sports seats as the centrepiece of the cockpit. Focus RS.

Lesson 5 – Body and Paint Instrument Panel
Instrument Panel
E215834
The Focus RS is equipped with SYNC II entertainment The RS logo is displayed in the IPC (instrument panel
system with an 8-inch touchscreen, DATC (dual cluster), stitched into the seat backrests, steering wheel
automatic temperature control) climate control system, and on the scuff plate molding trims.
sports steering wheel, aluminum pedals and Recaro part The RS drive mode selection switch and start stop
leather front seats.
switch is located beside the gear shift lever.

Vehicle Specific Body Construction Lesson 5 – Body and Paint
Vehicle Specific Body Construction
1 2
E218404
1 Structural foam 4 No spare wheel well in the luggage

compartment floor
2 Sidewall reinforcement ('lion's foot')
5 Reinforced luggage compartment floor
3 Shortened bolt at the bulkhead
The Focus RS body has been reinforced in several places

to accommodate the powertrain changes. The spare
wheel well has been sacrificed to cater for the sports
exhaust and the AWD (all-wheel drive) system.
Certain bolts which extrude from the engine
compartment bulkhead had to be shortened so they
would not foul with the TC (turbocharger).

List of Abbreviations
ABS anti-lock brake system
ACM audio front control module
APIM SYNC module
AWD all-wheel drive
BCM body control module
CAC charge air cooler
DDM driver door module
DRL daytime running lamps
DSP audio digital signal processing module
FDSM front distance sensing module
FRP fuel rail pressure
GPSM global positioning system module
HCM headlamp control module
HVAC heating, ventilation and air conditioning
ICM information center module
IPC instrument panel cluster
LIN local interconnect network
PAM parking assist control module
PCM powertrain control module
PCV positive crankcase ventilation
PDM passenger door module
PSCM power steering control module
RCM restraints control module
RFA remote function actuator
SASM steering angle sensor module
TC turbocharger
VCT variable camshaft timing
Service Training 81

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FORD TRAINING

Technical Service Training

New Model Introduction - Supplement

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Service Training (G1821216) 1

2 (G1821216) Service Training

Lesson 1 – General Information

Jacking and Lifting....................................................................................................................................... 14

Wheels and Tires........................................................................................................................................... 20

Vehicle Dynamic Suspension........................................................................................................................ 21

Fuel Charging and Controls........................................................................................................................ 35

Intake Air Distribution and Filtering......................................................................................................... 46

Electronic Engine Controls.......................................................................................................................... 48

Four-Wheel Drive Systems........................................................................................................................... 52

Lesson 5 – Body and Paint

Vehicle Specific Body Construction............................................................................................................ 80

Introduction • Manual transmission MMT6

1 Front fog lamps

6 (G1821216) Service Training

1 Twin exhaust system 3 Rear diffuser

NOTE: Rear LED fog light market dependant

Opening the Hood and Closing the Hood

Service Training (G1821216) 7

• To close the hood and allow it to drop under its own

Data Link Connector

Passenger Compartment Fuse Box

8 (G1821216) Service Training

Load Compartment Fuse Box

F21 15A Fuel control relay. Damper control relay

Service Training (G1821216) 9

Capless Fuel Filler

• Twist the screwdriver in the position shown (3) to

WARNING: If you use a high pressure spray

Keyless Remote Control Battery 5

NOTE: Do not touch the battery contacts or the printed

10 (G1821216) Service Training

Tire Repair Kit

This vehicle is equipped with a tire repair kit as standard.

Service Training (G1821216) 11

Towing Vehicles CANNOT be flat-towed (all wheels on the

12 (G1821201) Service Training

1 Coolant reservoir 6 BJB (battery junction box)

Various systems may be altered or are disabled when

Service Training (G1821202) 13

Jacking and Lifting

14 (G1822861) Service Training

Only raise the vehicle when positioned on a

Service Training (G1822861) 15

The front suspension uses a MacPherson strut system.

16 (G1821294) Service Training

1 Outer tie-rod locknut

Service Training (G1821299) 17

1 Upper arm 3 Reinforced lower connecting rods

1 Rear shock absorbers - electronic 4 Rear lower trailing arms

• Modified side members

Service Training (G1821298) 19

Wheels and Tires

1 'Ronal' light alloy rim, available in silver or

20 (G1821752) Service Training