light FORD FOCUS 2003 1.G Repair Manual

Note:Use of Motorcraft Cooling System Stop Leak Pellets, VC-6, may
darken the color of Motorcraft Premium Gold Engine Coolant from
yellow to golden tan.
•Do not add/mix an orange-colored, extended life coolant such
as Motorcraft Speciality Orange Engine Coolant, VC-2 (US) or
CXC-209 (Canada), meeting Ford specification WSS-M97B44–D
with the factory-filled coolant.Mixing Motorcraft Speciality Orange
Engine Coolant or any orange-colored extended life product with your
factory filled coolant can result in degraded corrosion protection.
•A large amount of water without engine coolant may be added, in case
of emergency, to reach a vehicle service location. In this instance, the
cooling system must be drained and refilled with a 50/50 mixture of
engine coolant and distilled water as soon as possible. Water alone
(without engine coolant) can cause engine damage from corrosion,
overheating or freezing.
•Do not use alcohol, methanol, brine or any engine coolants
mixed with alcohol or methanol antifreeze (coolant).Alcohol
and other liquids can cause engine damage from overheating or
freezing.
•Do not add extra inhibitors or additives to the coolant.These
can be harmful and compromise the corrosion protection of the engine
coolant.
For vehicles with overflow coolant systems with a non-pressurized cap
on the coolant recovery system, add coolant to the coolant recovery
reservoir when the engine is cool. Add the proper mixture of coolant and
water to the“cold full”level. For all other vehicles, which have a coolant
degas system with a pressurized cap, or if it is necessary to remove the
coolant pressure relief cap on the radiator of a vehicle with an overflow
system, follow these steps to add engine coolant.
To reduce the risk of personal injury, make sure the engine is
cool before unscrewing the coolant pressure relief cap. The
cooling system is under pressure; steam and hot liquid can come out
forcefully when the cap is loosened slightly.
1. Before you begin, turn the engine off and let it cool.
2. When the engine is cool, wrap a thick cloth around the coolant
pressure relief cap on the coolant reservoir (an opaque plastic bottle).
Slowly turn cap counterclockwise (left) until pressure begins to release.
3. Step back while the pressure releases.
Maintenance and Specifications
174

How fail-safe cooling works
If the engine begins to overheat:
•The engine coolant temperature
gauge will move to the red (hot)
area.
•The“Multi-function warning light:
automatic transaxle/cooling
system”will illuminate (2.0L
Zetec engine only).
•The“Check Engine”indicator light will illuminate.
If the engine reaches a preset over-temperature condition, the engine
will automatically switch to alternating cylinder operation. Each disabled
cylinder acts as an air pump and cools the engine.
When this occurs the vehicle will still operate. However:
•The engine power will be limited.
•The air conditioning system will be disabled.
Continued operation will increase the engine temperature:
•The engine will completely shut down.
•Steering and braking effort will increase.
Once the engine temperature cools, the engine can be re-started. Take
your vehicle to a service facility as soon as possible to minimize engine
damage.
When fail-safe mode is activated
You have limited engine power when in the fail-safe mode, so drive the
vehicle with caution. The vehicle will not be able to maintain high speed
operation and the engine will run rough. Remember that the engine is
capable of completely shutting down automatically to prevent engine
damage, therefore:
1. Pull off the road as soon as safely possible and turn off the engine.
2. Arrange for the vehicle to be taken to a service facility.
3. If this is not possible, wait a short period for the engine to cool.
4. Check the coolant level and replenish if low.
Never remove the coolant reservoir cap while the engine is
running or hot.
Maintenance and Specifications
177

Octane recommendations
Your vehicle is designed to use
“Regular”unleaded gasoline with
pump (R+M)/2 octane rating of 87.
We do not recommend the use of
gasolines labeled as“Regular”that
are sold with octane ratings of 86 or lower in high altitude areas.
Do not be concerned if your engine sometimes knocks lightly. However, if
it knocks heavily under most driving conditions while you are using fuel
with the recommended octane rating, see your dealer or a qualified
service technician to prevent any engine damage.
Fuel quality
If you are experiencing starting, rough idle or hesitation driveability
problems during a cold start, try a different brand of“Regular”unleaded
gasoline.“Premium”unleaded gasoline is not recommended (particularly
in the United States) because it may cause these problems to become
more pronounced. If the problems persist, see your dealer or a qualified
service technician.
It should not be necessary to add any aftermarket products to your fuel
tank if you continue to use high quality fuel of the recommended octane
rating. Aftermarket products could cause damage to the fuel system.
Repairs to correct the effects of using an aftermarket product in your
fuel may not be covered by your warranty.
Many of the world’s automakers
issued the World-wide Fuel Charter
that recommends gasoline
specifications to provide improved
performance and emission control
system protection for your vehicle.
Gasolines that meet the World-wide
Fuel Charter should be used when
available. Ask your fuel supplier
about gasolines that meet the
World-wide Fuel Charter. In Canada,
look for fuels that display theAuto
Makers’Choice
logo.
Cleaner air
Ford endorses the use of reformulated“cleaner-burning”gasolines to
improve air quality.
87(R+M)/2 METHOD
Maintenance and Specifications
181

•Adding certain accessories to your vehicle (for example bug
deflectors, rollbars/light bars, running boards, ski/luggage racks) may
reduce fuel economy.
•Using fuel blended with alcohol may lower fuel economy.
•Fuel economy may decrease with lower temperatures during the first
12–16 km (8–10 miles) of driving.
•Driving on flat terrain offers improved fuel economy as compared to
driving on hilly terrain.
•Transaxles give their best fuel economy when operated in the top
cruise gear and with steady pressure on the gas pedal.
•Close windows for high speed driving.
EPA window sticker
Every new vehicle should have the EPA window sticker. Contact your
dealer if the window sticker is not supplied with your vehicle. The EPA
window sticker should be your guide for the fuel economy comparisons
with other vehicles.
It is important to note the box in the lower left corner of the window
sticker. These numbers represent the Range of L/100 km (MPG)
expected on the vehicle under optimum conditions. Your fuel economy
may vary depending upon the method of operation and conditions.
EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
•Use only the specified fuel listed.
•Avoid running out of fuel.
•Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
•Have the items listed in your scheduled maintenance guide performed
according to the specified schedule.
The scheduled maintenance items listed in the scheduled maintenance
guide are essential to the life and performance of your vehicle and to its
emissions system.
Maintenance and Specifications
185

If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the
indicator, charging system warning light or the
temperature warning light, fluid leaks, strange odors, smoke or loss of
engine power, could indicate that the emission control system is not
working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle’s emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult yourWarranty Guidefor complete emission warranty
information.
On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). This OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists the
service technician in properly servicing your vehicle. When theCheck
Engine/Service Engine Soonlight illuminates, the OBD-II system has
detected a malfunction. Temporary malfunctions may cause yourCheck
Engine/Service Engine Soonlight to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run
poorly.)
2. Poor fuel quality or water in the fuel.
Maintenance and Specifications
186

3. The fuel cap may not have been securely tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, theCheck Engine/Service Engine Soonlight should turn off.
(A driving cycle consists of a cold engine startup followed by mixed
city/highway driving.) No additional vehicle service is required.
If theCheck Engine/Service Engine Soonlight remains on, have your
vehicle serviced at the first available opportunity.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your
indicator is on, refer to the
description in theWarning lights and chimessection of the
Instrument Clusterchapter. Your vehicle may not pass the I/M test with
the
indicator on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a“not ready for I/M test”
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
•First, at least 10 minutes of driving on an expressway or highway.
•Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
Maintenance and Specifications
187

Travel equipment
Automatic headlamp system
Daytime running lights (DRL)
First aid kit
Fog lights
Highway safety kit
Luggage/cargo basket
Navigation system
Removable luggage rack
Removable luggage rack adapters (bike, ski and snowboard)
Speed control
Protection and appearance equipment
Car cover
Carpet floor mats
Chrome exhaust trim
Door edge guards
Door sill scuff plates
Exterior B-pillar trim
Flat splash guards
Front end covers (full and mini)
Ground effects kit
Hood Deflectors
Leather wrap steering wheel
Molded splash guards
Molded vinyl floor mats
Projector headlamps
Side window deflector
Spoilers
Accessories
206

Index
A
AdvanceTrac ..............................113
Air bag supplemental restraint
system ..............................89–90, 93
and child safety seats ..............91
description ..........................90, 93
disposal ......................................95
driver air bag ......................91, 94
indicator light ...........................93
operation .............................91, 94
passenger air bag ...............91, 94
side air bag ................................93
Air cleaner filter .......................196
Antifreeze (see Engine
coolant) .....................................172
Anti-lock brake system
(see Brakes) ..............................111
Anti-theft system ........................71
arming the system ....................71
disarming a triggered system ..71
Automatic transaxle
fluid, adding ............................189
fluid, checking ........................189
fluid, specification ..................200
Automatic transmission ............115
driving an automatic
overdrive .................................117
fluid, refill capacities ..............196
Axle
lubricant specifications ..........198
refill capacities ........................196
B
Battery .......................................170
acid, treating emergencies .....170
jumping a disabled battery ....138
maintenance-free ....................170replacement, specifications ...196
servicing ..................................170
BeltMinder ...................................84
Brakes ........................................111
anti-lock ...................................111
anti-lock brake system (ABS)
warning light ...........................111
fluid, checking and adding ....188
fluid, refill capacities ..............196
fluid, specifications .........198, 200
lubricant specifications ..198, 200
parking ....................................112
shift interlock ..........................115
C
Capacities for refilling fluids ....196
Cargo cover .................................60
Cell phone use ............................58
Certification Label ....................203
Child safety restraints ................96
child safety belts ......................96
Child safety seats ........................99
attaching with tether straps ..103
in front seat ............................101
in rear seat ..............................101
LATCH .....................................105
Cleaning your vehicle
engine compartment ..............155
instrument panel ....................158
interior .....................................159
plastic parts ............................158
washing ....................................154
waxing .....................................154
wheels ......................................155
wiper blades ............................158
Climate control (see Air
conditioning or Heating) ......35–36
Index
208

capacity ...................................196
choosing the right fuel ...........180
comparisons with EPA fuel
economy estimates .................185
detergent in fuel .....................181
filling your vehicle with
fuel ...........................178, 180, 182
filter, specifications ........182, 196
fuel pump shut-off switch .....126
improving fuel economy ........182
octane rating ...................181, 200
quality ......................................181
running out of fuel .................182
safety information relating to
automotive fuels .....................178
Fuel pump shut-off switch .......126
Fuses ..................................127, 129
G
Gas cap (see Fuel cap) ............180
Gas mileage (see Fuel
economy) ...................................182
Gauges .........................................14
GAWR (Gross Axle Weight
Rating) .......................................120
definition .................................120
driving with a heavy load ......120
location ....................................120
GVWR (Gross Vehicle Weight
Rating) .......................................120
calculating ...............................120
definition .................................120
driving with a heavy load ......120
location ....................................120
H
Hazard flashers .........................126
Headlamps ...................................38aiming ........................................39
bulb specifications ....................43
daytime running lights .............38
flash to pass ..............................39
high beam .................................39
turning on and off ....................38
Heating
heater only system ...................35
Hood ..........................................162
I
Ignition ...............................107, 200
Infant seats (see Safety seats) ..99
Inspection/maintenance (I/M)
testing ........................................187
Instrument panel
cleaning ...................................158
cluster ........................................10
lighting up panel and
interior .......................................39
J
Jump-starting your vehicle ......138
K
Keys
positions of the ignition .........107
L
Lamps
bulb replacement
specifications chart ............42–43
cargo lamps ...............................39
daytime running light ...............38
fog lamps ...................................38
headlamps .................................38
headlamps, flash to pass ..........39
Index
210

instrument panel, dimming .....39
interior lamps ...........................42
Lane change indicator
(see Turn signal) ........................41
Liftgate ........................................59
Lights, warning and indicator ....10
anti-lock brakes (ABS) ..........111
Load limits .................................120
GAWR ......................................120
GVWR ......................................120
trailer towing ..........................120
Locks
childproof ..................................63
Lubricant specifications ...198, 200
M
Manual transaxle
lubricant specifications ..........200
Manual transmission .................119
fluid capacities ........................196
reverse .....................................119
Mirrors .........................................53
side view mirrors (power) .......53
Moon roof ....................................56
Motorcraft parts ................182, 196
O
Octane rating ............................181
Oil (see Engine oil) ..................166
P
Parking brake ............................112
Parts (see Motorcraft parts) ....196
Power distribution box
(see Fuses) ...............................131Power steering ..........................115
fluid, checking and adding ....188
fluid, refill capacity ................196
fluid, specifications .........198, 200
Power Windows ...........................52
R
Rear window defroster ...............37
Relays ........................................127
Remote entry system .................65
locking/unlocking doors ...........62
opening the trunk .....................66
Roadside assistance ..................125
S
Safety Belt Maintenance ............88
Safety belts (see Safety
restraints) ........................76, 79–83
Safety defects, reporting ..........153
Safety restraints ..............76, 79–83
belt minder ...............................84
extension assembly ..................88
for adults .............................80–82
for children .........................95–96
safety belt maintenance ...........88
warning light and chime ..........84
Safety seats for children ............99
Seat belts (see Safety
restraints) ....................................76
Seats ............................................72
child safety seats ......................99
Servicing your vehicle ..............161
Spare tire (see Changing the
Tire) ...........................................135
Spark plugs,
specifications .....................196, 200
Index
211