1997-2002 Ford Puma Service and Repair Manual

This 1997-2002 Ford Puma Service and Repair Manual Covers

Engine and Drivetrain

• Complete repair procedures for the 16-valve Sigma/Zetec-SE inline-4 engines (1.4L, 1.6L, 1.7L VCT, and Tickford-tuned 1.7L)
• Electronic multipoint fuel injection system diagnostics and repair procedures
• Variable Camshaft Timing (VCT) system service specifications for the 1.7L variant
• Engine cooling system and mechanical water pump service specifications
• Exhaust and emissions control system repairs including catalytic converter and oxygen sensor maintenance
• Transmission overhaul and troubleshooting procedures for the IB5 close-ratio 5-speed manual gearbox
• Driveshaft, constant velocity (CV) joints, and front-wheel-drive axle service procedures

Chassis and Suspension

• Front MacPherson strut suspension repair procedures specific to the Ford Mark 4 Fiesta platform
• Rear twist-beam suspension and uprated damper repair procedures
• Power-assisted rack and pinion steering system diagnostics and service specifications
• Wheel alignment specifications and manual tracking adjustment procedures
• Front and rear wheel bearing replacement procedures
• Suspension bushing, anti-roll bar, and track control arm diagnostics

Braking Systems

• Teves ABS diagnostic and hydraulic actuator procedures
• Brake hydraulic system bleed and service specifications
• Front disc brake caliper and pad replacement procedures
• Rear self-adjusting drum brake shoes and wheel cylinder repairs (disc setup for Racing Puma)
• Cable-operated parking brake service and mechanical adjustment procedures
• Brake master cylinder and vacuum servo inspection and replacement procedures

Electrical and Wiring

• Complete factory wiring diagrams and chassis ground point locations
• Battery load testing, alternator charging, and starter motor system diagnostics
• Central Timer Module (CTM) and EEC-V engine management diagnostics
• Power distribution box, passenger fuse box schematics, and relay layouts
• Exterior lighting, analog dashboard cluster, and indicator diagnostics
• Factory Ford audio units, analog clock, and Passive Anti-Theft System (PATS) immobilizer troubleshooting

Air Conditioning and HVAC

• Manual climate control and cable-driven heater matrix diagnostics
• Blower motor, resistor pack, and HVAC component replacement procedures
• R134a refrigerant specifications, capacity, and system evacuation/charging procedures
• Heating, ventilation, and air recirculation flap troubleshooting

Body and Interior

• Interior door card, center console, and sport seat removal and installation procedures
• Exterior body repair information, underbody rust prevention, and panel alignment
• Electric window lifter, manual sunroof, and central locking system diagnostics
• Hatchback gas strut and mechanical tailgate latch repairs
• Drivers-side airbag and seatbelt pyrotechnic pretensioner restraint system service procedures

Diagnostics and Troubleshooting

• Ford EEC-V Diagnostic Trouble Code (DTC) lookup procedures
• Star tester and Ford FDS2000 / WDS tool hookup and scan tool procedures
• Component voltage, resistance, and reference testing specifications
• Step-by-step troubleshooting workflows for engine hesitation, rough idle, and stalling
• Powertrain Control Module (PCM) diagnostic pinout procedures

Common Error Codes Covered

This manual provides diagnostic and repair procedures for thousands of manufacturer-specific fault codes, including:

Engine Codes

• P0102: Mass Air Flow (MAF) sensor circuit low input
• P0113: Intake Air Temperature (IAT) sensor circuit high input
• P0133: Heated Oxygen Sensor (HO2S) circuit slow response (Bank 1, Sensor 1)
• P0340: Camshaft Position (CMP) sensor circuit malfunction
• P1390: Variable Camshaft Timing (VCT) circuit malfunction / timing solenoid fault

Transmission Codes

• P0704: Clutch switch input circuit malfunction (IB5 manual starter interlock)
• P0500: Vehicle Speed Sensor (VSS) circuit malfunction (gearbox output sensor)

ABS and Chassis Codes

• C1145: Front right wheel speed sensor input circuit failure
• C1155: Front left wheel speed sensor input circuit failure
• C1233: Speed wheel sensor front left input signal missing

Network Communication Codes

• U1147: SCP (Standard Corporate Protocol) invalid or missing data for vehicle state
• U1262: SCP (J1850) communication bus fault / engine to instrument cluster link error

Body Control Codes

• B1318: Battery voltage low (detected by Central Timer Module / PATS module)
• B1600: PATS (Passive Anti-Theft System) ignition key transponder signal not received

This manual is ideal for:

• Professional automotive workshops
• Independent repair garages
• Mobile mechanics
• Automotive technicians
• Vehicle owners performing DIY repairs
• Automotive training institutions

• 1997 Ford Puma
• 1998 Ford Puma
• 1999 Ford Puma
• 2000 Ford Puma
• 2001 Ford Puma
• 2002 Ford Puma