2015-18 Focus RS III – Training Manual | Tài liệu môn Công nghệ kĩ thuật Ô tô Trường đại học sư phạm kỹ thuật TP. Hồ Chí Minh

FORD TRAINING Technical Service Training FORD Focus
New Model Introduction - Supplement P346 R010 01 CGAPA/S en
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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 Front fog lamps 2 Trapezoid grille 3 Bi - Xenon head lamps 6 (G1821216) Service Training Introduction 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
• Pull the handle to unlatch the bonnet
• Move the yellow catch to the right Service Training (G1821216) 7 Introduction
• To close the hood and allow it to drop under its own
weight from the last 20 – 30 centimetres Data Link Connector
• 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.
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). 8 (G1821216) Service Training Introduction
Load Compartment Fuse Box
NOTE: Only additional fuses and relays which are fitted to the RS are listed below.
F21 15A Fuel control relay. Damper control relay
F22 10A Active noise cancellation. Electronic sound enhancement
R4 Fuel control module. Damper control module Service Training (G1821216) 9 Introduction Capless Fuel Filler
• Twist the screwdriver in the position shown (3) to
separate the two halves of the remote control
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.
NOTE: When you insert the fuel nozzle, a spring loaded
inhibitor will open if the correct size nozzle is detected.
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 Replacement
NOTE: Do not touch the battery contacts or the printed
circuit board with the screwdriver.
• 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 10 (G1821216) Service Training Introduction Tire Repair Kit
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. Service Training (G1821216) 11
Lesson 1 – General Information 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. 12 (G1821201) Service Training
Lesson 1 – General Information Service Points 2.3L EcoBoost 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 Service Training (G1821202) 13 Jacking and Lifting
Lesson 1 – General Information
3. Press and release the brake pedal 5 times
NOTE: When exiting Transport mode, the IPC message
center will indicate NORMAL MODE when the
4. Press and release the hazard switch 2 times
procedure has been successfully completed.
5. Place the ignition in the OFF position 6. Start the engine Jacking and Lifting
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) . 14 (G1822861) Service Training
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. Service Training (G1822861) 15 Front Suspension Lesson 2 – Chassis Front Suspension 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: 16 (G1821294) Service Training 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 • Larger front anti-roll bar 1 Outer tie-rod locknut 2
Inner tie-rod adjustment rotate either clockwise or counterclockwise Service Training (G1821299) 17 Rear Suspension Lesson 2 – Chassis Rear Suspension 1 Upper arm 3
Reinforced lower connecting rods 2 Reinforced areas 4 Wheel knuckle 5 Wheel bearing and hub (AWD ) 18 Service Training