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Vehicle Specific Body Construction

E218404

Structural foam

Sidewall reinforcement ('lion's foot')

Shortened bolt at the bulkhead

No spare wheel well in the luggage
compartment floor

Reinforced luggage compartment floor

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).

(G1821799)

Service Training

Lesson 5 – Body and Paint

Vehicle Specific Body Construction

Содержание Focus RS 2016

Страница 1: ...FORD TRAINING Technical Service Training FORD Focus New Model Introduction Supplement E223796 P346 R010 01 CGAPA S en...

Страница 2: ...ical photocopy recording translation or by any other means without prior permission of Ford Werke GmbH No liability can be accepted for any inaccuracies in this publication although every possible car...

Страница 3: ...ormance 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 seat...

Страница 4: ...d 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 da...

Страница 5: ...ttery Replacement 11 Tire Repair Kit Lesson 1 General Information 12 Towing 12 13 Service Points 13 2 3L EcoBoost 13 Transport Mode 13 Transport Mode Deactivation 14 Jacking and Lifting 14 Lesson 2 Ch...

Страница 6: ...d Exhaust Manifold IEM 43 Charge Air Cooler CAC 44 Accessory Drive 45 Engine Ignition 45 46 Intake Air Distribution and Filtering 48 Electronic Engine Controls 48 2 3L EcoBoost Electronic Engine Contr...

Страница 7: ...l Cluster IPC 67 70 Exterior Lighting 70 75 Communications Network 75 Lesson 5 Body and Paint 78 Front Seats 78 79 Instrument Panel 79 80 Vehicle Specific Body Construction 80 81 List of Abbreviations...

Страница 8: ...ertrain Engine 2 3L EcoBoost 257 Kw Manual transmission MMT6 AWD all wheel drive Exhaust System Electrical Instrument panel Adaptive exterior lighting Body Instrument panel and console Vehicle body st...

Страница 9: ...S branding 2 Rear diffuser 3 Rear LED fog light 4 NOTE Rear LED fog light market dependant Opening the Hood and Closing the Hood E73698 Pull the handle to unlatch the bonnet E133239 Move the yellow ca...

Страница 10: ...dditional fuses and relays which are fitted to the RS are listed below E129925 30A Rear drive unit control F17 20A Pump electronic module 2 feed F30 7 5A Exhaust valve F36 Pump electronic module 2 fee...

Страница 11: ...and relays which are fitted to the RS are listed below E224216 15A Fuel control relay Damper control relay F21 10A Active noise cancellation Electronic sound enhancement F22 Fuel control module Dampe...

Страница 12: ...2 1 1 Press and hold the buttons on the key edges 1 to release the cover Carefully remove the cover Remove the key blade 2 E105362 3 Twist the screwdriver in the position shown 3 to separate the two h...

Страница 13: ...ts 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 N...

Страница 14: ...88 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 G1821201 Service Training 12 Lesson 1 General...

Страница 15: ...re the vehicle is not used While in transport mode the IPC displays TRANSPORT MODE CONTACT DEALER in the message center Various systems may be altered or are disabled when in the transport mode The ve...

Страница 16: ...arms on the lift points that sre shown on the above diagram Incorrect positioning could result in vehicle slipping or falling causing significant damage to the vehicle Never get underneath a vehicle t...

Страница 17: ...mage 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 lin...

Страница 18: ...spension uses a MacPherson strut system This suspension system incorporates a strut assembly that takes the place of the upper arm and ball joint The strut performs the function of a shock absorber an...

Страница 19: ...riving Torsion resistant steering knuckles Shorter wishbones and reinforced mounts Larger front anti roll bar Front Suspension Alignment and Adjustment Front Toe Adjustment 2 E67410 1 2 Outer tie rod...

Страница 20: ...ar Suspension E224060 1 1 2 2 3 5 4 2 2 Upper arm 1 Reinforced areas 2 Reinforced lower connecting rods 3 Wheel knuckle 4 Wheel bearing and hub AWD 5 Service Training 18 Lesson 2 Chassis Rear Suspensi...

Страница 21: ...to the wheel knuckle and along with the spring controls vertical movement The stabilizer bar and links control suspension lean sway One of the main objectives is to make the new Focus RS more resistan...

Страница 22: ...n with the Dicastal forged rim The Dicastal forged wheels are much lighter than cast wheels They also have a better mass ratio unsprung masses This optimizes the vehicle s suspension performance and r...

Страница 23: ...ting 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 agg...

Страница 24: ...holding pin 5 Anti rattle plate 6 Brake fluid crossover pipe 7 The Focus RS is fitted with Brembo four piston monoblock brake calipers at the front axle The housing is made from a single piece There...

Страница 25: ...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 The MK100 module is 20 percent sm...

Страница 26: ...ion 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 whe...

Страница 27: ...s available with the following powertrain components Engine 2 3L EcoBoost four cylinder engine Transmission MMT6 6 speed manual transmission incorporating transfer case AWD System Electronically contr...

Страница 28: ...ly greater air flow along with a much bigger intercooler to maximise charge density Engine breathing also is enhanced through a less restrictive intake system design and a large bore high performance...

Страница 29: ...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 ti...

Страница 30: ...larger compressor wheel from 60 mm to 63 mm and new turbine wheel 4 PCV positive crankcase ventilation flow increased from 17 liters per minute to 45 liters per minute 5 New wiring loom with increased...

Страница 31: ...he 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...

Страница 32: ...er 4 Turbocharger oil filter 5 Turbocharger oil supply tube 6 Turbocharger 7 Intake VCT variable camshaft timing unit 8 Exhaust VCT unit 9 Camshaft front bearing cap 10 Exhaust VCT oil control solenoi...

Страница 33: ...ngine uses a new synthetic oil for greater lubrication and improved durability The heart of the system is a positive displacement internal gear oil pump Generically this design is known as a gear roto...

Страница 34: ...ankshaft position Improved power from low to high engine speeds broadening of the torque curve is achieved by varying the valve overlap and camshaft timing to match all operating ranges and ambient co...

Страница 35: ...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 cams...

Страница 36: ...reating additional space within the front of the vehicle to house a significantly larger radiator pack the biggest ever fitted to a Focus The radiator was designed to provide the level of cooling dema...

Страница 37: ...uel pump drive unit 4 High pressure fuel pump 5 The high pressure fuel system consists of the following components Mechanical high pressure fuel pump with incorporated fuel metering valve High pressur...

Страница 38: ...ure In homogenous operating mode the fuel charging and combustion are similar to manifold injection Heat Catalytic Converter Operating Mode The heat catalytic converter operating mode serves to quickl...

Страница 39: ...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 is turned ON The FRP sensor is located on the...

Страница 40: ...re variable capacitance sensor located at the end of the fuel rail The PCM supplies a 5 volt reference VREF signal which the FRP sensor uses to produce a linear analog voltage indicating fuel pressure...

Страница 41: ...en ports to protect from debris It is important that no foreign material enter the system The turbocharger compressor vanes are susceptible to damage from even small particles All components should be...

Страница 42: ...charger is mounted to the cylinder head This configuration improves engine responsiveness turbo lag due to the close proximity of the exhaust turbine to the cylinder head This also leads to an improve...

Страница 43: ...ergy to the turbine wheel The result is a quicker torque delivery reduced lag E203664 1 3 4 2 Compressor wheel 1 Twin scrolls 2 Turbine wheel 3 Housing 4 The Focus RS twin scroll turbocharger is equip...

Страница 44: ...he inner and outer pairs of cylinders are kept separate as they flow into the two scrolls of the turbocharger Separating the exhaust pulses until they reach the turbine wheel minimizes the backflow in...

Страница 45: ...CAC E221230 1 Charge Air Cooler CAC 1 A larger charge air cooler is used in combination with the TC to increase the air density in the combustion chamber 43 Service Training G1821776 Turbocharger Les...

Страница 46: ...ory drive belt tensioner 1 Accessory drive belt 2 Drive belt idler pulley assembly 3 Crankshaft belt pulley 4 Belt A C compressor 5 Pulley A C compressor 6 Generator pulley 7 Coolant pump pulley 8 G18...

Страница 47: ...r 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 config...

Страница 48: ...primary ignition coil is controlled by the COP electronics When the ignition coil driver is switched ON current rapidly builds up to a maximum value determined by the coil inductance and resistance Wh...

Страница 49: ...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 3 Install a new air filter element 4 Install the a...

Страница 50: ...nsor and switch inputs Based on the strategy and calibration stored within the PCM the PCM generates the appropriate output The system is designed to minimize emissions and optimize fuel economy and d...

Страница 51: ...dle drive and a ramp ring between the Belleville washer and pressure plate The lining wear is compensated by turning the ramp ring The installation position of the Belleville washer and the actuation...

Страница 52: ...e next tooth and drives the pinion which compensates for wear A mechanical freewheel locks the position of the pinion A redesigned dual mass flywheel is also installed to minimize undesired noise vibr...

Страница 53: ...en adapted to suit the 2 3L EcoBoost RS engine A neutral position sensor is installed for the Auto Start Stop functionality This minimizes the fuel consumption and enables the CO targets to be reached...

Страница 54: ...wheel drive and four wheel drive vehicles The system is active all the time and requires no input from the driver The system comprises of two elements Torque vectoring control Automatically applies b...

Страница 55: ...nd 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...

Страница 56: ...the road surface when cornering in the conditions listed below High speed Wet road surface Uneven road surface Narrow curve radius With the conventional traction control system wheelspin on the insid...

Страница 57: ...case power transfer unit 1 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 55 Servic...

Страница 58: ...em monitors temperature sensor and when the temperature limits are exceeded the AWD functionality is deactivated The transfer case ring gear has been reinforced in order to withstand higher torques va...

Страница 59: ...nit 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...

Страница 60: ...The clutch pack hydraulic fluid can not be replaced The clutches are wet running multi plate clutches with a carbon lining and are immersed in Pentison CMF11S 275 ml hydraulic fluid Carbon is used on...

Страница 61: ...rive unit The electro hydraulic servo drive uses a 3 phase brushless electronically controlled DC direct current motor The motor is connected to a pump that provides the line pressure for two control...

Страница 62: ...at 13 V NOTE The AWD electronic control unit can be replaced using the familiar inhale exhale method NOTE During normal operation the rear drive unit fluid will not need to be changed or checked The r...

Страница 63: ...valve ensures a balance between sufficient back pressure and a sporty sound The electronically controlled valve enables Minimal exhaust restriction and sporty sound during performance driving conditio...

Страница 64: ...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 fuel is stored in two separate chambers and therefore two fu...

Страница 65: ...n 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...

Страница 66: ...er 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 m...

Страница 67: ...y the required fuel to the high pressure pump via a pressure control valve There is a pre filter in the reservoir and a main filter outside the fuel tank The pre filter is not subject to change interv...

Страница 68: ...Electric fuel pumps 8 9 Pressure control valve G1821780 Service Training 66 Lesson 3 Powertrain Fuel System...

Страница 69: ...ough the gears a small RS indicator illuminates in the IPC when the powertrain reaches the optimum upshift point The RS indicator flashes when the engine is close to reaching the RPM limiter and when...

Страница 70: ...beside the gearshift lever which is used to select the desired drive mode Pressing the button repeatedly will enable the driver to scroll through all available modes which are displayed in the message...

Страница 71: ...est possible acceleration when launching from a standing start The following must be carried out to switch the feature on NOTE The vehicle must be completely stationary 1 Fully depress the clutch peda...

Страница 72: ...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 t...

Страница 73: ...mechanism Stepper motor for multifunction unit 1 Reflector 2 Lens 3 Stepper motor for adaptive front light 4 The Bi Xenon HID headlamp assembly has an integrated solenoid activated shutter which chan...

Страница 74: ...ing 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...

Страница 75: ...ed at speeds 30 km h This light mode is used at speeds from 31 to 50 km h Cornering Light Mode E197678 This light is used to illuminate tight bends intersections or entryways at low speed 73 Service T...

Страница 76: ...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 fr...

Страница 77: ...ivate HS CAN is used for rapid interference free data exchange The HS CAN bus the HS CAN multimedia bus and the private HS CAN bus have a speed of 500 kBit s The MS CAN bus and the private MS CAN bus...

Страница 78: ...ween the HS CAN and MS CAN The IPC between the MS CAN and HS CAN multimedia Module acronyms ACM audio front control module DSP audio digital signal processing module EFP electronic finisher panel APIM...

Страница 79: ...ABS anti lock braking system module FLCM fuel level control module RDU rear drive unit 77 Service Training G1828300 Communications Network Lesson 4 Electrical...

Страница 80: ...formance character of the RS is reflected inside the car with heavily bolstered partial leather Recaro sports seats as the centrepiece of the cockpit Signature RS Recaro shell seats with authentic mot...

Страница 81: ...steering wheel aluminum pedals and Recaro part leather front seats The RS logo is displayed in the IPC instrument panel cluster stitched into the seat backrests steering wheel and on the scuff plate...

Страница 82: ...oor 5 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...

Страница 83: ...module GPSM headlamp control module HCM heating ventilation and air conditioning HVAC information center module ICM instrument panel cluster IPC local interconnect network LIN parking assist control...

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