Manual Coverage
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Systems Covered
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Body Systems:
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Front End Body Panels, Body Closures, Interior Trim and Ornamentation, Rear View Mirrors, Seating, Glass, Frames and Mechanisms, Instrument Panel and Console, Handles, Locks, Latches and Entry Systems, Wipers and Washers, Bumpers, Safety Belt System, Supplemental Restraint System
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Chassis And Frame:
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Covers structural integrity, frame repair techniques, and potential damage assessment to the underlying chassis.
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Paint Systems:
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Details on paint preparation, priming, application, curing, and finishing for OEM-quality results.
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Interior Trim Systems:
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Guidance on the removal, repair, and reinstallation of interior panels, seats, and trim components.
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Glass And Sealing:
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Procedures for windshield, side glass, and rear glass replacement, including proper sealing techniques.
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Procedures Included
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Body Repairs:
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General Information, Noise, Vibration and Harshness (NVH), Plastic Repairs, Paintless Dent Removal (PDR), Vehicle Specific Information, Tolerance Checks
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Sheet Metal Repairs:
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Front End Sheet Metal Repairs, Roof Sheet Metal Repairs, Side Panel Sheet Metal Repairs, Rear End Sheet Metal Repairs
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Paint Procedures:
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Paint - General Information
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Dent Removal Techniques:
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Covers both conventional methods and Paintless Dent Removal (PDR) techniques for minor imperfections.
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Plastic Component Repair:
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Methods for repairing cracked or damaged plastic bumpers, trim pieces, and other components.
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Safety Systems Repair:
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Specific instructions for handling and repairing components related to the Safety Belt System and Supplemental Restraint System (SRS), including airbag system precautions.
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Technical Depth
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Depth:
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Comprehensive body and paint repair procedures, including diagnostics, repair techniques, material specifications, and finishing processes.
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Specific Procedures:
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Detailed steps for door alignment, panel replacement (hood, fenders, doors, bumpers), chassis straightening, glass installation, trim removal/installation, and paint defect correction.
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Diagnostic Support:
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Guidance on diagnosing common body and paint issues, including water leaks, NVH problems, and cosmetic imperfections.
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Material Specs:
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Information on specific body materials used (e.g., steel grades, aluminum components, plastic types) and recommended repair materials and adhesives.
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Tolerance Checks:
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Provides critical dimensional data and tolerances for key body components to ensure proper fit and alignment after repair.
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Tooling Requirements:
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Implicitly or explicitly may reference specialized tools required for body and paint work, such as welders, dent pullers, measuring equipment, and spray guns.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 10,000 km or 12 months, whichever comes first, depending on driving conditions and engine oil used. Refer to specific manual for exact details.
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Filter Replacement Interval:
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Air filter and cabin filter typically every 20,000-40,000 km. Fuel filter for diesel models usually around 40,000-60,000 km.
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Fluid Specifications
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Engine Oil Type:
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Varies by engine. Commonly Ford WSS-M2C913-D (e.g., 5W-30 synthetic) for petrol, and specific diesel engine oils for TDCi variants. Consult manual for exact API/ACEA specifications.
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Coolant Type:
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Ford Super Plus Premium Antifreeze (Orange) or equivalent meeting WSS-M97B44-D specification.
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Brake Fluid Type:
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DOT 3 or DOT 4 brake fluid.
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Known Issues
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Common Problems:
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Some owners have reported issues with clutch wear (especially in heavy traffic), minor electrical gremlins, and suspension wear in certain conditions. Body panel fitment and paint durability can vary. The manual would provide specific repair guidance for these.
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Body Paint Specific:
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Potential for stone chip damage on front bumper and hood, minor rust spots on lower body panels in corrosive environments if not properly maintained. This manual is critical for addressing these.
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