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Ford Tourneo Connect 2002, Owner'S Manual, Page: 2669 / 2797

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Ford Tourneo Connect 2002 Owner'S Manual Download Page 2669

All weld beads must be ground down after all welding is completed, taking care not to 
weaken the material. 

Any unevenness at joints is removed using lead loading. 

If necessary, spot weld missing T-pins for trim strip clamps into position. The vehicle must 
be completely cleaned of sanding dust and metal swarf because of the danger of corrosion. 

Clean and prime all internal areas and those to be sealed. 

Seal all welded areas and joints, apply underbody protection. 

NOTE: The primer must be dry before sealing mastic or underbody protection is applied. 
Do not use thinner when applying sealing mastic (the mastic would not dry). 

The noise damping mats and cavity foam applied in production must be re-applied. 

After painting, apply cavity protection to all cavities in all parts which have been renewed 
(especially at weld seams). 

Partial renewal 

The procedure to follow when partially renewing components is the same as described in 
the section "Welded components". 

The main difference when components are partially rather than completely renewed 
concerns the preparation of butt or lap joints. 

When bodywork components are cut through, attention must be paid to the adequate 
removal of the paint and zinc coatings on inner areas. This specially applies to areas 
which are difficult to access internally.  
It is important for the weld quality that the inner area is bare metal. Zinc and paint 
residues in the weld area burn and cause serious hole formation during welding.  
If the zinc layer and the paint coating are not removed, the zinc and paint will burn 
during welding. The soot produced prevents satisfactory cavity protection. 

Procedure 

The paint layer must be removed for a width of 30mm from the line of the weld using a 
rotating tress wire brush.  
This operation must be carried out on both the new and the old parts of the bodywork.  
Depending on the bodywork component, a 10mm width of the underlying zinc layer must 
also be removed along the weld line. 

NOTE: A flat scraper or a wire brush can be used instead of the rotating brush if the 
cavity is small. Do not use an angle grinder, which would weaken the structure. 

Application of cavity protection on a door sill after partial repair. 

  

 

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Summary of Contents for Tourneo Connect 2002

Page 1: ...rrectly may result in personal injury CAUTION Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the vehicle or equipment being used NOTE Notes are used to provide additional essential information required to carry out a complete and satisfactory repair As you read through this manual you will come across WARNINGS CAUTIONS and NOTES A warning caution...

Page 2: ...er pinpoint tests have two columns CONDITIONS and DETAILS RESULTS ACTIONS The CONDITIONS column is used exclusively for graphics and icons with or without captions and the DETAILS RESULTS ACTIONS column provides direction to another test step or specific corrective actions The boxed numbers indicate the order in which the described action is to be performed Item Designation Description 1 Special t...

Page 3: ...meters If multiple measurements are made in a single graphic the test leads are drawn with a solid line until the test lead splits to indicate the multiple measurements at which point dashed lines are used Breakout box type testers are represented by a double circle test pin Test pins are labeled with the pin number Special Tools and Torque Figures Any requirement for special tools will picture th...

Page 4: ...ve impervious apron gloves and goggles Do not breath mists Make sure access to eye wash bottles shower and soap are readily available for splashing accidents Display Eye Hazard sign Air Bags See also Fire Chemical Materials Highly flammable explosive observe No Smoking policy Used as a safety restraint system mounted in the steering wheel and passenger side of the instrument panel The inflator con...

Page 5: ...rostbite Instructions given by the manufacturer must be followed Avoid naked lights wear suitable protective gloves and goggles If refrigerant comes into contact with the skin or eyes immediately rinse the affected areas with water Eyes should also be rinsed with an appropriate irrigation solution and should not be rubbed SEEK MEDICAL ASSISTANCE IF NECESSARY Air Conditioning Refrigerant Do Nots Do...

Page 6: ...issue is bonded cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION Do not attempt to pull tissue apart Use in well ventilated areas as vapors can cause irritation to the nose and eyes For two pack systems see Resin based and Isocyanate Adhesives Sealers Isocyanate Polyurethane Adhesives Sealers See also Resin based Adhesives Individuals suffering from asthma or respiratory allergies...

Page 7: ...s See Asbestos Brake Fluids Polyalkylene Glycols See also Fire Splashes to the skin and eyes are slightly irritating Avoid skin and eye contact as far as possible Inhalation vapor hazards do not arise at ambient temperatures because of the very low vapor pressure Brazing See Welding Chemical Materials See also Legal Aspects Chemical materials such as solvents sealers adhesives paints resin foams b...

Page 8: ...emicals particularly solvents and fuels will dry the skin and may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities Do not use emptied containers for other materials except when they have been cleaned under supervised conditions Do not sniff or smell chemical materials Brief exposure to high concentrations of fumes can be toxic or harmful Chlorof...

Page 9: ...any way faulty The results could be fatal Make sure that the cables of mobile electrical equipment cannot get trapped and damaged such as in a vehicle hoist Make sure that the designated electrical workers are trained in basic First Aid In cases of electrocution switch off the power supply before approaching the victim if this is not possible push or drag the victim from the source of electricity ...

Page 10: ...resh air immediately If effects persist consult a doctor If liquids are swallowed inadvertently consult a doctor giving him the information on the container or label Do not induce vomiting unless this action is indicated on the label Fluoroelastomer See Viton Foams Polyurethane See also Fire Used in sound and noise insulation Cured foams used in seat and trim cushioning Follow manufacturers instru...

Page 11: ...tion in the event of vapor build up arising from spillages in confined spaces Special precautions apply to cleaning and maintenance operations on gasoline storage tanks Gasoline should not be used as a cleaning agent It must not be siphoned by mouth See First Aid Gas oil Diesel Fuel Combustible Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin disorders i...

Page 12: ...ropriate markings Cylinders should be stored in well ventilated enclosures and protected from ice and snow or direct sunlight Fuel gases for example acetylene and propane should not be stored in close proximity to oxygen cylinders Care should be exercised to prevent leaks from gas cylinders and lines and to avoid sources of ignition Only trained personnel should undertake work involving gas cylind...

Page 13: ...tive equipment requirements Draw attention to the existence of Material Safety Datasheets MSDS s for the fluids available from Ford Customer Service Division These MSDS s contain detailed information on hazards and appropriate controls Control measures Workplace risk assessments made under national chemical control regulations should identify operations involving the fluids as potentially hazardou...

Page 14: ...afety Data Sheets Safety Data Sheets which detail specific material handling instructions and precautions are available from the respective national sales company and via internet www msds ford com Used Engine Oil Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin leading to dryness irritation and dermatitis In addition used engine oil contains...

Page 15: ... produced by the application of any flame to surfaces coated with grease and inhalation of these should be avoided Removal of excess solder should be undertaken with care to make sure that fine lead dust is not produced which can give toxic effects if inhaled Respiratory protection may be necessary Solder spillage and filings should be collected and removed promptly to prevent general air contamin...

Page 16: ...gaskets which contain a material known as Viton Viton is a fluoroelastomer that is a synthetic rubber type material which contains Fluorine It is commonly used for O rings gaskets and seals of all types Although Viton is the most well known fluoroelastomer there are others including Fluorel and Tecmoflon When used under design conditions fluoroelastomers are perfectly safe If however they are expo...

Page 17: ... where the general ventilation is poor or where considerable welding work is anticipated In extreme cases or confined spaces where adequate ventilation cannot be provided air fed respirators may be necessary Gas Welding and Cutting Oxy acetylene torches may be used for welding and cutting and special care must be taken to prevent leakage of these gases with consequent risk of fire and explosion Th...

Page 18: ...f any kind 2 2 Components or assemblies displaying the warning triangle with the electrified arrow and open book symbol give warning of inherent high voltages Never touch these with the engine running or the ignition switched on See Electric Shock in this subsection 3 3 Vehicles and replacement components which contain asbestos are identified by this symbol See Asbestos in this subsection http vnx...

Page 19: ...se of naked lights or flames within the immediate vicinity due to the presence of highly flammable or explosive liquids or vapors See Fire in this subsection 6 6 Displaying this symbol normally in conjunction with 5 above warn of the presence of potentially explosive matter within the immediate vicinity 7 7 Displaying this symbol warn that children should not be allowed in the immediate vicinity u...

Page 20: ...ring turn signal lamps horn and stop lamps be operational Failure to follow these instructions may result in personal injury NOTE The removable towing eye if equipped has a left hand thread and must be fully tightened before towing can commence When towing is necessary the vehicle towing eyes should be used The rope must be securely fastened to the towing eyes and must also be attached to the othe...

Page 21: ...even cause the battery to explode Failure to follow these instructions may result in personal injury Always connect the jumper cables in the following sequence Slave battery positive first and then vehicle battery positive Slave battery negative next and then vehicle ground at least 12 inches 300 mm from the battery terminal for example engine lifting eye Always reduce the engine speed to idle bef...

Page 22: ...dling and some are harmful Refer to Health and Safety Precautions and to the manufacturers literature for the relevant safety precautions Failure to follow these instructions may result in personal injury Various solvents are available which are suitable for component cleaning Some components such as brake hydraulic parts and electrical assemblies should be cleaned only with recommended solvents r...

Page 23: ...s follow the manufacturers instructions If in doubt about any substance particularly a solvent DO NOT use it CAUTION If in doubt about the suitability of any proprietary solvent or sealer for a particular application contact the manufacturer of the product for information regarding storage handling and application The Health and Safety Precautions subsection refers to some commonly used chemicals ...

Page 24: ...re is sufficient fuel in the tank to complete the test all around the engine transmission and under the vehicle for oil coolant hydraulic and fuel leaks Make a note of any apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on completion of the test Starting the Engine NOTE On initial drive away from cold and within the first 1 5 km 1 mile do not ...

Page 25: ... and effectively the brake operation and efficiency Brake Testing WARNING When brake testing avoid breathing the fumes from hot brakes this may contain asbestos dust which is hazardous to health Failure to follow this instruction may result in personal injury For additional information refer to Health and Safety Precautions 100 00 General Information Description and Operation CAUTIONS Avoid brake ...

Page 26: ...g as often as possible Do not force the eyelid open Seek medical attention for any persistent eye irritation or abnormality SWALLOWED Fuel is moderately toxic and tends to foam on vomiting If drawn into the lungs inflammation may develop Do not induce vomiting If spontaneous vomiting occurs place the victim in a forward position to reduce the risk of fuel being drawn into the lungs Give nothing by...

Page 27: ...e that any protective clothing worn is clean and made from lint free non flocking material Make sure to wear non powdered latex type gloves Make sure to protect all electrical components and connectors with lint free non flocking material before using the suitable evaporative cleaning agent NOTE Soot discomfort and irritation usually give adequate warning of hazardous fume concentrations http vnx ...

Page 28: ...mmediate medical attention SKIN CONTACT If acid comes into contact with the skin flush immediately with plenty of running water for a minimum of 15 minutes Seek immediate medical attention SWALLOWED If acid is swallowed rinse the mouth with plenty of water and then drink plenty of water or milk Do not induce vomiting Seek immediate medical attention Batteries normally produce explosive gases Do no...

Page 29: ...technic residue may be rapidly absorbed through the skin in toxic quantities Wash with plenty of water Do not use soap Seek medical attention SWALLOWED Unburned pyrotechnic residue is extremely toxic If conscious drink plenty of water then induce vomiting Seek immediate medical attention If unconscious or in convulsions do not attempt to induce vomiting or give anything by mouth Seek immediate med...

Page 30: ...s must be placed in a suitable cage when removed from the vehicle The air bag or trim cover must be facing upwards Do not install a rearward facing child safety seat to the passenger seat with an activated passenger air bag CAUTIONS Pyrotechnic components must not be subjected to temperatures higher than 110 C Never install aftermarket accessories to the vehicle on or adjacent to the supplemental ...

Page 31: ...terisk The Vehicle Identification Number VIN number for identifying the vehicle is stamped into the body on the right hand sill The VIN is also located on the instrument panel visible through the windshield The vehicle identification plate VIN plate is located on the B pillar on the passenger side item 1 Description VIN plate Visible VIN behind the windshield VIN an example of VIN shown Item 1 2 P...

Page 32: ...n 4 and 10 Body Type VIN Position 5 and 6 Constant X VIN Position 7 and 8 Product Source Company and Assembly Plant VIN Position 9 Model Item 1 2 3 4 5 6 7 8 Code World Manufacturer WF0 Ford Werke AG Germany European vehicles NMO Ford Otomotiv Sanayi A S Turkey for the Turkish market Code Body Type G 5 seat van N1 H Combi short wheelbase M1 J Combi long wheelbase M1 K 5 seat van long wheelbase N1 ...

Page 33: ...t Tourneo Connect Code Year of Manufacture 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 Build month 2002 2003 2004 2005 2006 2007 2008 2009 January L C B J L C B J February Y K R U Y K R U March S D A M S D A M April T E G P T E G P May J L C B J L C B June U Y K R U Y K R July M S D A M S D A August P T E G P T E G September B J L C B J L C October R U Y K R U Y K November A M S D A M ...

Page 34: ...e type approval A unique code required by legislation in certain territories Item 2 VIN Vehicle Identification Number Item 3 GVM Indicates the maximum legal laden mass in territories where this is required Item 4 GTM Indicates the maximum combined mass of vehicle and trailer or caravan Item 5 Maximum permissible front axle mass Maximum permissible loading on the front wheels of the vehicle Item 6 ...

Page 35: ...with tailgate sliding door on LHS H 5 door with tailgate J 4 door with high roof K 5 door with high roof sliding door on RHS L 5 door with high roof sliding door on LHS M 6 door with high roof Code Suspension AA Standard IL strengthened construction Code Drive J Left hand drive K Right hand drive L Left hand drive M Right hand drive Code Body Color BD Saffron Yellow or Sand Yellow EC Pepper Red or...

Page 36: ...atec DOHC Zetec Turkey EYPC 1 8L Duratec DOHC Zetec LPG Europe EYPD 1 8L Duratec DOHC Zetec CNG Europe BHPA 1 8L Duratorq TDDi Lynx 55 kW 75 PS Europe BHPB 1 8L Duratorq TDDi Lynx 55 kW 75 PS Turkey HCPA 1 8L Duratorq TDCi Lynx 66 kW 90 PS Europe HCPB 1 8L Duratorq TDCi Lynx 66 kW 90 PS Europe HCPC 1 8L Duratorq TDCi Lynx 66 kW 90 PS Turkey P7PA 1 8L Duratorq TDCi Lynx VNT 56 kW 76 PS Europe R2PA ...

Page 37: ...00 2025 2825 T220 2230 3030 T200 2035 2835 T200 2035 2835 T220 2240 3040 T210 2080 2880 T220 2260 3060 T230 2260 3060 T230 2340 3140 T230 2340 3140 K200 2045 2845 K210 2110 2910 K220 2175 2975 K230 2340 3140 http vnx su ...

Page 38: ...d for jacking up and supporting the vehicle CAUTION Park the vehicle on a flat level and stable surface If the vehicle must be lifted on a soft surface the supporting forces must be spread by using a suitable base under the jack Place a wheel chock against the wheel opposite the jack Injury may occur if these instructions are not followed http vnx su ...

Page 39: ...ng Transit Tourneo Connect 2002 5 06 2002 Print Description and Operation WARNING Only raise the vehicle at the specified lifting points CAUTION Place blocks underneath the hoist points if a two column ramp is used http vnx su ...

Page 40: ... cause of the condition is usually found the first time through the system Know the System Know how the parts go together Know how the system operates as well as its limits and what happens when the system goes wrong Sometimes this means checking the system against one that is known to be working correctly Know the History of the System A clue in any one of these areas may save time How old or new...

Page 41: ...omponents They help discover the cause of a condition in the least time Diagnostic charts combine many areas of diagnosis into one visual display Probability of certain things occurring in a system Speed of checking certain components or functions before others Simplicity of performing certain tests before others Elimination of checking huge portions of a system by performing simple tests Certaint...

Page 42: ... series of Road Test Quick Checks are provided to make sure that a cause is either pinpointed or eliminated Name the condition proceed to the appropriate section and locate the correct diagnosis When the condition is identified the job is partly done Follow the diagnostic procedure as outlined Quick Checks are described within the step while more involved tests and adjustments are outlined in Gene...

Page 43: ...ough it may be louder and occurs on acceleration or deceleration The teardown will disclose what has to be corrected Clicking popping or grinding noises may be caused by the following worn damaged or incorrectly installed wheel bearing suspension or brake component Check and rule out tires exhaust and trim items before disassembling the transmission to diagnose and correct gear noise The noises de...

Page 44: ...at speed It may also produce a moaning sound depending on what component is causing it REFER to Tip in Moan in the Driveline Noise and Vibration Symptom Chart 2 2 Acceleration Deceleration With slow acceleration and deceleration a shake is sometimes noticed in the steering wheel column seats front floor panel front door trim panel or front end sheet metal It is a low frequency vibration around 9 1...

Page 45: ...ns Is the noise from when the vehicle was new Can the noise be repeated constantly or is it random Check the condition of the vehicle age mileage and service record Interview the customer to find the operating condition in which the noise will occur Test the vehicle based on the detail s from the customer interview Follow the power steering operation noise condition tables below to find which cond...

Page 46: ...system NVH concerns column B REFER to steering system NVH concerns column C REFER to steering system NVH concerns column D REFER to steering system NVH concerns column E REFER to steering system NVH concerns column F Steering System operation condition column A to F Noise Driving condition A B C D E F Moan Parking between lock stops at engine idle and also increased engine speed X O Whine Driving ...

Page 47: ...ring wheel 3 3 Engine speed at 1250 50 rpm with no steering action 4 4 Engine speed at 1250 50 rpm with slow 90 degrees per second turning of the steering wheel Symptom Possible Sources Action Power steering system moan noise A continuous low pitched humming noise occurs when the steering wheel is turned and the steering system is loaded Noise frequency changes with engine rpm changes Particularly...

Page 48: ...loaded Power steering fluid aeration BLEED the power steering system REFER to Power Steering System Bleeding 211 00 Steering System General Information General Procedures Incorrect power steering fluid FLUSH the power steering system REFER to Power Steering System Flushing 1 8L Duratec DOHC 85kW 115PS Zetec 211 00 Steering System General Information General Procedures Power Steering System Flushin...

Page 49: ...seal Power steering gear valve design Certain amount of noise level acceptable not a safety critical item Power steering system hydraulic design Certain amount of noise level acceptable not a safety critical item NOTE Engine speed at idle holding the steering wheel against a steering lock for three seconds Do not hold for more than five seconds Power steering system hiss noise a continuous noise l...

Page 50: ... noise clear knock noise from steering gear linkage area Worn tie rod ball joints inner and outer ball joints REFER to Steering System REFER to Steering System 211 00 Steering System General Information Diagnosis and Testing Symptom Possible Sources Action Power steering system knock noise loud metallic sound if hitting the suspension crossmember with a hammer sounds like metallic noise but is cre...

Page 51: ...automatic transmission in P PARK or manual transmission in neutral and the windows closed 1 1 Slowly turn the steering wheel from lock to lock 2 2 Tilt and extend the steering column in various positions and slowly turn the steering wheel from lock to lock flow rate by design safety critical item Symptom Possible Sources Action Power steering system column knock noise a loose sounding rattle or vi...

Page 52: ...pplemental Restraint System Removal and Installation Symptom Possible Sources Action Power steering system zip noise occurs when hydraulic fluid does not flow freely through the power steering pump supply hose from steering fluid reservoir to power steering pump causing cavitation at the pump Zip is primarily a cold weather start up phenomenon below 10 C High viscosity of power steering fluid at l...

Page 53: ...HECK THE AIR CLEANER Check the condition of the air cleaner mounts inlet tube outlet tube resonators and all other components associated with the air induction system for correct installation and tightness of all connections 1 Are the components OK Yes GO to B2 No REPAIR or INSTALL new components as necessary ROAD TEST as necessary B2 CHECK THE EXHAUST SYSTEM Carry out the exhaust system neutraliz...

Page 54: ...ings and bushings for security and condition Check the radiator installation for any component that may have a touch condition 1 Is the installation and bushings OK Yes GO to C3 No REPAIR or INSTALL new components as necessary ROAD TEST as necessary C3 CHECK THE EXHAUST SYSTEM Carry out the exhaust system neutralizing procedure REFER to in this section 1 Is the exhaust system OK Yes GO to C4 No RE...

Page 55: ...ctions ROAD TEST as necessary No INSTALL new wheels or tires as necessary REFER to Wheel and Tire 204 04 Wheels and Tires Removal and Installation ROAD TEST as necessary PINPOINT TEST E NON AXLE NOISE TEST CONDITIONS DETAILS RESULTS ACTIONS E1 INSPECT THE VEHICLE TRIM Check the radiator grille and trim panels to see if they are the source of the noise 1 Are the vehicle trim components causing the ...

Page 56: ... the noise For example touch condition body to frame antennas deflectors and fog lights 1 Are the accessories the cause of the noise Yes ADJUST REPAIR or INSTALL new accessories or fasteners as required ROAD TEST as necessary No VERIFY the customer concern http vnx su ...

Page 57: ...olts 3 NOTE Support the powertrain drivetrain in an approximate position and height NOTE Make sure that the right hand mount and left hand insulator align over the studs on the powertrain and drivetrain to allow the fixings to be assembled through the large holes in the support insulator bracket without overstraining Check the powertrain drivetrain mount alignment 4 Tighten the powertrain drivetra...

Page 58: ... to 1 07 Short wheelbase kombi 0 70 0 20 to 1 20 0 42 0 12 to 1 12 Long wheelbase van 0 52 0 02 to 1 02 0 31 0 01 to 1 01 Long wheelbase kombi 0 61 0 11 to 1 11 0 37 0 07 to 1 07 Derivative Tolerance Range Setting Adjustment If Required All variants decimal degrees 0 22 Toe in 0 15 All variants degrees and minutes 0 13 Toe in 0 09 All variants mm 1 5 Toe in 1 0 Derivative Tolerance Range Setting A...

Page 59: ...Torque Specifications Description Nm lb ft lb in Tie rod end locknut 47 35 http vnx su ...

Page 60: ...abiliser link rods are provided with an Allen screw fixing Overview Description McPherson strut Stabiliser link rod Front axle crossmember Stabiliser depending on vehicle variant Mounting for L shaped suspension lower arm L shaped suspension lower arm The front track for all vehicle variants is 1505 mm Depending on vehicle variant the wheel base is 2665 mm short wheel base or 2912 mm long wheel ba...

Page 61: ...wo separate routes for independently deflecting the spring and shock absorber forces into the body This reduces the level of noise transmitted from the road surface Springs with various ratings may be installed depending on the vehicle variant The shock absorbers are twin tube gas shock absorbers Dampers with various characteristics may be installed depending on the vehicle variant The ball joint ...

Page 62: ...Front Suspension Front Suspension Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 204 00 Suspension System General Information http vnx su ...

Page 63: ...0 Adapter for 205 074 205 074 01 15 064 Installer Rear Hub Oil Seal 205 075 15 036 Remover Bearing Gear 204 348 Installer Aligner Crankshaft Rear Oil Seal 303 172 03 21 102 03 1 Remove the wheel knuckle For additional information refer to Wheel Knuckle 204 01 Front Suspension Removal and Installation 2 Using the special tools remove the wheel hub from the wheel knuckle 3 Remove the circlip from th...

Page 64: ... and discard the wheel bearing 1 CAUTION Make sure the wheel bearing is installed into the wheel knuckle with the wheel speed sensor ring colored black towards the inner face of the wheel knuckle NOTE Install a new wheel bearing Using the special tool install the new wheel bearing 2 NOTE Make sure the circlip does not cover the wheel speed sensor Install the circlip 3 Using the special tools insta...

Page 65: ...4 Install the wheel knuckle For additional information refer to Wheel Knuckle 204 01 Front Suspension Removal and Installation http vnx su ...

Page 66: ...g a soft cloth to prevent damage Protect the heat shield using a soft cloth to prevent damage Using a suitable two leg puller detach the lower arm from the wheel knuckle 1 Use a soft faced hammer to strike the lower arm 2 Remove and discard the retaining nut 4 Remove the lower arm 1 Remove and discard the front retaining bolt 2 Remove and discard the rear clamp retaining nuts bolts and ball bearin...

Page 67: ...l joint retaining nut Failure to follow this instruction may result in personal injury CAUTION Protect the heat shield using a soft cloth to prevent damage NOTE Use a T50 Torx driver to prevent the ball joint from rotating Attach the lower arm to the wheel knuckle 5 Install the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 6 Check the toe setting and adjust as ...

Page 68: ...ls are in the straight ahead position Centralize the steering and lock it in position 2 Disconnect the steering column shaft from the steering gear pinion extension Discard the bolt 3 Remove the front wheels and tires For additional information refer to Section 204 04 Wheels and Tires 4 CAUTION Leave the tie rod end retaining nut in place to protect the ball joint stud NOTE Use a 5 mm Allen key to...

Page 69: ...retaining nut in place to protect the ball joint stud Protect the ball joint seal using a soft cloth to prevent damage Protect the heat shield using a soft cloth to prevent damage Using a suitable two leg puller detach the lower arm from the wheel knuckle 1 Use a soft faced hammer to strike the lower arm 2 Remove and discard the retaining nut 8 NOTE Use a 5 mm Allen key to prevent the ball joint f...

Page 70: ...0 mm 14 Remove and discard the crossmember ball bearing washers 15 Remove the stabilizer bar clamp on both sides 16 Remove the stabilizer bar 17 Remove the stabilizer bar bushing on both sides 1 Check the lower arm ball joint heat shield for damage Install a new heat shield if necessary For additional information refer to Lower Arm Ball Joint in this section 2 CAUTION The stabilizer bar bushings m...

Page 71: ... the stabilizer bar to the installation setting Using cable ties support the stabilizer bar on both sides 6 Install the stabilizer bar 7 Remove the cable ties 8 CAUTION Make sure the crossmember ball bearing washers are installed correctly NOTE Install new ball bearing washers Using a suitable transmission jack and the special tool position and align the crossmember 1 Insert the alignment pins thr...

Page 72: ... sides 13 WARNING Install a new lower arm ball joint retaining nut Failure to follow this instruction may result in personal injury CAUTION Protect the heat shield using a soft cloth to prevent damage NOTE Use a T50 Torx driver to prevent the ball joint from rotating Attach the lower arm to the wheel knuckle on both sides 14 WARNING Install a new tie rod end retaining nut Failure to follow this in...

Page 73: ... Failure to follow this instruction may result in personal injury NOTE Make sure the road wheels are in the straight ahead position Connect the steering column shaft to the steering gear pinion extension 17 Check the toe setting and adjust as necessary For additional information refer to Section 204 00 Suspension System General Information http vnx su ...

Page 74: ...l Joint 211 020 13 006 Two leg puller Three leg puller 1 Loosen the wheel hub retaining nut 2 Loosen the strut and spring assembly top mount retaining nuts by five turns 3 Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 4 CAUTION Suspend the brake caliper and anchor plate to prevent load being placed on the brake hose Detach the brake caliper and ancho...

Page 75: ...place to protect the ball joint stud NOTE Use a 5 mm Allen key to prevent the ball joint stud from rotating Loosen the tie rod end retaining nut 8 CAUTION Protect the ball joint seal using a soft cloth to prevent damage Using the special tool detach the tie rod end from the wheel knuckle 1 Release the tie rod end 2 Remove and discard the tie rod end retaining nut 9 Remove and discard the wheel hub...

Page 76: ...cloth to prevent damage Using a suitable two leg puller detach the lower arm from the wheel knuckle 1 Use a soft faced hammer to strike the lower arm 2 Remove and discard the retaining nut 12 CAUTION Support the halfshaft The inner joint must not be bent more than 18 degrees The outer joint must not be bent more than 45 degrees Using a suitable three leg puller detach the wheel hub from the halfsh...

Page 77: ...he halfshaft 4 WARNING Install a new lower arm ball joint retaining nut Failure to follow this instruction may result in personal injury CAUTION Protect the heat shield using a soft cloth to prevent damage NOTE Use a T50 Torx driver to prevent the ball joint from rotating Attach the lower arm to the wheel knuckle 5 WARNING Install a new tie rod end retaining nut Failure to follow this instruction ...

Page 78: ... WARNING Install a new wheel hub retaining nut Failure to follow this instruction may result in personal injury With the aid of another technician apply the brakes and pre load the wheel bearing by installing the new wheel hub retaining nut 10 Install the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 11 Tighten the wheel hub retaining nut http vnx su ...

Page 79: ...12 Tighten the strut and spring assembly top mount retaining nuts http vnx su ...

Page 80: ...er to Section 204 04 Wheels and Tires 2 NOTE Use a 5 mm Allen key to prevent the ball joint from rotating Detach the stabilizer bar connecting link from the suspension strut 3 Remove the wheel knuckle to suspension strut pinch bolt 4 Using the special tool detach the suspension strut from the wheel knuckle 5 CAUTION With the aid of another technician support the strut and spring assembly Remove th...

Page 81: ... and spring assembly 2 Attach the suspension strut to the wheel knuckle 3 NOTE Use a 5 mm Allen key to prevent the ball joint from rotating Attach the stabilizer bar connecting link to the suspension strut 4 Install the wheel and tire For additional information refer to Section 204 04 Wheels and Tires http vnx su ...

Page 82: ...For additional information refer to Wheel Knuckle 204 01 Front Suspension Removal and Installation 2 CAUTION Make sure that vise jaw protectors are used Secure the wheel knuckle in a vise 3 Remove the circlip 4 Using the special tools remove the lower arm ball joint and heat shield 1 CAUTION Make sure that the heat shield is correctly located to prevent damage to the ball joint Using the special t...

Page 83: ...he vise 5 Install the wheel knuckle For additional information refer to Wheel Knuckle 204 01 Front Suspension Removal and Installation 6 Check the toe setting and adjust as necessary For additional information refer to 204 00 Suspension System General Information Specifications Specifications Front Toe Adjustment General Procedures http vnx su ...

Page 84: ...tension care must be taken at all times Failure to follow this instruction may result in personal injury Using the special tools compress the spring 2 CAUTION Use an Allen key to prevent the piston rod from rotating Loosen the thrust bearing retaining nut 3 Disassemble the strut and spring assembly 1 Remove the thrust bearing retaining nut 2 Remove the top mount 3 Remove the thrust bearing 4 Remov...

Page 85: ...Assembly 1 CAUTION The ends of the spring must locate correctly against the spring seats To assemble reverse the disassembly procedure http vnx su ...

Page 86: ...bolt retaining nuts 125 92 Spring rear mounting retaining bolts 115 85 Wheel spindle retaining bolts 115 85 Wheel hub retaining nut 340 251 Brake hose to brake caliper union 15 11 Wheel speed sensor retaining bolt 9 80 Stabilizer bar to connecting link retaining nut 100 74 Stabilizer bar connecting link to beam axle retaining nut 100 74 Stabilizer bar clamp retaining bolts 70 52 Spring front mount...

Page 87: ...e rear mounting is moveable in order to cater for the variation in the length of the leaf springs as they deflect under vehicle movement Description Leaf spring shown two fold spring Rear leaf spring mounting movable Stabiliser mounting Shock absorber variant for long wheel base Shock absorber variant for short wheel base Front leaf spring mounting not moveable Stabiliser bar Mounting for load dep...

Page 88: ...es without ABS a bracket for a load dependent brake pressure apportioning valve LAV is provided on the rear axle Wheel suspension Description Rubber bump stop Securing bolt for stub axle Steel tube Mounting for stub axle Stub axle Wheel studs Wheel hub Nut Dust cap The mounting for the stub axle is permanently joined to the axle body and cannot be changed separately The stub axle is secured to the...

Page 89: ...Rear Suspension Rear Suspension Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 204 00 Suspension System General Information http vnx su ...

Page 90: ... All vehicles Installation 1 Remove the brake drum For additional information refer to Section 206 02 Drum Brake 2 Remove the brake disc For additional information refer to Section 206 04 Rear Disc Brake 3 Remove the wheel hub For additional information refer to Wheel Hub in this section 4 Remove the wheel spindle 1 To install reverse the removal procedure http vnx su ...

Page 91: ...king and Lifting Description and Operation Lifting 100 02 Jacking and Lifting Description and Operation 2 NOTE Use a 6 mm Allen key to prevent the ball joint from rotating Detach the stabilizer bar connecting link from the stabilizer bar on both sides Discard the retaining nuts 3 Remove the stabilizer bar clamp on both sides 4 Remove the stabilizer bar 5 Remove the stabilizer bar bushings 1 CAUTIO...

Page 92: ...both sides 4 NOTE Install new stabilizer bar connecting link to stabilizer bar retaining nuts NOTE Use a 6 mm Allen key to prevent the ball joint from rotating Attach the stabilizer bar connecting link to the stabilizer bar on both sides 5 Lower the vehicle http vnx su ...

Page 93: ...table transmission jack support the beam axle 3 Remove the spring U bolts Discard the retaining nuts 4 Remove the guide plate 5 Remove the spring rear locknut and retaining bolt Discard the locknut 6 NOTE When removing the right hand spring front locknut and retaining bolt take note of the position of the spacer to aid installation Remove the spring front locknut and retaining bolt Discard the loc...

Page 94: ...ing When installing the right hand spring front locknut and retaining bolt make sure that the spacer is correctly positioned to prevent damage to the fuel tank NOTE Do not fully tighten the spring front locknut at this stage Install the spring front locknut and retaining bolt 2 WARNING Install a new locknut Failure to follow this instruction may result in personal injury NOTE Do not fully tighten ...

Page 95: ...5 Lower and remove the transmission jack 6 Lower the vehicle 7 Tighten the spring front locknut 8 Tighten the spring rear locknut 9 Tighten the spring U bolt retaining nuts http vnx su ...

Page 96: ...m axle is secured to the transmission jack Failure to follow this instruction may result in personal injury Using a suitable securing strap secure the beam axle to a transmission jack 3 Detach the shock absorbers from the beam axle 4 Detach the brake load sensor proportioning valve from the beam axle 5 NOTE Use a 6 mm Allen key to prevent the ball joint from rotating Detach the stabilizer bar conn...

Page 97: ... the beam axle spacer if equipped 2 Using a suitable transmission jack locate the beam axle 3 Install the guide plate 4 NOTE Install new spring U bolt retaining nuts NOTE Do nut fully tighten the spring U bolt retaining nuts at this stage Install the beam axle Install the retaining nuts 5 NOTE Do nut fully tighten the stabilizer bar connecting link to beam axle retaining nuts at this stage NOTE Us...

Page 98: ...ock absorber retaining nuts at this stage Attach the shock absorbers to the beam axle 8 Remove the securing strap 9 Lower and remove the transmission jack 10 Install the brake backing plates For additional information refer to Section 206 02 Drum Brake 11 Tighten the spring U bolt retaining nuts 12 NOTE Use a 6 mm Allen key to prevent the ball joint from rotating Tighten the stabilizer bar connect...

Page 99: ...i lock brakes 13 Tighten the shock absorber lower mounting retaining nuts 14 Adjust the brake load sensor proportioning valve For additional information refer to Section 206 00 Brake System General Information http vnx su ...

Page 100: ...fer to Section 206 02 Drum Brake 2 Remove the brake disc For additional information refer to Section 206 04 Rear Disc Brake 3 Remove the dust cap 4 Remove the wheel hub Remove and discard the wheel hub retaining nut 1 WARNING Install a new wheel hub retaining nut Failure to follow this instruction may result in personal injury NOTE If the dust cap is damaged a new dust cap must be installed To ins...

Page 101: ...port the vehicle Refer to Jacking 100 02 Jacking and Lifting Description and Operation Refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 CAUTION Make sure that the ball joint ball does not rotate NOTE Note the position of the component before removal Torque 100 Nm 1 NOTE Make sure that this component is installed to the noted removal position To install reverse the removal pr...

Page 102: ...Wheels and Tires Specifications Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Wheel nuts Alloy wheel 120 89 Wheel nuts Steel wheel 90 66 http vnx su ...

Page 103: ...the tyre Description Manufacturer Symbol North American D epartment 0 f T ransportation Manufacturer code for product size and design Date of production week year Theoretical width of the tyre profile in millimetres Height to width ratio in Tyre construction type arrangment of the carcass in the tyre earlier also diagonal Rim diameter in inches Load index Speed rating Mark showing running directio...

Page 104: ...e optimum driving characteristics Running direction dependent tyres only install in the direction given on the sidewall arrow mark Asymmetrical tyres must always be installed in the correct position in relation ot the axle i e acccording to the marking on the sidewall Example SIDE FACING INWARDS this means that this tyre wall must be towards the centre of the vehicle Example OUTSIDE this means tha...

Page 105: ...e maximum speed of 80 km h 50 mph must be present on the tyre Winter tyres When using winter tyres it is a requirement that the maximum permitted speed for the winter tyres should be displayed in an obvious position in the field of vision of the driver In order to comply with the regulations a sticker must be used to advise the vehicle driver of the maximum speed of the winter tyres being used Ite...

Page 106: ...pending on payload tyres with the load rating of 91T or 95T are used The wheel size is 6Jx15 the hole pitch circle 107 95 mm These are also available as light alloy wheels No special wheel bolts are needed for these It is possible however to secure the wheels against theft using special wheel bolts 91AB 1A043 AA All tyres can be driven with snow chains http vnx su ...

Page 107: ...ear on non driven wheels Severely incorrect toe settings will also cause other unusual wear patterns Tire Vibration Diagnosis A tire vibration diagnostic procedure always begins with a road test The road test and customer interview if available will provide much of the information needed to find the source of a vibration During the road test drive the vehicle on a road that is smooth and free of u...

Page 108: ...e pressure s Vehicle overloaded CORRECT as necessary Incorrect wheel alignment ADJUST the wheel alignment REFER to 204 00 Suspension System General Information Specifications Specifications Front Toe Adjustment General Procedures Tire s show excess wear in center of tread Tire s over inflated ADJUST the tire pressure s Other excessive tire wear concerns Incorrect tire pressure s ADJUST the tire pr...

Page 109: ...OVE the water Bent wheel INSTALL a new wheel and tire assembly REFER to Wheel and Tire 204 04 Wheels and Tires Removal and Installation Incorrectly seated tire bead SPIN the wheel on the vehicle EXAMINE the area where the tire and the wheel meet If that section of the tire appears to waver while being rotated the tire bead may not be correctly seated on the wheel REMOVE the tire and CLEAN the bead...

Page 110: ...s If corrosion is slight wire brush away If corrosion is excessive INSTALL new wheel studs and nuts REFER to 204 04 Wheels and Tires Specifications Specifications Wheel and Tire Removal and Installation If the condition persists LUBRICATE the first three threads of each wheel stud with a graphite based lubricant Vehicle overloaded CORRECT as necessary http vnx su ...

Page 111: ...tion and Operation 3 Remove the wheel and tire 1 WARNING Remove any corrosion or dirt from the mounting surfaces of the wheel wheel hub brake drum or brake disc Corrosion or dirt on the mounting surfaces may cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion Failure to follow this instruction may result in personal injury Clean the wheel hub and mating surfaces...

Page 112: ...ecifications Item Nm lb ft lb in Intermediate shaft center bearing 25 18 Wheel hub retaining nut 320 236 Strut and spring assembly top mount nuts 25 18 Constant velocity CV joint boot retaining clamps 21 15 Tie rod end retaining nut 47 35 Lower arm ball joint retaining nut 150 111 http vnx su ...

Page 113: ...f grease to show on the outside of the front wheel driveshaft CV joint boot This condition is normal NOTE Halfshafts are not balanced and do not contribute to rotational vibration 6 6 If the concerns remain after the inspection determine the symptoms and go to the Symptom Chart For additional Noise Vibration and Harshness NVH REFER to Section 100 04 Noise Vibration and Harshness Symptom Chart Symp...

Page 114: ...essary Halfshaft Joint Pullout Inboard driveshaft bearing retainer circlip missing or not correctly seated in differential side gear INSPECT and REPAIR or INSTALL new as necessary Engine transaxle assembly mispositioned CHECK engine mounts for damage or wear REPAIR or INSTALL new as necessary Frame rail or strut tower out of position or damaged CHECK underbody dimensions REFER to REFER to Section ...

Page 115: ... 14 041 Remover Halfshaft 204 226 16 092 Adapter for 204 226 204 226 01 16 092 01 Slide Hammer 205 047 15 011 Separator Ball Joint 211 020 13 006 Three leg puller Two leg puller Name Manual transmission fluid 1 Loosen the strut and spring assembly top mount nuts by five turns 2 CAUTION Use a socket to loosen the wheel hub retaining nut to prevent damage Remove the wheel hub retaining nut Discard t...

Page 116: ... tool detach the tie rod end from the wheel knuckle 1 Release the tie rod end 2 Remove the tie rod end retaining nut Discard the nut 6 NOTE Use a T50 Torx driver to prevent the ball joint from rotating Loosen the lower arm ball joint retaining nut 7 CAUTIONS Leave the lower arm ball joint retaining nut in place to protect the ball joint stud Protect the ball joint seal using a soft cloth to preven...

Page 117: ...irt ingress Using the special tool remove the halfshaft Discard the snap ring Allow the oil to drain into a suitable container 1 CAUTIONS Support the halfshaft The inner joint must not be bent more than 18 degrees The outer joint must not be bent more than 45 degrees Do not damage the halfshaft seal Make sure that the snap ring is correctly seated NOTE Install a new snap ring Attach the left hand ...

Page 118: ...struction may result in personal injury With the aid of another technician apply the brakes and preload the wheel bearing by installing the new wheel hub retaining nut 6 Check the transmission fluid level For additional information refer to Section 308 03 Manual Transmission Transaxle 7 Install the front wheel and tire For additional information refer to Section 204 04 Wheels and Tires 8 CAUTION U...

Page 119: ... nuts by five turns 2 CAUTION Use a socket to loosen the wheel hub retaining nut to prevent damage Loosen the wheel hub retaining nut Discard the nut 3 Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 4 CAUTION Leave the tie rod end retaining nut in place to protect the ball joint stud NOTE Use a 5 mm Allen key to prevent the ball joint from rotating Lo...

Page 120: ...lower arm from the wheel knuckle 1 Use a soft faced hammer to strike the lower arm 2 Remove and discard the retaining nut 8 CAUTION Secure the halfshaft to prevent damage to the CV joints The inner CV joint must not be bent more than 18 degrees The outer CV joint must not be bent more than 45 degrees Using a suitable three leg puller detach the halfshaft from the wheel hub 9 CAUTIONS Secure the ha...

Page 121: ...nt boot halfshaft shown removed for clarity 1 Use a suitable screwdriver under the boot to allow air to escape 2 Insert the CV joint as far as it will go then pull it back approximately 20 mm 4 CAUTION Make sure the halfshaft is completely installed into the wheel hub Using the special tool install the halfshaft 5 CAUTION Protect the heat shield using a soft cloth to prevent damage NOTE Use a T50 ...

Page 122: ...n apply the brakes and preload the wheel bearing by installing the new wheel hub retaining nut 8 Check the transmission fluid level For additional information refer to Section 308 03 Manual Transmission Transaxle 9 Install the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 10 Tighten the wheel hub retaining nut 11 Tighten the strut and spring assembly top mount ...

Page 123: ...mation refer to Section 204 04 Wheels and Tires 3 CAUTION Do not unscrew the track rod end retaining nut from the ball joint in order to protect the thread NOTE Counterhold the ball joint with a 5 mm Allen key Loosen the left track rod end retaining nut 4 CAUTION Protect the ball joint gaiter using a soft cloth to prevent damage Detach the track rod end from the spindle carrier using the special t...

Page 124: ...gaiter clamping strap for the halfshaft joint 8 CAUTION Secure the halfshaft to prevent damage to the constant velocity joints The inner constant velocity joint must not be bent by more than 18 degrees The outer constant velocity joint must not be bent by more than 45 degrees Detach the right halfshaft from the tripode housing and secure it to one side Discard the grease filling 9 CAUTIONS Secure ...

Page 125: ...g contacts the rib of the intermediate shaft bracket Install the intermediate shaft in the transmission Install the center bearing cap and locknuts 3 CAUTION Secure the halfshaft to prevent damage to the constant velocity joints The inner constant velocity joint must not be bent by more than 18 degrees The outer constant velocity joint must not be bent by more than 45 degrees Attach the right half...

Page 126: ... 7 NOTE Install a new track rod end retaining nut NOTE Counterhold the ball joint with a 5 mm Allen key Attach the track rod end to the spindle carrier 8 Check the transmission fluid level and top up the manual transmission fluid if necessary For additional information refer to Section 308 03 Manual Transmission Transaxle 9 Install the wheel For additional information refer to Section 204 04 Wheel...

Page 127: ... bushing and oil seal transmission extension 308 046 16 016 Grip wrench Hazet 1847 1 Expanding pliers snap ring Name Grease inner joint 1 Remove the drive halfshaft For additional information refer to Left hand drive halfshaft Right hand drive halfshaft in this section 2 CAUTION Use a vice with protective jaw covers NOTE Hold the intermediate shaft in a vice Clamp the constant velocity joint into ...

Page 128: ...pecial tool Take off the boot and discard it 1 Insert a new boot 2 NOTE Renew the boot clamp Install a new inner boot clamp using the special tool 3 NOTE Chamfer points towards front drive halfshaft Attach the tripod using the special tool Slide on the boot http vnx su ...

Page 129: ... grease 6 Assemble the constant velocity joint 1 Slide a small screwdriver under the boot seat to allow the air to escape 2 Slide the constant velocity joint in as far as it will go then pull it back out 20 mm 7 NOTE Renew the boot clamp Install a new outer boot clamp using a grip wrench 8 Install the drive halfshaft For additional information refer to Left hand drive halfshaft Right hand drive ha...

Page 130: ...tallation 2 CAUTION Use a vice with protective jaw covers Remove the outer CV joint boot Cut and discard the boot clamps Remove and discard the rubber boot Remove the grease packing 1 NOTE Install a new rubber boot Install the outer CV joint boot Pack the CV joint with grease For additional information refer to Specifications 205 04 Front Drive Halfshafts Specifications Press the rubber boot into ...

Page 131: ...ping strap into the ring groove of the rubber boot and tighten with the special tool 4 Install the inner CV joint boot For additional information refer to Inner Constant Velocity CV Joint Boot 205 04 Front Drive Halfshafts Removal and Installation http vnx su ...

Page 132: ...Special Tool s Materials General Equipment Removal 204 169 Clamping Tool Boot Retaining Clamp 205 080 Installer Differential Bearing 205 310 Remover Bearing Gear 303 255 Installer Timing Cover Seal Name Specification Grease FD R WSS M1C259 A1 3M5J M1C259 AA Flat bladed screwdriver Hydraulic press 1 2 http vnx su ...

Page 133: ...Installation 3 Special Tool s 205 310 General Equipment Hydraulic press 1 Special Tool s 205 080 303 255 General Equipment Hydraulic press 2 Material Grease FD R WSS M1C259 A1 3M5J M1C259 AA http vnx su ...

Page 134: ...3 1 Release any trapped air General Equipment Flat bladed screwdriver 4 General Equipment Flat bladed screwdriver 4 Special Tool s 204 169 http vnx su ...

Page 135: ... servo Wheel speed sensors Internally ventilated front brake discs Rear disk brake MK 25 ABS Drum Brake Load dependent brake pressure apportioning valve The brake pressure regulating valve is mounted on the chassis and regulates the brake pressure applied to each rear wheel depending on the vehicle load This ensures that the braking forces applied to the front wheels are always greater than those ...

Page 136: ...hicle braking performance with the performance standards expected by the driver The ability of the test driver to make valid comparisons and detect performance deficiencies will depend on experience The driver should have a thorough knowledge of the brake system operation and accepted general performance guidelines to make good comparisons and detect performance concerns An experienced technician ...

Page 137: ...a concern exists use the Brake System Symptom Chart in order to isolate it to a specific sub system and condition description From this description a list of possible sources can be used to further narrow the cause to a specific component or condition Symptom Chart Symptom Possible Sources Action Brakes pull or drift Worn or damaged brake shoes or brake pads and linings INSTALL new brake shoes or ...

Page 138: ...trol Removal and Installation Anti Lock Brake System ABS Module 206 09A Anti Lock Control Removal and Installation Shorted indicator circuit REPAIR as necessary Vibration when the brakes are applied Grease or fluid on the brake shoes or brake pads glazed linings INSTALL new brake shoes or brake pads REFER to Brake Shoes 206 02 Drum Brake Removal and Installation Brake Pads 206 04 Rear Disc Brake R...

Page 139: ...ads push the brake caliper piston back into the brake caliper Caused by excessive brake disc lateral runout or loose wheel bearings CARRY OUT a brake disc runout check REFER to Brake Disc Runout Check 206 00 Brake System General Information General Procedures Worn brake shoes or brake pads INSTALL new brake shoes or brake pads REFER to Brake Shoes 206 02 Drum Brake Removal and Installation Brake P...

Page 140: ...ormation General Procedures Brake drag Incorrectly adjusted stop lamp switch ADJUST the stop lamp switch GO to Pinpoint Test B Incorrectly adjusted speed control deactivation switch if equipped ADJUST the speed control deactivation switch GO to Pinpoint Test B Incorrectly adjusted parking brake ADJUST the parking brake cable REFER to Parking Brake Cable Adjustment 206 05 Parking Brake and Actuatio...

Page 141: ...ng brake adjustment and ADJUST as necessary REFER to Parking Brake Cable Adjustment 206 05 Parking Brake and Actuation General Procedures If the condition still exists BLEED the brake system REFER to Brake System Bleeding 206 00 Brake System General Information General Procedures Brake System Pressure Bleeding 206 00 Brake System General Information General Procedures TEST the system for normal op...

Page 142: ...g 206 00 Brake System General Information General Procedures TEST the system for normal operation No GO to B3 B3 CHECK THE AIR INTAKE FILTER Check the air intake filter 1 Is the filter damaged in any way Yes REPAIR as necessary TEST the system for normal operation No GO to B4 B4 PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST Carry out a brake master cylinder bypass Condition Test Refer to t...

Page 143: ...ONDITIONS DETAILS RESULTS ACTIONS C1 CHECK THE BRAKE BOOSTER Check the brake booster push rod alignment and pedal travel 1 Is the push rod and pedal travel OK Yes TEST the brake pedal application GO to Pinpoint Test D No INSTALL a new brake booster REFER to Brake Booster LHD FWD 206 07 Power Brake Actuation Removal and Installation Brake Booster RHD FWD 206 07 Power Brake Actuation Removal and Ins...

Page 144: ...ngine at idle 1 Using a suitable vacuum gauge check the vacuum pressure 2 Is the vacuum pressure above 40 5 kPa 0 4 bar with the brake booster non operational Yes GO to D6 No INSTALL a new vacuum hose and fittings TEST the system for normal operation D6 CHECK THE BRAKE BOOSTER Check the brake booster REFER to the Brake Booster Operation Check in this procedure 1 Is the brake booster OK Yes VERIFY ...

Page 145: ...booster check valve TEST the system for normal operation PINPOINT TEST F SLOW OR INCOMPLETE BRAKE PEDAL RETURN TEST CONDITIONS DETAILS RESULTS ACTIONS F1 CHECK FOR BRAKE PEDAL RETURN Run the engine at approximately 1200rpm whilst making several brake applications 1 Pull the brake pedal upwards with approximately 44 5 N 10 lbs force 2 Release the brake pedal and measure the distance to the floor pa...

Page 146: ...increased resistance to the pedal travel occurs 5 5 Hold the brake pedal in the applied position and raise the engine speed to approximately 2000 rpm NOTE The additional movement of the brake pedal is the result of the increased engine manifold vacuum which exerts more force on the brake booster during engine rundown This means that additional stroke is available in the brake master cylinder and t...

Page 147: ... FWD 206 07 Power Brake Actuation Removal and Installation Brake Booster RHD FWD 206 07 Power Brake Actuation Removal and Installation If the brake pedal movement feels spongy bleed the brake system REFER to Brake System Bleeding 206 00 Brake System General Information General Procedures Brake System Pressure Bleeding 206 00 Brake System General Information General Procedures Brake Master Cylinder...

Page 148: ... indicator is ON This may be caused by low fluid level ignition wire routing too close to the fluid level indicator assembly or float assembly damage Bypass Condition Test 1 1 Check the fluid in the brake master cylinder reservoir Fill the brake master cylinder reservoir if low or empty 2 2 Observe the fluid level in the brake master cylinder reservoir If after several brake applications the fluid...

Page 149: ...c System WDS 1 CAUTION The brake fluid reservoir must remain full with new clean brake fluid at all times during bleeding Install the bleed tube to the bleed nipple 2 Immerse the end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid 3 Position the bleed jar base at least 300 mm above the bleed nipple to maintain fluid pressure and prevent air leaking past the thr...

Page 150: ... the brake fluid level Add brake fluid as necessary 2 Apply the brakes several times and make sure the pedal feel is not spongy If necessary bleed the brake system For additional information refer to Brake System Bleeding in this section 3 Check the brake fluid level and verify that the fluid level is actually dropping 4 NOTE If the brake fluid level drops and no external leak is evident check for...

Page 151: ...rake load sensor proportioning valve will result in inefficient braking The brake load sensor proportioning valve adjustment lever must be set in the correct position Failure to follow this instruction may result in personal injury CAUTIONS Whilst depressing the valve adjustment lever make sure that excessive force is not placed on the special tool Whilst tightening the tension spring coupling lin...

Page 152: ... note the readings 2 NOTE Using paint or typing correction fluid mark the position of the wheel in relation to the wheel hub Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 3 Remove the brake pads For additional information refer to Section 206 03 Front Disc Brake 206 04 Rear Disc Brake 4 Install the wheel nuts and tighten the wheel nuts to 10 Nm to ho...

Page 153: ...ification 9 If the brake disc runout measurement without the wheel and tire fitted is outside the specification check the wheel hub face runout 10 NOTE Using paint or typing correction fluid mark the position of the brake disc in relation to the wheel hub Remove the brake disc For additional information refer to Section 206 03 Front Disc Brake 206 04 Rear Disc Brake 11 NOTE Make sure that the whee...

Page 154: ... ESA M1C171 A Grease brake shoe adjuster ESE M1C171 A Super DOT 4 brake fluid ESD M6C57 A Description mm New brake drum nominal diameter 228 3 Worn brake drum discard diameter 230 2 Brake shoe width 55 Worn brake shoe lining discard thickness 1 Brake shoe adjuster pre set diameter 228 Description Nm lb ft lb in Wheel spindle retaining bolts 115 85 Wheel cylinder retaining bolts 10 89 Brake hose to...

Page 155: ...Drum Brake Drum Brake Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 206 00 Brake System General Information http vnx su ...

Page 156: ... Installation 2 Remove the hold down springs wheel spindle shown removed for clarity 3 CAUTION Do not damage the wheel cylinder boots NOTE Hold the wheel cylinder pistons in place with a rubber band Detach the brake shoes from the wheel cylinder wheel spindle shown removed for clarity 4 NOTE Fully release the brake shoe adjuster Remove the brake shoe return springs wheel spindle shown removed for ...

Page 157: ...he brake drum NOTE Install a new parking brake cable retaining clip To install reverse the removal procedure Apply grease to the brake shoe adjuster strut Clean the backing plate and apply silicon dielectric compound to the brake shoe contact points 2 Adjust the parking brake cable For additional information refer to Parking Brake Cable Adjustment 206 05 Parking Brake and Actuation General Procedu...

Page 158: ...additional information refer to Brake Shoes in this section 2 Loosen the brake hose to wheel cylinder union 1 Using a suitable brake hose clamp clamp the brake hose 2 Loosen the union 3 Detach the wheel cylinder from the brake backing plate 4 CAUTION Cap the brake hose to prevent fluid loss or dirt ingress Remove the wheel cylinder 1 To install reverse the removal procedure 2 Bleed the brake syste...

Page 159: ... of the thread Discard the retaining clip 4 Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 5 Remove the brake drum Remove and discard the retaining washer if equipped 1 NOTE Install a new parking brake cable retaining clip To install reverse the removal procedure 2 Adjust the parking brake cable For additional information refer to Section 206 05 Parki...

Page 160: ...to Section 204 02 Rear Suspension 2 Remove the wheel cylinder For additional information refer to Wheel Cylinder in this section 3 Detach the parking brake cable from the brake backing plate 1 Depress the retaining clip 2 Detach the cable 4 Remove the brake backing plate Using a suitable electric hand drill remove the rivets 1 NOTE Using a suitable blind rivet gun hand install new rivets To instal...

Page 161: ...s Torque Specifications Specifications Super DOT 4 brake fluid ESD M6C57 A Description mm Brake disc diameter 278 New brake disc nominal thickness 24 Worn brake disc discard thickness 22 Worn brake pad discard thickness 2 Description Nm lb ft lb in Brake caliper anchor plate retaining bolts 133 98 Brake caliper retaining bolts 30 22 Brake hose to brake caliper union 14 10 Wheel speed sensor retain...

Page 162: ...Front Disc Brake Front Disc Brake Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 206 00 Brake System General Information http vnx su ...

Page 163: ... Caliper Piston 206 005 12 014 Name Super DOT 4 brake fluid High temperature grease 1 Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 2 Detach the brake caliper retaining clip 3 CAUTION Suspend the caliper to prevent load being placed on the brake hose Detach the brake caliper from the brake caliper anchor plate 1 Remove the bolt covers if equipped 2 R...

Page 164: ...to the brake fluid reservoir Using the special tool fully retract the brake caliper pistons 2 To install reverse the removal procedure Apply high temperature grease to the brake pad contact points 3 Depress the brake pedal check the fluid level in the brake fluid reservoir and top up if necessary with brake fluid http vnx su ...

Page 165: ...r Brake hose clamp Name High temperature grease 1 Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 2 Remove the brake caliper retaining clip 3 Loosen the brake hose to brake caliper union 1 Using a suitable brake hose clamp clamp the brake hose 2 Loosen the union 4 Detach the brake caliper from the brake caliper anchor plate 1 Remove the bolt covers if ...

Page 166: ... the brake hose from the caliper Rotate the caliper counterclockwise 8 Remove the brake caliper 1 To install reverse the removal procedure Apply high temperature grease to the brake pad contact points 2 Bleed the brake system For additional information refer to Section 206 00 Brake System General Information http vnx su ...

Page 167: ...itional information refer to Section 204 04 Wheels and Tires 2 CAUTION Suspend the brake caliper and anchor plate to prevent load being placed on the brake hose Detach the brake caliper and anchor plate from the wheel knuckle 3 Remove the brake disc Remove and discard the retaining washer if equipped 1 To install reverse the removal procedure http vnx su ...

Page 168: ...age to the caliper piston may result Extract the caliper piston from the caliper housing using compressed air 3 Remove the caliper piston 4 Remove and discard the dust seal 5 Remove and discard the piston seal 6 Inspect the caliper piston and the piston bore for pitting or scoring and install a new piston as necessary 1 Lubricate the piston bore piston seal and the caliper piston with high perform...

Page 169: ...al onto the caliper piston 4 CAUTION Do not scratch or damage the caliper piston when installing it into the caliper bore Install the caliper piston into the caliper bore 5 Seat the dust seal 6 Install the caliper For additional information refer to Caliper Front Brake in this section http vnx su ...

Page 170: ...ds Torque Specifications Specifications Super DOT 4 brake fluid ESD M6C57 A Description mm Brake disc diameter 278 New brake disc nominal thickness 11 Worn brake disc discard thickness 9 Worn brake pad discard thickness 2 Description Nm lb ft lb in Brake caliper anchor plate retaining bolts 133 98 Brake caliper retaining bolts 28 21 Brake hose to brake caliper union 14 10 Wheel speed sensor retain...

Page 171: ...scription Brake disc Combination caliper Brake cylinder piston On vehicles with Anti lock Brake System ABS brake discs with a diameter of 278 mm and a thickness of 11 mm are used together with a combination caliper The hand brake operates through the combination caliper on the brake disc Item 1 2 3 Part Number http vnx su ...

Page 172: ...Rear Disc Brake Rear Disc Brake Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 206 00 Brake System General Information http vnx su ...

Page 173: ...nformation refer to Brake Pads in this section 2 Loosen the brake hose to brake caliper union 1 Using a suitable brake hose clamp clamp the brake hose 2 Loosen the union 3 CAUTION Cap the brake hose to prevent fluid loss or dirt ingress Disconnect the brake hose from the brake caliper Rotate the caliper counterclockwise 4 Remove the brake caliper 1 To install reverse the removal procedure 2 Bleed ...

Page 174: ...etractor Rear Brake Caliper Piston 206 085 12 025 Name Super DOT 4 brake fluid High temperature grease 1 Remove the parking brake control boot 2 Release the parking brake 3 Loosen the parking brake cable adjustment nut to the end of the thread Discard the retaining clip 4 Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 5 Disconnect the parking brake ca...

Page 175: ...y a spring clip Remove the inner brake pad Slide the brake pad out 9 Remove the outer brake pad 1 CAUTIONS When the brake caliper piston is retracted into the piston housing brake fluid will be displaced into the brake fluid reservoir Support the brake caliper piston during brake caliper retraction NOTE To retract the left hand or the right hand brake caliper piston the piston must be rotated cloc...

Page 176: ...ase to the brake pad contact points 3 Depress the brake pedal check the fluid level in the brake fluid reservoir and top up if necessary with brake fluid 4 Adjust the parking brake cable For additional information refer to Section 206 05 Parking Brake and Actuation http vnx su ...

Page 177: ... the retaining clip 4 Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 5 Detach the parking brake cable from the brake caliper lever 6 CAUTION Suspend the brake caliper and anchor plate to prevent load being placed on the brake hose Detach the brake caliper and anchor plate from the wheel spindle brake caliper shown removed for clarity 7 Remove the brak...

Page 178: ...1 To install reverse the removal procedure 2 Adjust the parking brake cable For additional information refer to Section 206 05 Parking Brake and Actuation http vnx su ...

Page 179: ...2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Parking brake cable adjusting nut 2 6 24 Parking brake control retaining nuts 20 15 Parking brake cable clips retaining bolts 7 62 Parking brake cable support bracket retaining bolts 11 8 http vnx su ...

Page 180: ...onnect 2002 5 06 2002 Print Description and Operation Parking brake Description Parking brake cable Brake disc Combination caliper Variant with drum brakes Balance arm Adjusting screw Contact switch parking brake lever Item 1 2 3 4 5 6 7 Part Number http vnx su ...

Page 181: ... the parking brake system with disc brakes the parking brake operates on the brake disc through a combination caliper Parking brake adjustment is carried out at the adjustment screw on the left beside the parking brake lever Two separate cables run from the balance arm to the brakes http vnx su ...

Page 182: ...le 206 05 Parking Brake and Actuation Removal and Installation Parking brake warning circuit REFER to Instrument Cluster 413 01 Instrument Cluster Diagnosis and Testing Symptom Possible Sources Action The parking brake will not apply Parking brake control Cable and conduit GO to Pinpoint Test A The parking brake will not release Parking brake control Cable and conduit GO to Pinpoint Test B PINPOIN...

Page 183: ...eration With the aid of another technician release the parking brake and check the operation of the brake cables and levers 1 Did the parking brake release Yes CHECK the other causes such as conventional brake system components REPAIR or INSTALL new components as necessary No GO to B2 B2 CHECK PARKING BRAKE CABLES Loosen the parking brake cable tension Rotate the rear wheels by hand 1 Did the rear...

Page 184: ... freely Yes INSTALL a new parking brake control lever on the rear drum brakes or caliper assembly on rear disc brakes REFER to Brake Shoes 206 02 Drum Brake Removal and Installation Brake Caliper 206 04 Rear Disc Brake Removal and Installation TEST the system for normal operation No REFER to Brake System 206 00 Brake System General Information Diagnosis and Testing http vnx su ...

Page 185: ...y located 5 NOTE Prior to carrying out adjustment to a new or relocated parking brake cable settle the parking brake system Settle the parking brake system in three stages Stage 1 Raise the parking brake control seven notches Stage 2 Tighten the adjustment nut to 6 Nm Stage 3 Loosen the adjustment nut to the end of the thread 6 Using a suitable rolling road carry out a brake test For additional in...

Page 186: ...All vehicles 11 Depress and release the brake pedal 12 Raise the parking brake control seven notches 13 Tighten the parking brake cable adjustment nut Install a new retaining clip 14 Install the parking brake control boot http vnx su ...

Page 187: ...ifting 3 Remove the floor console For additional information refer to Section 501 12 Instrument Panel and Console 4 Disconnect the electrical connector 5 Remove the parking brake cable adjustment nut 1 Remove the clip 2 Remove the adjustment nut 6 Remove the parking brake control 1 NOTE After installation adjust the parking brake For additional information refer to Parking Brake Cable Adjustment i...

Page 188: ...e adjustment nut to the end of the thread Discard the retaining clip 4 Remove the rear wheels and tires For additional information refer to Section 204 04 Wheels and Tires 5 Detach the center section of the exhaust system heat shield from the floor panel 6 Detach the right hand section of the exhaust system heat shield from the floor panel 7 Detach the fuel tank section of the exhaust system heat ...

Page 189: ... actuating lever 2 Detach the cable 3 Depress the clip 10 Disconnect the parking brake cable from the brake caliper lever 11 Detach the parking brake cable from the parking brake equalizer 1 Detach the cables from the bracket 2 Detach the cables from the equalizer 12 NOTE There is a sleeve on the cable outer to indicate the right hand cable Note the position of the sleeve to aid installation Detac...

Page 190: ... both sides 14 Remove the parking brake cable 1 NOTE The parking brake cable support bracket cable carrier must face the front of the vehicle NOTE The right hand cable can be identified by a sleeve on the cable outer To install reverse the removal procedure 2 Adjust the parking brake For additional information refer to Parking Brake Cable Adjustment in this section http vnx su ...

Page 191: ...escription Nm lb ft lb in Brake master cylinder retaining nuts 25 18 Brake tube to master cylinder unions M10 14 10 Brake tube to master cylinder unions M12 18 13 Brake booster retaining nuts 25 18 Brake pedal retractor retaining nuts 48 35 Brake pedal shaft nut 23 17 Clutch master cylinder retaining nuts 9 80 Bleed nipple 5 44 Wiring harness bracket to brake booster retaining nut 20 15 http vnx s...

Page 192: ...n can lead to injuries Description Retaining bolt Noise Vibration and Harshness NVH weight Lever mechanism Spindle Brake pedal The brake pedal is equipped with a safety device which moves the brake pedal downwards by up to 8 cm if a severe frontal collision occurs to reduce the risk of injury to the driver This is achieved by a mechanism which joins the brake pedal stop to the vehicle body If a se...

Page 193: ...Hydraulic Brake Actuation Hydraulic Brake Actuation Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 206 00 Brake System General Information http vnx su ...

Page 194: ...nt panel lower panel from the instrument panel 1 Remove the retaining screws 2 Release the clips 2 Remove the instrument panel lower panel Disconnect the headlamp control switch electrical connector 3 Disconnect the electrical connectors from the pedal position switches 1 Speed control deactivation switch if equipped 2 Stop lamp switch 3 Clutch position switch 4 CAUTION Make sure the clutch pedal ...

Page 195: ...Remove the brake booster retaining nuts 8 NOTE Make sure the road wheels are in the straight ahead position Centralize the steering and lock it in position 9 Detach the steering column shaft from the steering gear pinion extension 1 Remove the bolt 1 Discard the retaining bolt 2 Release the pinion shaft extension from the steering column 10 Detach the clutch master cylinder from the pedal bracket ...

Page 196: ...brake pedal bracket 1 NOTE Make sure the brake pedal locates into the brake booster actuator rod clevis Install the brake pedal bracket 2 NOTE Do not fully tighten the brake booster retaining nuts at this stage Install the brake booster retaining nuts 3 NOTE Do not fully tighten the brake pedal retractor arm retaining bolt at this stage Install the brake pedal retractor arm retaining bolt if equip...

Page 197: ...l the clip 6 NOTE Install a new brake booster actuating rod pin Install the brake booster actuating rod pin 1 Depress the brake pedal 2 Install the brake booster actuating rod pin 7 CAUTION Make sure there is clearance between the brake pedal and the brake pedal retractor to allow free movement Align the brake pedal retractor arm to the brake pedal bracket if equipped 8 Tighten the brake booster r...

Page 198: ...clutch position switch colored red is not adjustable NOTE From 08 2003 only non adjustable stop lamp switches are available Pull out the speed control deactivation switch if equipped and the stop lamp switch if equipped with an adjustable stop lamp switch plungers until they are fully extended Measure the plunger length 1 Speed control deactivation switch colored green XX mm 24 mm 2 Stop lamp swit...

Page 199: ...an adjustable stop lamp switch is normal Install the pedal position switches 1 Clutch position switch colored red 2 Stop lamp switch colored grey 3 Speed control deactivation switch colored green if equipped 14 NOTE The colors of the electrical connectors and switches are identical Connect the electrical connectors to the pedal switches 1 Speed control deactivation switch if equipped 2 Stop lamp s...

Page 200: ...Hydraulic Brake Actuation Brake Pedal and Bracket Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 2 3 4 http vnx su ...

Page 201: ...5 6 7 8 http vnx su ...

Page 202: ...Installation 1 NOTE Only tighten the nuts and bolt finger tight at this stage 2 Torque 9 Nm http vnx su ...

Page 203: ...3 2 Torque 50 Nm 3 Torque 23 Nm 4 5 Torque 28 Nm http vnx su ...

Page 204: ...6 7 8 http vnx su ...

Page 205: ...oth sides in order to completely drain the brake fluid reservoir Drain the brake fluid reservoir 1 Connect one end of a suitable piece of clear plastic pipe to the bleed nipple and place the other end into a suitable container 2 Loosen the bleed nipple 3 Depress the brake pedal until all the brake fluid is drained from the brake fluid reservoir 4 Tighten the bleed nipple 3 Install the brake fluid ...

Page 206: ...er cylinder feed hose to prevent fluid loss or dirt ingress Disconnect the brake master cylinder feed hose from the brake master cylinder 10 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress Disconnect the brakes tubes from the brake master cylinder 11 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress Disconnect the brakes tubes from the brake master cylinder http v...

Page 207: ...y positioned before installation 12 Remove the brake master cylinder Discard the nuts 1 To install reverse the removal procedure 2 Bleed the brake system For additional information refer to Brake System Bleeding 206 00 Brake System General Information General Procedures http vnx su ...

Page 208: ...luid reservoir cap must not become contaminated Remove the brake fluid reservoir cap Disconnect the low brake fluid warning indicator switch electrical connector 3 NOTE It will be necessary to carry out this step on both sides in order to completely drain the brake fluid reservoir Drain the brake fluid reservoir 1 Connect one end of a suitable piece of clear plastic pipe to the bleed nipple and pl...

Page 209: ...r from the wheelhouse assembly and position it to one side 9 Remove the cowl panel grille For additional information refer to Radiator Grille Opening Panel Vehicles Built Up To 04 2009 501 02 Front End Body Panels Removal and Installation Radiator Grille Opening Panel Vehicles Built From 04 2009 501 02 Front End Body Panels Removal and Installation 10 Disconnect the vacuum hoses and the electrical...

Page 210: ...um pipe support bracket from the cowl panel 13 WARNING Wear ear protectors when working with the glass cutting tool Failure to follow this instruction may result in personal injury Remove the water guide Using a suitable direct glazing cutter cut the PU adhesive 14 Remove the pollen filter 15 Detach the cowl panel from the fender on both sides http vnx su ...

Page 211: ... feed hose to prevent fluid loss or dirt ingress Disconnect the brake master cylinder feed hose from the brake master cylinder 18 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress Disconnect the brakes tubes from the brake master cylinder 19 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress Disconnect the brakes tubes from the brake master cylinder http vnx su ...

Page 212: ...t 100mm of PU adhesive as this may have a reduced working time NOTE To avoid water leaks and breakage in the continuous bead the continuous bead must be over lapped by 20 mm NOTE Before installing the water guide apply the PU adhesive in a continuous bead of between 8 and 10mm in height to the windshield glass flange along the bond line Using a hot air gun apply warm air to the windshield glass fl...

Page 213: ...with cold water Disconnect the electrical connector from the filler cap 1 Pull back the tab 2 Depress the clips 3 Disconnect the electrical connector 2 CAUTION Make sure the filler cap does not become contaminated Remove the brake fluid reservoir filler cap 3 Using a suitable clean suction device drain the reservoir 4 Install the brake fluid reservoir filler cap 5 Detach the reservoir 6 Detach the...

Page 214: ...ap the hose connections to prevent fluid loss or dirt contamination Disconnect the brake master cylinder feed hose 9 CAUTION Cap the hose connections to prevent fluid loss or dirt contamination Disconnect the clutch master cylinder feed hose 10 Disconnect the brake fluid reservoir wiring harness http vnx su ...

Page 215: ...1 NOTE After installation bleed the brake system For additional information refer to Section 206 00 Brake System General Information To install reverse the removal procedure http vnx su ...

Page 216: ...ealers and Adhesives Torque Specifications Specifications Super DOT 4 brake fluid ESD M6C57 A Description Nm lb ft lb in Brake booster retaining nuts 25 18 Brake pedal retractor retaining nuts 48 35 Engine support insulator center bolt 50 37 Engine front mount bracket retaining bolts 48 35 http vnx su ...

Page 217: ...Power Brake Actuation Power Brake System Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 206 00 Brake System General Information http vnx su ...

Page 218: ...ol Traction Control 206 09C Anti Lock Control Stability Assist 3 Detach the instrument panel lower panel from the instrument panel 1 Remove the retaining screws 2 Release the clips 4 Remove the instrument panel lower panel Disconnect the headlamp control switch electrical connector 5 Disconnect the electrical connectors from the pedal position switches 1 Speed control deactivation switch if equipp...

Page 219: ...e the brake booster retaining nuts 9 Remove the brake booster Discard the gasket 1 CAUTIONS Make sure that the brake booster actuating rod is correctly positioned through the bulkhead rubber boot Make sure the brake booster gasket is correctly positioned on the brake booster before installation NOTE Install a new gasket To install reverse the removal procedure http vnx su ...

Page 220: ...charge air cooler if equipped For additional information refer to Section 303 12 Intake Air Distribution and Filtering 3 Disconnect the electrical connectors from the pedal position switches 1 Speed control deactivation switch if equipped 2 Stop lamp switch 3 Clutch position switch 4 Remove the pedal position switches 1 Speed control switch colored green if equipped 2 Stop lamp switch colored grey...

Page 221: ...heel and tire shown removed for clarity 9 Disconnect the high pressure cut off switch electrical connector 10 Disconnect the low pressure cut off switch electrical connector 11 CAUTION Cap the refrigerant line connections to prevent fluid loss and dirt ingress Using the special tool disconnect the refrigerant line to the accumulator at the evaporator Discard the O rings 12 CAUTION Cap the refriger...

Page 222: ...o prevent fluid loss and dirt ingress Detach the refrigerant line from the condenser Discard the O rings 15 Detach the refrigerant lines from the wheelhouse assembly 16 Detach the dehydrator from the fender 1 Disconnect the refrigerant line from the dehydrator 2 Remove the dehydrator bolts and nut 17 NOTE Pull the refrigerant lines through the hole in the fender Remove the refrigerant lines from t...

Page 223: ...ve the engine support insulator centre bolt 21 Lower the vehicle 22 Disconnect the headlamp wiring harness ground cable 23 Using the special tool and a suitable engine hoist support the engine 24 Detach the engine front mount bracket from the side member 25 CAUTION Make sure excessive force is http vnx su ...

Page 224: ...the gasket 1 CAUTIONS Make sure that the brake booster actuating rod is correctly positioned through the bulkhead rubber boot Make sure the brake booster gasket is correctly positioned on the brake booster before installation NOTE Install a new brake booster gasket NOTE Install new O rings on the refrigerant lines NOTE Coat the O rings for the refrigerant lines with clean refrigerant oil prior to ...

Page 225: ...5 06 2002 Print Removal and Installation Removal 1 Remove the air intake cover 2 Detach the air intake hose clips 3 Detach the intercooler 4 Disconnect the intercooler electrical connector 5 Remove the intercooler 6 Detach the vacuum hose from the vacuum pump http vnx su ...

Page 226: ... plug electrical connector 9 Disconnect the oil pressure switch 10 Detach the oil separator 1 Detach the engine coolant temperature sensor electrical connector 2 Detach the oil separator drain hose 3 Remove the bolt 11 Detach the vacuum pump oil drain hose http vnx su ...

Page 227: ... parking brake 15 Move the car forwards rotating the engine until the vacuum pump becomes loose 16 Remove the vacuum pump 1 Loosen the lower retaining bolt 2 Remove the upper retaining bolt 3 Remove the vacuum pump 17 Remove the vacuum pump seal Discard the seal 1 Install a new vacuum pump seal http vnx su ...

Page 228: ...drain hose 4 Attach the oil separator 1 Install the retaining bolt 2 Attach the oil separator drain hose 3 Attach the engine coolant temperature sensor electrical connector 5 Connect the oil pressure switch 6 Attach the glow plug electrical connector http vnx su ...

Page 229: ...the oil seperator upper and lower hoses 8 Attach the vacuum hose to the brake vacuum pump 9 Install the intercooler 10 Connect the intercooler electrical connector 11 Attach the air intake hose clips http vnx su ...

Page 230: ...12 Install the air intake cover http vnx su ...

Page 231: ...rake fluid ESD M6C57 A Description Nm lb ft lb in Hydraulic control unit HCU support bracket retaining bolts 25 18 HCU retaining bolts 9 80 HCU to anti lock brake system ABS module retaining bolts 2 18 Brake tube to HCU unions M10 14 10 Brake tube to HCU unions M12 18 13 Brake tube to master cylinder unions M12 18 13 Wheel speed sensor retaining bolt 9 80 http vnx su ...

Page 232: ...he following chart Visual Inspection Chart 3 3 If the inspection reveals an obvious concern rectify this before continuing 4 4 If the concern remains after the inspection use FDS 2000 to diagnose the system Diagnostic Tool FDS2000 Mechanical Electrical Check the condition and attachment of all sensors and sensor indicators Loose or corroded connections to sensors Wiring harness s Loose or corroded...

Page 233: ...sides in order to completely drain the brake fluid reservoir Drain the brake fluid reservoir 1 Connect one end of a suitable piece of clear plastic pipe to the bleed nipple and place the other end into a suitable container 2 Loosen the bleed nipple 3 Depress the brake pedal until all the brake fluid is drained from the brake fluid reservoir 4 Tighten the bleed nipple 3 Install the brake fluid rese...

Page 234: ...oden blocks to protect the transaxle NOTE Secure the transaxle with securing straps Using a suitable transmission jack support the transaxle 11 Remove and discard the engine rear mount center retaining nut 12 Remove the engine rear mount retaining nuts 13 Remove the air cleaner bracket Detach the transaxle breather tube from the bracket http vnx su ...

Page 235: ...ket and position to one side Depress the locking tangs 17 Disconnect the anti lock braking system ABS module electrical connector 1 Release the retainer 2 Disconnect the electrical connector 18 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress NOTE Make a note of the position of the brake tubes to aid installation http vnx su ...

Page 236: ...tion refer to Section 412 02A Heating and Ventilation 412 02B Auxiliary Heating 20 Detach the brake tubes from the bulkhead 21 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress Remove the master cylinder to HCU brake tubes 22 Detach the HCU and ABS module assembly from the support bracket 23 Remove the HCU to ABS module retaining bolts http vnx su ...

Page 237: ...e HCU 1 NOTE Install a new engine rear mount center retaining nut To install reverse the removal procedure 2 Bleed the brake system For additional information refer to Section 206 00 Brake System General Information http vnx su ...

Page 238: ...3 Detach the wheel speed sensor wiring harness from the wheel knuckle and floor panel 1 Disconnect the electrical connector 2 Detach the clips 4 Remove the brake disc For additional information refer to Section 206 04 Rear Disc Brake 5 NOTE The wheel speed sensor wiring harness is routed through the wheel knuckle Detach the wheel spindle and wheel hub assembly from the wheel knuckle 6 Remove the w...

Page 239: ...Make sure that the wheel speed sensor housing is free from contamination and moisture To install reverse the removal procedure http vnx su ...

Page 240: ... the wheel and tire assembly For additional information refer to Section 204 04 Wheels and Tires 3 NOTE If the dust cap is damaged on removal a new dust cap must be used on installation Remove the dust cap 4 Release the parking brake 5 Remove the brake drum 1 Remove the hub retaining nut 2 Remove the brake drum 6 Remove the wheel speed sensor ring drum brake shown disc brake similar Discard the wh...

Page 241: ...ed on slowly and squarely until fully seated Do not exceed a maximum load of 10 kn Using a suitable hydraulic press install a new wheel speed sensor ring 2 Install the rear wheel hub For additional information refer to Section 204 02 Rear Suspension 3 CAUTION Rotate the drum in the opposite direction when tightening the hub nut to prevent damage to the bearing Install the brake drum 4 Install the ...

Page 242: ...th sides in order to completely drain the brake fluid reservoir Drain the brake fluid reservoir 1 Connect one end of a suitable piece of clear plastic pipe to the bleed nipple and place the other end into a suitable container 2 Loosen the bleed nipple 3 Depress the brake pedal until all the brake fluid is drained from the brake fluid reservoir 4 Tighten the bleed nipple 3 Install the brake fluid r...

Page 243: ...oden blocks to protect the transaxle NOTE Secure the transaxle with securing straps Using a suitable transmission jack support the transaxle 11 Remove and discard the engine rear mount center retaining nut 12 Remove the engine rear mount retaining nuts 13 Remove the air cleaner bracket Detach the transaxle breather tube from the bracket http vnx su ...

Page 244: ...ket and position to one side Depress the locking tangs 17 Disconnect the anti lock braking system ABS module electrical connector 1 Release the retainer 2 Disconnect the electrical connector 18 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress NOTE Make a note of the position of the brake tubes to aid installation http vnx su ...

Page 245: ...tion refer to Section 412 02A Heating and Ventilation 412 02B Auxiliary Heating 20 Detach the brake tubes from the bulkhead 21 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress Remove the master cylinder to HCU brake tubes 22 Detach the HCU and ABS module assembly from the support bracket 23 Remove the ABS module to HCU retaining screws http vnx su ...

Page 246: ...S module 1 NOTE Install a new engine rear mount center retaining nut To install reverse the removal procedure 2 Bleed the brake system For additional information refer to Section 206 00 Brake System General Information http vnx su ...

Page 247: ...r DOT 4 brake fluid ESD M6C57 A Description Nm lb ft lb in Hydraulic control unit HCU support bracket retaining bolts 25 18 HCU retaining bolts 9 80 HCU to anti lock brake system ABS module retaining bolts 2 18 Brake tube to HCU unions M10 14 10 Brake tube to HCU unions M12 18 13 Brake tube to master cylinder unions M12 18 13 Wheel speed sensor retaining bolt 9 80 http vnx su ...

Page 248: ...from locking during braking and therefore the keeps the vehicle stabile can be steered and kept on track TCS prevents the driven wheels from spinning if too much power is applied Electronic brake distribution ensures optimum distribution of the braking force between the front and rear wheels The MK 25 ABS differs from the MK 20 ABS in having a faster response an improved software a revised connect...

Page 249: ...uring traction control brake pressure is created without the driver operating the brakes The relay semiconductor relay for system changeover and for the pump motor and also the relay semiconductor relay for the solenoid valves are integrated in the electronic control unit as electronic components The pump motor and the electronic controller with the relays as drivers are bolted directly to the hyd...

Page 250: ...river with fixed voltage regulator and two semiconductor relays as drivers for the valves and the pump motor The reliability is increased by the extreme integration and the very small number of chips The microcontroller prepares the signals of the wheel sensors and of the brake light switch and then processes the wheel speed information and control algorithms The connection to the vehicle electron...

Page 251: ...system warning lamp warning lamp for electronic brake distribution Warning lamp ABS Stoplamp switch Electronic control unit MK 25 ABS control unit Pump motor Separation valves changeover valves outlet valves and inlet valves Ground DLC Active wheel sensors Power supply Warning lamps in the instrument cluster Warning lamp ABS 8 9 10 11 12 13 Item 1 2 3 4 5 6 7 8 9 10 11 Part Number http vnx su ...

Page 252: ...ously if the MK 25 ABS control unit has detected a fault in the traction control Braking system warning lamp warning lamp for electronic brake distribution The braking system warning lamp warning lamp for electronic brake distribution illuminates after the ignition is switched on until the end of the self test continuously if the MK 25 ABS control unit has detected a fault in the electronic brake ...

Page 253: ...i Lock Control Traction Control Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 206 09A Anti Lock Control 206 09B Anti Lock Control Traction Control 206 09C Anti Lock Control Stability Assist http vnx su ...

Page 254: ...Sensor Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 For additional information refer to Section 206 09A Anti Lock Control 206 09B Anti Lock Control Traction Control 206 09C Anti Lock Control Stability Assist http vnx su ...

Page 255: ...5 06 2002 Print Description and Operation Control Diagram Description Brake Booster Primary hydraulic circuit Secondary hydraulic circuit Pulsation damper Pulsation damper HCU Damping chamber Dual circuit hydraulic pump D C motor Solenoid operated pilot valve 2 off Solenoid operated priming valve 2 off Item 1 2 3 4 5 6 7 8 9 10 11 http vnx su ...

Page 256: ...sary it actuates the inlet and outlet valves of the relevant brake and starts the hydraulic return pump The inlet valve closes to isolate the brake from pressurized fluid the outlet valve opens to release pressure from the brake into the accumulator and the return pump circuit The brake releases slightly and the wheel starts to turn again The ABS control unit then operates the inlet and outlet val...

Page 257: ...GEM Powertrain Control Module PCM Instrument Cluster Data link connector DLC Steering Wheel Rotation Sensor ABS ESP module or hydraulic control unit HCU Combined yaw rate sensor and lateral acceleration sensor longitudinal acceleration sensor Front wheel sensor Item 1 2 3 4 5 6 7 8 9 10 http vnx su ...

Page 258: ...of the curve The rear wheel is braked heavily so that a high amount of slip is caused In this way the cornering force of the rear axle is heavily reduced and the centrifugal force that now becomes effective turns the rear of the vehicle back into the curve The front wheel is not braked as hard The braking force that is transmitted via the front wheel to the road surface generates a torque with the...

Page 259: ...emergency brake light automatically switches on the hazard flasher system to warn drivers of other vehicles that emergency braking is being initiated Based on a defined delay value the ABS ESP module sends a signal to the generic electronic module GEM via the CAN data bus The GEM activates the hazard flasher system that then flashes 7 times Prerequisites for activation of the emergency brake light...

Page 260: ...nsing the sensor transmits a specific signal to the module for each steering angle position in relation to one turn of the steering wheel The straight ahead position of the steering is therefore defined in the sensor On an absolute steering angle sensor several photoelectric barrier modules are distributed around the segment disk at varying distances The gaps between segments of the segment disk a...

Page 261: ...s is carried out via two separate processors that also monitor each other Combined yaw rate sensor and lateral acceleration sensor The heart of the combined yaw rate sensor and lateral acceleration sensor is a small double sided tuning fork made of a piezo crystal A The exciter side of this tuning fork is set to a resonance of 11 kHz with the aid of an alternating current The measuring side of the...

Page 262: ... work in accordance with the Hall effect principle and generate a square wave output signal The signal acts in proportion to the rotational speed of the sensor ring The ABS sensor rings are built into the seals in the front wheel bearings The ABS ESP module evaluates the signals from all four sensors to calculate a vehicle speed signal based on the rotational speeds of all wheels The road speed is...

Page 263: ...pletely drain the brake fluid reservoir Drain the brake fluid reservoir 1 Connect one end of a suitable piece of clear plastic pipe to the bleed nipple and place the other end into a suitable container 2 Loosen the bleed nipple 3 Depress the brake pedal until all the brake fluid is drained from the brake fluid reservoir 4 Tighten the bleed nipple 3 Install the brake fluid reservoir cap 4 Remove th...

Page 264: ...air cleaner bracket 10 NOTE Use suitable wooden blocks to protect the transaxle NOTE Secure the transaxle with securing straps Using a suitable transmission jack support the transaxle 11 Remove and discard the engine rear mount center retaining nut 12 Remove the engine rear mount retaining nuts http vnx su ...

Page 265: ...connectors 15 Remove the BJB retaining screw 16 Detach the BJB from the BJB support bracket and position to one side Depress the locking tangs 17 Remove the booster heater if equipped For additional information refer to Booster Heater 412 02B Auxiliary Heating Removal and Installation 18 Detach the brake tubes from the bulkhead http vnx su ...

Page 266: ...irt ingress NOTE Make a note of the position of the brake tubes to aid installation Disconnect the brake tubes from the hydraulic control unit HCU 21 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress NOTE Left hand drive vehicles only Remove the master cylinder to HCU brake tubes 22 Detach the HCU and ABS module assembly from the support bracket 23 Remove the HCU to ABS module reta...

Page 267: ...TE Make a note of the position of the brake tubes to aid installation Disconnect the brake tubes from the hydraulic control unit HCU 27 CAUTION Cap the brake tubes to prevent fluid loss or dirt ingress NOTE Left hand drive vehicles only Remove the master cylinder to HCU brake tubes left hand drive vehicles only 28 Remove the HCU and ABS module assembly and the support bracket 29 Detach the HCU and...

Page 268: ... retaining nut To install reverse the removal procedure 2 Bleed the brake system For additional information refer to 206 00 Brake System General Information Brake System Bleeding General Procedures Brake System Pressure Bleeding General Procedures http vnx su ...

Page 269: ...val steps in this procedure may contain installation details Installation 1 Refer to Floor Console 501 12 Instrument Panel and Console Removal and Installation Refer to Floor Console Vehicles Built From 04 2009 501 12 Instrument Panel and Console Removal and Installation 2 Torque 9 Nm 1 To install reverse the removal procedure http vnx su ...

Page 270: ...sor Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 Refer to Clockspring Vehicles Built From 04 2009 501 20B Supplemental Restraint System Removal and Installation 1 To install reverse the removal procedure http vnx su ...

Page 271: ... 5 06 2002 Print Lubricants Fluids Sealers and Adhesives Turning Circle Steering Wheel Alignment Specifications Power steering fluid WSA M2C195 A Meters Wall to wall Short wheelbase 10 68 Long wheelbase 11 55 Degrees Maximum allowable steering wheel mis alignment 3 00 http vnx su ...

Page 272: ...eering hoses for damage kinks or restrictions INSTALL new components as necessary REFER to Section 211 02 Power Steering Fluid contamination FLUSH the power steering system REFER to Power Steering System Flushing Power Steering System Flushing in this section Fluid aeration BLEED the power steering system REFER to Power Steering System Bleeding in this section Seized suspension ball joints CARRY O...

Page 273: ...4 4 If the steering linkage is worn install new components as necessary REFER to Section 211 03 Steering Linkage The steering column cannot be repaired install a new steering column REFER to Section 211 04 Steering Column Steering gear backlash cannot be adjusted install a new steering gear REFER to Section 211 02 Power Steering Worn suspension ball joints CARRY OUT the suspension ball joint inspe...

Page 274: ...211 02 Power Steering Removal and Installation TIE RODS Using a straight edge and feeler gauge check the tie rods to see if they are straight If the distance between the tie rod and straight edge is greater than 0 5 mm install a new steering gear REFER to Steering Gear 211 02 Power Steering Removal and Installation Check the tightening torque of the tie rod end to wheel knuckle nut REFER to Tie Ro...

Page 275: ...his position for 5 seconds with a turning effort torque of 15 Nm at the steering wheel rim Turn the steering wheel away from the right hand steering lock stop Check for power steering fluid leaks at the steering gear housing and the power steering line connections to the steering gear If there is a power steering fluid leak at the steering gear install a new steering gear REFER to Steering Gear 21...

Page 276: ...isconnect the crankshaft position CKP sensor electrical connector 3 Lower the vehicle until the wheels are clear of the floor to allow the steering wheel to be rotated from lock to lock 4 Detach the coolant expansion tank from the wheelhouse assembly and position to one side 1 Remove the bolt 2 Detach the coolant expansion tank 5 Detach the power steering fluid reservoir from the wheelhouse assemb...

Page 277: ...aeration The fluid level should be checked with the fluid cold Fill the power steering fluid reservoir to the MAX mark with clean Power Steering Fluid 11 CAUTION Do not continuously crank the engine for more than 30 seconds as damage to the starter motor may result NOTE When flushing the power steering system make sure that the power steering fluid in the reservoir does not fall below the minimum ...

Page 278: ...ng from lock to lock With the aid of another technician add a further 1 liter of clean Power Steering Fluid 14 When all the fluid has been used turn the ignition switch to the OFF position 15 Using the special tool install the spark plugs 16 Connect the spark plug wires 17 Remove the blanking cap from the power steering fluid reservoir and connect the power steering fluid cooler return line 18 Att...

Page 279: ...ort the vehicle For additional information refer to Section 100 02 Jacking and Lifting 21 Connect the CKP sensor electrical connector 22 Lower the vehicle 23 Fill and bleed the power steering system For additional information refer to Power Steering System Bleeding in this section http vnx su ...

Page 280: ...ion tank 2 Detach the power steering fluid reservoir from the wheelhouse assembly 3 NOTE Using a suitable blanking cap cap the power steering fluid reservoir Disconnect the power steering fluid cooler return line from the power steering fluid reservoir Allow the fluid to drain into a suitable container 4 Place the end of the power steering fluid cooler return line into a suitable container 5 CAUTI...

Page 281: ... ventilation PCV hose from the valve cover and position to one side 8 Disconnect the glow plug electrical connectors 9 Remove the glow plugs 10 Disconnect the fuel injection pump electrical connector 1 Pull out the locking handle 2 Disconnect the electrical connector 11 Disconnect the glow plug electrical connectors http vnx su ...

Page 282: ...rvoir make sure the power steering fluid is clean and not agitated prior to use The fluid should be poured slowly into the reservoir to minimize the possibility of aeration The fluid level should be checked with the fluid cold Fill the power steering fluid reservoir to the MAX mark with clean Power Steering Fluid 16 CAUTION Do not continuously crank the engine for more than 30 seconds as damage to...

Page 283: ...fall below the minimum mark While cranking the engine for no more than 30 seconds turn the steering from lock to lock With the aid of another technician add a further 1 liter of clean Power Steering Fluid 19 When all the fluid has been used turn the ignition switch to the OFF position 20 Lower the vehicle 21 Remove the blanking cap from the power steering fluid reservoir and connect the power stee...

Page 284: ...lectrical connector 2 Push in the locking handle 25 Install the glow plugs 26 Connect the glow plug electrical connectors 27 Install the glow plugs 28 Connect the glow plug electrical connectors 29 Connect the fuel injector electrical connectors http vnx su ...

Page 285: ...he valve cover 31 Attach the oil level indicator tube to the engine 32 Install the glow plug relay fuse 33 Fill and bleed the power steering system For additional information refer to Power Steering System Bleeding in this section http vnx su ...

Page 286: ...are just clear of the floor For additional information refer to 100 02 Jacking and Lifting Jacking Description and Operation Lifting Description and Operation 3 NOTE Do not start the engine at this stage NOTE Make sure that the power steering fluid in the power steering fluid reservoir does not fall below the MIN mark as air could enter the system Slowly turn the steering wheel from lock to lock a...

Page 287: ...OFF the engine and examine the power steering hose connections steering gear boots power steering valve body and power steering pump for external leaks 9 Check the power steering fluid level Fill the power steering fluid reservoir to the MAX mark with the appropriate power steering fluid For additional information refer to Specifications 211 00 Steering System General Information Specifications 10...

Page 288: ...ng System General Information Specifications 12 Start the engine turn the steering wheel from lock to lock If excessive noise is apparent repeat the power steering bleeding procedure 13 Lower the vehicle 14 If the noise level is still unacceptable leave the vehicle standing overnight then repeat the power steering system bleeding procedure http vnx su ...

Page 289: ...the vehicle making sure that the road wheels are just clear of the floor For additional information refer to 100 02 Jacking and Lifting Jacking Description and Operation Lifting Description and Operation 3 NOTE Do not start the engine at this stage NOTE Make sure that the power steering fluid in the power steering fluid reservoir does not fall below the MIN mark as air could enter the system Slowl...

Page 290: ...hould be checked for leaks 7 Remove the special tools Fill the power steering fluid reservoir to the MAX mark with the appropriate power steering fluid as necessary For additional information refer to Specifications 211 00 Steering System General Information Specifications 8 Lower the vehicle http vnx su ...

Page 291: ... bolt 22 16 Power steering line to valve cover retaining nut vehicles with 1 8L Zetec engine 9 80 Power steering line to cylinder head retaining nut vehicles with 1 8L Zetec engine 23 17 Power steering line to crankcase breather assembly vehicles with 1 8L diesel engine 22 16 Power steering line to power steering pump union vehicles with 1 8L diesel engine 22 16 Power steering pump retaining bolts...

Page 292: ...n the line between the steering gear and the reservoir This is mounted below the bumper at the front of the vehicle The reservoir is located in the engine compartment at the front right hand side The steering column is horizontally and vertically adjustable as standard Description Vehicles with petrol engine Vehicles with diesel engine Power steering pump Power Steering Pressure PSP switch PAS res...

Page 293: ...Power Steering Power Steering Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 211 00 Steering System General Information http vnx su ...

Page 294: ... not disconnect the power steering pump pressure adapter from the power steering pump Cap the power steering line to prevent fluid loss or dirt ingress Cap the power steering pump pressure adapter to prevent fluid loss or dirt ingress Disconnect the power steering line from the power steering pump 1 Using a suitable wrench hold the power steering pump pressure adapter 2 Disconnect the union Allow ...

Page 295: ...mp connection to prevent fluid loss or dirt ingress Disconnect the power steering fluid supply hose from the power steering pump 9 Detach the oil level indicator from the engine block and position to one side 10 Detach the air conditioning A C pipe from the radiator grille opening panel and position it to one side 11 Remove the power steering pump upper retaining bolts http vnx su ...

Page 296: ...wer steering pump to steering gear line union 2 To install reverse the removal procedure 3 Fill and bleed the power steering system For additional information refer to Power Steering System Filling 211 00 Steering System General Information General Procedures Power Steering System Bleeding 211 00 Steering System General Information General Procedures http vnx su ...

Page 297: ...or additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 2 Remove the power steering pump lower retaining bolts 3 Lower the vehicle 4 Detach the coolant expansion tank from the wheelhouse assembly and position it to one side 1 Remove the bolt 2 Detach the coolant expansion tank 5 Detach the...

Page 298: ...e 8 Remove the charge air cooler outlet hose 1 Remove the retaining nuts 2 Release the retaining clips 9 NOTE Note the position of the power steering line to aid installation Detach the power steering line from the camshaft cover 10 NOTE Note the position of the power steering line to aid installation Detach the power steering line from the engine lifting eye 11 CAUTIONS Do not disconnect the powe...

Page 299: ...itable container Discard the O ring seal 12 Remove the power steering pump 13 Remove the power steering hose 1 CAUTION Care must be taken to prevent dirt ingress Install a new O ring seal onto the power steering pump to steering gear line union 2 To install reverse the removal procedure 3 Fill and bleed the power steering system For additional information refer to Power Steering System Filling 211...

Page 300: ... tank from the wheelhouse assembly and position it to one side 1 Remove the retaining bolt 2 Release the clip 3 Detach the power steering fluid reservoir from the wheelhouse assembly 4 Disconnect the power steering fluid cooler return line from the power steering fluid reservoir Allow the fluid to drain into a suitable container 5 Raise and support the vehicle For additional information refer to L...

Page 301: ...uid cooler hose quick release coupling Allow the fluid to drain into a suitable container 8 Detach the power steering fluid reservoir to power steering fluid cooler line from the wheelhouse assembly 9 Disconnect the steering gear to power steering fluid cooler hose from the power steering fluid cooler Allow the fluid to drain into a suitable container 10 Remove the radiator splash shield 11 Remove...

Page 302: ...dure 2 Fill the power steering system For additional information refer to Power Steering System Filling 211 00 Steering System General Information General Procedures 3 Bleed the power steering system For additional information refer to Power Steering System Bleeding 211 00 Steering System General Information General Procedures http vnx su ...

Page 303: ...allation details 307 242 Remover Transmission Fluid Cooler 1 Refer to Front Bumper Cover Vehicles Built From 08 2006 501 19 Bumpers Removal and Installation 2 3 Torque 15 Nm 4 WARNING Be prepared to collect escaping fluids CAUTION Make sure that all openings are sealed 5 1 WARNING Be prepared to collect escaping fluids CAUTION Make sure that all openings are sealed Special Tool s 307 242 2 Torque ...

Page 304: ...o install reverse the removal procedure 2 1 Fill the power steering system Refer to Power Steering System Filling 211 00 Steering System General Information General Procedures 2 Bleed the power steering system Refer to Power Steering System Bleeding 211 00 Steering System General Information General Procedures http vnx su ...

Page 305: ...m the steering gear 3 CAUTIONS Cap the power steering lines to prevent fluid loss or dirt ingress Cap the steering gear valve body to prevent fluid loss or dirt ingress Disconnect the power steering lines from the steering gear valve body left hand drive shown 1 Remove the retaining bolt 2 Rotate the clamp plate Allow the fluid to drain into a suitable container Discard the O ring seals 4 Lower th...

Page 306: ...al 7 Remove the power steering pump to steering gear pressure line 1 CAUTION Care must be taken to prevent dirt ingress Install a new O ring seal onto the power steering pump to steering gear line union 2 Install new O ring seals onto the power steering lines 3 To install reverse the removal procedure 4 Fill and bleed the power steering system For additional information refer to Power Steering Sys...

Page 307: ...Operation Lifting 100 02 Jacking and Lifting Description and Operation 2 NOTE Note the position of the power steering lines to aid installation Detach the power steering lines from the steering gear 3 CAUTIONS Cap the power steering lines to prevent fluid loss or dirt ingress Cap the steering gear valve body to prevent fluid loss or dirt ingress Disconnect the power steering lines from the steerin...

Page 308: ...er steering line to aid installation Detach the power steering pump to steering gear pressure line from the engine lifting eye 10 NOTE Note the position of the power steering line to aid installation Detach the power steering pump to steering gear pressure line from the valve cover 11 CAUTIONS Do not disconnect the power steering pump pressure adapter from the power steering pump Cap the power ste...

Page 309: ...r pressure line 1 CAUTION Care must be taken to prevent dirt ingress Install a new O ring seal onto the power steering pump to steering gear line union 2 Install new O ring seals onto the power steering lines 3 To install reverse the removal procedure 4 Fill and bleed the power steering system For additional information refer to Power Steering System Filling 211 00 Steering System General Informat...

Page 310: ...n installation details Right hand drive vehicles Left hand drive vehicles All vehicles 1 Raise and support the vehicle Refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 Torque 7 Nm 3 NOTE Note the position of the component before removal Torque 7 Nm 4 NOTE Note the position of the component before removal Torque 7 Nm 5 NOTE Note the position of the component before removal To...

Page 311: ...to a suitable container 7 Lower the vehicle 8 WARNING Be prepared to collect escaping fluid CAUTION Make sure that all openings are sealed 1 2 3 1 Torque 22 Nm 2 Torque 22 Nm 4 To install reverse the removal procedure 5 Fill the power steering system Refer to Power Steering System Filling 211 00 Steering System General Information General http vnx su ...

Page 312: ...Procedures 6 Bleed the power steering system Refer to Power Steering System Bleeding 211 00 Steering System General Information General Procedures http vnx su ...

Page 313: ...t from the steering gear pinion extension Discard the retaining bolt 3 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 4 Disconnect the steering gear to power steering fluid hose quick release coupling from the power steering fluid cooler 1 Press the power steering fluid cooler hose quick release coupling locking tangs 2 Disconnect the power ste...

Page 314: ...d from the wheel knuckle on both sides 1 Release the tie rod end 2 Remove and discard the tie rod end retaining nut 7 NOTE Use a 5 mm Allen key to prevent the ball joint stud from rotating Detach the stabilizer bar connecting link from the strut and spring assembly on both sides 8 Remove the engine support insulator center retaining bolt 9 Remove the steering gear heat shield 10 Detach the power s...

Page 315: ...rossmember 13 Remove the crossmember retaining bolts transmission jack shown removed for clarity 14 Using the transmission jack and the wooden block support the crossmember 15 Lower the front crossmember to gain access to the steering gear 16 Remove and discard the crossmember ball bearing washers 17 Remove the steering gear pinion extension shaft 1 Detach the floor seal from the steering gear 2 R...

Page 316: ...ering gear pinion extension shaft to steering gear pinion pinch bolt Failure to follow this instruction may result in personal injury Install the steering gear pinion extension shaft 1 Install the retaining bolt 2 Attach the floor seal to the steering gear 4 Connect the power steering lines to the steering gear valve body 1 Rotate the clamp plate http vnx su ...

Page 317: ...ugh the crossmember alignment holes and the washers 2 Slide the locking plates on top of the washers and into the groove of the tool and tighten the alignment pin sleeve 3 Raise the crossmember engaging the alignment pins into the chassis aligning holes 7 CAUTION Make sure the crossmember does not move while tightening the crossmember retaining bolts Install the crossmember assembly transmission j...

Page 318: ...s 13 NOTE Use a 5 mm Allen key to prevent the ball joint from rotating Attach the stabilizer bar connecting link to the strut and spring assembly on both sides 14 NOTE Make sure the collar on the hose is inserted fully into the quick release coupling Connect the power steering reservoir return hose quick release coupling to the power steering fluid cooler 15 Lower the vehicle 16 WARNING Install a ...

Page 319: ...pinion extension 17 Fill and bleed the power steering system For additional information refer to Section 211 00 Steering System General Information 18 Check the toe setting and adjust as necessary For additional information refer to Section 204 00 Suspension System General Information http vnx su ...

Page 320: ...steering gear For additional information refer to Steering Gear in this section 2 CAUTIONS Make sure vise jaw protectors are used Clamp the steering gear reinforcement boss Do not clamp the steering gear body Secure the steering gear in a vise 3 Using the special tools remove the steering gear insulator bushing on both sides 1 Lubricate the steering bushing with rubber suspension insulator lubrica...

Page 321: ...3 Install the steering gear For additional information refer to Steering Gear in this section http vnx su ...

Page 322: ...kage Specifications Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Tie rod end retaining nut 47 35 Tie rod end locknut 63 46 Tie rod to steering gear 80 59 http vnx su ...

Page 323: ...Steering Linkage Steering Linkage Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 211 00 Steering System General Information http vnx su ...

Page 324: ...ud NOTE Use a 5 mm Allen key to prevent the ball joint stud from rotating Loosen the tie rod end locknut and the tie rod end retaining nut 1 Loosen the locknut 2 Loosen the retaining nut 3 CAUTION Protect the ball joint seal using a soft cloth to prevent damage Using the special tool detach the tie rod end from the wheel knuckle 1 Release the tie rod end 2 Remove and discard the tie rod end retain...

Page 325: ...int from rotating Tighten the tie rod end locknut and the tie rod end retaining nut 1 Tighten the retaining nut 2 Tighten the locknut 3 Lower the vehicle 4 Check the toe setting and adjust as necessary For additional information refer to 204 00 Suspension System General Information Specifications Specifications Front Toe Adjustment General Procedures http vnx su ...

Page 326: ...ring gear For additional information refer to Section 211 02 Power Steering 2 NOTE Make a note of the number of turns used to remove the tie rod end Remove the tie rod end and the tie rod end locknut 1 Remove the tie rod end 2 Remove the tie rod end locknut 3 NOTE Make sure the tie rod is clean before removing the steering gear boot Remove and discard the steering gear boot clamps 4 Remove and dis...

Page 327: ...he tie rod clamp the steering rack teeth in a suitable vise Do not clamp the steering gear body Secure the steering rack in a vise and using a suitable pipe wrench remove the tie rod 1 Using the special tool install the tie rod 2 NOTE Lubricate the steering gear boot Install a new steering gear boot 3 Using a suitable pair of pincers install a new steering gear boot inner clamp http vnx su ...

Page 328: ...able pair of pincers install a new steering gear boot outer clamp 5 NOTE Install the tie rod end using the same number of turns used to remove it Install the tie rod end and the tie tie rod end locknut 6 Install the steering gear For additional information refer to Section 211 02 Power Steering http vnx su ...

Page 329: ...emove the tie rod end For additional information refer to Tie Rod End in this section 2 Remove the tie rod end locknut 3 NOTE Make sure the tie rod is clean before removing the steering gear boot Remove the steering gear boot Discard the clamps 1 NOTE Lubricate the steering gear boot Install the steering gear boot 2 Using a suitable pair of pincers install a new steering gear boot inner clamp http...

Page 330: ...s located over the recess in the tie rod Using a suitable pair of pincers install a new steering gear boot outer clamp 4 Install the tie rod end locknut 5 Install the tie rod end For additional information refer to Tie Rod End in this section http vnx su ...

Page 331: ...2 5 06 2002 Print Torque Specifications Item Nm lb ft lb in Steering wheel retaining bolt 48 35 Steering column retaining nuts 16 12 Steering column retaining screw 17 13 Steering column shaft to steering gear pinion extension retaining bolt 28 21 http vnx su ...

Page 332: ...Steering Column Steering Column Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 211 00 Steering System General Information http vnx su ...

Page 333: ...g and lock it in position 3 Detach the instrument panel lower panel from the instrument panel 1 Remove the retaining screws 2 Release the clips 4 Remove the instrument panel lower panel Disconnect the headlamp control switch electrical connector 5 Detach the steering column upper shroud from the steering column lower shroud Using a thin bladed screwdriver release the two clips one each side 6 Deta...

Page 334: ...r 2 Remove the retaining screws 9 Disconnect the passive anti theft system PATS transceiver windshield wiper washer switch and clockspring electrical connectors 10 Disconnect the ignition switch and turn signal flash to pass electrical connectors 11 Detach the wiring harness from the steering column 1 Release the locating pin 2 Detach the wiring harness http vnx su ...

Page 335: ...ailure to follow this instruction may result in personal injury Install new steering column shaft to cross car beam retaining nuts and screw Failure to follow this instruction may result in personal injury 12 Detach the steering column shaft from the steering gear pinion extension Discard the retaining bolt 13 Remove the steering column Discard the retaining nuts Discard the retaining screw 1 To i...

Page 336: ...r air bag module For additional information refer to Driver Air Bag Module 501 20B Supplemental Restraint System Removal and Installation 2 NOTE Make sure that the road wheels are in the straight ahead position Centralize the steering and lock it in position 3 Remove the steering wheel 1 To install reverse the removal procedure http vnx su ...

Page 337: ...3 NOTE Make sure the clockspring is not allowed to rotate Secure in the central position with a piece of suitable tape Remove the clockspring Using a thin bladed screwdriver release the two clips one each side 4 Remove the multifunction switches 1 Depress the retaining tangs 2 Lift the switches upwards 5 Remove the passive anti theft system PATS transceiver http vnx su ...

Page 338: ... key to position I 2 Using a thin bladed screwdriver depress the detent 1 CAUTION Never rotate the ignition switch camshaft from position I if the ignition lock dummy cylinder has been removed If the ignition lock mechanism is moved when the ignition lock dummy cylinder is not in place the anti theft feature is activated The steering column will be permanently locked and can not be recovered Using...

Page 339: ...ck cylinder is not in place the anti theft feature is activated The steering column will be permanently locked and can not be recovered Using a suitable Allen key remove the ignition dummy lock cylinder 1 Insert the Allen key and turn the ignition dummy lock cylinder from the 0 position to position I 2 Remove and discard the ignition dummy lock cylinder http vnx su ...

Page 340: ...tion lock cylinder is correctly installed A new steering column must be installed if the ignition lock cylinder fails to operate correctly Check the operation of the ignition lock cylinder twice in the following sequence 1 Turn the ignition key to the 0 position and make sure the steering column is free to rotate 2 Remove the ignition key and make sure the steering column is locked 3 Insert the ig...

Page 341: ...ring column lower shroud Using a thin bladed screwdriver release the two clips one each side 4 Detach the audio control switch from the steering column lower shroud if equipped Using a thin bladed screwdriver release the locking tang 5 Remove the audio control switch if equipped Disconnect the electrical connector 6 Remove the steering column lower shroud 1 Release the steering column locking leve...

Page 342: ...NING Make sure the steering column adjustment lever is in the locked position Failure to follow this instruction may result in personal injury CAUTION Make sure the ignition switch and lock housing are in the OFF position To install reverse the removal procedure http vnx su ...

Page 343: ...formation Engine Transit Tourneo Connect 2002 5 06 2002 Print Description and Operation Engine transmission combinations Description 1 8L Zetec E 1 8L Duratorq DI 1 8L Duratorq TDCi MTX 75 Item 1 2 3 4 Part Number http vnx su ...

Page 344: ... compressed air lines into the spark plug hole of each cylinder in turn apply compressed air and check for escaping air when the oil filler cap is removed If there is a perceptible flow of air inspect the cylinder liner surfaces and pistons for damage REFER to General Procedures in this section Leaking as a result of damaged oil seal or incorrect oil seal carrier alignment Camshaft oil seal Front ...

Page 345: ...engine REFER to Section 303 01A Engine 303 01B Engine 1 8L diesel engine REFER to Section 303 01A Engine 303 01B Engine Check the mating faces and cylinder head gasket and check the flatness of the cylinder head mating face REFER to General Procedures in this section Renew the cylinder head if necessary Valve stem oil seals are damaged and engine oil can enter the combustion chamber between valve ...

Page 346: ...aner Faulty idle air control valve Check the intake system REFER to Section 303 12 Intake Air Distribution and Filtering Fault in valve train Burned out exhaust valve Timing incorrectly adjusted Cracked or damaged timing belt Connect compressed air to the cylinders If air flows out through the intake manifold or the exhaust pipe check the valve train Faulty engine components Burned through piston ...

Page 347: ...ine REFER to Section 303 07A Engine Ignition 303 07B Glow Plug System Check the engine cooling REFER to Section 303 03 Engine Cooling Remove the carbon deposits by using fuel additives and driving the vehicle carefully Check the valve timing Fault in valve train Check the valve train Valve clearance too large resulting from faulty bucket tappet or incorrect valve clearance setting Set the valve cl...

Page 348: ...ck the engine for leaks 5 Check the engine for oil leaks using a suitable UV leak tester 6 6 Rectify any leaks found and recheck the engine for oil leaks Measure the compression pressure 21 111 0 NOTE The powertrain control module PCM receives an error message when the relay is removed out or electrical components are disconnected This error message must be deleted from the fault memory by connect...

Page 349: ...mpression pressure recorder carry out the measurement on every cylinder 6 6 Refit the components in reverse order observing the prescribed torques Coat the spark plug connector seal with silicone grease A960 M1C AA before fitting Coat the spark plug thread with lubricant ESE M1244 A Valve cover torque Stage 1 2 Nm stage 2 7 Nm Spark plug torque 15 Nm 7 7 Reset the PCM fault memory Measure the comp...

Page 350: ...nd can ignite Failure to follow these instructions may result in personal injury 1 1 Open the central junction box CJB and remove the glow plug relay 2 2 Remove the engine upper cover 3 3 Remove the charge air cooler inlet and outlet pipes 4 4 Remove the charge air cooler air guide http vnx su ...

Page 351: ...connect the intake air temperature sensor IAT electrical connector 6 6 Remove the charge air cooler 7 7 Disconnect the fuel injection pump electrical connector 8 8 Remove the glow plug power supply http vnx su ...

Page 352: ...NOTE Crank the engine with the starter motor until the reading on the compression tester stops rising 11 11 Carry out the measurement on all cylinders following the measuring equipment manufacturer s instructions 12 12 Detach the compression tester and adapter 13 13 Install the glow plugs http vnx su ...

Page 353: ...14 14 Install the glow plug power supply 15 15 Connect the fuel injection pump electrical connector 16 16 Install the charge air cooler 17 17 Connect the IAT sensor electrical connector http vnx su ...

Page 354: ... Install the charge air cooler inlet and outlet pipes 20 20 Install the engine upper cover 21 21 Install the glow plug relay 22 22 Reset the PCM fault memory Measure the compression pressure 1 8L diesel engine with common rail fuel injection http vnx su ...

Page 355: ...ction system without checking the fuel pressure has dropped to zero and that the fuel temperature is below 30 C Failure to follow these instructions may result in personal injury 1 1 Using datalogger in world wide diagnostic system WDS check that the fuel pressure has dropped to zero and that the fuel temperature is below 30 C 2 2 Open the central junction box CJB and remove the glow plug relay 3 ...

Page 356: ...ove the charge air cooler air guide 6 6 Disconnect the intake air temperature sensor IAT electrical connector 7 7 Remove the charge air cooler 8 8 Disconnect the fuel injector electrical connectors http vnx su ...

Page 357: ...th adapter into the glow plug bore NOTE Crank the engine with the starter motor until the reading on the compression tester stops rising 12 12 Carry out the measurement on all cylinders following the measuring equipment manufacturer s instructions 13 13 Detach the compression tester and adapter http vnx su ...

Page 358: ...14 14 Install the glow plugs 15 15 Install the glow plug power supply 16 16 Connect the fuel injector electrical connectors 17 17 Install the charge air cooler http vnx su ...

Page 359: ...t the intake air temperature sensor IAT electrical connector 19 19 Install the charge air cooler air guide 20 20 Install the charge air cooler inlet and outlet pipe 21 21 Install the engine upper cover http vnx su ...

Page 360: ...R to Section 100 02 Jacking and Lifting 2 2 Disconnect the oil pressure switch electrical connector and remove the oil pressure switch 3 3 Attach the oil pressure gauge with oil pressure gauge connector and arrange it so that the reading can be made from above 4 4 Lower the vehicle 5 5 Check the oil pressure 6 6 Raise and support the vehicle REFER to Section 100 02 Jacking and Lifting 7 7 Detach t...

Page 361: ...1 8L diesel engine 1 1 Remove the engine upper cover 2 2 Detach the charge air cooler inlet and outlet pipe 3 3 Detach the charge air cooler air guide 4 4 Disconnect the oil pressure switch electrical connector from the oil pressure switch http vnx su ...

Page 362: ...00 rev min 6 6 Attach the oil pressure gauge with the oil pressure gauge connector 7 7 Check the oil pressure 8 8 Detach the oil pressure gauge and the oil pressure gauge connector 9 9 Coat the oil pressure switch with sealer WSK M2G349 A7 10 10 Install the oil pressure switch http vnx su ...

Page 363: ...ch the charge air cooler inlet and outlet pipe 14 14 Install the engine upper cover Valve train analysis static engine off Detach the valve cover Check all valve train components for damage and wear Ensure that only original components are installed and that all bolts and nuts have been tightened to the correct tightening torque http vnx su ...

Page 364: ...s 1 Determine the diameter of the camshaft journals Using a micrometer measure the diameter at 90 degrees intervals to determine if the journals are out of round Measure at two different points on the journal to determine if there is any tapering If the measurements are out of the specified range install a new camshaft http vnx su ...

Page 365: ... a width of plastigage on the bearing cap Insert the camshaft without lubrication into the cylinder head Position a plastigage strip which should be equal to the width of the bearing cap on the bearing journal 2 Following the tightening specification install the camshaft bearing caps Refer to the corresponding Section 303 01 3 NOTE Do not strike the bearing caps Remove the camshaft bearing caps re...

Page 366: ...e sure that the camshaft is to specification Using a Dial Indicator Gauge measure the end play Slide the camshaft in both directions Read and note the maximum and minimum values on the Dial Indicator Gauge 1 End play maximum value minus minimum value If the measurement is out of specification install new components http vnx su ...

Page 367: ...tion Camshaft Surface Inspection Transit Tourneo Connect 2002 5 06 2002 Print General Procedures 1 Inspect the camshaft lobes for pitting or damage in the active area Minor pitting is acceptable outside the active area http vnx su ...

Page 368: ...n Camshaft Lobe Lift Transit Tourneo Connect 2002 5 06 2002 Print General Procedures 1 Determine the cam lift Using a micrometer measure the cam in two directions The difference between the two measurements is the cam lift http vnx su ...

Page 369: ...es General Equipment Micrometer 1 Measure the diameter of the main bearing journals and the big end bearing journals Repeat the measurement with the micrometer offset by 90 in order to determine any eccentricity which may be present Measure the journal at two different positions to determine any conicity which may be present http vnx su ...

Page 370: ...General Procedures General Equipment Dial indicator Dial indicator fixture 1 Determine the end float Place on the dial indicator and bracket Determine the end float by raising the crankshaft with the aid of a screwdriver If necessary correct the end float by using new thrust half washers http vnx su ...

Page 371: ...d to the specified torque however the bearing shells should not be installed Measure the cylinder bore with an internal micrometer Carry out the measurements in different directions and at different heights to determine if there is any out of roundness or tapering If the measurement is out of the specified range install a new block or hone out the cylinder block if aplicable allowed http vnx su ...

Page 372: ...es 1 CAUTION Do not use any aggressive cleaning fluid or a wire brush to clean the piston Carry out a visual inspection Clean the piston skirt pin bush ring grooves and crown and check for wear or cracks If there are signs of wear on the piston skirt check whether the connecting rod is twisted or bent http vnx su ...

Page 373: ...06 2002 Print General Procedures 1 NOTE The piston and piston pin form a matched pair Do not mix up the components Measure the diameter of the piston pin bore Measure the diameter in two directions If the values are not to specification install both a new piston and a new piston pin http vnx su ...

Page 374: ...iston Diameter Transit Tourneo Connect 2002 5 06 2002 Print General Procedures General Equipment Micrometer 1 NOTE Mark the piston to make sure the piston is installed correctly Using a Micrometer measure the piston diameter http vnx su ...

Page 375: ...nt General Procedures 1 CAUTION Do not mix up the piston rings Install the piston rings in the same position and location Take the piston ring and use a piston without rings to push the piston ring about 30 mm into the cylinder bore 2 Using the Feeler Gauge measure the piston ring gap http vnx su ...

Page 376: ...02 Print General Procedures General Equipment Feeler Gauge 1 NOTE The piston ring must protrude from the piston groove To determine the piston ring clearance insert the Feeler Gauge right to the back of the groove behind the wear ridge Using the Feeler Gauge measure the piston ring clearance http vnx su ...

Page 377: ...02 5 06 2002 Print General Procedures 1 NOTE The piston and piston pin are a matched pair Do not mix up the components Measure the piston pin diameter Measure the diameter in two directions If the values are not to specification install a new piston and a new piston pin http vnx su ...

Page 378: ...e End Bore Transit Tourneo Connect 2002 5 06 2002 Print General Procedures 1 Measure the bearing bore in two directions The difference is the connecting rod bore out of round Verify the out of round and the bearing bore is within specification http vnx su ...

Page 379: ...mation Valve Stem Diameter Transit Tourneo Connect 2002 5 06 2002 Print General Procedures 1 Using a micrometer measure the diameter of the valve stems If the measurements are not to specification install a new valve http vnx su ...

Page 380: ...el Inspection Transit Tourneo Connect 2002 5 06 2002 Print General Procedures 1 Inspect the flywheel If there is evidence of the following install a new flywheel 1 Cracks 2 Worn ring gear teeth 3 Chipped or cracked ring gear teeth http vnx su ...

Page 381: ...e is evidence of the following install a new flywheel Cracks Worn ring gear teeth Chipped or cracked ring gear teeth 2 Check the flywheel for lateral movement Rotation movement in either one or both directions or rock on it s axis in relation to the primary mass is acceptable If there is any lateral movement install a new flywheel 3 CAUTION Make sure that the three locating dowels are installed Ch...

Page 382: ... Connect 2002 5 06 2002 Print General Procedures General Equipment Feeler gauge Straight edge 1 Using a straight edge and feeler gauge measure the cylinder head distortion Measure the mating face distortion Refer to Specifications in the appropriate engine section http vnx su ...

Page 383: ... Tourneo Connect 2002 5 06 2002 Print General Procedures 1 Using a Straight Edge and a Feeler Gauge measure the cylinder block cylinder head distortion Measure the mating face distortion If the value is not to specification rework the mating face if allowed http vnx su ...

Page 384: ...neo Connect 2002 5 06 2002 Print General Procedures 1 Inspect the cylinder head joining flanges of the exhaust manifold for evidence of exhaust gas leaks 2 Inspect the exhaust manifold for cracks damaged gasket surfaces or other damage that would make it unfit for further use http vnx su ...

Page 385: ...Procedures 1 Inspect bearings for the following defects 1 Cratering fatigue failure 2 Spot polishing incorrect seating 3 Imbedded dirt engine oil 4 Scratching dirty engine oil 5 Base exposed poor lubrication 6 Both edges worn journal damaged 7 One edge worn journal tapered or bearing not seated http vnx su ...

Page 386: ...ourneo Connect 2002 5 06 2002 Print General Procedures General Equipment Valve seat width scale 1 Measure the width of the valve seat Measure the valve seat width using the Valve seat width scale If the value is not to specification rework the valve seat http vnx su ...

Page 387: ... 5W30 below 20 C to above 40 C Ford Formula E Economy Motor Oil WSS M2C913 A or WSS M2C912 A1 Alternative engine oils SAE 10W40 20 C to above 40 C Ford XR High performance High lubricity Engine Oil ACEA A3 B3 SAE 5W40 below 20 C to above 40 C Ford Formula S Synthetic Engine Oil ACEA A3 B3 Litres Engine oil initial fill including filter 4 35 Engine oil including filter change 4 25 Engine oil exclud...

Page 388: ...tic converter retaining bolt 47 35 Intermediate shaft center bearing retaining nuts 25 18 Generator retaining bolts 25 18 Generator retaining bracket retaining nut 25 18 Generator retaining bracket retaining bolts 65 48 Transaxle retaining bolts 47 35 Starter motor retaining bolts 35 26 Engine rear mount center retaining nut 133 98 Engine front mount retaining nuts 80 59 Engine front mount retaini...

Page 389: ...g bolts 18 13 Lower crankcase retaining bolts 30 22 Crankshaft rear oil seal carrier retaining bolts 20 15 Crankcase ventilation pipe retaining bracket 23 17 Positive crankcase ventilation housing 10 89 Crankshaft pulley retaining bolt 115 85 Crankshaft position CKP sensor mounting bracket retaining bolt 21 15 CKP sensor retaining bolt 8 71 Accessory drive belt idler pulley 40 30 Air conditioning ...

Page 390: ...en by a timing belt Mechanical bucket tappet operated valves Cylinder head and lower crankcase made of aluminium Engine management ECC V engine management system PCM with 60 pins Sequential fuel injection Mass Air Flow MAF sensor with integrated Intake Air Temperature IAT sensor Cylinder Head Temperature CHT sensor for measurement of the engine temperature Pre cat and post cat heated oxygen sensor...

Page 391: ...ssion control Meets the European level III emissions standard 3 way catalytic converter EVAPorative emission EVAP system Diagnosis Can be diagnosed via the Data Link Connector DLC in the passenger compartment Engine power and torque Description Torque curve Power curve Item 1 2 Part Number http vnx su ...

Page 392: ...Engine 1 8L Duratec DOHC 85kW 115PS Zetec Engine Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 303 00 Engine System General Information http vnx su ...

Page 393: ...rotation Turn the engine until each piston is at top dead center TDC and measure the valve clearances 3 NOTE Note down each cylinder number and the valve clearances measured Using a suitable set of feeler gauges measure the valve clearances 4 NOTE Only carry out the following steps when the valve clearance must be adjusted For additional information refer to Specifications in this section Install ...

Page 394: ...e clearance the required valve clearance For additional information refer to Specifications in this section 7 Install the correct shim 8 Remove the special tool 9 Check the valve clearance after adjustment is complete 10 Install the valve cover For additional information refer to Valve Cover in this section http vnx su ...

Page 395: ...e intake manifold lower retaining bolts engine shown removed for clarity 4 Lower the vehicle 5 Detach the accelerator cable from the throttle body and position it to one side 1 Detach the accelerator outer cable from the accelerator cable bracket 2 Detach the accelerator inner cable from the throttle body lever 6 Disconnect the camshaft position CMP sensor electrical connector 7 Disconnect the cyl...

Page 396: ...el rail 11 Remove the intake manifold engine shown removed for clarity 1 NOTE Clean and inspect the intake manifold gasket Install a new intake manifold gasket if necessary Install the intake manifold engine shown removed for clarity 2 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting http vnx su ...

Page 397: ...e and fuel return line to the fuel rail 6 Connect the brake booster vacuum pipe to the brake booster 7 Connect the vacuum hoses to the throttle body 8 Connect the cylinder head temperature CHT sensor and the powertrain control module PCM electrical connectors 9 Connect the camshaft position CMP sensor electrical connector http vnx su ...

Page 398: ...ttach the accelerator outer cable to the accelerator cable bracket 2 Attach the accelerator inner cable to the throttle body lever 11 Install the air cleaner For additional information refer to Section 303 12 Intake Air Distribution and Filtering http vnx su ...

Page 399: ...1 243 1 Remove the timing belt For additional information refer to Timing belt in this section 2 NOTE FRONT marking and installation position of the timing pulley thrust washer Remove the crankshaft timing pulley 1 Pull off the crankshaft timing pulley 2 Remove the timing pulley key and thrust washer 3 Remove the crankshaft front oil seal 1 NOTE Correct seating of sealing lip on the installation s...

Page 400: ...t of the crankshaft vibration damper Draw in the crankshaft front oil seal using the special tool to the fully home position 6 NOTE FRONT marking and installation position of the timing pulley thrust washer Install the crankshaft timing pulley 1 Push on the timing pulley thrust washer and key 2 Attach the crankshaft timing pulley 7 Install the timing belt For additional information refer to Timing...

Page 401: ...afts in this section Remove the valve tappets and lay them in order to one side 2 WARNING Always wear protective goggles when working with compressed air Failure to do so can result in injury Remove the spark plug from cylinder no 1 and attach the special tool 3 CAUTION Use compressed air at 7 to 10 bar Attach the special tools and apply compressed air to the cylinder 1 Compress the valve spring 2...

Page 402: ...2 Detach Special Tool 303 363 and screw in the spark plug 3 Repeat the operations for all the other cylinders 4 Coat the valve tappets with engine oil and insert 5 Install the camshafts For additional information refer to Camshafts in this section http vnx su ...

Page 403: ...For additional information refer to Camshafts in this section Remove the valve tappets and lay them in order to one side 2 WARNING Always wear protective goggles when working with compressed air Failure to do so can result in injury Unscrew the spark plug from cylinder no 1 and attach the special tool 3 CAUTION Use compressed air at 7 to 10 bar Attach the special tools and apply compressed air to ...

Page 404: ...em and remove the oil seal installation sleeve 2 NOTE Check that the valve collets are correctly seated Install the valve springs with the valve spring retainers 1 Compress the valve springs 2 Install the valve collets 3 Detach Special Tool 303 363 4 Repeat the operations for all the other cylinders 5 Coat the valve tappets with engine oil and insert 6 Install the camshafts For additional informat...

Page 405: ...ste Engine oil 1 NOTE Lay the cylinder head on the workbench on a clean surface Remove the cylinder head For additional information refer to Cylinder head in this section 2 NOTE Place wooden wedges in the combustion chamber recesses of the cylinder head to hold the valves in place during removal Remove the valve 1 Compress the valve spring 2 Remove the valve collets 3 NOTE Lay all parts in order t...

Page 406: ...y traces of grinding paste 3 Coat valve stem withlubricant and insert 4 Install the valve stem oil seal Cover the grooves in the valve stems with the oil seal installation sleeve Slide the valve stem seal onto the valve stem and remove the installation sleeve 5 NOTE Check that the valve collets are correctly seated Install the valve springs with the valve spring retainers 1 Compress the valve spri...

Page 407: ...7 Install the cylinder head For additional information refer to Cylinder Head in this section http vnx su ...

Page 408: ...rmation refer to Timing Belt in this section 2 NOTE Only carry out the following step if reusing the original valve train components Check the valve clearance For additional information refer to Valve Clearance Adjustment in this section 3 Using the special tool remove the camshaft pulleys 4 CAUTION Loosen the camshaft bearing cap retaining bolts in the sequence shown NOTE Working in several stage...

Page 409: ...tages tighten each camshaft bearing cap retaining bolt two turns at a time Install the camshaft bearing cap retaining bolts Tighten the bolts in the sequence shown in two stages Stage 1 10 Nm Stage 2 19 Nm 5 NOTE Only carry out the following step if using new valve train components Check and adjust the valve clearance For additional information refer to Valve Clearance Adjustment in this section 6...

Page 410: ...8 Install the timing belt For additional information refer to Timing Belt in this section http vnx su ...

Page 411: ...rench Universal 205 072 15 030A Installer Engine Front Cover Oil Seal 303 039 21 009B Name Sealant Engine oil 1 Remove the timing belt For additional information refer to Timing belt in this section 2 Detach the timing pulleys from the camshafts using the special tool Unscrew the bolts 3 Detach both front camshaft bearing caps Discard the camshaft oil seals 1 Thinly coat the camshaft bearing caps ...

Page 412: ...sealing lip of the oil seals with engine oil Install new oil seals using the special tool a washer and an M10x70 bolt NOTE The camshaft timing pulleys must be able to turn freely on the camshafts Do not tighten the bolts Attach the camshaft timing pulleys 4 Install a new timing belt For additional information refer to Timing belt in this section http vnx su ...

Page 413: ...tional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Remove the valve cover For additional information refer to Valve Cover 303 01A Engine 1 8L Duratec DOHC 85kW 115PS Zetec In vehicle Repair 3 Remove the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratec DOHC 85kW 115PS Zetec 303 05 Accessory Dri...

Page 414: ...rom the wheel housing and position it to one side 10 Detach the power steering fluid reservoir from the wheel housing and position it to one side 11 Using a trolley jack and a suitable wooden block under the oil pan raise the engine so that the engine front mount is free from load 12 Remove the engine front mount http vnx su ...

Page 415: ... special tool remove the spark plugs 16 Slacken the timing belt tensioner 1 Loosen the bolt and rotate the timing belt tensioner washer clockwise 2 Remove the bolt and the timing belt tensioner and discard it 17 Remove the timing belt engine shown removed for clarity Discard the timing belt http vnx su ...

Page 416: ... not kink the timing belt the bend diameter must not be less than 35 mm Do not rotate the crankshaft If necessary check if the crankshaft is touching the timing peg NOTE The clip of the timing belt tensioner must not be hooked into the pressed steel cover NOTE Install a new timing belt Install the timing belt http vnx su ...

Page 417: ...ion the timing belt 1 Hook the timing belt tensioner into the pressed steel cover 2 Rotate the timing belt tensioner washer counterclockwise until the arrow points the mark and tighten the bolt 3 Check if the arrow points the mark after tightening the bolt 6 Using the special tool tighten the camshaft pulley retaining bolts 7 Remove the special tool 8 Raise and support the vehicle For additional i...

Page 418: ...haft pulley 13 Lower the vehicle 14 CAUTION It is possible that the timing belt tensioner marks do not align after rotating the crankshaft Do not re tighten the timing belt if the timing belt tensioner marks do not align Install the special tool check the valve timing Loosen the camshaft pulleys correct the camshaft alignment if necessary 15 Remove the special tool 16 Raise and support the vehicle...

Page 419: ...e 20 Apply sealer to the camshaft front bearing caps 21 Using the special tool install the spark plugs 22 NOTE Do not tighten the bolts at this stage Install the timing belt upper cover 23 Install the engine front mount retaining bracket http vnx su ...

Page 420: ...the wheel housing 26 Attach the coolant expansion tank to the wheel housing 27 Remove the trolley jack 28 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 29 Install the timing belt lower cover http vnx su ...

Page 421: ...ccessory Drive Removal and Installation 32 Install the valve cover For additional information refer to Valve Cover 303 01A Engine 1 8L Duratec DOHC 85kW 115PS Zetec In vehicle Repair 33 Connect the battery ground cable For additional information refer to Accessory Drive Belt 1 8L Duratec DOHC 85kW 115PS Zetec 303 05 Accessory Drive Removal and Installation http vnx su ...

Page 422: ...nal information refer to Section 100 02 Jacking and Lifting 2 Detach the exhaust manifold bracket and disconnect the plugs for the heated oxygen sensor H02S 3 Lower the vehicle 4 Detach the heat shield 5 Detach the exhaust manifold from the catalytic converter 6 Detach the exhaust manifold from the cylinder head 1 Attach the exhaust manifold to the cylinder head http vnx su ...

Page 423: ...nifold to the catalytic converter 3 Attach the heat shield 4 Raise the vehicle For additional information refer to Section 100 02 Jacking and Lifting 5 Tighten the exhaust manifold bracket and connect the HO2S plugs 6 Lower the vehicle http vnx su ...

Page 424: ...303 397 24 003 Spatula Name Engine Oil 1 Release the fuel system pressure For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 2 Drain the cooling system For additional information refer to Section 303 03 Engine Cooling 3 Using a suitable splint or wrap support the exhaust flexible pipe 4 Detach the catalytic converter bracket ...

Page 425: ... PCM electrical connectors 8 Disconnect the fuel supply and return line quick release couplings For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 9 Disconnect the ground cable from the engine front lifting eye 10 Disconnect the vacuum hoses from the throttle body http vnx su ...

Page 426: ...tube from the cylinder head 13 Detach the catalytic converter from the exhaust manifold and secure it to the radiator grille opening panel Discard the gasket 14 Detach the electronic ignition EI coil from the cylinder head 15 Detach the thermostat housing from the cylinder head Discard the O ring seal http vnx su ...

Page 427: ...iator grille opening panel Detach the degas hose from the coolant distribution pipe 18 Remove the power steering pump bracket upper retaining bolts 19 Remove the exhaust manifold engine shown removed for clarity Discard the gasket 20 Detach the generator from the generator bracket 1 Loosen the bolt 2 Remove the bolt http vnx su ...

Page 428: ...r head must have cooled to below 30 C before removal Using the special tool remove the cylinder head bolts in the sequence shown Discard the cylinder head gasket Discard the cylinder head bolts as necessary 24 NOTE Place the cylinder head on a clean surface Remove the cylinder head 1 Check the cylinder head for distortion For additional information refer to Section 303 00 Engine System General Inf...

Page 429: ...ng studs 7 NOTE Install new cylinder head bolts as necessary Using the special tool tighten the cylinder head bolts in the sequence shown in three stages Stage 1 20 Nm Stage 2 40 Nm Stage 3 90 degrees 8 Install the camshafts For additional information refer to Camshafts in this section 9 NOTE Install a new exhaust manifold gasket NOTE Install new spacers to the outer studs Install the exhaust mani...

Page 430: ...et 13 NOTE Install a new O ring seal Attach the thermostat housing to the cylinder head 14 Connect the positive crankcase ventilation PCV hose to the PCV tube 15 Attach the coolant distribution pipe to the radiator grille opening panel Attach the degas hose to the coolant distribution pipe http vnx su ...

Page 431: ...head 18 NOTE Install a new catalytic converter gasket Attach the catalytic converter to the exhaust manifold 19 Install the exhaust manifold heat shield 20 Connect the fuel supply and return line quick release couplings For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information http vnx su ...

Page 432: ...rtrain control module PCM electrical connectors 23 Connect the vacuum hoses to the throttle body 24 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 25 Connect the oil pressure switch electrical connector 26 Connect the brake booster pipe to the intake manifold http vnx su ...

Page 433: ...cket to the engine 28 Detach the wrap from the exhaust flexible pipe 29 Fill and bleed the cooling system For additional information refer to Section 303 03 Engine Cooling 30 NOTE Install a new oil filter Change the engine oil http vnx su ...

Page 434: ...ation refer to Crankshaft front oil seal in this section 2 Detach the air conditioning compressor from the bracket and secure it on the radiator crossmember 3 Remove the A C compressor bracket engine shown removed for clarity 4 Remove the intermediate shaft centre bearing bracket 5 Remove the oil pan For additional information refer to Oil Sump in this section 6 Remove the oil intake tube Discard ...

Page 435: ...8 Remove the auxiliary drive belt tensioner 9 Remove the oil pump shown with engine removed for clarity Discard the gasket 1 NOTE Renew the oil pump gasket NOTE Do not fully tighten the oil pump retaining bolts at this stage Install the oil pump shown with engine removed for clarity 2 Align the oil pump on both sides using a knife edge straight edge so that the contact surface lies 0 3 mm 0 8 mm a...

Page 436: ...n the bolts on the transmission NOTE Install a new ladder frame gasket Install the lower crankcase shown with engine removed for clarity 6 NOTE Renew the oil intake tube O ring Install the oil intake 7 Install the oil sump For additional information refer to Oil Sump in this section 8 Install the intermediate shaft centre bearing bracket 9 Install the A C compressor bracket engine shown removed fo...

Page 437: ...10 Install the air conditioning compressor on the bracket 11 Install the front crankshaft oil seal For additional information refer to Crankshaft front oil seal in this section http vnx su ...

Page 438: ...6067 Locking tool flywheel 303 254 21135 Puller oil seal 303 291 21141 Remover oil seal 303 293 21143 Name High temperature grease 1 Detach the clutch Lock the flywheel using Special Tool 303 254 Slacken the bolts of the clutch pressure plate evenly Detach the clutch pressure plate and the clutch disc 2 NOTE Mark the installation position Detach the flywheel Remove Special Tool 303 254 3 Remove th...

Page 439: ...eal using a hammer handle 1 Incorrect installation 2 Correct installation 2 Draw in the oil seal Draw in the oil seal with the special tool and two flywheel bolts 3 NOTE Clear the remainder of the locking compound from the threaded holes on the crankshaft NOTE Use new bolts Attach the flywheel 4 NOTE Apply a layer of high temperature grease This should be so thin that no grease is expelled from th...

Page 440: ...perature grease 5 Center the clutch disc on the clutch pressure plate 6 Install the clutch 1 Install the clutch pressure plate with centered clutch disc 2 Working diagonally tighten the bolts in several stages one turn at a time 3 Check the centering and correct if necessary 7 Detach the special tools http vnx su ...

Page 441: ...Detach the accelerator outer cable from the throttle body bracket 2 Detach the accelerator inner cable from the throttle body lever 2 Disconnect the spark plug electrical connectors 3 Disconnect the positive crankcase ventilation PCV hose from the valve cover 4 NOTE Do not remove the timing belt upper cover at this stage Loosen the timing belt upper cover retaining bolts 5 Remove the valve cover h...

Page 442: ...Installation 1 NOTE Install a new valve cover gasket if necessary To install reverse the removal procedure http vnx su ...

Page 443: ...l information refer to Section 309 00 Exhaust System 2 Drain the engine Allow the oil to drain into a suitable container 3 Remove the oil pan retaining bolts 4 CAUTION To prevent damage to the sealing surface only use the special tool shown to remove the oil pan NOTE Tighten the locknut against the oil pan and tap the special tool several times to release the oil pan from the lower crankcase Using...

Page 444: ...e removed once it comes into contact with the lower crankcase housing Install the oil pan Remove the ten M6 x 20 mm studs 6 Install the oil pan retaining bolts Tighten the bolts in the sequence shown in two stages Stage 1 6 Nm Stage 2 10 Nm 7 NOTE Inspect the oil drain plug seal for damage Install a new oil drain plug and seal if necessary Install the oil pan drain plug 8 Install the catalytic con...

Page 445: ...et Engine 303 122 21 068A Remover Installer Hose Clamp 303 397 24 003 Remover Halfshaft 308 192 16 057 Workshop table Retaining straps Engine hoist 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Remove the air cleaner For additional information refer to Section 303 12 Intake Air Distribution and Filtering 3 Loosen the strut an...

Page 446: ...er 6 Disconnect the ignition coil electrical connector 7 Disconnect the transaxle wiring harness electrical connector 8 Disconnect the fuel supply line and fuel return line from the fuel rail 9 Disconnect the ground cable from the engine front lifting eye 10 Disconnect the powertrain control module PCM electrical connector http vnx su ...

Page 447: ...m pipe from the brake booster 13 Disconnect the vacuum hoses from the throttle body 14 Disconnect the power steering hose from the power steering fluid reservoir Allow the fluid to drain into a suitable container 15 Disconnect the transaxle ventilation hose from the transaxle http vnx su ...

Page 448: ...he spring clip 17 Disconnect the reversing lamp switch electrical connector 18 Disconnect the catalyst monitor sensor electrical connector 19 Disconnect the heated oxygen HO2S sensor electrical connector 20 Drain the cooling system For additional information refer to Section 303 03 Engine Cooling 21 Remove the accessory drive belt For additional information refer to Section 303 05 Accessory Drive ...

Page 449: ...gaskets 24 Detach the air conditioning A C compressor from the bracket and secure it to one side 25 Disconnect the power steering pressure PSP switch electrical connector 26 Using the special tool disconnect the coolant hose from the water pump 27 Remove the intermediate shaft center bearing cap Discard the center bearing cap and locknuts 28 CAUTIONS http vnx su ...

Page 450: ...es The outer joint must not be bent more than 45 degrees Do not damage the halfshaft seal Cap the transaxle to prevent oil loss and dirt ingress Using the special tool detach the left hand halfshaft from the transaxle and secure it to one side Discard the snap ring Allow the oil to drain into a suitable container 30 Disconnect the vehicle speed sensor VSS electrical connector 31 Disconnect the cra...

Page 451: ...orkshop table under the vehicle and carefully lower the vehicle until the engine and transaxle assembly is supported by the workshop table 34 Using the special tool disconnect the coolant hoses from the thermostat housing 35 Disconnect the coolant hose from the coolant distribution pipe 36 Remove the engine rear mount center retaining nut Discard the nut 37 Remove the engine front mount retaining ...

Page 452: ... Using the special tool attach the engine and transaxle assembly to the engine hoist 40 Remove the starter motor and the ground cable 41 Remove the transaxle left hand retaining bolts 42 Remove the transaxle right hand retaining bolts 43 Remove the transaxle http vnx su ...

Page 453: ... Wrench Universal 205 072 15 030A Lifting bracket engine 303 122 21 068A Immobiliser flywheel 303 254 21 135 Socket cylinder head cover 303 293 21 143 Mounting Bracket for 303 435 303 435 04 21 064 Mounting Plate for 303 435 04 303 435 12A 21 150B Adapter for 205 047 303 633 21 227 1 Disconnect the plug of the oil pressure switch 2 Remove the oil pressure switch http vnx su ...

Page 454: ...rom the intake manifold 4 Remove the intake manifold 5 Remove the generator 1 Remove the positive cable 2 Unscrew the bolt 3 Undo the bolt 6 Remove the generator bracket 7 Remove the oil filter Discard the oil filter http vnx su ...

Page 455: ... special tool 9 Install the special tool 10 Attach the engine to the assembly stand 11 Remove the special tool 12 Remove the catalytic converter support bracket 13 Remove the exhaust manifold heat shield http vnx su ...

Page 456: ...front retaining strap of the catalytic converter 15 Remove the catalytic converter 16 Remove the oil level indicator and tube 17 Remove the power steering pump bracket 18 Remove the A C compressor bracket http vnx su ...

Page 457: ...positive crankcase ventilation PCV housing 20 Remove the water pump pulley 21 Remove the auxiliary drive belt idler pulley 22 Remove the front engine mounting bracket 23 Remove the upper timing belt cover http vnx su ...

Page 458: ...Remove the lower timing belt cover 27 Lock the flywheel using the special tool and undo the clutch disc and pressure plate bolts by two turns 28 Remove the clutch disc and pressure plate 29 Using the special tool immobilize the flywheel and remove the flywheel Discard the bolts http vnx su ...

Page 459: ...y before removing to loosen the seal Detach the ignition cables from the spark plugs 32 Remove the spark plugs 33 Remove the cylinder head cover 34 Slacken the timing belt 1 Undo the bolts and turn the washer of the timing belt tensioner clockwise 2 Loosen the bolts by a further four turns and unhook the timing belt tensioner 35 Remove the timing belt Discard the timing belt 36 Remove the timing b...

Page 460: ...shaft timing pulley and the timing belt thrust washer 39 Remove the water pump 40 Remove the camshaft timing pulley using the special tool 41 NOTE Loosen the camshaft bearing cap bolts by two turns each Remove the camshafts Discard the oil seals http vnx su ...

Page 461: ...the cylinder head temperature has dropped below 30 degrees C Remove the cylinder head bolts in the sequence shown 43 Remove the cylinder head Discard the cylinder head gasket 44 Drain the engine Collect the engine oil in a suitable container 45 Remove the oil pan bolts 46 Remove the oil pan using the special tool 47 Remove the oil intake tube Discard the O ring seal http vnx su ...

Page 462: ...front crankshaft oil seal using the special tool 50 Remove the oil pump Discard the gasket 51 Remove the crankshaft position CKP sensor and the CKP sensor bracket 52 Remove the crankshaft rear oil seal carrier Discard the gasket Discard the oil seal http vnx su ...

Page 463: ...http vnx su ...

Page 464: ...068A Immobiliser flywheel 303 254 21 135 Installer crankshaft rear oil seal 303 291 21 141 Timing Plate Camshaft Alignment 303 376 21 162 B Socket Cylinder Head Bolt 303 392 21 167 Installer crankshaft oil seal 303 395 21 171 Mounting Bracket for 303 435 303 435 04 21 064 Mounting Plate for 303 435 04 303 435 12A 21 150B Timing Peg Crankshaft 303 574 21 163 Installer crankshaft front oil seal 303 ...

Page 465: ...ot tighten the bolts of the crankshaft rear oil seal carrier for the moment Install the rear crankshaft oil seal carrier 2 Install the crankshaft position CKP sensor and the CKP sensor bracket 3 CAUTION The new crankshaft rear oil seal must be fully installed in the special tool NOTE Install the new crankshaft rear oil seal Install the crankshaft rear oil seal using the special tool and two used f...

Page 466: ... seal onto the special tool 8 NOTE For the moment do not fully install the crankshaft front oil seal NOTE The crankshaft journals must be clean and free of oil or grease Slide the crankshaft front oil seal with the special tool onto the crankshaft 9 Remove the special tool 10 Install the crankshaft front oil seal and crankshaft pulley bolt 11 Remove the special tool and the crankshaft pulley bolt ...

Page 467: ...t Align the lower crankcase using a steel rule max protrusion 0 10 mm Max gap 0 25 mm Apply sealant to the transitions between the cylinder block and the oil pump and the cylinder block and oil seal carrier 14 If necessary install lower crankcase spacer shims with a gap of 0 26 0 50 mm install 0 25 mm spacer washers with a gap of 0 51 0 75 mm install 0 50 mm spacer washers 15 Tighten the lower cra...

Page 468: ...1 6 Nm Stage 2 10 Nm 21 NOTE Check the seal of the oil drain plug for damage If necessary install a new oil drain plug and seal Install the oil drain plug 22 Immobilize the flywheel with the special tool 23 NOTE Install new flywheel bolts NOTE Remove any residual thread locking compound from the threaded bores Install the flywheel 24 NOTE Apply a layer of high temperature grease This should be so ...

Page 469: ...ure plate with the centered clutch disc 2 Working diagonally in several stages tighten the bolts a turn at a time 3 Check the centering and correct as necessary 27 Make two guide studs as shown in the diagram 28 CAUTION The choice of cylinder head gasket depends on the cast cylinder block number Check the cylinder block number 29 NOTE Install a new cylinder head gasket Lay a new cylinder head gask...

Page 470: ... marked areas on camshaft bearing caps 0 and 5 34 NOTE Only rotate the crankshaft in the normal direction of rotation Turn the crankshaft until piston no 1 is approx 60 degrees before top dead centre TDC 35 NOTE The identification numbers are located on the outside of the camshaft bearing caps NOTE Lay the camshaft in place so that none of the cams is at full lift NOTE Apply clean engine oil to th...

Page 471: ...lt of the crankshaft pulley for the moment Install the crankshaft belt pulley 39 NOTE Only rotate the crankshaft in the normal direction of rotation Turn the crankshaft until no 1 piston is at TDC 40 Remove the crankshaft belt pulley 41 NOTE Cylinders 1 and 4 are at TDC when the Woodruff key is pointing towards the pistons Remove the lower cylinder block plug and install the special tool http vnx ...

Page 472: ...e moment Install the camshaft timing pulleys 44 NOTE Install a new coolant pump gasket Install the coolant pump gasket 1 Lay the gasket in place 2 Secure the gasket by bending over the tabs 45 Install the water pump 46 NOTE Pay attention to the installation position of the crankshaft thrust washer Install the crankshaft timing pulley and the thrust washer http vnx su ...

Page 473: ...kshaft If necessary check whether the crankshaft is touching Special Tool 303 574 NOTE The clip of the timing belt tensioner must not be hooked into the pressed steel cover NOTE Install a new timing belt Install the timing belt Starting from the crankshaft timing pulley and working anti clockwise put the timing belt in place Pull the belt tight as you proceed 50 NOTE Make sure that a new component...

Page 474: ...e up 51 Tighten the camshaft timing pulley bolt using the special tool 52 Remove the special tool 53 Remove the special tool 54 NOTE Do not tighten the bolt of the crankshaft pulley for the moment Install the crankshaft belt pulley 55 NOTE Only rotate the crankshaft in the normal direction of rotation Turn the crankshaft two turns until no 1 piston is at TDC http vnx su ...

Page 475: ...line up the timing belt must not be re tensioned Install the special tool and check the valve timing Loosen the camshaft pulley bolts to adjust the valve timing 59 Remove the special tools 60 Install the lower cylinder block plug 61 Apply sealant thinly to the areas of the camshaft front bearing caps shown http vnx su ...

Page 476: ...if necessary Install the cylinder head cover Tighten the bolts in two stages Stage 1 2 Nm Stage 2 7 Nm 63 Install the spark plugs 64 Install the ignition cables 65 Install the lower timing belt cover 66 Install the crankshaft belt pulley http vnx su ...

Page 477: ... the bolts of the timing belt upper cover for the moment Install the timing belt upper cover 69 Install the front engine mounting bracket 70 Tighten the bolts of the timing belt upper cover 71 Install the auxiliary drive belt idler pulley http vnx su ...

Page 478: ... of the positive crankcase ventilation PCV Install the PCV housing 1 Tighten the bolts of the PCV housing 2 Tighten the bolts of the PCV pipe 74 Install the A C compressor bracket 75 Install the power steering pump bracket 76 Install the oil level indicator and tube http vnx su ...

Page 479: ... gasket NOTE Do not tighten the catalytic converter bolts for the moment Install the catalytic converter 79 Loosely attach the catalytic converter to the catalytic converter bracket using M8 x 40 bolts 80 Tighten the catalytic converter bolts 81 Install the front retaining strap of the catalytic converter http vnx su ...

Page 480: ...ear retaining strap of the catalytic converter 83 Remove the M8 x 40 bolts 84 Install the exhaust manifold heat shield 85 Install the special tool 86 Detach the engine from the assembly stand 87 Remove the special tool http vnx su ...

Page 481: ...er Install the oil filter 90 Install the generator bracket 91 Install the generator 1 Screw in and tighten the bolt 2 Tighten the bolt 3 Install the positive lead 92 NOTE If necessary install a new intake manifold gasket Install the intake manifold http vnx su ...

Page 482: ...93 Install the lower bolts of the intake manifold 94 Install the oil pressure switch 95 Push on the oil pressure switch connector http vnx su ...

Page 483: ...njury Lifting Bracket Engine 303 122 21 068A Remover Installer Hose Clamp 303 397 24 003 Workshop table Retaining straps Engine hoist 1 WARNING Support the engine and transaxle assembly on wooden blocks and secure it with suitable retaining straps Failure to follow these instructions may result in personal injury Using the special tool and the engine hoist position the engine and transaxle assembl...

Page 484: ...e front mount retaining nuts NOTE Do not tighten the engine front mount retaining nuts at this stage Install the engine front mount retaining nuts 9 NOTE Install a new rear mount center retaining nut NOTE Do not tighten the engine rear mount center retaining nut at this stage Install the engine rear mount center retaining nut 10 Raise the vehicle and remove the workshop table 11 Attach the gearshi...

Page 485: ...ees Do not damage the halfshaft seal NOTE Install a new center bearing cap and locknuts Attach the right hand halfshaft and the intermediate shaft to the transaxle Install the center bearing cap and locknuts 15 CAUTIONS Support the halfshaft The inner joint must not be bent more than 18 degrees The outer joint must not be bent more than 45 degrees Do not damage the halfshaft seal Make sure the sna...

Page 486: ...ng A C compressor to the bracket 19 NOTE Install new flexible exhaust pipe gaskets Install the flexible exhaust pipe 20 Install the crossmember For additional information refer to Section 502 00 Uni Body Subframe and Mounting System 21 Install the accessory drive belt For additional information refer to Section 303 05 Accessory Drive 22 Lower the vehicle 23 Tighten the engine front mount retaining...

Page 487: ... tool connect the coolant hoses to the thermostat housing 26 Using the special tool connect the coolant hose to the coolant distribution pipe 27 Connect the heated oxygen HO2S sensor electrical connector 28 Connect the catalyst monitor sensor electrical connector http vnx su ...

Page 488: ...th cold water NOTE Make sure the spring clip is correctly seated Connect the clutch slave cylinder supply hydraulic fluid line to the transaxle and install the spring clip 31 Connect the transaxle ventilation hose to the transaxle 32 Connect the power steering hose to the power steering fluid reservoir 33 Connect the vacuum hose to the throttle body http vnx su ...

Page 489: ...ster 35 Connect the generator electrical connector 36 Connect the powertrain control module PCM electrical connector 37 Connect the ground cable to the engine front lifting eye 38 Connect the fuel supply line and fuel return line to the fuel rail http vnx su ...

Page 490: ...tor 41 Attach the accelerator cable to the throttle body 1 Attach the accelerator outer cable to the accelerator cable bracket 2 Attach the accelerator inner cable to the throttle body lever 42 Connect the ground cable to body 43 Tighten the strut and spring assembly top mount nuts on both sides http vnx su ...

Page 491: ...er to Section 308 00 Manual Transmission Transaxle and Clutch General Information 47 Adjust the gearshift cables For additional information refer to Section 308 00 Manual Transmission Transaxle and Clutch General Information 48 Connect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 49 Install the air cleaner For additional information refer ...

Page 492: ...cket to cylinder block 48 35 Engine front mount retaining nuts 80 59 Engine front mount to body retaining bolts 90 66 Engine rear mount center retaining bolt 148 109 Engine rear mount to body retaining nuts 48 35 Wiring loom retaining bracket to transaxle 12 9 Engine support insulator retaining bracket to subframe 48 35 Engine support insulator center retaining bolt 120 89 Engine support insulator...

Page 493: ...a E SAE 5W 30 engine oil vehicles without common rail fuel injection WSS M2C912 A Ford Formula E SAE 5W 30 engine oil vehicles with common rail fuel injection WSS M2C913 A Coolant WSS M97B44 D Transmission fluid MTX WSD M2C200 C Power steering hydraulic fluid WSA M2C195 A Sealer oil pan to ladder frame WSE M4G323 A6 Sealer ladder frame to cylinder block Hylomar SPM 4G9112 H Sealer camshaft bearing...

Page 494: ...refore complies with EEC emissions standard D3 and all other requirements made on latest generation assemblies with regard to fuel consumption quiet running flexibility and power output Engine codes The engine codes for the Endura DI engines installed are 55 kW 75 PS BHPA 55 kW 75 PS BHPB Turkey only Location of the engine code on the cylinder block of the Endura DI engine Crankshaft The five main...

Page 495: ...g belt tensioner The initial setting of the timing belt tension is carried out by the adjustment cam The camshaft timing pulley is retained on the camshaft by a taper The required frictional force is applied to the camshaft by the center bolt Valve tappet adjusting shims The camshaft timing is transmitted to the valve springs by eight bucket tappets CAUTION The lettering must face the tappets when...

Page 496: ...t settle during installation the cylinder head bolts can be installed with lower clamping force However because of the rubber surface the gasket is also more susceptible to grooves and therefore it must be cleaned without using sharp objects Crankshaft oil seals NOTE The crankshaft rear oil seal is supplied with an alignment sleeve It aligns the oil seal to the crankshaft rear flange NOTE The cran...

Page 497: ...s must be free of contaminants at all times Oil Sump The oil pan is made of steel It is sealed using silcone based sealant WSE M4G 323 A6 CAUTIONS When removing the engine front mount do not place a workshop jack under the sump to support the engine Support the engine and transaxle on wooden blocks on the oil pan flange so that the oil pan is not under load http vnx su ...

Page 498: ...andard Stage III and all other requirements made on latest generation assemblies with regard to fuel consumption quiet running flexibility and power output Engine codes The engine code for the Duratorq TDCi is 66 kW 90 PS HCPA Stage III LDT 2 66 kW 90 PS HCPB Stage III Car LDT 1 66 kW 90 PS HCPC Stage I Location of the engine code on the cylinder block of the Duratorq TDCi engine Crankshaft The fi...

Page 499: ...on of the timing belt is maintained by an automatic timing belt tensioner The timing pulley is retained on the camshaft by a taper The required frictional force is applied to the camshaft by a central bolt Valve tappet adjusting shims The camshaft timing is transmitted to the valve springs by eight bucket tappets CAUTION The lettering must face the tappets when the adjusting shims are installed Ad...

Page 500: ...he gasket does not settle during installation the cylinder head bolts can be inserted with lower clamping force However because of the rubber surface the gasket is also more susceptible to grooves and therefore it must be cleaned without using sharp objects Crankshaft oil seals NOTE The rear crankshaft oil seal is supplied with an oil seal carrier It must be aligned using the tool shown CAUTION If...

Page 501: ...3 A6 CAUTIONS When removing the engine front mount do not place a workshop jack under the oil pan to support the engine Support the engine and transmission on wooden blocks on the subframe oil pan flange so that the oil pan is not under load The oil pan will be pushed in if the engine is supported on a workshop jack This can cause the oil supply to the oil intake pipe to be obstructed The oil drai...

Page 502: ...q DI 1 8L capacity with 55 kW 75 PS 66 kW 90 PS or 81 kW 110 PS Turbocharger with variable turbine geometry and intercooler Common rail fuel injection system Dual mass flywheel for the reduction of drive noise Steel crankshaft in the 110 PS variant Cast iron crankshaft in the 75 PS and 90 PS variants Common rail fuel injection system High pressure pump for the generation of pressure in the fuel ra...

Page 503: ...on sequence knock sensor KS for reducing combustion noise Electrical actuator for turbocharger guide vane adjustment for optimisation of boost pressure control Emission control Meets the European level IV emissions standard Oxidation catalytic converter Actuator motor controlled exhaust gas recirculation EGR valve with integral position sensor EGR cooler for reduction in oxides of nitrogen NOx emi...

Page 504: ...e 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Engine Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 303 00 Engine System General Information http vnx su ...

Page 505: ...esel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 2 Remove the oil baffle 3 Install the camshaft bearing cap retaining nuts 4 Using a suitable feeler gauge measure the valve clearance Rotate the crankshaft until the cam pair of the cylinder to be adjusted are pointing upwards Check the valve clearance and note the values If the values of one or more adjustment shims are outside the tolerance r...

Page 506: ...thickness of the adjustment shim marked on the underside of the shim Install the new adjustment shim to obtain the correct valve clearance 6 Remove the camshaft bearing cap retaining nuts 7 Install the oil baffle 8 Install the valve cover For additional information refer to Valve Cover 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair http vnx su ...

Page 507: ...rbocharger are serviced as one component and can not be renewed separately Remove the turbocharger For additional information refer to Turbocharger 1 8L Duratorq TDCi FGT 55kW 75PS Lynx 1 8L Duratorq TDCi FGT 66kW 90PS Lynx 1 8L Duratorq TDCi VNT 66kW 90PS Lynx 1 8L Duratorq TDCi VNT 55kW 75PS Lynx 303 04C Fuel Charging and Controls Turbocharger Removal and Installation http vnx su ...

Page 508: ...nd can not be serviced separately 1 Remove the EGR valve For additional information refer to Exhaust Gas Recirculation EGR Valve 75 PS 90 PS 303 08B Engine Emission Control 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation Exhaust Gas Recirculation EGR Valve 110 PS 303 08B Engine Emission Control 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Rem...

Page 509: ...2 5 06 2002 Print In vehicle Repair NOTE The intake manifold and exhaust gas recirculation EGR valve are one component and can not be serviced separately 1 Remove the EGR valve For additional information refer to Exhaust Gas Recirculation EGR Valve 75 PS 90 PS 303 08B Engine Emission Control 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation http vnx su ...

Page 510: ...arge air cooler outlet hose retaining clamp 2 Detach the charge air cooler outlet hose retaining clamp 3 Remove the charge air cooler outlet pipe retaining nuts 3 NOTE Make a note of the position of the turbocharger outlet hose and clamps Remove the charge air cooler intake pipe 1 Remove and discard the charge air cooler intake hose retaining clamp 2 Remove and discard the turbocharger outlet hose...

Page 511: ...n 5 Disconnect the camshaft position CMP sensor electrical connector 6 Remove the valve cover 1 NOTE Install a new valve cover gasket if necessary Install the valve cover Lubricate the valve cover gasket with clean engine oil before installation 2 Connect the camshaft position CMP sensor electrical connector http vnx su ...

Page 512: ...ent components NOTE Make sure that the inside of the charge air cooler intake hose is clean and free from any oil residue as this will reduce the installation grip of the hose to the charge air cooler NOTE Install a new charge air cooler intake hose retaining clamp Install the charge air cooler intake pipe Clean the inside of the charge air cooler intake hose Install a new charge air cooler intake...

Page 513: ...ow this instruction may cause premature failure of adjacent components NOTE Make sure that the inside of the charge air cooler outlet hose is clean and free from any oil residue as this will reduce the installation grip of the hose to the charge air cooler NOTE Install a new charge air cooler outlet hose retaining clamp Install the charge air cooler outlet pipe Clean the inside of the charge air c...

Page 514: ... 303 060 Adapter for 303 060 303 060 05 Installer Valve Stem Collets 303 362 Pliers Valve Stem Seal 303 390 Name Engine Oil 5W 30 1 Remove the camshaft For additional information refer to Camshafts 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 2 Position the apropriate piston at top dead center TDC 3 Using the special tools remove the valve springs ...

Page 515: ... special tool install the valve stem seals Coat the valve stem seals with clean engine oil 2 Using the special tools install the valve springs 3 Install the camshaft For additional information refer to Camshafts 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair http vnx su ...

Page 516: ... 1 Remove the timing belt For additional information refer to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 2 Remove the camshaft pulley 3 Using the special tool remove the camshaft seal Discard the camshaft seal 1 NOTE Install a new camshaft seal Using the spe...

Page 517: ...all the camshaft pulley 3 Install the timing belt For additional information refer to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair http vnx su ...

Page 518: ...tional information refer to Valve Clearance 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel General Procedures 3 CAUTION Loosen the nuts of camshaft bearing caps number one three and five by one turn each until the camshaft is released NOTE Keep the nuts and camshaft bearing caps in order Remove the camshaft 4 NOTE Keep the valve tappets and adjustment shims in order R...

Page 519: ... Check the valve clearances For additional information refer to Valve Clearance 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel General Procedures 5 Install the camshaft seal For additional information refer to Camshaft Seal 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair http vnx su ...

Page 520: ...3 293 21 143 Aligner Oil Pump 303 652 21 230 1 Remove the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 2 Using the special tool remove the crankshaft pulley Discard the bolt 3 Using the special tool remove the crankshaft seal Discard the seal 1 NOTE Install...

Page 521: ... Tighten the crankshaft pulley retaining bolt in two stages Stage 1 100 Nm Stage 2 180 degrees 3 Install the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation http vnx su ...

Page 522: ...ehicles Gauge Bolt Angle 303 174 21 540 Locking Tool Flywheel 303 393 21 168 1 Remove the clutch disc and pressure plate For additional information refer to Clutch Disc and Pressure Plate 308 01 Clutch Removal and Installation 2 Using the special tool lock the flywheel in position 3 Remove the flywheel Discard the bolts 4 Remove the crankshaft rear seal carrier Discard the carrier http vnx su ...

Page 523: ... the crankshaft rear seal carrier 2 Tighten the crankshaft rear seal carrier retaining bolts 3 Remove the crankshaft rear seal carrier alignment sleeve 4 NOTE Install new flywheel bolts NOTE Do not fully tighten the flywheel bolts at this stage Install the flywheel 5 Using the special tool lock the flywheel in position 6 Using the special tools install the flywheel Tighten the bolts in three stage...

Page 524: ...e 2 45 degrees 9 Remove the special tools 10 Inspect the dual mass flywheel For additional information refer to Flywheel Inspection Vehicles With Dual Mass Flywheel 303 00 Engine System General Information General Procedures 11 Install the clutch disc and pressure plate For additional information refer to Clutch Disc and Pressure Plate 308 01 Clutch Removal and Installation http vnx su ...

Page 525: ... A1 Removal Universal Flange Holding Wrench 205 072 15 030A Timing Peg Crankshaft TDC 303 193 21 104 Support Bar Engine 303 290A 21 140A Adapter for 303 290A 303 290 01 21 140 01 Adapter for 303 290A 303 290 02 21 140 02 Adapter for 303 290A 303 290 03A 21 140 03A Alignment Plate Camshaft 303 376 21 162B Locking Tool Flywheel 303 393 21 168 Remover Camshaft Sprocket 303 651 21 229 Name Coolant Eng...

Page 526: ...ct 414 01 Battery Mounting and Cables General Procedures 2 Remove the valve cover For additional information refer to Valve Cover 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 3 Detach the coolant expansion tank and position it to one side 4 Remove the charge air cooler cover 5 Disconnect the intake air temperature IAT sensor electrical connector 6 ...

Page 527: ...ional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 10 Remove the generator drive coupling 1 Driveshaft intermediate bearing retaining bolts 2 Vibration damper retaining bolts 11 Remove the generator For additional information refer to Generator 1 8L Duratorq TDCi Lynx Diesel Vehicles Built Fr...

Page 528: ...n of rotation Turn the crankshaft to TDC Turn the crankshaft slowly until the crankshaft stops 16 CAUTIONS Make sure that the crankshaft does not rotate during installation of the special tool Make sure crankshaft is at the TDC position before locking the special tool Make sure that the special tool engages correctly Using the special tool lock the crankshaft 17 Lower the vehicle 18 Install the sp...

Page 529: ...built up to 04 2001 Vehicles built 04 2001 onwards All vehicles 19 Remove the engine front mount 20 Remove the engine front mount 21 Remove the engine front mount stud 22 Remove the timing belt cover http vnx su ...

Page 530: ...ner 25 Discard the timing belt tensioner 26 Remove and discard the timing belt 27 Using the special tool loosen the camshaft pulley retaining bolt by five turns 28 Using the special tool loosen the camshaft pulley 1 NOTE Install only latest level timing belts These are identified by a laser etched Ford logo Check the new timing belt http vnx su ...

Page 531: ... to 3 o clock position Install the timing belt tensioner and tighten the bolt finger tight 5 CAUTIONS Never install a used timing belt Install the timing belt with the direction arrows in the direction of engine rotation Only install the timing belt after the engine has cooled to workshop temperature NOTE Install a new timing belt Install the timing belt 6 NOTE The camshaft pulley must be able to ...

Page 532: ...be positioned between the sides of the window 3 Tighten the timing belt tensioner retaining bolt 8 Using the special tool tighten the camshaft pulley retaining bolt 9 Remove the special tool 10 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 11 Release the special tool 12 Remove the special tool 13 NOTE Only turn the cr...

Page 533: ... special tool Make sure crankshaft is at the TDC position before locking the special tool Make sure that the special tool engages correctly Using the special tool lock the crankshaft 17 Lower the vehicle 18 NOTE The auto tensioner pointer may move slightly upwards in the window Check that the autotensioner pointer is positioned in between the sides of the window 1 If the pointer is in the window g...

Page 534: ...Do not damage the timing belt cover NOTE Only rework the timing belt cover if there was a mechanical timing belt tensioner installed Using a suitable file modify the timing belt cover 22 Install the timing belt cover 23 Install the engine front mount stud 24 Install the engine front mount http vnx su ...

Page 535: ...e the special tools 27 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 28 Remove the special tool and install the blanking plug 29 Attach the starter motor 30 Install the generator drive coupling http vnx su ...

Page 536: ...oval and Installation 33 Install the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 34 Attach the power steering pipe retaining bracket to the cylinder head 35 Install the charge air cooler 36 Connect the intake air temperature IAT sensor electrical connector...

Page 537: ...For additional information refer to Valve Cover 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 40 Connect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 41 Initialize the door window motors http vnx su ...

Page 538: ...Specification ESDM 97B49 A WSS M2C912 A1 Universal Flange Holding Wrench 205 072 15 030A Timing Peg Crankshaft TDC 303 193 21 104 Support Bar Engine 303 290A 21 140A Adapter for 303 290A 303 290 01 21 140 01 Adapter for 303 290A 303 290 02 21 140 02 Adapter for 303 290A 303 290 03A 21 140 03A Alignment Plate Camshaft 303 376 21 162B Locking Tool Flywheel 303 393 21 168 Remover Camshaft Sprocket 30...

Page 539: ...onnect 414 01 Battery Mounting and Cables General Procedures 2 Remove the valve cover For additional information refer to Valve Cover 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 3 Detach the coolant expansion tank and position it to one side 4 Remove the charge air cooler cover 5 Disconnect the intake air temperature IAT sensor electrical connecto...

Page 540: ...e the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 10 Remove the generator drive coupling 1 Driveshaft intermediate bearing retaining bolts 2 Vibration damper retaining bolts 11 Detach the starter motor and position it to one side http vnx su ...

Page 541: ...til the crankshaft stops 14 CAUTIONS Make sure that the crankshaft does not rotate during installation of the special tool Make sure crankshaft is at the TDC position before locking the special tool Make sure that the special tool engages correctly Using the special tool lock the crankshaft 15 Lower the vehicle 16 Install the special tools 17 Remove the engine front mount 18 Remove the engine fron...

Page 542: ... Remove the timing belt cover 20 Install the special tool 21 Remove the timing belt tensioner 22 Discard the timing belt tensioner 23 Remove and discard the timing belt 24 Using the special tool loosen the camshaft pulley retaining bolt by five turns http vnx su ...

Page 543: ...laser etched Ford logo Check the new timing belt 2 Install a new automatic timing belt tensioner 3 Check the automatic timing belt tensioner 1 Make sure that the tensioner pointer rotates clockwise freely 2 Arrow denotes counter clockwise rotation of tensioner 4 NOTE Move timing belt tensioner adjustment arm to 3 o clock position Install the timing belt tensioner and tighten the bolt finger tight ...

Page 544: ... the camshaft taper Tighten the camshaft pulley bolt finger tight and then loosen by 1 2 a turn 7 NOTE Using an allen key maintain tension until the tensioner bolt is tightened Tension the timing belt 1 Turn the timing belt tensioner adjustment arm counter clockwise to tension the timing belt slightly 2 The pointer must be positioned between the sides of the window 3 Tighten the timing belt tensio...

Page 545: ... Jacking and Lifting Description and Operation 11 Release the special tool 12 Remove the special tool 13 NOTE Only turn the crankshaft in the normal direction of rotation NOTE Using paint or typing correction fluid mark the crankshaft pulley to show top dead center TDC Turn the crankshaft six revolutions 14 Install the special tool http vnx su ...

Page 546: ...sioner pointer may move slightly upwards in the window Check that the autotensioner pointer is positioned in between the sides of the window 1 If the pointer is in the window go to the following step 2 If the pointer is not in the window repeat procedure from the previous steps 19 Install the special tool If the special tool cannot be installed repeat the procedure from the previous steps 20 Remov...

Page 547: ...ove the special tools 26 Raise and support the vehicle For additional information refer to Jacking 100 02 Jacking and Lifting Description and Operation Lifting 100 02 Jacking and Lifting Description and Operation 27 Remove the special tool and install the blanking plug http vnx su ...

Page 548: ...on refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 31 Attach the power steering pipe retaining bracket to the cylinder head 32 Install the charge air cooler 33 Connect the intake air temperature IAT sensor electrical connector http vnx su ...

Page 549: ... additional information refer to Valve Cover 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 37 Connect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures http vnx su ...

Page 550: ... All vehicles Lifting Bracket Engine 303 122 21 068A Gauge Bolt Angle 303 174 21 540 Support Bar Engine 303 290A 21 140A Adapter for 303 290A 303 290 01 21 140 01 Adapter for 303 290A 303 290 02 21 140 02 Adapter for 303 290A 303 290 03A 21 140 03A Remover Installer Hose Clamp 303 397 24 003 Name Engine oil Loctite 7070 ISO 4113 Lubricant 1 WARNINGS Do not smoke or carry lighted tobacco or open fl...

Page 551: ... is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices or lines Always carry out the cleaning process before carrying out any repairs to fuel injection system components to prevent foreign material entering the components Using datalogger in worldwide diagnostic system WDS check that the fuel pressure has drop...

Page 552: ...vehicles 7 Install the engine front mount 8 Install the engine front mount 9 Remove the special tools 10 Remove the air cleaner For additional information refer to Section 303 12 Intake Air Distribution and Filtering 11 Remove the air cleaner outlet pipe http vnx su ...

Page 553: ...it 13 Disconnect the Exhaust gas recirculation EGR vacuum hose from the EGR valve 14 Disconnect the EGR vacuum hose 15 Detach the electronic vacuum regulating valve support bracket from the intake manifold and position it to one side 16 Remove the oil baffle http vnx su ...

Page 554: ...tic converter from the catalytic converter bracket 20 Detach the oil supply and return pipes from the turbocharger 1 Remove the oil supply pipe retaining bolt 2 Remove the oil return pipe retaining bolts Discard the gaskets 21 Lower the vehicle 22 Disconnect the oil pressure switch electrical connector 23 Disconnect the engine wiring harness electrical http vnx su ...

Page 555: ...g pump Allow the fluid to drain into a suitable container 26 Detach the power steering high pressure pipe bracket from the timing belt cover stud connection 27 Detach the power steering high pressure pipe bracket from the lifting eye 28 Detach the power steering high pressure pipe from the bracket and position it to one side http vnx su ...

Page 556: ...al block 30 Detach the glow plug wire terminal block 31 Detach the oil level indicator and secure it to one side 32 Detach the vacuum pipe from the brake booster vacuum pump 33 Using the special tool detach the upper coolant hose from the thermostat housing http vnx su ...

Page 557: ...voir and secure it to one side Allow the fluid to drain into a suitable container 36 Detach the exhaust manifold from the catalytic converter 37 Using the special tool detach the upper coolant hose from the EGR cooler 38 Clean the area around the fuel injection supply manifold high pressure fuel supply lines and http vnx su ...

Page 558: ...ote of the orientation of the clamps to make sure it is positioned in exactly the same position when installed Remove the high pressure fuel supply line clamp 42 CAUTION Make sure the tool used to loosen the high pressure fuel supply line unions is used at the top of the union as this is where there is most material Failure to follow this instruction may result in damage to the union NOTE Maintain...

Page 559: ...e fuel supply lines 46 Remove the high pressure fuel supply line bracket 47 NOTE Maintain pressure on the high pressure fuel supply line to keep the olive in contact with the fuel injection pump and fuel supply manifold cone while unscrewing the unions NOTE While maintaining the pressure on the high pressure fuel supply line clean and vacuum foreign material from the line and unions Remove the hig...

Page 560: ...taining bolt 50 Remove the fuel supply manifold bracket and the fuel supply manifold 51 CAUTION Remove the cylinder head bolts in the sequence shown Remove the cylinder head bolts Discard the bolts 52 Using the special tool remove the cylinder head Discard the gasket http vnx su ...

Page 561: ... Clean the mating faces of the cylinder head and cylinder block with Loctite 7070 2 Check the cylinder head for distortion For additional information refer to Section 303 00 Engine System General Information 3 CAUTION The thickness of the new cylinder head gasket must be the same as that of the old one hole tooth marked NOTE TOP OBEN mark Install a new cylinder head gasket 4 NOTE The pistons must ...

Page 562: ...ge Install the fuel supply manifold bracket lower retaining bolt 8 NOTE Use new high pressure fuel supply line unions Lubricate the high pressure fuel supply line union threads with clean ISO 4113 lubricant from the high pressure fuel supply line parts kit 9 CAUTION Do not allow the unions to hit the olive ends of the high pressure fuel supply line as this may damage the ends of the line and allow...

Page 563: ...ure fuel supply line unions at this stage NOTE Maintain pressure on the high pressure fuel supply line to keep the olive in contact with the injector cone while hand tightening the union Install the high pressure fuel supply lines of cylinder one and four to the fuel supply manifold 11 NOTE Make sure the clamp is installed in the same position as removed Install the high pressure fuel supply line ...

Page 564: ...ow colored collar is positioned at the injector end and the blue colored collar is positioned at the fuel injection supply manifold end of the high pressure fuel supply line Install the high pressure fuel supply lines of cylinder two and three to the fuel injectors 15 CAUTION Do not allow the unions to hit the olive ends of the high pressure fuel supply line as this may damage the ends of the line...

Page 565: ...and the fuel supply manifold 20 Install the fuel supply manifold bracket lower retaining bolt 21 Install the high pressure fuel supply lines of cylinder one and four to the fuel injectors 22 Install the high pressure fuel supply lines of cylinder one and four to the fuel supply manifold http vnx su ...

Page 566: ...e fuel supply lines of cylinder two and three to the fuel injectors 25 Install the high pressure fuel supply lines of cylinder two and three to the fuel supply manifold 26 Using the special tool attach the upper coolant hose to the EGR cooler 27 Attach the exhaust manifold to the catalytic converter http vnx su ...

Page 567: ...fuel high pressure sensor electrical connector 30 NOTE Use a new gasket Install the thermostat housing 31 Using the special tool attach the upper coolant hose to the thermostat housing 32 Attach the vacuum pipe to the brake booster vacuum pump http vnx su ...

Page 568: ...ow plug wire terminal block 35 Attach the glow plug power supply to the glow plug wire terminal block 36 Attach the power steering high pressure pipe to the bracket 37 Attach the power steering high pressure pipe bracket to the lifting eye http vnx su ...

Page 569: ...tion 39 Attach the power steering high pressure pipe to the power steering pump 40 Connect the engine wiring harness electrical connector 41 NOTE Install the clip at a 45 degree angle to the horizontal Install the PCV housing 42 Connect the oil pressure switch electrical connector http vnx su ...

Page 570: ... supply and return pipes to the turbocharger 1 Install the oil return pipe retaining bolt 2 Install the oil supply pipe retaining bolts 45 Attach the catalytic converter to the catalytic converter bracket 46 Lower the vehicle 47 Remove the bearing cap nuts 48 Install the oil baffle 49 Attach the electronic vacuum regulating valves http vnx su ...

Page 571: ...nect the EGR vacuum hose to the EGR valve 52 Attach the vacuum hose to the turbo charger vacuum diaphragm unit 53 Install the air cleaner outlet pipe 54 Install the air cleaner For additional information refer to Section 303 12 Intake Air Distribution and Filtering 55 Install the special tools http vnx su ...

Page 572: ... All vehicles 56 Remove the engine front mount 57 Remove the engine front mount 58 Attach the timing belt rear cover engine shown removed for clarity 59 NOTE Do not tighten the camshaft pulley retaining bolt at this stage Install the camshaft pulley http vnx su ...

Page 573: ...ng 62 Fill and bleed the power steering system For additional information refer to Section 211 00 Steering System General Information 63 Install the battery tray and connect the battery For additional information refer to Section 414 01 Battery Mounting and Cables 64 Change the engine oil and the oil filter 65 Initialize the door window motors For additional information refer to Section 501 11 Gla...

Page 574: ...moval All vehicles Lifting Bracket Engine 303 122 21 068A Gauge Bolt Angle 303 174 21 540 Support Bar Engine 303 290A 21 140A Adapter for 303 290A 303 290 01 21 140 01 Adapter for 303 290A 303 290 02 21 140 02 Adapter for 303 290A 303 290 03A 21 140 03A Remover Installer Hose Clamp 303 397 24 003 Name Engine oil Loctite 7070 ISO 4113 Lubricant 1 WARNINGS Do not smoke or carry lighted tobacco or op...

Page 575: ...g with these components Always fit blanking plugs to any open orifices or lines Always carry out the cleaning process before carrying out any repairs to fuel injection system components to prevent foreign material entering the components Using datalogger in worldwide diagnostic system WDS check that the fuel pressure has dropped to zero and that the fuel temperature is below 30 C 2 Remove the batt...

Page 576: ...ach the timing belt rear cover engine shown removed for clarity 8 Install the engine front mount 9 Remove the special tools 10 Remove the air cleaner outlet pipe 11 Remove the air cleaner For additional information refer to Air Cleaner 303 12 Intake Air Distribution and Filtering http vnx su ...

Page 577: ...g bolt 3 Disconnect the oil pressure switch electrical connector 13 Disconnect the heater core to exhaust gas recirculation EGR cooler coolant hose from the EGR cooler 14 Disconnect the Exhaust gas recirculation EGR vacuum hose from the EGR valve 15 Detach the vacuum hose from the turbo charger vacuum diaphragm unit 16 Disconnect the EGR vacuum hose 17 Detach the vacuum regulating valve support br...

Page 578: ...fting Description and Operation 19 Detach the catalytic converter from the catalytic converter bracket 20 Detach the oil supply and return pipes from the turbocharger 1 Remove the oil supply pipe retaining bolt 2 Remove the oil return pipe retaining bolts Discard the gaskets 21 Lower the vehicle 22 Detach the exhaust manifold from the catalytic converter 23 Detach the wiring harness from the intak...

Page 579: ...t 25 NOTE Make a note of the position of the turbocharger to exhaust manifold retaining clamp Remove the turbocharger to exhaust manifold retaining clamp Discard the turbocharger to exhaust manifold retaining clamp 26 Remove the oil baffle 27 Install the camshaft bearing cap nuts 28 Disconnect the engine wiring harness electrical connector http vnx su ...

Page 580: ...trical connector 2 Fuel pressure regulator electrical connector 31 Detach the power steering high pressure pipe from the power steering pump Allow the fluid to drain into a suitable container 32 Detach the power steering high pressure pipe bracket from the timing belt cover stud connection 33 Detach the power steering high pressure pipe bracket from the lifting eye http vnx su ...

Page 581: ...n it to one side 35 Detach the glow plug wire terminal block 36 Detach the oil level indicator and secure it to one side 37 Detach the vacuum pipe from the brake booster vacuum pump 38 Using the special tool detach the upper coolant hose from the thermostat housing http vnx su ...

Page 582: ...n refer to Fuel Injection Component Cleaning Vehicles With Common Rail Fuel Injection 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel General Procedures 42 Disconnect the fuel pump fuel return line quick release coupling For additional information refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures 43 Disconnec...

Page 583: ...OTE While maintaining the pressure on the high pressure fuel supply line clean and vacuum foreign material from the line and union Detach the high pressure fuel supply lines from the fuel injectors 46 Protect the generator with lint free material to prevent contamination from the cleaning fluid 47 NOTE Protect the connector with lint free cloth to prevent contamination from the cleaning fluid Disc...

Page 584: ...intaining the pressure on the high pressure fuel supply line clean and vacuum foreign material from the line and unions Remove the high pressure fuel supply line Install blanking caps to the open threaded ports on the fuel injection pump and fuel injection supply manifold 51 NOTE Make a note of the orientation of the clamp to make sure it is positioned in exactly the same position when installed R...

Page 585: ...d gasket at this stage Using the special tool remove the cylinder head 1 WARNING Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components Highly flammable mixtures are always present and may ignite Failure to follow these instructions may result in personal injury CAUTIONS Diesel fuel injection equipment is http vnx su ...

Page 586: ...03 00 Engine System General Information General Procedures 3 CAUTION The thickness of the new cylinder head gasket must be the same as that of the old one hole tooth marked NOTE TOP OBEN mark Install a new cylinder head gasket Discard the old cylinder head gasket 4 NOTE The pistons must not be at TDC Make sure that the special tool is engaged in the camshaft groove Using the special tool position ...

Page 587: ...r retaining bolt 8 CAUTIONS Remove the blanking caps from the high pressure fuel supply lines fuel rail and fuel injectors at the last possible moment Failure to follow this instruction may result in foreign material ingress to the fuel injection system Do not allow the unions to hit the ends of the high pressure fuel supply line Failure to follow this instruction may result in damage to the ends ...

Page 588: ...s to the fuel injection system Do not allow the unions to hit the ends of the high pressure fuel supply line Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system NOTE Install a new fuel rail high pressure fuel supply line NOTE Do not fully tighten the fuel rail high pressure fuel supply line unions at this sta...

Page 589: ...cal connectors Attach the wiring harness clips to the cylinder head 15 Connect the fuel high pressure sensor electrical connector 16 Connect the fuel metering valve and fuel pressure regulator electrical connectors 1 Fuel metering valve electrical connector 2 Fuel pressure regulator electrical connector 17 Connect the fuel temperature sensor electrical connector http vnx su ...

Page 590: ...ng 310 00A Fuel System General Information General Procedures 19 Connect the heater core to EGR cooler coolant hose to the EGR cooler 20 Attach the power steering reservoir 21 NOTE Use a new gasket Install the thermostat housing 22 Using the special tool attach the upper coolant hose to the thermostat housing http vnx su ...

Page 591: ...24 Attach the oil level indicator 25 Attach the glow plug wire terminal block 26 Attach the power steering high pressure pipe bracket to the lifting eye 27 Attach the power steering high pressure pipe bracket to the timing belt cover stud connection http vnx su ...

Page 592: ...r steering high pressure pipe to the power steering pump 29 Connect the engine wiring harness electrical connector 30 Remove the bearing cap nuts 31 Install the oil baffle 32 33 Connect the exhaust gas recirculation EGR valve electrical connector and attach the wiring http vnx su ...

Page 593: ...haust manifold retaining clamp Install the turbocharger to exhaust manifold retaining clamp 36 Attach the exhaust manifold to the catalytic converter 37 Raise and support the vehicle For additional information refer to Jacking 100 02 Jacking and Lifting Description and Operation Lifting 100 02 Jacking and Lifting Description and Operation 38 NOTE Use new gaskets Attach the oil supply and return pi...

Page 594: ...acket 40 Lower the vehicle 41 Attach the vacuum regulating valves support bracket to the intake manifold 42 Connect the EGR vacuum hose 43 Connect the EGR vacuum hose to the EGR valve 44 Attach the vacuum hose to the turbo charger vacuum diaphragm unit http vnx su ...

Page 595: ...he cylinder head engine shown removed for clarity 48 NOTE Do not tighten the camshaft pulley retaining bolt at this stage Install the camshaft pulley 49 Install the timing belt For additional information refer to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 http vnx su ...

Page 596: ...ibution and Filtering Removal and Installation 53 Install the air cleaner outlet pipe 54 Fill and bleed the cooling system For additional information refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling General Procedures 55 Fill and bleed the power steering system For additional information refer to Power Steering System Filling 211 00 Steering System General Information Ge...

Page 597: ...uel related components Highly flammable mixtures are always present and may ignite Failure to follow these instructions may result in personal injury CAUTION Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices o...

Page 598: ...4 2001 Vehicles built 04 2001 onwards All vehicles 5 Detach the timing belt rear cover engine shown removed for clarity 6 Install the engine front mount 7 Install the engine front mount 8 Remove the special tools http vnx su ...

Page 599: ...r cleaner outlet pipe 11 Detach the vacuum hose from the vacuum diaphragm unit 12 Remove the oil baffle 13 Install the camshaft bearing cap nuts 14 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 15 Detach the catalytic converter from the catalytic converter bracket http vnx su ...

Page 600: ...he oil pressure switch electrical connector 19 Remove the oil separator 20 Detach the power steering high pressure pipe from the power steering pump Allow the fluid to drain into a suitable container 21 Detach the power steering high pressure pipe bracket from the timing belt cover stud connection http vnx su ...

Page 601: ...Detach the power steering high pressure pipe from the bracket and position it to one side 24 Detach the glow plug power supply from the glow plug wire terminal block 25 Detach the glow plug wire terminal block 26 Detach the oil level indicator and secure it to one side http vnx su ...

Page 602: ... special tool detach the upper coolant hose from the thermostat housing 29 Remove the thermostat housing Discard the gasket 30 Detach the high pressure fuel supply lines from the fuel injection pump 31 Remove the high pressure fuel supply lines Discard the lines http vnx su ...

Page 603: ...ust manifold from the catalytic converter Discard the nuts 34 Using the special tool detach the upper coolant hose from the exhaust gas recirculation EGR cooler 35 CAUTION Remove the cylinder head bolts in the sequence shown Remove the cylinder head bolts Discard the bolts http vnx su ...

Page 604: ...ditional information refer to Section 303 00 Engine System General Information 3 CAUTION The thickness of the new cylinder head gasket must be the same as that of the old one hole tooth marked NOTE TOP OBEN mark Install a new cylinder head gasket 4 NOTE Make sure that the special tool is engaged in the camshaft groove Using the special tool position the cylinder head on the cylinder block Remove t...

Page 605: ... sequence shown Stage 1 20 Nm Stage 2 54 Nm Stage 3 90 degrees Stage 4 short bolts 70 degrees Stage 4 long bolts 90 degrees 6 Using the special tool attach the upper coolant hose to the EGR cooler 7 NOTE Use new catalytic converter nuts Attach the exhaust manifold to the catalytic converter 8 Attach the power steering reservoir http vnx su ...

Page 606: ...e fuel injectors 10 Attach the high pressure fuel supply lines to the fuel injection pump 11 NOTE Use a new gasket Install the thermostat housing 12 Using the special tool attach the upper coolant hose to the thermostat housing 13 Attach the vacuum pipe to the brake booster vacuum pump http vnx su ...

Page 607: ...ow plug wire terminal block 16 Attach the glow plug power supply to the glow plug wire terminal block 17 Attach the power steering high pressure pipe to the bracket 18 Attach the power steering high pressure pipe bracket to the lifting eye http vnx su ...

Page 608: ... power steering pump 21 Connect the oil pressure switch electrical connector 22 NOTE Install the clip at a 45 degree angle to the horizontal Install the oil separator 23 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 24 NOTE Use a new gasket Attach the turbocharger oil supply and return http vnx su ...

Page 609: ...verter to the catalytic converter bracket 26 Lower the vehicle 27 Remove the camshaft bearing cap nuts 28 Install the oil baffle 29 Attach the vacuum hose to the vacuum diaphragm unit 30 Install the air cleaner outlet pipe http vnx su ...

Page 610: ...l the air cleaner For additional information refer to Section 303 12 Intake Air Distribution and Filtering 32 Install the special tools 33 Remove the engine front mount 34 Remove the engine front mount 35 Attach the timing belt rear cover engine shown removed for clarity http vnx su ...

Page 611: ...l information refer to Section 303 03 Engine Cooling 39 Fill and bleed the power steering system For additional information refer to Section 211 00 Steering System General Information 40 Install the battery tray and install the battery For additional information refer to Section 414 01 Battery Mounting and Cables 41 Change the engine oil and the oil filter 42 Initialize the door window motors For ...

Page 612: ...E Removal steps in this procedure may contain installation details Installation 1 Remove the oil filter element Refer to Oil Filter Element RHD FWD 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 2 3 NOTE The seals are to be reused unless damaged Torque 23 Nm 4 1 To install reverse the removal procedure http vnx su ...

Page 613: ...x Diesel Oil Filter Element RHD FWD Transit Tourneo Connect 2002 5 06 2002 Print In vehicle Repair Removal NOTE Removal steps in this procedure may contain installation details Installation 1 Torque 80 Nm 2 1 To install reverse the removal procedure http vnx su ...

Page 614: ...ne Sealant Engine Oil 5W 30 1 Raise and support the vehicle For additional information refer to 100 02 Jacking and Lifting Jacking Description and Operation Lifting Description and Operation 2 Drain the engine oil Allow the oil to drain into a suitable container 3 Remove the oil pan retaining nuts and bolts 4 Install the special tools to the oil pan 5 CAUTION To avoid damaging the mating faces onl...

Page 615: ...low this procedure may result in damage to the engine assembly NOTE Attach the oil pan within 10 minutes of applying the sealant NOTE Once the oil pan is in contact with the ladder frame it must not be removed Apply a 2 5 mm diameter bead of sealant to the ladder frame dotted line and install the oil pan Tighten the nuts and bolts in the sequence shown 3 NOTE Inspect the oil pan drain plug seal fo...

Page 616: ...5 Fill the engine with engine oil 5 Fill the engine with engine oil http vnx su ...

Page 617: ...lywheel 33 393 21 168 Aligner Oil Pump 303 652 21 230 Name Sealer 1 Remove the timing belt For additional information refer to 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Timing Belt 75 PS 90 PS In vehicle Repair Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 In vehicle Repair 2 Using the special tool remove the crankshaft...

Page 618: ...sory drive belt idler pulley 5 Remove the fuel pump pulley 6 Remove the fuel pump seal retainer Discard the seal 7 Remove the timing belt rear cover 8 Remove the timing chain housing cover Discard the gasket http vnx su ...

Page 619: ...vehicles 1 NOTE Install a new timing chain housing cover gasket Using the special tool install the timing chain housing cover 2 Install the timing belt rear cover 3 NOTE Install a new fuel pump seal retainer http vnx su ...

Page 620: ...jection pump pulley and to the outer edge of the fuel pump pulley bolt holes 5 Install the fuel pump pulley 6 Install the accessory drive belt idler pulley 7 NOTE Install a new crankshaft front seal Using the special tool install the crankshaft front seal 8 NOTE Install a new crankshaft pulley retaining bolt Using the special tool install the crankshaft pulley http vnx su ...

Page 621: ...l install the crankshaft pulley Tighten the retaining bolts in two stages Stage 1 100 Nm Stage 2 180 Nm 10 Install the timing belt For additional information refer to 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Timing Belt 75 PS 90 PS In vehicle Repair Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 In vehicle Repair http v...

Page 622: ...A Adapter for 303 290A 303 290A Support Bar Engine Hose clamp remover installer Mounting table set Pneumatic vacuum gun 1 Refer to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 2 NOTE Only tighten the bolt finger tight at this stage 3 NOTE Only tighten the nuts fin...

Page 623: ...03 290 303 290 03A 5 Refer to Catalytic Converter 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 309 00 Exhaust System Removal and Installation 6 7 8 CAUTION Note the position of the component before removal 9 10 http vnx su ...

Page 624: ... unions with blanking caps Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned Use an open ended wrench to prevent the component from turning General Equipment Pneumatic vacuum gun 13 14 15 http vnx su ...

Page 625: ...16 General Equipment Hose clamp remover installer 17 http vnx su ...

Page 626: ...18 19 General Equipment Hose clamp remover installer 20 General Equipment Hose clamp remover installer http vnx su ...

Page 627: ...21 22 Torque 20 Nm 23 24 NOTE Note the different lengths of the bolts 25 CAUTION Take extra care when handling the component General Equipment Mounting table set http vnx su ...

Page 628: ...ion 26 CAUTION Note the thickness of the gasket 1 NOTE Make sure that a new component is installed 2 CAUTIONS Take extra care when handling the component Make sure that the component is clean free of http vnx su ...

Page 629: ...Make sure that new bolts are installed Make sure that the component is clean free of foreign material and lubricant NOTE Note the different lengths of the bolts Torque 20 Nm 54 Nm 90 M12x137 70 M12x177 90 Stage 1 Stage 2 Stage 3 Stage 4 4 Torque 10 Nm 5 6 Torque 20 Nm http vnx su ...

Page 630: ...7 General Equipment Hose clamp remover installer 8 General Equipment Hose clamp remover installer Torque 1 23 Nm 2 10 Nm 9 Torque 10 Nm 10 http vnx su ...

Page 631: ...11 General Equipment Hose clamp remover installer Torque 23 Nm 12 Torque 18 Nm http vnx su ...

Page 632: ...line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned Use an open ended wrench to prevent the component from turning NOTE Make sure that new components are installed General Equipment Pneumatic vacuum gun Torque 1 25 Nm 2 38 Nm 15 NOTE Make sure that new components are installed http vnx su ...

Page 633: ...ore final tightening Torque 1 10 Nm 2 10 Nm 3 25 Nm 17 NOTE Make sure that the clamp is installed to the same orientation as when removed NOTE Make sure that a new clamp is installed 1 Torque Nm 18 Torque 1 25 Nm 2 25 Nm 19 Torque 23 Nm http vnx su ...

Page 634: ...oval and Installation 21 Install the following items 1 Special Tool s 303 290A 303 290 01 303 290 303 290 03A 22 23 24 Refer to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair http vnx su ...

Page 635: ...ler Hose Clamp 303 397 24 003 Remover Halfshaft 308 192 16 057 Workshop table Securing straps Two leg puller Transmission jack 1 Remove the battery tray For additional information refer to Battery Tray 414 01 Battery Mounting and Cables Removal and Installation 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling General ...

Page 636: ...let pipe 1 Remove and discard the charge air cooler outlet hose retaining clamp 2 Detach the charge air cooler outlet hose retaining clamp 3 Remove the charge air cooler outlet pipe retaining nuts 9 NOTE Make a note of the position of the turbocharger outlet hose and clamps Remove the charge air cooler intake pipe 1 Remove and discard the charge air cooler intake hose retaining clamp 2 Remove and ...

Page 637: ...10 Remove the charge air cooler air guide 11 Disconnect the intake air temperature IAT sensor electrical connector 12 Remove the charge air cooler 13 Remove the air cleaner outlet pipe http vnx su ...

Page 638: ...ect the glow plug wire from the terminal block 16 Disconnect the glow plug wiring harness from the terminal block 17 Remove the oil level indicator and oil level indicator tube 18 Detach the vacuum pipe from the brake booster vacuum pump http vnx su ...

Page 639: ... the thermostat housing 20 Remove the thermostat housing Discard the gasket 21 Disconnect the fuel pressure sensor electrical connector 22 Using the special tool detach the cooling hoses from the thermostat housing and from the coolant distribution pipe 23 Disconnect the generator battery positive cable http vnx su ...

Page 640: ... injection 24 Remove the generator electrical connector cover 25 Detach the vacuum hose from the vacuum diaphragm unit 26 Disconnect the engine wiring harness 27 Disconnect the injector driver module electrical connector http vnx su ...

Page 641: ...ose from the EGR valve 29 Disconnect the EGR vacuum hose 30 Detach the electronic vacuum regulating valves support bracket from the intake manifold and position it to one side 31 Detach the upper coolant hose from the EGR cooler 32 Detach the vacuum hoses and the electrical connector from the EGR valve http vnx su ...

Page 642: ... high pressure pipe from the power steering pump 35 Detach the power steering high pressure pipe bracket from the timing belt cover stud connection 36 Detach the power steering high pressure pipe bracket from the lifting eye 37 Detach the power steering high pressure pipe from the bracket http vnx su ...

Page 643: ...ne bracket 40 Disconnect the fuel supply line and fuel return line quick release coupling For additional information refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures 41 Using the special tool disconnect the lower coolant hose from the coolant expansion tank 42 Remove the coolant expansion tank and position it to one side http vnx su ...

Page 644: ...king 100 02 Jacking and Lifting Description and Operation Lifting 100 02 Jacking and Lifting Description and Operation 46 Remove the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 47 Disconnect the horn electrical connector and the horn wiring harness 48 Disc...

Page 645: ...rmation refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 52 Detach the stabilizer bar connecting link on both sides 53 CAUTION Leave the tie rod end retaining nut in place to protect the ball joint stud Loosen the left hand tie rod end retaining nut 54 CAUTION Using a soft cloth protect the ball joint seal Using the special tool detach the tie rod end 1 Discard the retainin...

Page 646: ...wer arm from the wheel knuckle on both sides left hand side shown 56 Remove the left hand fender splash shield 57 58 Disconnect the starter motor electrical connector and the power supply 59 Remove the radiator support bracket on both sides left hand side shown http vnx su ...

Page 647: ...ng it in 61 CAUTION Excessive bending of the exhaust flexible pipe may cause damage resulting in failure Using a support wrap or a suitable splint support the exhaust flexible pipe 62 Detach the exhaust flexible pipe from the exhaust system 1 Discard the retaining nuts 63 Remove the engine support insulator 64 CAUTIONS Support the halfshaft The inner joint must not be bent more than 18 degrees The...

Page 648: ...sing the special tool detach the left hand halfshaft from the transaxle and secure it to one side Allow the oil to drain into a suitable container 66 Detach the high pressure line from the clutch slave cylinder 1 Remove the retaining clip 2 Detach the bracket together with the rubber grommet 67 Detach the starter motor wiring harness bracket and engine ground cable from the transaxle housing 68 Re...

Page 649: ...ecuring strap secure the crossmember and lower arm assembly to the transmission jack 73 Remove the crossmember retaining bolts support shown removed for clarity 74 Remove the crossmember 75 WARNING Support the engine and transaxle assembly on wooden blocks Failure to follow these instructions may result in personal injury CAUTION Support the engine on the oil pan flange Using suitable securing str...

Page 650: ...76 Remove the engine rear mount 77 Remove the engine front mount 78 Raise the vehicle and remove the engine and transaxle assembly 79 Remove the engine from the transaxle http vnx su ...

Page 651: ...ore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices or lines Slide Hammer 205 047 15 011 Universal Flange Holding Wrench 205 072 15 030A Locking Tool Flywheel 303 393 21 168 Remover Installer Hose Clamp 303 397 24 003 Mounting Stand 303 435 21 187 Mounting Bracket for 303 435 303 435 06 21 031B Adapter for 205 047 30...

Page 652: ...t Mount the engine on the mounting stand 2 Drain the engine oil Allow the oil to drain into a suitable container 3 Detach the turbocharger oil supply tube from the turbocharger Discard the sealing washers 4 Remove the turbocharger oil supply line Discard the sealing washers 5 Detach the turbocharger oil return tube Discard the O ring seal 6 Remove the oil filter Discard the filter http vnx su ...

Page 653: ...ing the special tool detach the PCV hoses from the valve cover 10 Disconnect the cylinder head temperature CHT sensor electrical connector 1 Detach the electrical connector from the PCV housing 2 Disconnect the electrical connector 11 Remove the PCV housing 12 Using the special tool detach the PCV hose from the brake booster vacuum pump http vnx su ...

Page 654: ...g the components Detach the fuel injector return line from the fuel injectors 15 Remove the fuel injector return line 16 CAUTION Carry out the fuel injection component cleaning procedure before carrying out any repairs to fuel injection system components to prevent foreign material entering the components Disconnect the fuel injector electrical connectors 17 Disconnect the camshaft position CMP se...

Page 655: ...e bracket from the thermostat housing 20 Detach the glow plug wiring harness bracket from the oil level indicator tube bracket 21 Disconnect the knock sensor KS electrical connector 22 Disconnect the high pressure fuel sensor electrical connector from the fuel injection supply manifold http vnx su ...

Page 656: ...ct with the fuel injectors until all unions have been detached and cleaned Failure to follow this instruction may result in foreign matter ingress to the fuel injection system Cap the fuel injectors to prevent dirt ingress Detach the high pressure fuel supply lines from the fuel injectors 26 CAUTIONS Make sure that the high pressure fuel supply lines remain in contact with the fuel injection suppl...

Page 657: ...n foreign matter ingress to the fuel injection system Detach the high pressure fuel supply line and clamp from the fuel pump and the fuel injection supply manifold 31 Using the engine vacuum cleaner vacuum foreign material from the high pressure fuel supply line the fuel pump and the fuel injection supply manifold 32 Remove the high pressure fuel supply line 33 NOTE Make a note of the orientation ...

Page 658: ...e fuel injection supply manifold 39 Remove the fuel injection supply manifold retaining bracket 40 Using the special tool detach the coolant hose from the thermostat housing 41 Remove the timing belt cover http vnx su ...

Page 659: ... Remove the timing belt Discard the timing belt 44 Remove the timing belt tensioner 45 Using the special tool remove the camshaft pulley retaining bolt 46 Using the special tool remove the camshaft pulley 47 Using the special tool remove the fuel pump pulley http vnx su ...

Page 660: ...er Discard the seal 49 Remove the timing belt rear cover 50 Remove the valve cover 51 Remove the oil baffle 52 CAUTION Remove the cylinder head bolts in the sequence shown Remove the cylinder head Discard the gasket and the bolts http vnx su ...

Page 661: ...gine front mount bracket 54 Using the special tool remove the water pump pulley four bolts 55 Remove the water pump Discard the gasket 56 Using the special tool remove the crankshaft pulley Discard the bolt http vnx su ...

Page 662: ...57 Remove the accessory drive belt idler 58 Remove the timing chain housing cover Discard the gasket 59 Remove the timing chain tensioner 60 Detach the fuel pump sprocket http vnx su ...

Page 663: ...Vehicles built 08 2008 onwards 61 Remove the timing chain sprockets and guides 62 Remove the fuel pump bracket 63 Remove the fuel pump Discard the gasket 64 65 http vnx su ...

Page 664: ...tool detach the upper coolant hose from the coolant distribution pipe 68 Remove the coolant distribution pipe 69 Remove the fuel pump bracket 70 CAUTION Loosen the clutch pressure plate retaining bolts by two turns at a time in http vnx su ...

Page 665: ... tool remove the dual mass flywheel Discard the bolts 72 Remove the crankshaft position CKP sensor Discard the sensor 73 Remove the oil pan retaining nuts and bolts 16 bolts two nuts 74 Using the special tools remove the oil pan 75 Remove the CKP sensor retaining bracket http vnx su ...

Page 666: ...retainer 77 Remove the oil pump connecting pipe Discard the O ring seals 78 Remove the oil pump pickup tube Discard the O ring seal 79 Remove the air conditioning A C compressor retaining bracket 80 Remove the ladder frame 14 bolts Discard the gasket http vnx su ...

Page 667: ...ing Discard the gasket 82 NOTE Keep the connecting rod bearings and bearing caps in order for installation Remove the pistons 83 NOTE Keep the main bearings and main bearing caps in order for installation Remove the crankshaft http vnx su ...

Page 668: ...s observed when working with these components Always fit blanking plugs to any open orifices or lines All vehicles Slide Hammer 205 047 15 011 Universal Flange Holding Wrench 205 072 15 030A Locking Tool Flywheel 303 393 21 168 Remover Installer Hose Clamp 303 397 24 003 Mounting Stand 303 435 21 187 Mounting Bracket for 303 435 21 187 303 435 06 21 031B Adapter for 205 047 303 633 21 227 Remover ...

Page 669: ...e container 3 Detach the positive crankcase ventilation PCV housing Detach the ventilation hoses 4 Remove the high pressure fuel supply lines Discard the high pressure fuel supply lines 5 Remove the power steering pump lower retaining bolts 6 Remove the power steering pump 7 Remove the generator with driveshaft http vnx su ...

Page 670: ...turn lines Discard the sealing washers 9 Remove the oil filter Discard the filter 10 Remove the oil cooler Discard the gasket 11 Remove the generator bracket 12 Remove the valve cover 1 Remove the PCV hoses 2 Remove the valve cover bolts http vnx su ...

Page 671: ...ge air cooler Vehicles with charge air cooler All vehicles 13 Remove the timing belt lower cover 14 Remove the engine front mount bracket 15 Remove the timing belt cover 16 Remove the engine front mount bracket http vnx su ...

Page 672: ...nsioner bolt 18 Remove the timing belt Discard the timing belt 19 Remove the timing belt tensioner 20 Discard the timing belt tensioner 21 Using the special tool remove the camshaft pulley retaining bolt 22 Using the special tool remove the camshaft pulley 23 Remove the fuel injection pump pulley bolts http vnx su ...

Page 673: ...remove the fuel injection pump pulley 25 Remove the fuel injection pump oil seal retainer Discard the seal 26 Remove the timing belt rear cover 27 Remove the oil baffle 28 Remove the fuel injectors Discard the bolts http vnx su ...

Page 674: ... the sequence shown Remove the cylinder head Discard the gasket 30 Using the special tool remove the water pump pulley 31 Remove the water pump Discard the gasket 32 Using the special tool remove the crankshaft pulley Discard the bolt http vnx su ...

Page 675: ...33 Remove the accessory drive belt idler 34 Remove the timing chain housing cover Discard the gasket 35 Remove the timing chain tensioner 36 Detach the fuel injection pump sprocket http vnx su ...

Page 676: ...uides 38 Remove the fuel injection pump bracket 39 Remove the fuel injection pump Discard the gasket 40 Using the special tool detach the upper coolant hose from the coolant distribution pipe 41 Remove the coolant distribution pipe http vnx su ...

Page 677: ... sequence shown Remove the clutch disc and pressure plate 43 Using the special tool remove the flywheel Discard the bolts 44 Remove the crankshaft position CKP sensor 45 Remove the CKP sensor retaining bracket 46 Remove the crankshaft rear oil seal retainer Discard the retainer http vnx su ...

Page 678: ...d bolts 16 bolts two nuts 48 Using the special tools remove the oil pan 49 Remove the oil pump connecting pipe Discard the O ring seals 50 Remove the oil pump pick up tube Discard the O ring seal 51 Remove the air conditioning A C compressor retaining bracket http vnx su ...

Page 679: ... gasket 54 CAUTIONS Keep the connecting rod bearing caps in order for installation Keep the connecting rod bearing shells and connecting rod bearing cap shells in order for installation Remove the pistons 55 CAUTION Keep the main bearing lower and upper shells in order for installation Remove the crankshaft http vnx su ...

Page 680: ...ting Bracket Engine Differential 205 329 15 105A Installer Valve Stem Seal 303 037 21 007A Compressor Valve Spring 303 060 21 024 Adapter for 303 060 21 024 303 060 05 21 024 05 Installer Camshaft Seal 303 199A 21 110A Installer Valve Stem Collets 303 362 21 156 Pliers Valve Stem Seal 303 390 21 165 Remover Installer Hose Clamp 303 397 24 003 Mounting Stand 303 435 21 187 Mounting Bracket for 303 ...

Page 681: ...e to follow these instructions may result in personal injury CAUTIONS Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices or lines Do not disassemble fuel injectors or clean the nozzles even with an ultrasonic c...

Page 682: ...gasket 5 Remove the EGR cooler 6 Remove the exhaust manifold six bolts and two self locking nuts Discard the gasket the bolts and the nuts 7 Remove the intake manifold six bolts and two self locking nuts Discard the gasket the bolts and the nuts 8 Remove the EGR cooler Discard the EGR cooler gaskets http vnx su ...

Page 683: ...manifold gasket and retaining nuts 10 Remove the intake manifold Discard the intake manifold gaskets and retaining nuts 11 Remove the engine rear lifting eye 12 Remove the coolant outlet connector Discard the connector 13 Remove the oil pressure switch http vnx su ...

Page 684: ...remove the fuel injector fuel return line clip 2 Disconnect the fuel injector fuel return line from the fuel injector Install a clean blanking cap to the fuel injector return line port Discard the fuel injector fuel return line O ring seals and the fuel injector fuel return line clips 16 Remove the engine front lifting eye 17 Remove the glow plug wiring harness 18 Remove the glow plugs http vnx su...

Page 685: ...t caps to make sure they are installed in the same position Remove the camshaft Discard the camshaft oil seal 21 NOTE Make a note of the position of the valve tappets and adjustment shims to make sure they are installed in the same position Remove the valve tappets and valve adjustment shims 22 NOTE Make a note of the position of the camshaft lower bearing shells to make sure they are installed in...

Page 686: ...al tools remove the valve collets 27 NOTE Make a note of the position of the valve springs and valve retainers to make sure they are installed in the same position Remove the valve springs with valve retainers 28 Using the special tool remove the valve stem seals Discard the seals 29 NOTE Make a note of the position of the http vnx su ...

Page 687: ...rity 3 NOTE Install new valve stem seals Using the special tool install the valve stem seals 4 Remove the valve stem mounting sleeves 5 Install the valve springs and valve retainers 6 Using the special tools install the valve collets 7 Remove the special tools 8 Coat the brake booster vacuum pump drive tappet with clean engine oil 9 Install the brake booster vacuum pump drive tappet 10 NOTE Instal...

Page 688: ...haft lower bearing shells 14 Coat the camshaft lower bearing shells with clean engine oil 15 Coat the valve tappets and adjustment shims with clean engine oil 16 NOTE The lettering on the valve adjustment shims faces downwards Install the valve tappets and valve adjustment shims 17 NOTE The larger semi circle points upwards Position the camshaft on the cylinder head http vnx su ...

Page 689: ...Install the camshaft bearing caps 20 NOTE Tighten the camshaft bearing cap retaining nuts and bolts evenly a turn at a time Tighten the camshaft bearing cap retaining nuts and bolts 21 NOTE Install a new camshaft oil seal Using the special tool install the camshaft oil seal 22 NOTE Make sure that the fuel injectors are installed in their original position NOTE Install new fuel injector to cylinder...

Page 690: ...uel injector fuel return lines gently into the fuel injectors Failure to follow this instruction my result in damage to the fuel injector fuel return line O ring seals NOTE Install new fuel injector fuel return line O ring seals and new fuel injector fuel return line clips Attach the fuel return lines to the fuel injectors 1 Connect the fuel injector fuel return line to the fuel injector 2 Install...

Page 691: ...let connector Install the coolant outlet connector Apply sealantto the coolant outlet connector thread 30 Install the engine rear lifting eye 31 NOTE Install a new intake manifold gasket and new self locking nuts and bolts Install the intake manifold 32 NOTE Install a new exhaust manifold gasket and new self locking nuts and bolts Install the exhaust manifold http vnx su ...

Page 692: ...ew EGR cooler flange gasket Install the EGR cooler flange bolts 35 Install the EGR cooler outlet pipe flange bolts 36 NOTE Install new intake manifold gaskets and retaining nuts Install the intake manifold 37 NOTE Install a new exhaust manifold gasket retaining nuts Install the exhaust manifold http vnx su ...

Page 693: ...andstart all of the EGR cooler retaining bolts and then tighten in the sequence shown 39 Using the special tool connect the EGR cooler to cylinder head coolant hose to the EGR cooler 40 Using the special tool connect the EGR cooler to cylinder head coolant hose to the cylinder head 41 Detach the cylinder head from the mounting stand Remove the special tools http vnx su ...

Page 694: ...9022 AA WSS M2C912 A1 Disassembly Installer Valve Stem Seal 303 037 21 007A Compressor Valve Spring 303 060 21 024 Adapter for 303 060 21 024 303 060 05 21 024 05 Installer Camshaft Seal 303 199A 21 110 A Installer Valve Stem Collets 303 362 21 156 Pliers Valve Stem Seal 303 390 21 165 Socket Cylinder Head Temperature Sensor 303 680 21 239 Name Sealer Hypoid oil Engine oil 1 Remove the engine fron...

Page 695: ... special tool remove the cylinder head temperature CHT sensor and the oil pressure switch Discard the CHT sensor 6 Remove the oil pressure switch 7 Detach the components on the right hand side of the cylinder head 1 Engine lifting eye 2 Coolant connection Coolant hose http vnx su ...

Page 696: ...ove camshaft bearing caps two and four 2 Loosen the nuts on the other camshaft bearing caps evenly a turn at a time 3 Remove the brake vacuum pump plunger Remove the bearing caps bearing shells and the camshaft with the oil seal 11 NOTE Position the valve tappets in order to one side for further reuse Remove the valve tappets and valve adjustment shims 12 Loosen the valve collets Position a socket...

Page 697: ...tive sleeves NOTE Only remove the protective sleeves after the valve stem oil seals have been installed Coat the new valve seals with engine oil and install them 3 Coat the valves with hypoid oil and insert them 4 Install the valve springs Install the valve springs with the valve spring retainers 1 Using the special tool compress the valve springs 2 Install the valve collets into the grooves on th...

Page 698: ...nt to the bearing caps at the positions shown 10 NOTE The arrows on the camshaft bearing caps must point to the front of the engine NOTE Tighten the camshaft bearing caps evenly a turn at a time Install the camshaft 1 Install the brake vacuum pump plunger 2 Position camshaft bearing caps 1 3 and 5 and tighten the nuts fingertight 3 Position the other camshaft bearing caps and tighten the nuts fing...

Page 699: ...eal 13 Install the intake manifold 14 Tighten the exhaust manifold lower retaining bolts 15 Tighten the exhaust manifold upper retaining bolts Tighten the EGR flange bolts 2 bolts 16 Install the components on the right hand side of the cylinder head 1 Engine lifting eye 2 Coolant connection Coolant hose http vnx su ...

Page 700: ...Install the oil pressure switch 19 Install the brake vacuum pump 20 Install the glow plugs 21 NOTE Make sure that the fuel injectors are installed in their original position NOTE Install new fuel injector to cylinder head sealing washers NOTE Install new fuel injector retaining http vnx su ...

Page 701: ... injector retaining clamps retaining bolts Install the fuel injectors and retaining clamps Tighten the bolts in two stages 5 Nm 90 degrees 22 Install the glow plug wiring harness 23 Install the engine front lifting eye http vnx su ...

Page 702: ... 508 Pliers Valve Stem Seal Name Specification Engine Oil 5W 30 WSS M2C153 G Pneumatic vacuum gun Wooden Block 1 CAUTIONS Note the position of the components before removal Vacuum any foreign material from the fuel pump and fuel rail unions before sealing the unions with blanking caps Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the ar...

Page 703: ...7 8 9 10 11 12 13 CAUTION Note the position of the components before removal 14 CAUTION Note the position of the components before removal http vnx su ...

Page 704: ...onents before removal Special Tool s 303 060 303 060 05 303 362 General Equipment Wooden Block 18 CAUTION Note the position of the components before removal 19 CAUTION Note the position of the components before removal Special Tool s 303 508 20 http vnx su ...

Page 705: ...UTION Make sure that the components are installed to the position noted before removal Special Tool s 303 060 303 060 05 303 362 General Equipment Wooden Block 24 25 Material Engine Oil 5W 30 WSS M2C153 G 26 CAUTION Make sure that the components are installed to the position noted before removal 27 CAUTION Make sure that the components are installed to the position noted before removal Torque 20 N...

Page 706: ...28 Torque 20 Nm 29 Torque 23 Nm 30 Torque 1 23 Nm 2 45 Nm 3 15 Nm 4 20 Nm 31 Torque 24 Nm 32 Torque 10 Nm 33 Torque 24 Nm 34 Torque 22 Nm http vnx su ...

Page 707: ...alled 38 NOTE Make sure that new components are installed NOTE Install all the bolts finger tight before final tightening 1 CAUTION Make sure that new bolts are installed Torque 37 Nm 3 CAUTION Use an open ended wrench to prevent the component from turning Torque 40 Nm 4 Torque 40 Nm http vnx su ...

Page 708: ...2 15 030A Gauge Bolt Angle 303 174 21 540 Timing Peg Crankshaft TDC 303 193 21 104 Installer Camshaft Seal 303 199A 21 110A Alignment Plate Camshaft 303 376 21 162B Locking Tool Flywheel 303 393 21 168 Remover Installer Hose Clamp 303 397 24 003 Mounting Stand 303 435 21 187 Mounting Bracket for 303 435 303 435 06 21 031B Aligner Oil Pump 303 652 21 230 Timing Tool Crankshaft 303 710 21 257 Aligne...

Page 709: ...ator gauge holding fixture Dial indicator gauge Plastigage Engine vacuum cleaner Name Silicone gasket and sealant Sealer Engine oil SAE 5W 30 1 Coat the main bearing journals bearing shells and thrust half washers with clean engine oil 2 Install the main bearing shells to the cylinder block and to the main bearing caps 3 Position the crankshaft in the cylinder block 4 NOTE The grooves in the thrus...

Page 710: ...E Stamp the bolt heads with a center punch to indicate usage NOTE The big end bearing caps identification marks must point to the front of the engine Install the connecting rod bearing caps Tighten the bolts in four stages Stage 1 Tighten the bolts finger tight Stage 2 27 Nm Stage 3 60 degrees Stage 4 20 degrees After installation lubricate the journals with engine oil 9 NOTE Install a new timing ...

Page 711: ...ting pipe 14 NOTE A new crankshaft rear oil seal carrier is supplied with an alignment sleeve that must be removed following installation NOTE Do not fully tighten the crankshaft rear oil seal carrier retaining bolts at this stage Install the crankshaft rear oil seal carrier 15 Tighten the crankshaft rear oil seal carrier retaining bolts 16 Remove the crankshaft rear oil seal carrier alignment sle...

Page 712: ...Do not damage the mating faces NOTE The mating faces and blind holes must be free of oil and sealer residue Clean the mating faces of the oil pan and ladder frame 20 NOTE Install the oil pan within ten minutes of applying the sealer NOTE Once the oil pan has contact with the ladder frame it must not be removed Install the oil pan Apply a 2 5 mm diameter bead of silicone gasket and sealant to the l...

Page 713: ...position 24 NOTE Install new flywheel bolts NOTE Do not fully tighten the flywheel bolts at this stage Using the special tool install the dual mass flywheel Tighten the bolts in two stages in the sequence shown Stage 1 35 Nm Stage 2 45 degrees 25 Remove the special tool 26 Inspect the dual mass flywheel For additional information refer to Flywheel Inspection 303 00 Engine System General Informatio...

Page 714: ...orque Using the special tool install the clutch disc and pressure plate 29 NOTE Install a new crankshaft position CKP sensor NOTE The CKP sensor must make contact with the flywheel Install the CKP sensor 30 Install the fuel pump bracket 31 Install the coolant distribution pipe 32 Using the special tool attach the upper coolant hose to the coolant distribution pipe 33 1 26 Nm 2 50 Nm http vnx su ...

Page 715: ...All vehicles 34 35 36 NOTE Install a new fuel pump gasket Install the fuel pump 37 Install the fuel pump bracket 38 Install the timing chain sprockets and guides http vnx su ...

Page 716: ...NOTE Install a new timing chain housing cover gasket Using the special tool install the timing chain housing cover Tighten the bolts in the sequence shown in three stages Bolts 1 to 5 10 Nm Bolt 6 23 Nm Bolts 7 to 19 10 Nm 42 Install the accessory drive belt idler http vnx su ...

Page 717: ... new crankshaft pulley bolt Using the special tool install the crankshaft pulley Tighten the bolt in two stages Stage 1 100 Nm Stage 2 180 degrees 45 NOTE Install a new water pump gasket Install the water pump 46 Using the special tool install the water pump pulley 47 Install the engine front mount bracket http vnx su ...

Page 718: ...Install new cylinder head bolts Install the cylinder head bolts Using the special tool tighten the bolts in four stages in the sequence shown Stage 1 Tighten the bolts 1 through 10 to 20 Nm Stage 2 Tighten the bolts 1 through 10 to 54 Nm Stage 3 Tighten the bolts 1 through 10 to 90 degrees Stage 4 short bolts 70 degrees long bolts 90 degrees 50 Install the oil baffle 51 Install the timing belt rea...

Page 719: ... pump pulley to the fuel pump sprocket Apply sealant to the outer edge of the fuel pump pulley bolt holes 54 Install the fuel pump pulley 55 Using the special tool install the camshaft oil seal 56 NOTE Do not fully tighten the camshaft pulley retaining bolt at this stage Install the camshaft pulley retaining bolt http vnx su ...

Page 720: ...t slowly until the crankshaft stops 60 CAUTIONS Make sure that the engine does not rotate during installation of the special tool Make sure engine is at the TDC position before locking the special tool Make sure that the special tool engages correctly Using the special tool lock the engine in position 61 NOTE Use only latest level timing belts These are identified by a laser etched Ford logo Check...

Page 721: ... tensioner 65 CAUTIONS Never install a used timing belt Install the timing belt with the direction arrows in the direction of engine rotation NOTE Install a new timing belt Install the timing belt 66 NOTE The camshaft pulley must be able to turn freely on the camshaft taper Tighten the camshaft pulley bolt finger tight and then loosen by one half turn 67 NOTE Using an Allen key maintain the tensio...

Page 722: ...Using the special tool tighten the camshaft pulley retaining bolt 1 Install the special tool 2 Tighten the bolt 69 Remove the special tool 70 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 71 Remove the special tool 72 Remove the special tool 73 NOTE Only turn the engine in the normal http vnx su ...

Page 723: ...he engine is TDC position before locking the special tool Make sure that the special tool engages correctly Using the special tool lock the engine in position 77 Lower the vehicle 78 CAUTION If the pointer is not visible in the timing belt tensioner window the timing belt tensioning steps must be repeated Check that the timing belt tensioner pointer is positioned in the window 79 CAUTION If the sp...

Page 724: ...if necessary Install the valve cover 81 Install the timing belt cover 82 83 Install the fuel injectors Tighten the bolts in two stages Stage 1 5 Nm Stage 2 90 degrees 84 Install the fuel injection supply manifold retaining bracket http vnx su ...

Page 725: ...upply line as this may damage the ends of the line and allow foreign material to enter the fuel injection system Remove the blanking plugs from the high pressure fuel supply line the fuel injector and the fuel injection supply manifold at the last possible moment Failure to follow this instruction may result in foreign matter ingress to the fuel injection system NOTE To aid identification of the h...

Page 726: ...ons at this stage NOTE Maintain pressure on the high pressure fuel supply line to keep the lines in contact with the fuel injection supply manifold cones while installing the union Install the high pressure fuel supply lines of cylinder one and four to the fuel supply manifold Discard the blanking plugs 89 NOTE Make sure the clamp is installed in the same position as removed Install the high press...

Page 727: ...olive ends of the high pressure fuel supply line as this may damage the ends of the line and allow foreign material to enter the fuel injection system Remove the blanking plugs from the high pressure fuel supply line the fuel injector and the fuel injection supply manifold at the last possible moment Failure to follow this instruction may result in foreign matter ingress to the fuel injection syst...

Page 728: ...d cones while installing the union Install the high pressure fuel supply lines of cylinder two and three to the fuel supply manifold Discard the blanking plugs 94 Connect the fuel injector return line to the fuel injectors 95 NOTE Do not tighten the high pressure fuel supply line clamps at this stage NOTE Make sure the clamps are installed in the same position as removed Install the high pressure ...

Page 729: ...o the union Tighten the high pressure fuel supply line unions of cylinder one and four to the fuel injection supply manifold 100 CAUTION Make sure the tool used to tighten the high pressure fuel supply line unions is used at the top of the union as this is where there is most material Failure to follow this instruction may result in damage to the union Tighten the high pressure fuel supply line un...

Page 730: ...o and three to the fuel supply manifold 103 NOTE Make sure the clamps are installed in the same position as removed Tighten the high pressure fuel supply line clamps 104 CAUTION Cover the high pressure fuel pump opening to prevent dirt ingress Tighten the high pressure fuel supply line clamp retaining nut 105 Connect the high pressure fuel pump electrical connectors 106 Connect the high pressure f...

Page 731: ...bracket 109 Attach the oil level indicator tube bracket to the thermostat housing 110 Connect the oil pressure switch electrical connector 111 Connect the camshaft position CMP sensor electrical connector 112 Connect the high pressure fuel injector electrical connectors http vnx su ...

Page 732: ...ake booster vacuum pump 115 Using the special tool attach the positive crankcase ventilation PCV hose to the brake booster vacuum pump 116 Install the PCV housing 117 Connect the cylinder head temperature CHT sensor electrical connector 1 Connect the electrical connector 2 Attach the electrical connector to the PCV housing http vnx su ...

Page 733: ...al tool attach the PCV hoses to the lower PCV pipe 120 NOTE Install a new oil cooler gasket Install the oil cooler 121 NOTE Install a new oil filter Install the oil filter 122 NOTE Install a new turbocharger oil return tube O ring seal Attach the turbocharger oil return tube http vnx su ...

Page 734: ...ling washers Install the turbocharger oil supply line 124 NOTE Install new turbocharger oil supply line sealing washers Attach the turbocharger oil supply tube to the turbocharger 125 Fill the engine with engine oil 126 Remove the special tool http vnx su ...

Page 735: ...auge Bolt Angle 303 174 21 540 Timing Peg Crankshaft TDC 303 193 21 104 Installer Camshaft Seal 303 199A 21 110A Alignment Plate Camshaft 303 376 21 162B Locking Tool Flywheel 303 393 21 168 Remover Installer Hose Clamp 303 397 24 003 Mounting Stand 303 435 21 187 Mounting Bracket for 303 435 303 435 06 21 031B Aligner Oil Pump 303 652 21 230 Aligner Clutch Disc 308 204 16 067 Alignment Peg Cranks...

Page 736: ...earing upper and lower shells in the correct order Install the main bearing shells to the cylinder block and to the main bearing caps 3 Position the crankshaft in the cylinder block 4 NOTE The grooves in the thrust half washers must face outwards Install the crankshaft thrust half washers into the third main bearing with oil grooves facing outwards 5 NOTE Install the main bearing caps with arrows ...

Page 737: ...g caps identification marks must point to the front of the engine Install the connecting rod bearing caps Tighten the bolts in four stages Stage 1 Tighten the bolts finger tight Stage 2 27 Nm Stage 3 60 degrees Stage 4 20 degrees After installation lubricate the journals with engine oil 9 NOTE Install a new timing chain rear housing gasket Install the timing chain rear housing 10 NOTE Install a ne...

Page 738: ...ust be free of oil and sealer residue Clean the mating faces of the oil pan and ladder frame 15 CAUTION Make sure that the sealer does not enter the ladder frame blind holes Failure to follow this instruction may result in damage to the engine assembly NOTE Install the oil pan within ten minutes of applying the sealer NOTE Once the oil pan has contact with the ladder frame it must not be removed I...

Page 739: ...ing installation NOTE Do not fully tighten the crankshaft rear oil seal carrier retaining bolts at this stage Install the crankshaft rear oil seal carrier 18 Tighten the crankshaft rear oil seal carrier retaining bolts 19 Remove the crankshaft rear oil seal carrier alignment sleeve 20 NOTE Do not fully tighten the crankshaft position CKP sensor retaining bracket bolts at this stage Install the CKP...

Page 740: ...he special tool centralize the clutch disc on the pressure plate 24 CAUTION Tighten the clutch pressure plate retaining bolts finger tight and then by two turns at a time in the sequence shown to the specified torque Using the special tool install the clutch disc and pressure plate Remove the special tool 25 Using the special tool install the CKP sensor retaining bracket 26 Install the coolant dis...

Page 741: ...TE Install a new fuel injection pump gasket Install the fuel injection pump 29 Install the fuel injection pump bracket 30 Install the timing chain sprockets and guides 31 NOTE Do not tighten the fuel injection pump sprocket bolts at this stage Install the fuel injection pump sprocket http vnx su ...

Page 742: ...sing cover Tighten the bolts in the sequence shown in three stages Bolts 1 to 5 10 Nm Bolt 6 23 Nm Bolts 7 to 19 10 Nm 34 Install the accessory drive belt idler 35 Using the special tool install the crankshaft pulley Tighten the bolt in two stages Stage 1 100 Nm Stage 2 180 degrees http vnx su ...

Page 743: ...t slowly until the crankshaft stops 38 NOTE Using a 6 mm drill bit set the fuel injection pump to crankshaft TDC Install the fuel injection pump sprocket 39 Remove the special tool 40 NOTE Only turn the crankshaft in the normal direction of rotation NOTE Using a suitable marker mark the crankshaft pulley to show TDC Turn the crankshaft 90 degrees 41 NOTE Install a new water pump gasket http vnx su...

Page 744: ...harger oil return hose must be attached when the cylinder head is installed Install the cylinder head 45 CAUTION Install new cylinder head bolts Install the cylinder head bolts Using the special tool tighten the bolts in four stages in the sequence shown Stage 1 Tighten the bolts 1 through 10 to 20 Nm Stage 2 Tighten the bolts 1 through 10 to 54 Nm Stage 3 Tighten the bolts 1 through 10 to 90 degr...

Page 745: ...el injectors Tighten the bolts in two stages Stage 1 5 Nm Stage 2 90 degrees 47 Install the oil baffle 48 Install the timing belt rear cover 49 NOTE Install a new fuel injection pump oil seal retainer Install the fuel injection pump oil seal retainer http vnx su ...

Page 746: ...uter edge of the fuel injection pump pulley bolt holes 51 Install the fuel injection pump pulley 52 Using the special tool install the camshaft oil seal 53 NOTE Do not fully tighten the camshaft pulley retaining bolt at this stage Install the camshaft pulley retaining bolt 54 Install the special tool http vnx su ...

Page 747: ...tion of the special tool Make sure the crankshaft is at the TDC position before locking the special tool Make sure that the special tool engages correctly Using the special tool lock the crankshaft in position 58 NOTE Use only latest level timing belts These are identified by a laser etched Ford logo Check the timing belt 59 Install a new automatic timing belt tensioner 60 Check the timing belt te...

Page 748: ... belt 64 NOTE The camshaft pulley must be able to turn freely on the camshaft taper Tighten the camshaft pulley bolt finger tight and then loosen by one half turn 65 NOTE Using an Allen key maintain the tension on the timing belt until the timing belt tensioner bolt is tightened Tension the timing belt 1 Turn the timing belt tensioner adjustment arm counterclockwise to tension the timing belt slig...

Page 749: ...e special tool 68 Remove the special tool 69 Remove the special tool 70 NOTE Only turn the crankshaft in the normal direction of rotation Turn the crankshaft six revolutions 71 Install the special tool http vnx su ...

Page 750: ...ake sure that the special tool engages correctly Using the special tool lock the crankshaft in position 74 CAUTION If the pointer is not visible in the timing belt tensioner window the timing belt tensioning steps must be repeated Check that the timing belt tensioner pointer is positioned in the window 75 CAUTION If the special tool cannot be installed the timing belt tensioning steps must be repe...

Page 751: ...ver 78 Install the engine front mount bracket 79 Install the timing belt lower cover 80 NOTE Install a new valve cover gasket if necessary Install the valve cover 1 Lubricate the valve cover gasket with engine oil before installation 81 Install the generator bracket http vnx su ...

Page 752: ...stall the oil filter 84 NOTE Install new turbocharger oil supply line O ring seals Install the turbocharger oil supply line 85 NOTE Install a new turbocharger oil supply line O ring seal Attach the turbocharger oil supply line to the turbocharger 86 Install the generator and drive shaft http vnx su ...

Page 753: ...OTE Secure the oil separator to the engine lifting eye Tighten the engine lifting eye and then tighten the oil separator NOTE Install the clip at a 45 degree angle to the horizontal Attach the crankcase ventilation oil separator 89 Fill the engine with engine oil 90 Remove the special tool http vnx su ...

Page 754: ...rry lighted tobacco or open flame of any type when working on or near any fuel related components Highly flammable mixtures are always present and may ignite Failure to follow these instructions may result in personal injury Install the transaxle to the engine 2 Raise and support the vehicle For additional information refer to Jacking 100 02 Jacking and Lifting Description and Operation Lifting 10...

Page 755: ...Installation 7 Using a suitable transmission jack position and raise the crossmember until the crossmember is approximately 100 mm from the body 8 Install new power steering line O ring seals For additional information refer to Power Steering System Flushing 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 211 00 Steering System General Information General Procedures 9 Attach the powe...

Page 756: ... alignment pins through the crossmember alignment holes and the washers 2 Slide the locking plates on top of the washers and into the groove of the special tool and tighten the alignment pin sleeve 3 Raise the crossmember engaging the alignment pins into the chassis alignment holes 13 CAUTION Make sure that the crossmember does not move while tightening the crossmember retaining bolts Install the ...

Page 757: ...st not be bent more than 45 degrees Do not damage the halfshaft oil seal Attach the left hand halfshaft to the transaxle 18 CAUTIONS Support the halfshaft The inner joint must not be bent more than 18 degrees The outer joint must not be bent more than 45 degrees Do not damage the halfshaft oil seal NOTE Install new lock nuts and a new centre bearing caps Attach the right hand halfshaft to the tran...

Page 758: ...bracket 2 Attach the selector cable to the selector lever 3 Slacken the abutment collar by turning it counter clockwise and install the gearshift cable 4 Connect the gearshift cable to the gearshift lever 5 Install the adjusting mechanism by pressing in the tab 23 Install the radiator support bracket on both sides left hand side shown 24 Connect the starter motor electrical connector and the power...

Page 759: ...t the ball joint seal Attach the lower arm to the wheel knuckle on both sides left hand side shown 28 NOTE Install a new nut Attach the left hand tie rod end 29 Attach the stabiliser bar connecting link on both sides 30 Install the left front wheel and tire http vnx su ...

Page 760: ...ssor four bolts 33 Connect the air conditioning compressor clutch electrical connector and attach the wiring harness to the air conditioning compressor 34 Connect the horn electrical connector and the horn wiring harness 35 Install the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive R...

Page 761: ...pansion tank 40 Using the special tool connect the lower coolant hose to the coolant expansion tank 41 Connect the fuel supply and return line quick release coupling For additional information refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures 42 Attach the fuel supply and return line to the fuel line bracket http vnx su ...

Page 762: ...re pipe to the bracket 45 Attach the power steering high pressure pipe bracket to the lifting eye 46 Attach the power steering high pressure pipe bracket to the timing belt cover stud connection 47 Attach the power steering high pressure pipe to the power steering pump http vnx su ...

Page 763: ...onnect the fuel injection pump electrical connector 49 Attach the vacuum hoses and the electrical connector to the emission gas recirculation EGR valve 50 Attach the upper coolant hose to the EGR cooler 51 Attach the electronic vacuum regulating valves support bracket to the intake manifold http vnx su ...

Page 764: ...ct the EGR vacuum hose to the EGR valve 54 Connect the injector driver module electrical connector 55 Connect the engine wiring harness 56 Attach the vacuum hose to the vacuum diaphragm unit 57 Install the generator electrical connector cover http vnx su ...

Page 765: ...nerator battery positive cable 59 Using the special tool attach the cooling hoses to the thermostat housing and to the coolant distribution pipe 60 Connect the fuel pressure sensor electrical connector 61 NOTE Install a new gasket Install the thermostat housing http vnx su ...

Page 766: ...hermostat housing 63 Attach the vacuum pipe to the brake booster vacuum pump 64 Install the oil level indicator and oil level indicator tube 65 Connect the glow plug wiring harness to the terminal block 66 Connect the glow plug wire to the terminal block http vnx su ...

Page 767: ...r cleaner intake pipe 68 Install the air cleaner outlet pipe 69 Install the charge air cooler 70 Connect the intake air temperature IAT sensor electrical connector 71 Install the charge air cooler air guide http vnx su ...

Page 768: ...r cooler NOTE Install a new charge air cooler intake hose retaining clamp Install the charge air cooler intake pipe Clean the inside of the charge air cooler intake hose Install a new charge air cooler intake hose retaining clamp in the same position as when removed 74 CAUTION The charge air cooler to intake manifold hose retaining clamp must be installed in the same position as removed Failure to...

Page 769: ...aft to the steering gear pinion extension retaining bolt Failure to follow this instruction may result in personal injury NOTE Make sure that the road wheels are in the straight ahead position Connect the steering column shaft to the steering gear pinion extension 79 Install the air cleaner For additional information refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Ins...

Page 770: ...ditional information refer to Gearshift Cable Adjustment 308 00 Manual Transmission Transaxle and Clutch General Information General Procedures 83 Install the battery tray For additional information refer to Battery Tray 414 01 Battery Mounting and Cables Removal and Installation http vnx su ...

Page 771: ... 92 197 Thermostat opening temperature vehicles with diesel engine 88 190 Description Nm lb ft lb in Radiator support bracket retaining bolts 25 18 Water pump pulley retaining bolts 12 9 Water pump retaining bolts 18 13 Thermostat cover retaining bolts 5 44 Thermostat housing retaining bolts 20 15 Cooling fan motor retaining bolts 5 44 Roll restrictor retaining bolts 48 35 Engine front mounting to...

Page 772: ...em WDS Mechanical Electrical Coolant leaks Gaskets seals Core plug s Hose s hose joints Coolant expansion tank cap and seal Coolant expansion tank Radiator Water pump Thermostat housing Heater core Heater control valve Exhaust gas recirculation EGR cooler Accessory drive belt Fuse s Wiring harness Electrical connector s Cylinder head temperature CHT sensor Engine coolant temperature ECT sensor Coo...

Page 773: ...e Repair Cylinder Head 1 8L Duratorq TDDi Lynx Diesel 75 PS Vehicles Without Common Rail Fuel Injection 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair Cylinder Head 1 8L Duratorq TDCi Lynx Diesel 90 PS Vehicles With Common Rail Fuel Injection 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair Coolant level ...

Page 774: ...System Draining Filling and Bleeding 303 03 Engine Cooling General Procedures 6 6 All vehicles except with diesel engine check the engine for coolant leaks Drain REFER to Water Pump 1 8L Duratec DOHC 85kW 115PS Zetec 303 03 Engine Cooling Removal and Installation Water Pump 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 03 Engine Cooling Removal and Installation Cooling system r...

Page 775: ... to clean the area of the rubber seal and pressure relief valve Install the pressure tester and adapter and immerse the coolant expansion tank cap in water NOTE If the plunger of the pump is depressed too quickly an erroneous pressure reading will result 3 3 Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading ...

Page 776: ... only allows the ECT sensor to be displayed in volts refer to the following table for corresponding Celsius values The CHT sensor output is useful to examine the cylinder head temperature rise during the warm up cycle and later during the normal light throttle cruise test This sensor output may vary between vehicles with manual transmission and vehicles with automatic transmission and should be us...

Page 777: ...4 Drive the vehicle at a constant throttle opening and set speed until the ECT value settles into a shallow rise and fall signal close to a straight line This indicates that the thermostat is functioning correctly NOTE Some thermostats indicate the temperature s in Celsius and Fahrenheit The graphic below shows the location and an example of the opening temperature 88ºC and fully open temperature ...

Page 778: ...at and its sealing function within the thermostat housing must be checked 5 5 INSTALL a new thermostat REFER to Thermostat 1 8L Duratec DOHC 85kW 115PS Zetec 303 03 Engine Cooling Removal and Installation Thermostat 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 03 Engine Cooling Removal and Installation 6 6 Carry out another road test from step 1 using the same criteria to conf...

Page 779: ...flow in the normal coolant flow direction In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation it will be necessary to use the pressure flushing method using Cooling System Flusher Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local state or federal laws 2 Remove the radiator 3 ...

Page 780: ...om a tap with a male adapter into the end of the heater outlet hose Secure with a hose clamp 2 Connect a garden hose to the engine intake connector and secure with a hose clamp Allow the open end to drain into a suitable container or drain 3 Turn the water supply tap ON and OFF several times so that the surge action will help to dislodge larger stubborn particles from the heater core tubes Allow w...

Page 781: ...e cooling system pressure by slowly turning the expansion tank cap a quarter of a turn 2 Remove the cap when all the pressure has been released 3 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 4 NOTE Drain the coolant into a suitable container Open the radiator drain valve to drain the coolant 5 Close the drain valve when all the coolant has be...

Page 782: ...5 Install the expansion tank cap 6 Warm the engine up at 2750 RPM for two fan cycles 7 Leave the engine to cool down and then recheck the coolant level Top up to the MAX mark as required http vnx su ...

Page 783: ...illustration s and table s Description Thermostat cover retaining bolts Thermostat cover heat shield Thermostat cover See Removal Detail Thermostat Thermostat O ring seal See Removal Detail See Installation Detail 1 Drain the cooling system For additional information refer to Cooling System Draining Filling and bleeding in this section 2 Lower the vehicle Item 1 2 3 4 5 Part Number http vnx su ...

Page 784: ... Details Item 3 Thermostat cover Item 5 Thermostat O ring seal NOTE Discard the O ring seal Installation Details Item 5 Thermostat O ring seal NOTE Install a new O ring seal 1 Detach the thermostat housing cover and position it to one side http vnx su ...

Page 785: ...hermostat seal See Removal Detail See Installation Detail 4 To install reverse the removal procedure Removal Details Item 4 Thermostat seal NOTE Discard the O ring seal Installation Details Item 4 Thermostat seal NOTE Install a new O ring seal 1 Remove the charge air cooler For additional information refer to Section 303 12 Intake Air Distribution and Filtering 2 Drain the cooling system For addit...

Page 786: ...d in the following illustration s and table s Description Radiator to thermostat housing coolant hose retaining clamp See Removal Detail Radiator to thermostat housing coolant hose Remover Installer Hose Clamp 303 397 24 003 1 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 2 Lower the vehicle Item 1 2 Part Number http vnx s...

Page 787: ... coolant hose retaining clamp Heater core to thermostat housing coolant hose Thermostat housing and thermostat Description Thermostat cover retaining bolts Thermostat cover heat shield Thermostat cover Thermostat Thermostat O ring seal See Removal Detail See Installation Detail Thermostat housing 4 To install reverse the removal procedure Removal Details Item 1 Radiator to thermostat housing coola...

Page 788: ...the thermostat housing seal Item 16 Thermostat O ring seal NOTE Discard the O ring seal Installation Details Item 8 Thermostat housing seal NOTE Install a new thermostat housing seal Item 16 Thermostat O ring seal NOTE Install a new O ring seal http vnx su ...

Page 789: ...ndicated in the following illustration s and table s Description Remover Installer Hose Clamp 303 397 24 003 1 Remove the charge air cooler For additional information refer to Section 303 12 Intake Air Distribution and Filtering 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 3 Lower the vehicle Item http vnx su ...

Page 790: ...hermostat housing coolant hose retaining clamp Radiator to thermostat housing coolant hose Water pump to thermostat housing coolant hose retaining clamp Water pump to thermostat housing coolant hose Thermostat housing retaining bolts Thermostat housing assembly Thermostat housing seal See Removal Detail See Installation Detail Description Thermostat cover retaining bolts Thermostat cover 1 2 3 4 5...

Page 791: ...hermostat housing seal NOTE Discard the thermostat housing seal Item 15 Thermostat O ring seal NOTE Discard the O ring seal Installation Details Item 15 Thermostat O ring seal NOTE Install a new O ring seal Item 11 Thermostat housing seal NOTE Install a new thermostat housing seal 14 15 16 1 Detach the oil level indicator tube and position it to one side 1 Using the special tool detach the coolant...

Page 792: ...ted in the following illustration s and table s Description Remover Installer Hose Clamp 303 397 24 003 1 Remove the charge air cooler For additional information refer to Section 303 12 Intake Air Distribution and Filtering 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 3 Lower the vehicle ItemPart Number http vnx su ...

Page 793: ...ing clamp See Removal Detail Coolant expansion tank to thermostat housing coolant hose Radiator to thermostat housing coolant hose retaining clamp Radiator to thermostat housing coolant hose Thermostat housing retaining bolts Water pump to thermostat housing coolant hose retaining clamp Water pump to thermostat housing coolant hose Thermostat housing assembly Thermostat housing seal See Removal De...

Page 794: ... retaining clamp Item 14 Thermostat housing seal NOTE Discard the thermostat housing seal Item 18 Thermostat O ring seal NOTE Discard the O ring seal Installation Details Item 18 Thermostat O ring seal NOTE Install a new O ring seal Item 14 Thermostat housing seal NOTE Install a new thermostat housing seal Item 15 16 17 18 19 1 Detach the oil level indicator tube and position it to one side 1 Usin...

Page 795: ...mation refer to Section 414 01 Battery Mounting and Cables 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 3 Remove the splash shield 4 Loosen the water pump pulley retaining bolts 5 Remove the accessory drive belt 1 Rotate the accessory drive belt tensioner clockwise 2 Remove the accessory drive belt 6 Remove the roll res...

Page 796: ...wer the vehicle 8 Detach the coolant expansion tank and position to one side 9 Detach the engine ground cable 10 Remove the engine front mounting to body retaining bolts 11 Reposition the engine Slide the engine forward Secure in position using an engine mounting to body retaining bolt http vnx su ...

Page 797: ...e Installation Detail 13 To install reverse the removal procedure Removal Details Item 5 Water pump O ring seal Installation Details Item 5 Water pump O ring seal Item 1 Water pump pulley retaining bolts Item 1 2 3 4 5 1 Discard the O ring seal 1 Install a new O ring seal 1 Do not fully tighten the water pump pulley retaining bolts at this stage Part Number http vnx su ...

Page 798: ...e For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Remove the charge air cooler For additional information refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 75 PS 90 PS 303 12 Intake Air Distribution and Filtering Removal and Installation Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel...

Page 799: ...ling system For additional information refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling General Procedures 9 Remove the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 10 Remove the engine support insulator retaining bolt http vnx su...

Page 800: ... order indicated in the following illustration s and table s Description Engine front mounting bracket Power steering pipe retaining bracket See Removal Detail Timing belt cover 11 Lower the vehicle Item 1 2 3 Part Number http vnx su ...

Page 801: ...mp gasket 13 To install reverse the removal procedure Removal Details Item 2 Power steering pipe retaining bracket Item 6 Coolant pump upper retaining bolt Item 4 5 6 7 8 9 1 Detach the power steering pipe retaining clip from the cylinder head 1 Install the fabricated piece of laminated card between the timing belt and the coolant pump upper retaining bolt Using the fabricated piece of laminated c...

Page 802: ...aining bolt CAUTION Make sure the fabricated piece of laminated card is correctly positioned between the timing belt and coolant pump before installing the coolant pump upper retaining bolt Item 4 Coolant pump pulley retaining bolts coolant pump upper retaining bolt 1 Using the special tool raise the front of the engine by 60 mm 1 Install the coolant pump pulley retaining bolts hand tight 2 Using ...

Page 803: ...xtension Right hand front fender splash shield extension retaining bolts Right hand front fender splash shield extension Radiator splash shield retaining clips Radiator splash shield Remover Installer Hose Clamp 303 397 24 003 1 Remove the cooling fan motor and shroud For additional information refer to Cooling fan motor and shroud in this section 2 Drain the cooling system For additional informat...

Page 804: ...utlet hose retaining clamp Coolant expansion tank outlet hose Coolant expansion tank inlet hose retaining clamp Coolant expansion tank inlet hose Radiator support bracket retaining bolts Radiator support bracket retaining bolts See Removal Detail Radiator support bracket Radiator rubber insulators Radiator See Removal Detail Item 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part Number http vnx su ...

Page 805: ...ose retaining clamp Item 17 Radiator support bracket retaining bolts Item 20 Radiator 21 1 Using the special tool detach the radiator upper hose retaining clamp 1 With the aid of another technician support the radiator and air conditioning A C condenser 1 Detach the A C condenser from the radiator http vnx su ...

Page 806: ... the order indicated in the following illustration s and table s Description Cooling fan motor retaining bolts Cooling fan and motor 3 To install reverse the removal procedure 1 Remove the cooling fan motor and shroud For additional information refer to Cooling Fan Motor and Shroud in this section Item 1 2 Part Number http vnx su ...

Page 807: ...nditioning A C fan motor electrical connector Heated oxygen sensor HO2S electrical connector Power steering switch wiring harness retaining clips Power steering switch wiring harness retaining clip See Removal Detail See Installation Detail Cooling fan motor electrical connector Cooling fan shroud retaining nuts 1 Disconnect the battery ground cable For additional information refer to Section 414 ...

Page 808: ...an shroud retaining nuts Item 8 Cooling fan motor and shroud Installation Details Item 5 Power steering switch wiring harness retaining clip 8 1 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 1 Loosen the cooling fan shroud retaining nuts 1 Raise the cooling fan shroud to disengage from the radiator retaining clips 1 Lower the vehicle http vnx ...

Page 809: ... Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications a Refer to the procedure in this section Description Nm lb ft lb in Throttle body retaining bolts a Fuel pressure regulator retaining bolts 6 53 Fuel injection supply manifold retaining bolts 10 89 http vnx su ...

Page 810: ...lectrical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the concern is not visually evident verify the symptom and refer to WDS to diagnose the system Mechanical Electrical Fuel line s Vacuum line s Gasket s seal s Fuel pressure regulator Throttle body Fuel injection supply...

Page 811: ...oved 1 Remove the components in the order indicated in the following illustration s and table s Description Air cleaner outlet pipe to air cleaner retaining clamp Air cleaner outlet pipe to throttle body retaining clamp Air cleaner outlet pipe Accelerator cable inner cable to throttle body Accelerator cable outer cable to throttle body See Removal Detail Throttle position TP sensor electrical conn...

Page 812: ...dy seal NOTE Install a new throttle body seal Item 8 Throttle body NOTE Inspect the intake manifold to throttle body interface for loose plastic material produced by the throttle body retaining bolts during initial assembly Item 7 Throttle body retaining bolts 8 9 1 Rotate and detach the accelerator cable from the throttle body accelerator cable retaining bracket 1 NOTE Hand start each throttle bo...

Page 813: ...g clamp Air cleaner outlet pipe to throttle body retaining clamp Air cleaner outlet pipe Throttle position TP sensor electrical connector Camshaft position CMP electrical connector Idle air control IAC valve electrical connector Cylinder head temperature CHT sensor electrical connector See Installation Detail Oil pressure switch electrical connector 1 Disconnect the battery ground cable For additi...

Page 814: ...Details Item 8 Oil pressure switch electrical connector Item 9 Fuel charging wiring harness electrical connector Installation Details Item 8 Oil pressure switch electrical connector Item 7 Cylinder head temperature CHT sensor electrical connector 9 10 11 1 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 1 Lower the vehicle 1 Raise the vehicle 1 ...

Page 815: ...te Failure to follow these instructions may result in personal injury This procedure involves fuel handling Be prepared for fuel spillage at all times and always observe fuel handling precautions Failure to follow these instructions may result in personal injury The fuel system remains pressurized for a long time after the ignition is switched off The fuel pressure must be relieved before attempti...

Page 816: ...ining clamp Air cleaner outlet pipe to throttle body retaining clamp Air cleaner outlet pipe Accelerator cable to throttle body Accelerator cable to throttle body accelerator cable retaining bracket See Removal Detail Item 1 2 3 4 5 Part Number http vnx su ...

Page 817: ...etail Fuel injection supply manifold retaining bolts Fuel injector retaining clips Fuel injectors O ring seals See Installation Detail Fuel pressure regulator retaining bolts Fuel pressure regulator O ring seal See Installation Detail Fuel injection supply manifold fuel supply pipe retaining bolts Fuel injection supply manifold fuel supply pipe retaining clip Fuel injection supply manifold fuel su...

Page 818: ... 13 O ring seals CAUTION Do not use silicone grease to lubricate O ring seals as it will block the fuel injectors 20 21 1 Rotate and detach the accelerator cable from the throttle body accelerator cable retaining bracket 1 Protect the generator with lint free material to prevent contamination 2 Disconnect the fuel supply line from the fuel injection supply manifold fuel supply pipe For additional ...

Page 819: ...Failure to follow these instructions may result in personal injury This procedure involves fuel handling Be prepared for fuel spillage at all times and always observe fuel handling precautions Failure to follow these instructions may result in personal injury The fuel system remains pressurized for a long time after the ignition is switched off The fuel pressure must be relieved before attempting ...

Page 820: ...l reverse the removal procedure Removal Details Item 1 Fuel return line to fuel pressure regulator spring release coupling CAUTION The generator must be protected from contamination Failure to follow this instruction may cause premature failure of the generator Item 1 2 3 4 5 6 1 Protect the generator with lint free material to prevent contamination 2 Disconnect the fuel return line from the fuel ...

Page 821: ...ls Item 6 Fuel pressure regulator O ring seal CAUTION Do not use silicone grease to lubricate O ring seals as it will block the fuel injectors NOTE Install a new fuel pressure regulator O ring seal Information 1 Lubricate the fuel pressure regulator O ring seal with clean engine oil to aid installation http vnx su ...

Page 822: ...HC 85kW 115PS Zetec Fuel Injectors Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation 1 Remove the fuel injection supply manifold For additional information refer to Fuel Injection Supply Manifold in this section http vnx su ...

Page 823: ...ng bolt 12 9 Fuel injection pump retaining bolts 20 15 Fuel injection pump bracket retaining bolts 23 18 Generator bracket retaining bolts 25 18 Generator retaining bolts 25 18 Air conditioning compressor retaining bolts 25 18 Fuel injection supply manifold retaining bolts 28 21 High pressure fuel supply line clamp 33 24 Fuel injection pump sprocket retaining bolts 24 18 Fuel injector clamp retain...

Page 824: ...the fuel tank to the fuel pump A fuel metering valve is located in the supply port to the high pressure chamber of the fuel pump The fuel metering valve varies the quantity of fuel supplied to the fuel rail and fuel injector s in relation to the driving conditions The fuel is supplied at high pressure to the fuel rail and to the fuel injectors ready for injection Depending on engine operating cond...

Page 825: ...el return port Fuel pressure regulator High pressure fuel supply line port Fuel pump fuel supply port Fuel metering valve The fuel pump is driven clockwise at half the engine speed by the timing belt The fuel pump has three pump elements each offset from each other by 120 degrees The fuel transfer pump is incorporated into the fuel pump and is located on the drive flange The fuel transfer pump is ...

Page 826: ... the fuel injection system The fuel rail is made from forged steel and is retained by a support bracket located on the cylinder block The fuel is delivered to the fuel rail by one high pressure fuel supply line from the fuel pump From the fuel rail the fuel travels through high pressure fuel supply line s to the fuel injector s Fuel injectors Item 1 Part Number http vnx su ...

Page 827: ...egrees from vertical in the cylinder head upper section and are attached by means of retaining clamps The fuel injector s are sealed from the combustion chamber by means of a copper sealing washer located between the fuel injector and the cylinder head A new sealing washer must always be installed when carrying out installation work The fuel injectors are controlled directly by the PCM The fuel re...

Page 828: ... Charging and Controls Transit Tourneo Connect 2002 5 06 2002 Print Description and Operation 1 8L Duratorq DI 55 kW System overview Description Injector nozzle High pressure lines Pump control unit Bosch distributor injection pump VP 30 Low pressure lines Item 1 2 3 4 5 Part Number http vnx su ...

Page 829: ... Module PCM Fuel tank Fuel filter Fuel supply line Low pressure system high pressure system Electrical control is performed by the pump control unit The low pressure system consists of the following components Fuel reservoir Fuel filter Low pressure fuel lines Fuel tank Item 1 2 3 4 5 6 7 8 9 Part Number http vnx su ...

Page 830: ...ip The control valve is made of bi metal It closes the return to the fuel tank at low temperatures This causes the warmed fuel to flow from the injection pump back into the fuel filter thus warming it after which the fuel flows on to the distributor pump The fuel lines have a push fit connection and can be separated after the retainers have been disengaged The feed and return fuel lines are colour...

Page 831: ... details of how to drain the water from the fuel filter Injector nozzle Description Copper sealing ring Injector Retaining bolt Retainer NOTE The securing bolts of the retainers must be tightened to the specified torque The bolts and the copper sealing rings must not be re used refer to the current service literature The 5 hole fuel injectors are a push fit in the cylinder head A copper sealing ri...

Page 832: ...eginning of the injection process This pre injection ensures a gentle increase in the combustion pressure and achieves the ignition conditions for the main fuel quantity which will be injected at high pressure by the second spring Because of the gentle rise in pressure in the combustion chamber the mechanical load on the crank assembly is less and the combustion noise is lower Description Injector...

Page 833: ... be installed without strain Distributor injection pump VP 30 Description Vane cell pump Rotational angle sensor Roller ring Pump control unit Plug connection Axial piston High pressure solenoid valve Pressure valve Solenoid valve adjustment of start of injection Injection regulator Item 1 2 3 4 5 6 7 8 9 10 Part Number http vnx su ...

Page 834: ...ponse to the fuel quantity regulation by fast switching of the high pressure solenoid valve The pump control unit is mounted on the top of the injection pump It uses information from the rotational angle sensor and from the PCM to calculate the control signals for the high pressure solenoid valve and the start of injection timing NOTE Before the electrical plug connection of the pump control unit ...

Page 835: ...high pressure solenoid valve determines the injection quantity and the injection time for each individual injection At the bottom dead centre position of the eccentric disc of the axial piston high pressure pump the high pressure solenoid valve is closed through the needle valve by a control impulse from the PCM The closing timing of the valve determines the start of fuel delivery from the injecti...

Page 836: ...lve closes the supply channel The moment at which the needle valve closes defines the instant which is described as start of supply From this time the pressure begins to rise within the high pressure system End of supply The axial piston is still moving forwards the control slot is opened more At a moment determined by the pump control unit the high pressure solenoid valve is opened again and the ...

Page 837: ...ection regulator the roller ring and therefore the rotational angle sensor is rotated in the direction of advancing or retarding the injection timing The signal from the rotational angle sensor is transmitted via a flexible conductor film to the pump control unit and then used for the following tasks Measurement of the current rotational speed of the distribution injection pump Determination of th...

Page 838: ... injection regulator which is required for adjustment of the injection timing is also determined by comparing the signals from the CKP sensor and the rotational angle sensor 1 8L Duratorq TDCi 66 kW The 1 8L Duratorq TDCi engine with common rail injection system is based on the 1 8L Endura DI diesel engine with the distributor injection pump System overview Description Fuel filter Injector Common ...

Page 839: ...The high pressure system consists of the following components High pressure pump with fuel temperature sensor and fuel metering valve Common rail with fuel pressure sensor Solenoid valve controlled injector valve High pressure fuel lines Description High pressure pump Fuel temperature sensor Fuel metering valve Fuel pressure sensor Common rail Fuel injectors PCM Item 1 2 3 4 5 6 7 Part Number http...

Page 840: ...stem is installed in order to guarantee problem free operation of the fuel injection system The fuel filter is provided with a water collection chamber in order to prevent the fuel injection system being damaged by condensed water Description Water indication sensor Connection Water drain valve On vehicles for Turkey a water indication sensor is installed on the base of the fuel filter 8 9 A B C I...

Page 841: ...led by a bi metal strip When the fuel heats up the bi metal closes the return to the filter progressively so that at temperatures above 50 C only a very small amount of fuel can get to the fuel filter The feed and return fuel lines are colour coded feed white return red High pressure pump Description Position of pressure control valve Transfer pump Eccentric ring Bore between transfer pump and hig...

Page 842: ...he high pressure chamber There is a pressure control valve located in the low pressure circuit between the transfer pump and the high pressure chamber and this limits the transfer pressure Low pressure fuel return The low pressure fuel return has the following functions Cooling and lubrication of the high pressure pump by internal return of the low pressure fuel to the fuel tank Return of the leak...

Page 843: ...ing overrun This causes an increase in pressure in the feed and return bores If this pressure reaches a value of approx 6 bar at approx 2500 rev min the pressure control valve opens The pressure control valve is connected to the transfer pump by a bore The excess fuel partly flows back to the suction side of the transfer pump and back into the fuel tank through the venturi nozzle in the fuel retur...

Page 844: ...chamber Leak off fuel from the injectors Fuel return to tank High pressure chamber Transfer pump Fuel feed Fuel to suction side transfer pump High pressure pump Description Intake valve Cam ring Item 1 2 3 4 5 6 7 8 9 Item High pressure chamber 1 2 Part Number Part Number http vnx su ...

Page 845: ...aust valve To high pressure channel high pressure connection Pump piston Creation of high pressure in the high pressure chamber When a cam begins to run onto the roller shoe of the pump piston the piston moves towards the centre of the high pressure chamber As this occurs the supply pressure of the pump piston exceeds the transfer pressure and the inlet valve is closed As soon as the pressure in t...

Page 846: ...eep the pressure fluctuations to a minimum For fast starting the volume in the common rail is small enough to allow build up of the required fuel pressure in the shortest possible time The fuel supplied by the high pressure pump passes through a high pressure line to the high pressure reservoir The fuel is supplied to each fuel injector by the four fuel injection lines all of which are the same le...

Page 847: ...een the fuel distribution pipe and the injectors all have the same length Fuel injectors Description Upper inlet choke control chamber Solenoid valve Solenoid valve spring Needle valve Drain bore Control chamber drain choke Control chamber Nozzle openings Nozzle needle Nozzle chamber Nozzle chamber inlet choke Control chamber lower inlet choke NOTE When a fuel injector is changed the fuel injector...

Page 848: ...s which can be identified by a number on the injector In order to be able to calculate the correct fuel quantity the PCM must be notified of a change in the system in this case the changing of the injectors Fuel injector closed Description Solenoid valve Fuel return Needle valve Control chamber Nozzle spring Nozzle needle Nozzle chamber Fuel feed Fuel under pressure is passed from the common rail ...

Page 849: ...hamber The solenoid valve is actuated by the PCM and the needle valve opens the fuel return Because of the opening of the needle valve the pressure in the control chamber can dissipate through the control chamber drain choke The pressure drop is suitably delayed by the control chamber drain choke so that the injector still remains closed Fuel injector completely opened fuel injection Item 1 2 3 4 ...

Page 850: ...eturn is still open As soon as the pressure in the nozzle chamber is higher than that in the control chamber hydraulic pressure plus spring pressure is less than the pressure in the nozzle chamber the nozzle needle begins to open start of injection Fuel injection is stopped Description Solenoid valve Item 1 2 3 4 Item 1 Part Number Part Number http vnx su ...

Page 851: ...ring fuel combustion are lowered and the engine management system can perform fuel metering more easily and more precisely This has a positive effect on the exhaust emissions and on fuel consumption For this reason controlled pressure reduction in the common rail is necessary The pressure drop occurs when the solenoid valve applies current to the injector valves at short intervals Each time the pu...

Page 852: ...lash continuously when a hard diagnostic trouble code DTC is detected by the powertrain control module PCM Soft DTCs are also stored by the PCM but will only be known if the system is checked for DTCs using WDS NOTE If a DTC is detected all DTCs must be cleared after the cause is repaired Failure to clear all DTCs may cause driveability concerns NOTE If the fuel level in the fuel tank drops below ...

Page 853: ...stem General Information 310 00B Fuel System General Information Sensor s Fuel injection pump Glow plugs PCM REFER to WDS Incorrect valve timing REFER to Section 303 01A Engine 303 01B Engine Fuel injection pump timing CHECK the fuel injection pump timing REFER to Fuel Injection Pump 1 8L Diesel 75PS in this section Poor starting and glow plug indicator is flashing DTC detected REFER to WDS Poor s...

Page 854: ...as required only after the specialist agent checks have been carried out Fuel injection pump timing CHECK the fuel injection pump timing REFER to Fuel Injection Pump 1 8L Diesel 75PS in this section Engine stumbling and glow plug indicator is flashing DTC detected REFER to WDS Engine stumbling Air ingress into the fuel lines REFER to Section 310 00A Fuel System General Information 310 00B Fuel Sys...

Page 855: ...correct valve timing CHECK the valve timing REFER to Section 303 01A Engine 303 01B Engine Fuel injector s Have the fuel injectors checked by an appropriate fuel injection specialist agent CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out Low cylinder compression REFER to Section 303 00 Engine System General Informat...

Page 856: ... intake system for blockages REPAIR and INSTALL new components as necessary EGR system REFER to Section 303 08A Engine Emission Control 303 08B Engine Emission Control Turbocharger REFER to Section 303 04A Fuel Charging and Controls 303 04B Fuel Charging and Controls 303 04C Fuel Charging and Controls Turbocharger 303 04D Fuel Charging and Controls Fuel injector s Have the fuel injectors checked b...

Page 857: ...components REFER to Section 303 01A Engine 303 01B Engine Fuel injection pump REFER to WDS Fuel injector s Have the fuel injectors checked by an appropriate fuel injection specialist agent CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out Engine knock at idle and glow plug indicator is flashing DTC detected REFER to ...

Page 858: ...l System General Information Sensor s REFER to WDS Incorrect engine oil INSTALL a new oil filter and engine oil Clutch worn or slipping REFER to Section 308 00 Manual Transmission Transaxle and Clutch General Information EGR system REFER to Section 303 08A Engine Emission Control 303 08B Engine Emission Control Incorrect valve timing CHECK the valve timing REFER to Section 303 01A Engine 303 01B E...

Page 859: ... Diagnosis and Testing Special Tool s General Equipment Principles of Operation System overview Diagnostic Tool Common Rail Fuel Injection 310 129 Hand Pressure Pump with Adapter Kit 310 110 Test Hose for 310 025 310 025 18 Test Hose for 310 025 310 025 19A Worldwide Diagnostic System WDS Pneumatic vacuum gun Brake hose clamp Magnet Transparent container http vnx su ...

Page 860: ...my improved driving characteristic s lower noise output and increased power output from modern diesel engines the vehicle requires a fuel supply system which can deliver small fuel droplets at high speed with refined control The common rail fuel injection system has been introduced to the diesel engine to meet these demands The Delphi system fitted to the 1 8L diesel engine fulfills this role by u...

Page 861: ...uel supply than conventional fuel filters To aid with the rapid warm up of the fuel supply to the fuel pump the fuel filter is fitted with a temperature conscious fuel return bypass valve At temperatures below 50 C the bypass valve is fully open and the majority of the returned fuel is circulated through the fuel filter and back to the fuel pump When the fuel temperature in the fuel filter has rea...

Page 862: ...M A fuel pressure sensor input signal is used by the PCM to calculate the position required by the fuel metering valve to achieve the desired fuel rail pressure The fuel metering valve reduces the cross sectional area of the high pressure pump low pressure fuel inlet channel and so decreases the quantity of fuel allowed to reach the high pressure fuel pump chamber Located in the rear of the fuel p...

Page 863: ... components of the high pressure fuel pump Fuel enters the high pressure fuel pump chamber through a fuel inlet valve The inlet valve will only allow fuel to enter the fuel pump chamber if the fuel pressure in the chamber is lower than the pressure in the high pressure pump low pressure fuel inlet channel Fuel entering the high pressure fuel pump chamber forces the fuel pump piston s outwards and ...

Page 864: ...il Fuel from the high pressure fuel pump chamber will enter the fuel rail until the fuel pump pistons have reached the maximum delivery movement At this point the fuel pressure in the high pressure fuel pump chamber drops to below the pressure of the fuel in the fuel rail and the fuel outlet valve is closed For each full rotation of the fuel pump cam ring the fuel pump pistons go through four comp...

Page 865: ...fuel pump chamber unrestricted where it is compressed and delivered to the fuel rail A small proportion of fuel is diverted through the calibrated fuel pump fuel return bore This returned fuel is used to lubricate and cool the high pressure pump As the fuel exits through the fuel return line venturi the accelerated flow across the injector return line orifice creates a partial vacuum in the fuel i...

Page 866: ...high pressure pump fuel supply As the pressure in the high pressure pump low pressure fuel inlet channel increases the low pressure fuel control valve opens and recirculates low pressure fuel through the fuel transfer pump Fuel rail Description Fuel rail Fuel pressure sensor Fuel pump high pressure fuel line connection Fuel injector high pressure fuel line connections The fuel rail function is to ...

Page 867: ...l tight seal capable of withstanding the high fuel pressures cannot be guaranteed So the fuel rail and fuel pressure sensor must be renewed as one component If the fuel pressure sensor does not see a minimum preset value during cranking the PCM will not allow the fuel injectors to inject and the engine will not start If the fuel pressure sensor signal to the PCM is lost or the value indicated does...

Page 868: ...d spring control All injectors are calibrated to take into account manufacturing tolerances These calibrations are indicated on the exterior of the injector by a code The code is used by the PCM to adjust the duration of the injection cycle If the codes for the individual injector s are incorrectly matched to the codes stored in the PCM the engine may exhibit rough idle increased combustion noise ...

Page 869: ...arts with a voltage being applied to the solenoid valve with a pull in current of 12 amperes The solenoid valve moves the injection control valve against the pressure of the injection control valve spring The injection control valve releases the high fuel pressure from the injector needle upper chamber and vents the excess pressure out through the fuel injector fuel return bore The fuel pressure d...

Page 870: ...valve in the open position As the fuel pressure in the injector needle upper chamber decays the fuel pressure in the injector needle lower chamber forces the injector needle open against the injector needle control spring Fuel is injected into the engine combustion chamber Fuel will continue to be injected as long as the fuel pressure in the injector needle lower chamber is higher than the combine...

Page 871: ... chamber as the injector needle closes the fuel entering the chamber is restricted by the injector needle lower chamber fuel inlet choke Fuel injector fuel return The fuel injector fuel return is required to make the fuel injectors function The amount of return fuel developed during the normal functioning of a fuel injector indicates the condition of that injector By measurement and comparison of ...

Page 872: ...or electrical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 NOTE A PCM calibration update should only be carried out if it is applicable to the symptoms exhibited by the vehicle 4 If the cause is not visually evident verify the symptom and refer to WDS Check for the availability...

Page 873: ...inated fuel is found GO to Pinpoint Test C Glow plugs REFER to WDS Crankshaft position CKP sensor REFER to WDS Camshaft position CMP sensor REFER to WDS Cylinder head temperature CHT sensor REFER to WDS PCM REFER to WDS Fuel injection supply manifold fuel pressure sensor REFER to WDS Fuel inlet metering valve REFER to WDS Incorrect valve timing CHECK the valve timing Low cylinder compression CHECK...

Page 874: ...t metering valve REFER to WDS Catalytic converter blocked REMOVE and visually INSPECT the catalytic converter for damage INSTALL a new catalytic converter as necessary REFER to Catalytic Converter 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 309 00 Exhaust System Removal and Installation Low cylinder compression TEST the engine cylinder compression Engine starts but immediately st...

Page 875: ...esting EGR valve sticking open EGR vacuum regulator valve REFER to Engine Emission Control 75 PS 90 PS 303 08B Engine Emission Control 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Diagnosis and Testing IAT sensor REFER to WDS MAP sensor REFER to WDS CKP sensor REFER to WDS Knock sensor KS REFER to WDS Fuel injection supply manifold fuel pressure sensor REFER to WDS Fuel inlet mete...

Page 876: ...PECT the vacuum line s for visible signs of damage or blockage CLEAN REPAIR or INSTALL new parts as necessary REFER to Turbocharger 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 04C Fuel Charging and Controls Turbocharger Description and Operation EGR valve sticking open EGR vacuum regulator valve REFER to Engine Emission Control 75 PS 90 PS 303 08B Engine Emission Control 1 8L Duratorq TDCi ...

Page 877: ...mage or blockage CLEAN REPAIR or INSTALL new parts as necessary REFER to Turbocharger 75 PS 90 PS Vehicles Built Up To 08 2006 303 04C Fuel Charging and Controls Turbocharger Diagnosis and Testing CHT sensor REFER to WDS IAT sensor REFER to WDS MAP sensor REFER to WDS Fuel injection supply manifold fuel pressure sensor REFER to WDS Incorrect valve timing CHECK the valve timing Catalytic converter ...

Page 878: ...TALL a new air cleaner element EGR valve sticking open EGR vacuum regulator valve REFER to Engine Emission Control 75 PS 90 PS 303 08B Engine Emission Control 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Diagnosis and Testing Turbocharger vacuum diaphragm unit REFER to Turbocharger 75 PS 90 PS Vehicles Built Up To 08 2006 303 04C Fuel Charging and Controls Turbocharger Diagnosis a...

Page 879: ...ger Diagnosis and Testing White smoke and glow plug indicator is flashing DTC detected REFER to WDS White smoke Water in fuel CHECK for signs of water in the diesel If contaminated fuel is found GO to Pinpoint Test C Knock sensor REFER to WDS Fuel injector s GO to Pinpoint Test A EGR valve sticking open EGR vacuum regulator valve REFER to Engine Emission Control 75 PS 90 PS 303 08B Engine Emission...

Page 880: ...S IAT sensor REFER to WDS MAP sensor REFER to WDS Knock sensor REFER to WDS Fuel injection supply manifold fuel pressure sensor REFER to WDS Low cylinder compression CHECK the cylinder compression Worn or damaged valve s tappet s or camshaft s REMOVE the cylinder head INSPECT the cylinder head valves tappets and camshafts for signs of wear or damage REFER to Cylinder Head 1 8L Duratorq TDCi Lynx D...

Page 881: ...k during acceleration and glow plug indicator is flashing DTC detected REFER to WDS Engine knock during acceleration Knock sensor REFER to WDS Fuel injector s GO to Pinpoint Test A Fuel inlet metering valve REFER to WDS Fuel pump GO to Pinpoint Test B Major mechanical engine failure INSPECT the engine components Excessive fuel consumption and glow plug indicator is flashing DTC detected REFER to W...

Page 882: ...REFER to Manual Transaxle and Clutch 308 00 Manual Transmission Transaxle and Clutch General Information Diagnosis and Testing Low cylinder compression CHECK cylinder compression Dual mass flywheel INSPECT the dual mass flywheel for damage INSTALL a new dual mass flywheel as necessary Engine cuts out during hard acceleration CMP sensor REFER to WDS CKP sensor REFER to WDS Fuel injection supply man...

Page 883: ...em pressure test 4 Is the fuel system pressure greater than 1050 bar Yes GO to A2 No GO to A4 A2 CHECK THE FUEL INJECTOR BACK LEAK AFTER 1 MINUTE ENGINE RUN TIME Remove the special tool 1 Empty the special tool of fuel 2 Remove the brake hose clamp from the fuel injector fuel return line 3 Connect the fuel injector fuel return lines to the fuel injectors 4 Connect the fuel metering valve electrica...

Page 884: ...ctors 1 8L Duratorq TDCi Lynx Diesel 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation TEST the system for normal operation If the fuel volumes for all four fuel injectors exceed the length of clear plastic hose using WDS Program Module Routine INPUT the fuel injector correction values TEST the system for normal operation A3 C...

Page 885: ...EST the system for normal operation A4 CHECK THE FUEL INJECTOR BACK LEAK AFTER FUEL SYSTEM PRESSURE TEST Invert the containers of the special tool raise the containers above the engine and allow the collected fuel to drain into the clear plastic hoses connecting the containers to the fuel injectors 1 Measure and record the length of clear plastic hose containing fuel for each fuel injector 2 Do on...

Page 886: ...el injectors for recorded values greater than 21 cm REFER to Fuel Injectors 1 8L Duratorq TDCi Lynx Diesel 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation TEST the system for normal operation No GO to A7 A7 FUEL INJECTOR BACK LEAK TEST FAILURE MODE 3 Compare the recorded values for the clear plastic hoses containing fuel 1 A...

Page 887: ...harging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel General Procedures 1 Disconnect the fuel tank to fuel filter fuel supply line quick release coupling REFER to Quick Release Coupling 310 00A Fuel System General Information General Procedures 2 Install the special tool adapter to the fuel tank to fuel filter fuel supply line 3 Install the special tool adapter to the...

Page 888: ...stic run the fuel system pressure test CHECK the fuel pump high pressure fuel supply pressure No CHECK for air ingress into the fuel lines REFER to Fuel System 75 PS 90 PS 310 00A Fuel System General Information Diagnosis and Testing B3 CHECK THE FUEL PUMP FUEL RETURN PRESSURE NOTE Before this test can be carried out the latest calibration must be programed into the PCM and IDM if applicable Remov...

Page 889: ...e engine 9 Disconnect the WDS pressure transducer from the special tool 310 110 10 Connect the WDS pressure transducer to the WDS pressure transducer adaptor GV2323 11 Using WDS select the digital multimeter DMM function from the toolbox menu Select the pressure vacuum transducer PVT function and configure the DMM to display pressure vacuum 12 Start the engine 13 Make a note of the value displayed...

Page 890: ... Fuel System General Information General Procedures Install a blanking plug to the open end of the fuel pump union 3 Place the open end of the fuel pump fuel supply line into a clean container 4 Operate the hand pressure pump at least three times in rapid succession and observe the value displayed by WDS 5 Does the fuel pressure indicated by WDS when operating the hand pressure pump instantly fall...

Page 891: ... WDS guided diagnostic run the fuel system pressure test 4 Is the fuel system pressure greater than 1050 bar Yes No fault is indicated with the high pressure fuel supply system components To continue with the diagnostics return to the symptom chart No GO to C2 C2 CHECK THE FUEL INJECTOR BACK LEAK AFTER FUEL SYSTEM PRESSURE TEST Invert the containers of the special tool raise the containers above t...

Page 892: ...jectors for those injectors where no fuel is present within the clear plastic hose REFER to Fuel Injectors 1 8L Duratorq TDCi Lynx Diesel 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation TEST the system for normal operation C5 FUEL INJECTOR BACK LEAK TEST FAILURE MODE 2 Compare the recorded values for the clear plastic hoses ...

Page 893: ...p To 03 2008 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation TEST the system for normal operation C7 FUEL PUMP MECHANICAL FAILURE TEST Disconnect the fuel filter fuel return line Install a blanking cap to the open port of the fuel filter 1 Position a clean transparent container under the open union of the fuel filter fuel re...

Page 894: ... Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation Fuel Injection Supply Manifold 1 8L Duratorq TDCi Lynx Diesel 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation Fuel Injection Pump 1 8L Duratorq TDCi FGT 55kW 75PS Lynx 1 8L Duratorq TDCi 66kW 90PS Lynx 1 8L Duratorq TDCi FGT 66kW 90PS Lynx 1 8L Duratorq TDCi VNT...

Page 895: ...e must not be cranked until the fuel pump has been primed Using WDS REPEAT the fuel system high pressure test If the fuel system pressure test result is not above 1050 bar INSTALL a new fuel pump REFER to Fuel Injection Pump 1 8L Duratorq TDCi FGT 55kW 75PS Lynx 1 8L Duratorq TDCi 66kW 90PS Lynx 1 8L Duratorq TDCi FGT 66kW 90PS Lynx 1 8L Duratorq TDCi VNT 66kW 90PS Lynx 1 8L Duratorq TDCi VNT 55kW...

Page 896: ... fuel supply union Fuel pressure regulator High pressure fuel supply line port Fuel metering valve The fuel pump consists of a transfer pump and a high pressure fuel delivery pump The transfer pump draws fuel from the fuel tank through the fuel filter and delivers the fuel to the three high pressure fuel pump chambers through a fuel metering valve Fuel is also delivered to the high pressure fuel p...

Page 897: ...etering valve which is also controlled by the PCM Description Transfer pump Fuel metering valve High pressure fuel pump chambers Fuel pressure regulator Fuel pump internal pressure regulator Scavenging valve Fuel pump fuel supply port High pressure fuel supply port Fuel pump fuel return port Fuel rail Item 1 2 3 4 5 6 a b c Part Number http vnx su ...

Page 898: ...g of the pressure surges in high pressure fuel system Attached to the fuel rail is a FRP sensor The FRP sensor monitors the fuel pressure in the fuel rail The FRP sensor provides a controlled variable voltage signal to the PCM which is converted into a pressure signal Fuel injectors Description Fuel injector electrical connector Fuel injector Item 1 2 Item 1 2 Part Number Part Number http vnx su ...

Page 899: ...le valve Injection control valve Fuel injection valve High pressure fuel chamber Fuel injector fuel delivery holes The fuel injectors have a Piezoelectric actuator The advantages of using Piezoelectric instead of traditional solenoid actuators are the reduction in reaction switching times and the lower switching currents Both of which improve the control and therefore the efficiency of the fuel in...

Page 900: ...very precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices or lines NOTE As well as carrying out its normal function the glow plug indicator also acts as an engine check lamp which will flash continuously when a hard diagnostic trouble code DTC is detected by the power...

Page 901: ... anti theft system PATS LED is flashing PATS system fault detected REFER to Anti Theft Passive 419 01B Anti Theft Passive Diagnosis and Testing Engine does not crank and glow plug indicator is flashing DTC detected REFER to the WDS Engine does not crank Starting system REFER to Starting System Vehicles Built From 08 2006 303 06 Starting System Diagnosis and Testing Engine cranks but does not start...

Page 902: ...he WDS Poor starting Low fuel tank fuel level CHECK the fuel tank fuel level is greater than four liters If the fuel tank fuel level is less then four liters FILL with fuel Fuel filter blocked INSTALL a new fuel filter element REFER to Fuel Filter 1 8L Duratorq TDCi Lynx Diesel 310 01A Fuel Tank and Lines Removal and Installation Air cleaner element blocked INSTALL a new air cleaner element Glow p...

Page 903: ... INSTALL a new air cleaner element Air ingress into the fuel lines REFER to Fuel System 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 310 00A Fuel System General Information Diagnosis and Testing PCM relay CARRY OUT the relay component test REFER to Wiring Diagrams CKP sensor REFER to the WDS CMP sensor REFER to the WDS CHT sensor REFER to the WDS PCM REFER to the W...

Page 904: ...l Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation Fuel Injection Supply Manifold 1 8L Duratorq TDCi Lynx Diesel 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation Fuel Injectors 1 8L Duratorq TDCi Lynx Diesel 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx ...

Page 905: ...STALL a new fuel filter element REFER to Fuel Filter 1 8L Duratorq TDCi Lynx Diesel 310 01A Fuel Tank and Lines Removal and Installation Kinked or restricted fuel lines REFER to Fuel System 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 310 00A Fuel System General Information Diagnosis and Testing Air ingress into the fuel lines REFER to Fuel System 1 8L Duratorq TDC...

Page 906: ... to Fuel Filter 1 8L Duratorq TDCi Lynx Diesel 310 01A Fuel Tank and Lines Removal and Installation INSTALL a new fuel pump fuel injectors fuel rail and high pressure fuel supply lines REFER to Fuel Injection Pump 1 8L Duratorq TDCi FGT 55kW 75PS Lynx 1 8L Duratorq TDCi 66kW 90PS Lynx 1 8L Duratorq TDCi FGT 66kW 90PS Lynx 1 8L Duratorq TDCi VNT 66kW 90PS Lynx 1 8L Duratorq TDCi VNT 55kW 75PS Lynx ...

Page 907: ... a new catalytic converter as necessary CHT sensor REFER to the WDS MAF sensor REFER to the WDS MAP sensor REFER to the WDS Fuel injector s REFER to the WDS FRP sensor REFER to the WDS Intake manifold EGR throttle CHECK the intake manifold EGR throttle butterfly for obstructions and correct operation REFER to the WDS Intake manifold EGR throttle vacuum control solenoid CHECK the intake manifold EG...

Page 908: ...L Duratorq TDDi Lynx Diesel Diagnosis and Testing Catalytic converter blocked REMOVE and visually INSPECT the catalytic converter for damage INSTALL a new catalytic converter as necessary APP sensor REFER to the WDS CKP sensor REFER to the WDS Fuel injector s REFER to the WDS FRP sensor REFER to the WDS Intake manifold EGR throttle CHECK the intake manifold EGR throttle butterfly for obstructions ...

Page 909: ...esel 1 8L Duratorq TDDi Lynx Diesel Diagnosis and Testing Incorrect or contaminated fuel CHECK for signs of contamination such as strange odors from the fuel tank CHECK for signs of water or petrol in the diesel If contaminated fuel is found DRAIN the complete fuel system FLUSH the fuel system through with clean diesel REFER to Fuel Tank Draining 310 00A Fuel System General Information General Pro...

Page 910: ...ator is flashing DTC detected REFER to the WDS White smoke Water in fuel CHECK for signs of water in the diesel If contaminated fuel is found DRAIN the complete fuel system FLUSH the fuel system through with clean diesel REFER to Fuel Tank Draining 310 00A Fuel System General Information General Procedures INSTALL a new fuel filter element REFER to Fuel Filter 1 8L Duratorq TDCi Lynx Diesel 310 01...

Page 911: ...ters If the fuel tank level is less than four liters FILL with fuel Incorrect or contaminated fuel CHECK for signs of contamination such as strange odors from the fuel tank CHECK for signs of water or petrol in the diesel If contaminated fuel is found DRAIN the complete fuel system FLUSH the fuel system through with clean diesel REFER to Fuel Tank Draining 310 00A Fuel System General Information G...

Page 912: ...ad INSPECT the cylinder head gasket and cylinder bores for wear or damage REFER to Cylinder Head 75 PS 90 PS 110 PS Vehicles Built From 08 2006 Vehicles With Common Rail Fuel Injection 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair Engine overheats REFER to Engine Cooling 303 03 Engine Cooling Diagnosis and Testing CHT sensor REFER to the WDS CKP sen...

Page 913: ...ing and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation Incorrect valve timing CHECK the valve timing REFER to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair Excessive carbon build up REMOVE the cylinder head INSPE...

Page 914: ...iesel 1 8L Duratorq TDDi Lynx Diesel Diagnosis and Testing Air ingress into the fuel lines REFER to Fuel System 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 310 00A Fuel System General Information Diagnosis and Testing Incorrect valve timing CHECK the valve timing REFER to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303...

Page 915: ...CHECK the intake manifold EGR throttle vacuum control solenoid vacuum lines for kinks or restrictions REFER to the WDS Engine cuts out during hard acceleration CMP sensor REFER to the WDS CKP sensor REFER to the WDS FRP sensor REFER to the WDS Fuel pressure regulator REFER to the WDS Fuel pump REFER to the WDS http vnx su ...

Page 916: ... clean and dust free as possible Areas in which work on clutches brakes or where welding or machining are carried out are not suitable in view of the risk of contamination to the fuel system Make sure that clean non plated tools are used Clean tools using a new brush that will not lose its bristles and fresh suitable evaporative cleaning agent prior to starting work on the vehicle Use a steel topp...

Page 917: ...s brush a suitable evaporative cleaning agent onto the components being removed and onto the surrounding area 5 Using the pneumatic vacuum gun remove all traces of evaporative cleaning agent and foreign material 6 Dispose of any unused evaporative cleaning agent and the brush after completing the repair http vnx su ...

Page 918: ...nufactured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices or lines 3 Remove the components in the order indicated in the following illustration s and table s 1 Disconnect the battery ground cable For additional information refer to Battery Disconnect and...

Page 919: ...jector clamp retaining bolts See Removal Detail See Installation Detail Fuel injector clamps Fuel injectors See Removal Detail See Installation Detail High pressure fuel supply line to fuel injector unions See Installation Detail High pressure fuel supply line to fuel injection pump unions High pressure fuel supply lines See Removal Detail See Installation Detail Fuel injector clamp retaining bolt...

Page 920: ... NOTE Discard the fuel injector clamp retaining bolts Item 13 Fuel injectors 12 13 5 Using the special tool prime the fuel injection pump until clean fuel is seen entering the vacuum pump reservoir 6 Remove the special tool 7 Turn the ignition switch to position three engine cranking Crank the engine until clean fuel escapes from the high pressure fuel supply line unions 8 Tighten the high pressur...

Page 921: ...s NOTE Install new fuel injector copper heat shield washer Item 3 High pressure fuel supply lines NOTE Install new high pressure fuel supply lines Item 1 High pressure fuel supply line to fuel injector unions 1 NOTE Install new fuel injector clamp retaining bolts Install the fuel injector bolts Tighten the bolts in two stages Stage 1 5 Nm Stage 2 90 degrees 1 Do not tighten the high pressure fuel ...

Page 922: ...re or is below 30 C whichever is greater Failure to follow these instructions may result in personal injury Wait at least one minute after the engine stops before commencing any repair to the fuel injection system Failure to follow this instruction may result in personal injury CAUTIONS Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore e...

Page 923: ... and Filtering Removal and Installation 4 CAUTION The generator must be protected from contamination Failure to follow this instruction may cause premature failure of the generator Protect the generator with lint free material to prevent contamination 5 CAUTION Protect the fuel injector electrical connectors with lint free material to prevent contamination from the cleaning fluid Clean the fuel in...

Page 924: ...Description Camshaft position CMP sensor electrical connector Positive crankcase ventilation PCV hose retaining clamp PCV hose PCV hose retaining clamp PCV hose Item 1 2 3 4 5 Part Number http vnx su ...

Page 925: ...fuel supply line to fuel injection supply manifold union See Removal Detail Number four fuel injector high pressure fuel supply line See Removal Detail See Installation Detail Number four fuel injector fuel injection supply manifold blanking caps See Installation Detail Number four fuel injector clamp retaining bolt See Installation Detail Number four fuel injector retaining clamp Number four fuel...

Page 926: ...injection system Make sure that the tool used to loosen the high pressure fuel supply line union is used at the top of the union as this is where there is most material Failure to follow this instruction may result in damage to the union Item 10 High pressure fuel supply line to fuel injection supply manifold union CAUTIONS Make sure that the high pressure fuel supply line remains in contact with ...

Page 927: ...refer to Fuel Injection Component Cleaning in this Section Item 16 Number four fuel injector sealing washer NOTE Discard the fuel injector sealing washer Installation Details Item 16 Number four fuel injector sealing washer NOTE Install a new fuel injector sealing washer Item 15 Number four fuel injector NOTE Remove and discard the fuel injector nozzle blanking plug Item 13 Number four fuel inject...

Page 928: ... to hit the ends of the high pressure fuel supply line Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system NOTE Lubricate the high pressure fuel supply line union threads with clean lubricant NOTE To aid installation of the high pressure fuel supply line the union at the fuel injector end is etched with the c...

Page 929: ...http vnx su ...

Page 930: ...ing Vehicles With Common Rail Fuel Injection 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel General Procedures 5 CAUTIONS Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned Vacuum any foreign material from the fuel pump and fuel rail unions before...

Page 931: ...d the blanking caps 5 Torque 24 Nm 6 CAUTION Make sure that the fuel line union does not rotate Tighten in the sequence shown Torque 25 Nm 7 Tighten in the sequence shown Torque 38 Nm 8 General Equipment Hose clamp remover installer 9 Refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures http vnx su ...

Page 932: ...ter motor operation must not exceed 10 seconds at a time After 10 seconds turn the ignition switch to position 0 and allow the starter motor to cool for 30 seconds before operating the starter motor again Start the engine and allow it to idle until it reaches normal operating temperature 13 Stop the engine 14 Remove the special tool 15 Connect the fuel tank to fuel filter fuel supply line to the f...

Page 933: ...e essential that absolute cleanliness is observed when working with these components Always install blanking plugs to any open orifices or lines Hand Pressure Pump with Adapter Kit 310 110 Pneumatic vacuum gun Small screwdriver 1 Remove the charge air cooler For additional information refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 75 PS 90 PS 303 12 Intake...

Page 934: ...with these components Always install blanking plugs to any open orifices or lines 6 NOTE Fuel injection pump shown removed for clarity Remove the fuel injection one way valves Discard the fuel injection one way valves 7 NOTE Fuel injection pump shown removed for clarity Using a clean small screwdriver carefully remove the sealing washers Discard the sealing washers 1 Lubricate the fuel injection o...

Page 935: ...ghten the high pressure fuel supply lines at this stage Connect the high pressure fuel supply lines to the fuel injection pump 6 NOTE Do not tighten the high pressure fuel supply lines at this stage Connect the high pressure fuel supply lines to the fuel injectors 7 NOTE Install new high pressure fuel supply lines Tighten the high pressure fuel supply lines to the fuel injection pump 8 Disconnect ...

Page 936: ...l tool adapter on the fuel filter 11 Install the hand pressure pump special tool adapter to the fuel tank to fuel filter fuel supply line 12 NOTE Make sure that the hand primer arrow indicating the direction of fuel flow is pointing towards the fuel filter Install the hand pressure pump special tool to the hand pressure pump special tool adapter on the fuel tank to fuel filter fuel supply line 13 ...

Page 937: ... starter motor for more than 10 seconds at a time After 10 seconds turn the ignition switch to position 0 and allow the starter motor to cool for 30 seconds before attempting to start the engine again Start the engine and allow it to idle until it reaches normal operating temperature 19 Switch the engine off 20 Remove the hand pressure pump special tool from the hand pressure pump special tool ada...

Page 938: ...ank to fuel filter fuel supply line to the fuel filter 25 Install the charge air cooler For additional information refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 75 PS 90 PS 303 12 Intake Air Distribution and Filtering Removal and Installation http vnx su ...

Page 939: ...ailure to follow these instructions may result in personal injury CAUTION Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always install blanking plugs to any open orifices or lines Vehicles with air conditioning Hand Vacuum Pressure Pump 416 D001 23 036...

Page 940: ...connector retaining nut Battery positive cable Generator electrical connector Special tool 303 193 21 104 See Removal Detail See Installation Detail Generator retaining bolts Generator Generator bracket retaining nut Generator bracket retaining bolts Generator retaining bracket Item 1 2 3 4 5 6 7 8 9 Part Number http vnx su ...

Page 941: ...l injection pipe to fuel injector unions See Installation Detail High pressure fuel injection pipe to fuel injection pump unions High pressure fuel injection pipes See Removal Detail See Installation Detail Fuel injection pump supply line See Removal Detail Fuel injection pump return line See Removal Detail See Installation Detail Fuel injection pump electrical connector Fuel injection pump suppor...

Page 942: ...njection pump sprocket retaining bolts Fuel injection pump retaining bolts See Removal Detail Fuel injection pump Fuel injection pump gasket See Removal Detail See Installation Detail 5 To install reverse the removal procedure Item 22 23 24 25 26 27 28 29 6 Configure the fuel injection pump to the powertrain control module PCM For additional information refer to WDS 7 Using the special tool prime ...

Page 943: ...position three engine cranking Crank the engine until clean fuel escapes from the high pressure fuel injection pipe unions 10 Tighten the high pressure fuel injection pipe unions 1 Raise the vehicle 1 For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 For additional information refer to Section 310 00A Fuel System General I...

Page 944: ...seal Item 24 Fuel injection pump seal retaining nuts Item 23 Fuel injection pump pulley Item 22 Fuel injection pump pulley retaining bolts 1 Access the bolts through the holes provided The fuel injection pump bolts cannot be removed completely 1 Tighten the nuts in the sequence shown 1 Using sealer seal the fuel injection pump pulley to the fuel injection pump sprocket 1 Using sealer apply a thin ...

Page 945: ...ection pipe to fuel injector unions NOTE Do not tighten the high pressure fuel injection pipe unions at this stage Item 13 High pressure fuel injection pipes NOTE Install new high pressure fuel injection pipes Item 11 High pressure fuel injection pipe to fuel injector unions NOTE Do not tighten the high pressure fuel injection pipe unions at this stage Item 4 Special tool 303 193 21 104 1 Lower th...

Page 946: ...ge at all times and always observe fuel handling precautions Failure to follow these instructions may result in personal injury Do not carry out any repairs to the fuel injection system with the engine running The fuel pressure within the system can be as high as 1600 bar Failure to follow this instruction may result in personal injury Do not carry out any repairs to the fuel injection system with...

Page 947: ...ustration s and table s 1 Using datalogger in WDS check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30 C whichever is greater 2 Remove the timing belt For additional information refer to Section 303 01A Engine 303 01B Engine 3 CAUTION The generator must be protected from contamination Failure to follow this instruction...

Page 948: ...il High pressure fuel supply line to fuel injection supply manifold union See Removal Detail See Installation Detail High pressure fuel supply line assembly See Removal Detail See Installation Detail Fuel pump high pressure fuel outlet blanking cap See Installation Detail Fuel injection supply manifold high pressure fuel inlet blanking cap See Installation Detail High pressure fuel supply line cla...

Page 949: ...ctor See Removal Detail Fuel pump to fuel filter fuel supply line pump union blanking cap See Installation Detail Fuel pump venturi to fuel injector fuel return line connector See Removal Detail See Installation Detail Description Fuel pump pulley retaining bolts See Removal Detail See Installation Detail Fuel pump pulley See Removal Detail See Installation Detail Fuel pump sprocket seal retaining...

Page 950: ...sure fuel supply line to fuel injection supply manifold union CAUTION Make sure that the high pressure fuel supply line remains in contact with the fuel pump and the fuel injection supply manifold until all unions have been detached and cleaned Failure to follow this instruction may result in foreign matter ingress to the 22 23 24 25 26 27 7 CAUTION Make sure that a new clean piece of plastic pipe...

Page 951: ...rts 1 Make a note of the orientation of the clamp to make sure it is positioned in exactly the same position when installed Discard the high pressure fuel supply line 1 For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System G...

Page 952: ...uel pump pulley 1 Discard the fuel pump gasket 1 Install a new fuel pump gasket 1 Align the hole in the fuel pump drive with the etched line on the fuel pump body 1 Tighten the bolts evenly in order to pull the fuel pump squarely into position 1 Install a new fuel pump sprocket seal 1 Tighten the nuts in the sequence shown 1 Using loctite RTV 5910 seal the fuel pump pulley to the fuel pump sprocke...

Page 953: ...1 Using loctite 518 apply a thin bead of sealer to the outer edge of the fuel pump pulley retaining bolt holes 1 Discard the blanking plugs 1 Discard the blanking plugs 1 Do not remove the fuel pump to fuel filter fuel return line pump union blanking cap at this stage 1 Do not install the fuel pump to fuel filter fuel return line connector at this stage 1 Make sure the clamp is installed on the ne...

Page 954: ... until both unions are installed NOTE Maintain pressure on the high pressure fuel supply line to keep the line in contact with the fuel pump and fuel injection supply manifold cones while installing the unions Item 4 High pressure fuel supply line to fuel pump union CAUTION Make sure the tool used to tighten the high pressure fuel supply line unions is used at the top of the union as this is where...

Page 955: ...ambient temperature or is below 30 C whichever is greater Failure to follow these instructions may result in personal injury Wait at least one minute after the engine stops before commencing any repair to the fuel injection system Failure to follow this instruction may result in personal injury CAUTIONS Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances ...

Page 956: ...m the valve cover 5 CAUTION The generator must be protected from contamination Failure to follow this instruction may cause premature failure of the generator Protect the generator with lint free material to prevent contamination 6 CAUTION Protect the fuel injector electrical connectors with lint free material to prevent contamination from the cleaning fluid Clean the fuel injectors fuel injection...

Page 957: ...ition CMP sensor electrical connector Fuel pressure sensor electrical connector Fuel injection wiring harness retaining clip Fuel injector electrical connectors Description Item 1 2 3 4 Item Part Number Part Number http vnx su ...

Page 958: ...pressure fuel supply line clamp See Removal Detail See Installation Detail Description Fuel injector high pressure fuel supply lines clamp See Removal Detail See Installation Detail Fuel injector high pressure fuel supply line See Removal Detail See Installation Detail Fuel injector high pressure fuel supply line See Removal Detail See Installation Detail Fuel injector high pressure fuel supply li...

Page 959: ...hten the fuel injector high pressure fuel supply line to fuel injector unions 2 Tighten the fuel injector high pressure fuel supply line to fuel injection supply manifold unions 3 Tighten the high pressure fuel supply line to fuel pump union 4 Tighten the high pressure fuel supply line to fuel injection supply manifold union 5 Tighten the fuel injection supply manifold retaining bolts 1 Clean the ...

Page 960: ...sult in damage to the ends of the line and allow foreign material to enter the fuel injection system Remove the blanking plugs from the fuel injector high pressure fuel supply line at the last possible moment Failure to follow this instruction may result in foreign matter ingress to the fuel injection system NOTE To aid identification of the fuel injector high pressure fuel supply lines the unions...

Page 961: ...lamp CAUTIONS Do not allow the unions to hit the ends of the high pressure fuel supply line Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system Remove the blanking plugs from the high pressure fuel supply line at the last possible moment Failure to follow this instruction may result in foreign matter ingress ...

Page 962: ...ssure fuel supply line unions at this stage 1 Lubricate the high pressure fuel supply line union threads with clean lubricant 2 Remove and discard the blanking caps from the fuel pump and the fuel injection supply manifold http vnx su ...

Page 963: ...ore essential that absolute cleanliness is observed when working with these components Pneumatic vacuum gun Heat gun Blunt plastic tool Cable ties 1 Remove the charge air cooler For additional information refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 75 PS 90 PS 303 12 Intake Air Distribution and Filtering Removal and Installation 2 Remove the fuel inject...

Page 964: ...retaining bolts 7 Remove the fuel injection pump support bracket retaining bolts 8 Remove the fuel injection pump back plate and support bracket assembly Remove the fuel injection pump back plate retaining bolts 9 Detach the fuel injection timing solenoid Remove and discard the fuel injection timing solenoid retaining bolts http vnx su ...

Page 965: ... blunt plastic tool Failure to follow this instruction may result in damage to the fuel injection pump Inspect the fuel injection timing solenoid to make sure both O ring seals are still fitted If the fuel injection timing solenoid O ring seal s is missing from the fuel injection timing solenoid the missing fuel injection timing solenoid O ring seal s must be removed from the fuel injection pump u...

Page 966: ...id between the fuel injection pump and engine block 2 Connect the fuel injection timing solenoid wiring harness 1 Trim the new fuel injection timing solenoid wiring harness and the fuel injection pump fuel injection timing solenoid wiring harness to produce staggered joints 2 Using the pink crimp electrical connectors supplied in the service kit join the new fuel injection timing solenoid wiring h...

Page 967: ...support bracket assembly Install the fuel injection pump back plate retaining bolts hand tight 9 Install the fuel injection pump support bracket retaining bolts 10 Tighten the fuel injection pump back plate retaining bolts 11 Install the coolant transfer pipe retaining bolts 12 Install the generator support bracket http vnx su ...

Page 968: ...03 414 02 Generator and Regulator Removal and Installation Generator 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Vehicles Built From 05 2003 414 02 Generator and Regulator Removal and Installation Generator 1 8L Duratorq TDCi Lynx Diesel Vehicles Built From 05 2007 414 02 Generator and Regulator Removal and Installation 15 Install the fuel injection pump back plate and support br...

Page 969: ...Ci Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 75 PS 90 PS 303 12 Intake Air Distribution and Filtering Removal and Installation Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 12 Intake Air Distribution and Filtering Removal and Installation http vnx su ...

Page 970: ...e instructions may result in personal injury Wait at least one minute after the engine stops before commencing any repair to the fuel injection system Failure to follow this instruction may result in personal injury CAUTIONS Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible Foreign matter from work on clutches brakes or from machining or w...

Page 971: ...re failure of the generator Protect the generator with lint free material to prevent contamination 5 CAUTION Protect the fuel metering valve and fuel temperature sensor electrical connectors to prevent contamination with the cleaning fluid Clean the fuel pump and surrounding areas For additional information refer to Fuel Injection Component Cleaning Vehicles With Common Rail Fuel Injection 303 04B...

Page 972: ... precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always install blanking plugs to any open orifices or lines NOTE Install a new fuel metering valve and O ring seal 1 Remove and discard the blanking plug from the fuel pump 2 Using the Pneumatic vacuum gun vacuum foreign material from the fuel pump open port 3 ...

Page 973: ...S 90 PS 303 12 Intake Air Distribution and Filtering Removal and Installation Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 12 Intake Air Distribution and Filtering Removal and Installation 8 Connect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures ...

Page 974: ...efore essential that absolute cleanliness is observed when working with these components Always install blanking plugs to any open orifices or lines Wrench Fuel Pump Solenoid 303 1286 Bench vice fitted with soft jaws Small screwdriver Heat gun 1 Remove the fuel injection pump For additional information refer to Fuel Pump 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 04B Fuel Charging and Cont...

Page 975: ...6 Using a clean small screwdriver carefully remove the sealing washers Discard the sealing washers 7 Pull back the protection sleeve to expose the fuel injection pump wiring 8 Cut the wiring at the fuel metering valve 9 Using the special tool loosen the fuel metering valve by 4 turns 10 Twist and pull the fuel metering valve to loosen the O ring sealing washers http vnx su ...

Page 976: ...erances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always install blanking plugs to any open orifices or lines 11 Remove the fuel metering valve Discard the fuel metering valve 1 To aid installation lightly lubricate the two fuel metering valve O ring seals with Renap 220 oil supplied in the parts kit 2 Install the sealing...

Page 977: ... metering valve must be in the 12 o clock position after final tightening Using the special tool tighten the fuel metering valve in two stages Stage 1 25 Nm Stage 2 50 degrees 7 If the fuel metering valve is not in the 12 o clock position after final tightening remove it install a new sealing washer and repeat the installation steps 8 Lubricate the fuel injection one way valves with Renap 220 oil ...

Page 978: ...nction of the new fuel metering valve Slide the protection sleeve and connector insulation sleeves supplied in the parts kit over the wiring Join the fuel injection pump wiring to the fuel metering valve wiring by crimping the electrical connectors supplied in the parts kit 14 CAUTION The electrical connectors must be correctly sealed to prevent water ingress which could affect the operation of th...

Page 979: ...fuel injection pump For additional information refer to Fuel Pump 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation http vnx su ...

Page 980: ... Locking MS WSK M2G349 A7 2U7J M2G349 AA 1 Refer to Diesel Fuel System Health and Safety Precautions 100 00 General Information Description and Operation 2 Remove the timing belt Refer to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 3 CAUTION Use lint free clo...

Page 981: ...terial from the fuel pump and fuel rail unions before sealing the unions with blanking caps Make sure that all openings are sealed Use new blanking caps Discard the high pressure fuel supply line 6 Discard the fuel pump seal 7 NOTE Access the fuel pump bolts through the holes provided The bolts cannot be removed 8 Special Tool s 205 072 9 http vnx su ...

Page 982: ...Installation Vehicles built up to 04 2008 10 11 12 Special Tool s 303 249 1 Special Tool s 205 072 Torque 45 Nm http vnx su ...

Page 983: ...08 onwards 2 Material Thread Locking MS WSK M2G349 A7 2U7J M2G349 AA 3 NOTE Access the fuel pump bolts through the holes provided The bolts cannot be removed Torque 20 Nm 4 Torque 24 Nm 5 Torque 1 26 Nm 2 50 Nm http vnx su ...

Page 984: ...t is installed Torque 10 Nm 7 Material Silicone Sealant LB WSE M4G323 A4 2U7J M4G323 AA 8 Material Thread Locking MS WSK M2G349 A7 2U7J M2G349 AA 9 Torque 42 Nm 10 NOTE Make sure that a new component is installed Discard the blanking plugs http vnx su ...

Page 985: ...l 12 Install the timing belt Refer to Timing Belt 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 13 Install a new fuel filter element Refer to Fuel Filter 1 8L Duratorq TDCi Lynx Diesel 310 01A Fuel Tank and Lines Removal and Installation http vnx su ...

Page 986: ...repair to the fuel injection system Hose clamp remover installer 1 Remove the charge air cooler Refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 12 Intake Air Distribution and Filtering Removal and Installation 2 CAUTION Use lint free cloth Protect the generator to prevent contamination 3 Clean the fuel pump fuel rail high pressure fuel s...

Page 987: ...nd fuel rail unions before sealing the unions with blanking caps Make sure that the fuel line union does not rotate Make sure that all openings are sealed Use new blanking caps Discard the high pressure fuel supply lines 7 1 NOTE Only tighten the bolts finger tight at this stage 2 NOTE Make sure that a new component is installed NOTE Only tighten the union nuts finger tight at this stage Discard t...

Page 988: ...3 Torque 24 Nm 4 CAUTION Make sure that the fuel line union does not rotate Tighten in the sequence shown Torque 25 Nm 5 Torque 38 Nm 6 Torque 23 Nm http vnx su ...

Page 989: ...uilt From 08 2006 303 12 Intake Air Distribution and Filtering Removal and Installation 10 Refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures 11 Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter union making sure that the arrow on the hand pressure pump indicating the direction of flow is pointing to...

Page 990: ...ol for 30 seconds before operating the starter motor again Start the engine and allow it to idle until it reaches normal operating temperature 14 Stop the engine 15 Remove the special tool 16 Connect the fuel tank to fuel filter fuel supply line to the fuel filter Refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures http vnx su ...

Page 991: ...nstructions may result in personal injury Wait at least one minute after the engine stops before commencing any repair to the fuel injection system Failure to follow this instruction may result in personal injury CAUTIONS Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible Foreign matter from work on clutches brakes or from machining or weld...

Page 992: ...ctors to prevent contamination with the cleaning fluid Clean the fuel pump and surrounding areas For additional information refer to Fuel Injection Component Cleaning Vehicles With Common Rail Fuel Injection 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel General Procedures 6 Disconnect the fuel metering valve and fuel temperature sensor electrical ...

Page 993: ...se instructions may result in personal injury CAUTIONS return line and the fuel return line venturi 9 Disconnect the fuel injector fuel return line from the fuel return line venturi Install blanking plugs to the fuel injector fuel return line and the fuel return line venturi 10 Remove the fuel pump shield from the fuel pump fuel pump shown removed for clarity 11 Using the pneumatic vacuum gun vacu...

Page 994: ...fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always install blanking plugs to any open orifices or lines 1 Remove and discard the blanking plug from the fuel pump 2 Using the Pneumatic vacuum gun vacuum foreign material from the fuel pump open port 3 Using a...

Page 995: ...Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 75 PS 90 PS 303 12 Intake Air Distribution and Filtering Removal and Installation Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 12 Intake Air Distribution and Filtering Removal and Installation 12 Connect the battery ground cable For additional information refer to ...

Page 996: ...ith M10 nuts 47 35 Flexible pipe flange to muffler nuts 47 35 Support insulator retaining bolt 48 35 Description Nm lb ft lb in Charge air cooler hose clamps 4 35 Exhaust gas recirculation EGR cooler clamp bolt 5 44 Charge air cooler intake pipe nuts 9 80 Turbocharger oil supply pipe and oil return tube bolts vehicles with fixed vane turbocharger 10 89 Turbocharger oil return tube bolts vehicles w...

Page 997: ...urbine uses the flow of the exhaust gas to drive the compressor The compressor draws air through the air cleaner and forces it into the intake manifold The turbocharger is designed to improve engine induction and engine performance The list below details the possible concerns relating to turbocharger performance High engine speed produces excessive turbine speed and therefore creates excessive tur...

Page 998: ...angle The shallow intake cross section this creates for the stream of exhaust gas allows the turbocharger boost pressure to build up rapidly and easily at low engine speeds Regulation at Moderate Engine Speed As the engine speed increases and the quantity of exhaust gas increases the vane adjustment solenoid moves the adjusting ring so that the vanes are set at a steeper angle The steeper angle op...

Page 999: ...ine through the oil supply pipe The oil is returned to the oil pan through the oil return tube The turbine element of the turbocharger uses the energy of the exhaust gas to drive the compressor The compressor draws in air through the charge air cooler The turbocharger is governed by means of a wastegate The wastegate redirects some of the exhaust gas past the turbine The wastegate is controlled by...

Page 1000: ... noisy or seize Do not install a new turbocharger due to oil inside the turbocharger or the air intake components If a leak is detected in the oil supply or return tubes or connections locate and rectify the source Do not install a new turbocharger due to an oil leak 1 1 Verify the customer concern 2 2 Visually inspect for obvious signs of mechanical damage Visual Inspection Chart 3 3 If an obviou...

Page 1001: ...is factory set and must not be adjusted CHECK the paint seal on the actuator rod has not been broken If the paint seal has been broken INSTALL a new turbocharger REFER to Turbocharger in this section TEST the system for normal operation If the paint seal has not been broken GO to Pinpoint Test C PINPOINT TEST A BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE TEST CONDITIONS DETAILS RESULTS ACTIONS A1...

Page 1002: ...ousing with no excessive movement Yes GO to A4 No INSTALL a new turbocharger REFER to Turbocharger in this section TEST the system for normal operation A4 CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE Disconnect the oil supply tube from the turbocharger 1 Attach a small piece of known good hose to the oil supply tube and gently blow down the hose 2 Are there any signs of blockage Yes INSTALL...

Page 1003: ...he system for normal operation PINPOINT TEST C POOR ENGINE PERFORMANCE TEST CONDITIONS DETAILS RESULTS ACTIONS C1 CHECK THE BOOST PRESSURE NOTE The boost pressure is factory set and must not be adjusted Using the special tool connect the boost pressure gauge between the wastegate control actuator and the turbocharger 1 Start and run the engine until the cooling fan has operated 2 Raise the engine ...

Page 1004: ...Turbocharger 303 04D Fuel Charging and Controls No INSTALL a new turbocharger REFER to Turbocharger in this section TEST the system for normal operation http vnx su ...

Page 1005: ...upply or return tubes or connections locate and rectify the source Do not install a new turbocharger due to an oil leak 1 1 Verify the customer concern 2 2 Visually inspect for obvious signs of mechanical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the cause is not visual...

Page 1006: ...s REPAIR as necessary Unauthorized adjustment of the wastegate control valve actuator rod The wastegate control valve actuator rod is factory set and must not be adjusted CHECK the paint seal on the wastegate control valve actuator rod has not been broken If the paint seal has been broken INSTALL a new turbocharger REFER to Turbocharger 1 8L Duratorq TDCi Kent Diesel 110 PS Vehicles With Fixed Van...

Page 1007: ...feel rough and uneven but should rotate freely after a few turns Make sure that the turbocharger rotor spins freely within the housing 1 With the turbocharger stationary gently lift the shaft the shaft will naturally lay in the bottom of the bearings 2 Make sure that the rotor spins freely within the housing 1 Does the rotor spin freely within the housing Yes GO to A4 No INSTALL a new turbocharger...

Page 1008: ...turbocharger REFER to Turbocharger 1 8L Duratorq TDCi 81kW 110PS Lynx 303 04C Fuel Charging and Controls Turbocharger Removal and Installation TEST the system for normal operation PINPOINT TEST B BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK THE TURBOCHARGER OIL RETURN TUBE Remove the turbocharger oil return tube 1 Check the turbocharger oil retur...

Page 1009: ...ACTUATOR DIAPHRAGM FOR LEAKS Connect the free end of the wastegate control line to the wastegate actuator 1 Operate the hand vacuum pump and observe the reading 2 Does the pump hold vacuum Yes GO to Fuel Charging and Controls for further diagnostics REFER to Fuel Charging and Controls 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1...

Page 1010: ...ide the turbocharger or the air intake components If a leak is detected in the oil supply or return tubes or connections locate and rectify the source Do not install a new turbocharger due to an oil leak 1 1 Verify the customer concern 2 2 Visually inspect for obvious signs of mechanical or electrical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is fou...

Page 1011: ...TURBOCHARGER NOISE TEST CONDITIONS DETAILS RESULTS ACTIONS A1 INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE CAUTION Make sure that the inside of the pipe ends are clean and free of oil residue Remove the turbocharger intake pipe 1 Inspect the turbocharger rotor vanes for damage 2 Is there visible damage to the rotor vanes Yes GO to A2 No GO to A3 A2 CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR S...

Page 1012: ...A4 CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE Remove the turbocharger REFER to Turbocharger 1 8L Duratorq TDCi Kent Diesel 110 PS Vehicles With Variable Vane Turbocharger 303 04C Removal and Installation 1 Using workshop compressed air and a compressed air nozzle check the oil supply tube for blockage 2 Is the oil supply tube free from blockage Yes GO to A5 No INSTALL a new turbocharger a...

Page 1013: ... to Lifting 100 02 Jacking and Lifting Description and Operation 1 NOTE Discard the gasket s Remove the turbocharger oil return pipe 2 Check the turbocharger oil return pipe for blockage or signs of damage 3 Is the turbocharger oil return pipe free from blockage and signs of damage Yes GO to Fuel Charging and Controls for further diagnostics REFER to Fuel Charging and Controls 75 PS 90 PS 110 PS V...

Page 1014: ... 414 01 Battery Mounting and Cables General Procedures 2 Refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 3 CAUTION Make sure that the inside of the pipe ends are clean and free of oil residue NOTE Make sure that the positive crankcase ventilation PCV hose and the turbocharger intake pipe are not disturbed 4 NOTE Install all the bolts finger tight before f...

Page 1015: ...l the bolts finger tight before final tightening Torque 47 Nm 8 NOTE Install all the bolts finger tight before final tightening Torque 25 Nm 9 NOTE Make sure that a new component is installed Torque 10 Nm 10 NOTE Make sure that new components are installed Torque 20 Nm http vnx su ...

Page 1016: ...hat a new component is installed 1 To install reverse the removal procedure 2 NOTE Make sure that the clamp is installed to the same orientation as when removed NOTE Make sure that a new component is installed Torque 5 Nm http vnx su ...

Page 1017: ...ties 1 Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Refer to Lifting 100 02 Jacking and Lifting Description and Operation 3 4 CAUTION Make sure that the exhaust flexible pipe is not forcibly bent or twisted General Equipment Cable ties 5 6 7 CAUTION Make sure that the inside of the pipe ends are clean and free of oil residue 8 http vnx su ...

Page 1018: ...Installation 9 10 11 12 1 NOTE Make sure that a new component is installed Torque 35 Nm 2 NOTE Make sure that new components are installed http vnx su ...

Page 1019: ...que 35 Nm 5 NOTE Make sure that a new component is installed NOTE Make sure that the clamp is installed to the same orientation as when removed Torque 5 Nm 6 CAUTION Make sure that the inside of the pipe ends are clean and free of oil residue 7 Torque 47 Nm 8 Torque 25 Nm 9 NOTE Install all the bolts finger tight before final tightening http vnx su ...

Page 1020: ...rectly aligned Torque 25 Nm 10 CAUTION Make sure that the exhaust flexible pipe is not forcibly bent or twisted General Equipment Cable ties 11 Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures http vnx su ...

Page 1021: ... Tourneo Connect 2002 5 06 2002 Print Description Nm lb ft lb in Alternative fuel control module bracket retaining bolts 10 89 Fuel vaporizer fuel supply line union 17 13 Fuel vaporizer retaining bolts 10 89 Fuel vaporizer bracket retaining nuts 23 17 Fuel vaporizer filter element retaining nut 36 27 http vnx su ...

Page 1022: ...Controls Transit Tourneo Connect 2002 5 06 2002 Print Description and Operation Description LPG select switch Alternative fuel control module LPG fuel vaporizer and filter LPG fuel injection supply manifold LPG injector s Alternative fuel system Data Link Connector DLC Item 1 2 3 4 5 6 Part Number http vnx su ...

Page 1023: ... LPG Fuel Vaporizer The LPG fuel vaporizer changes liquid gas from the LPG tank to a dry gas The vaporizer is connected to the engine coolant system and will only switch to LPG if the coolant temperature is above 10 degrees centigrade Alternative Fuel Control Module The alternative fuel control module monitors the various engine sensors when the vehicle is operating on LPG If the LPG fuel tank run...

Page 1024: ...uated prior to tank removal Failure to follow this instruction may result in personal injury Eye hand and ear protection are required to be worn during depressurizing or removal and installation of fuel system components Failure to follow this instruction may result in personal injury Always ground the vehicle and alternative fuel system High pressure gas escaping can cause static electricity buil...

Page 1025: ...rouble Code DTC Index Chart Diagnostic Trouble Codes DTC s Index Chart NOTE The WDS must be used to communicate with the AFCM It is not possible to use the IDS to communicate with the AFCM NOTE The secondary data link connector DLC must be used for alternative fuel system diagnostics On left hand drive vehicles the secondary DLC is located behind the glove compartment On right hand drive vehicles ...

Page 1026: ...rmation 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG General Procedures P0200 LPG fuel injector circuit concern LPG fuel injectors GO to Pinpoint Test B P0336 Crankshaft position CKP sensor circuit CKP sensor GO to Pinpoint Test E P0340 Camshaft position CMP sensor circuit CMP sensor REFER to the WDS P1230 Main power relay primary circuit Main power relay INSTALL a new main power...

Page 1027: ...itch CHECK the operation of the LPG select switch REPAIR as necessary TEST the system for normal operation LPG mixture is weak CHECK and ADJUST the differential pressure settings in the fuel vaporizer distributor REFER to Fuel System Differential Pressure Check 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG General Procedures TEST the system ...

Page 1028: ... settings CHECK and ADJUST the differential pressure settings in the fuel vaporizer distributor REFER to Fuel System Differential Pressure Check 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG General Procedures TEST the system for normal operation Kinked or restricted fuel lines CHECK the fuel lines from the fuel distributor to the injectors ...

Page 1029: ...5kW 115PS Zetec Liquefied Petroleum Gas LPG General Procedures TEST the system for normal operation The LPG indicator lamp is constantly illuminated Switch CHECK the switch electrical connector is correctly installed REPAIR as necessary TEST the system for normal operation LPG mixture is rich CHECK and ADJUST the differential pressure settings in the fuel vaporizer distributor REFER to Fuel System...

Page 1030: ...perature sensor C653 pin 1 circuit 8 RJ5 WH harness side and AFCM C406 pin 28 circuit 8 RJ5 WH harness side 2 Is the resistance less than 5 ohms Yes GO to A3 No REPAIR the circuit TEST the system for normal operation A3 CHECK CIRCUIT 9 RJ5 FOR OPEN Measure the resistance between the fuel vaporizer coolant temperature sensor C653 pin 2 circuit 9 RJ5 BN harness side and AFCM C405 pin 34 circuit 9 RJ...

Page 1031: ...1S RL12D BK BU harness side AFCM C406 pin 11 circuit 31S RL13D BK OG harness side 7 Are the resistances greater than 10 000 ohms Yes GO to B2 No REPAIR the circuit s TEST the system for normal operation B2 CHECK FOR POWER TO THE LPG FUEL INJECTORS Disconnect LPG fuel injector C671 1 Disconnect LPG fuel injector C672 2 Disconnect LPG fuel injector C673 3 Disconnect LPG fuel injector C674 4 Ignition...

Page 1032: ...n 5 ohms Yes GO to B4 No REPAIR the circuit s TEST the system for normal operation B4 CHECK THE LPG FUEL INJECTORS FOR OPEN REMOVE the LPG fuel injectors REFER to Fuel Injectors 303 04D Fuel Charging and Controls 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Removal and Installation 1 Measure the resistance across the following LPG fuel injectors LPG fuel injector C671 pin 1 compo...

Page 1033: ...uit s TEST the system for normal operation B6 CHECK CIRCUIT 15 RH28 FOR POWER Ignition switch in position II 1 Measure the voltage between LPG main relay C725 pin 3 circuit 15 RH28 GN OG harness side and ground 2 Is the voltage greater than 10 volts Yes GO to B7 No REPAIR the circuit TEST the system for normal operation B7 CHECK THE LPG MAIN RELAY Ignition switch in position 0 1 Carry out the rela...

Page 1034: ...perating correctly Yes GO to C2 No INSTALL a new MAP sensor TEST the system for normal operation C2 CHECK CIRCUITS 7 RJ20 8 RJ20 AND 9 RJ20 FOR OPEN Ignition switch in position 0 1 Disconnect AFCM C406 2 Disconnect MAP sensor C833 3 Measure the resistance between the following electrical connectors AFCM C406 pin 16 circuit 7 RJ20 YE GN harness side and MAP sensor C833 pin C circuit 7 RJ20 YE GN ha...

Page 1035: ...TP sensor C703 3 Measure the resistance between AFCM C406 pin 6 circuit 8 RJ28B WH harness side and TP sensor C703 pin 2 circuit 8 RJ28 WH harness side 4 Is the resistance less than 5 ohms Yes INSTALL a new AFCM REFER to Gas Control Module 303 04D Fuel Charging and Controls 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Removal and Installation TEST the system for normal operation ...

Page 1036: ...RD harness side AFCM C406 pin 5 circuit 9 RJ4B BN RD harness side and CKP sensor C643 pin 2 circuit 9 RJ4 BN RD harness side 4 Are the resistances less than 5 ohms Yes INSTALL a new AFCM REFER to Gas Control Module 303 04D Fuel Charging and Controls 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Removal and Installation TEST the system for normal operation No REPAIR the circuit s T...

Page 1037: ...ection 414 01 Battery Mounting and Cables 3 Disconnect the fuel injection supply manifold fuel supply line Discard the retaining clip 4 Remove the intake manifold For additional information refer to Section 303 01A Engine 303 01B Engine 5 NOTE The fuel injector electrical connectors are numbered with each cylinder Disconnect the fuel injector electrical connectors and remove from the bracket 6 Rem...

Page 1038: ...ry out the fuel system leak test Failure to follow this instruction may result in personal injury Check the fuel system for leaks For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information http vnx su ...

Page 1039: ...dditional information refer to Section 414 01 Battery Mounting and Cables 3 Remove the air cleaner For additional information refer to Section 303 12 Intake Air Distribution and Filtering 4 Disconnect the fuel vaporizer to fuel filter supply line from the fuel filter Discard the retaining clip 5 Disconnect the alternative fuel control module electrical connectors 6 Disconnect the fuel vaporizer fu...

Page 1040: ...orizer vacuum lines from the fuel vaporizer and manifold absolute pressure MAP sensor 9 Detach the brake fluid reservoir 10 Disconnect the fuel vaporizer electrical connector 11 Remove the fuel vaporizer bracket retaining bolt 12 Remove the fuel vaporizer bracket retaining nut http vnx su ...

Page 1041: ...ect the fuel vaporizer and MAP sensor electrical connectors 15 Remove the fuel vaporizer retaining bracket 16 Disconnect the fuel supply line from the vaporizer 1 Discard the O ring seal 1 NOTE Install a new retaining clip NOTE Install a new O ring seal To install reverse the removal procedure http vnx su ...

Page 1042: ...on 310 00A Fuel System General Information 310 00B Fuel System General Information 4 CAUTION If a new fuel vaporizer has been installed the fuel system differential pressure setting will have to be checked and adjusted to specification Before the vehicle is tested for normal operation carry out the fuel system differential pressure check Check the fuel system differential pressure settings For add...

Page 1043: ...ent 1 Hold the fuel vaporizer filter housing with a 29mm Spanner spanner to prevent the fuel vaporizer filter housing from turning 2 Remove the fuel vaporizer filter element retaining nut Discard the fuel vaporizer filter element O ring seal 1 NOTE Install a new fuel vaporizer filter element O ring seal NOTE Install a new fuel vaporizer filter element Install the fuel vaporizer filter element 1 Ho...

Page 1044: ...e the vehicle is tested for normal operation carry out the fuel system leak test Failure to follow this instruction may result in personal injury Check the fuel system for leaks For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information http vnx su ...

Page 1045: ...the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Remove the air cleaner For additional information refer to Section 303 12 Intake Air Distribution and Filtering 3 Disconnect the alternative fuel control module electrical connectors Release the locking tangs 4 Remove the alternative fuel control module 1 To install reverse the removal procedu...

Page 1046: ... DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Fuel Injection Supply Manifold Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 For additional information refer to Fuel Injectors in this section http vnx su ...

Page 1047: ...ft lb in Accessory drive belt idler pulley retaining bolt 48 35 Accessory drive belt tensioner retaining nuts 48 35 Charge air cooler outlet pipe retaining nuts 9 80 Power steering line support bracket retaining nut 5 44 Power steering pump retaining bolts 25 18 Description Nm lb ft lb in Accessory drive belt idler pulley retaining bolt 48 35 Accessory drive belt tensioner retaining bolts 25 18 ht...

Page 1048: ...rvice literature for the change interval for the multi groove belt An automatic belt tensioner is used to tension the belt To release the tension on the multi groove belt press the belt tensioner counter clockwise against the force of the spring Description Vehicles without air conditioning Vehicles with air conditioning Generator Idler pulley Power steering pump Coolant pump Multi groove belt Cra...

Page 1049: ... the current service literature for the change interval for the multi groove belt An automatic belt tensioner is used to tension the belt To release the tension on the multi groove belt press the tension roller of the belt tensioner counter clockwise against the force of the spring Description Vehicles without air conditioning Vehicles with air conditioning Power steering pump Automatic belt tensi...

Page 1050: ...belt Only if the crack is deep enough to reach the bottom of the groove to expose the cord or any chunks are found to be missing from the accessory drive belt is the accessory drive belt condition considered to be unacceptable 1 1 Check the accessory drive belt for cracks If the damage exceeds the acceptable limit install a new accessory drive belt REFER to Accessory Drive Belt 1 8L Duratec DOHC 8...

Page 1051: ...left on the accessory drive belt during the manufacturing process These are worn off and form into small balls of rubber that then get trapped in the grooves of the accessory drive belt This condition will usually clear itself within 4800 km 8000 km 3000 miles 5000 miles of normal driving 3 3 Check the accessory drive belt for pilling The condition of the accessory drive belt should be compared ag...

Page 1052: ... and Installation Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 6 Heavy deposits in the grooves Possible noise and stability concern INSTALL a new accessory drive belt REFER to Accessory Drive Belt 1 8L Duratec DOHC 85kW 115PS Zetec 303 05 Accessory Drive Removal and Installation Accessory Drive Belt 1 8L Duratorq...

Page 1053: ... 303 05 Accessory Drive Removal and Installation 5 High amount of fraying with cord cuts INSTALL a new accessory drive belt REFER to Accessory Drive Belt 1 8L Duratec DOHC 85kW 115PS Zetec 303 05 Accessory Drive Removal and Installation Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation Incorrect fitment Accessory driv...

Page 1054: ...y Drive Removal and Installation TEST the system for normal operation Pulley s CHECK the pulley s for damage freedom of rotation stone entrapment and alignment INSTALL new components as necessary TEST the system for normal operation Lubricant or other contamination CHECK the accessory drive belt for contamination or damage RECTIFY the source of the leak and INSTALL a new accessory drive belt REFER...

Page 1055: ...l operation NOTE Chirp is defined as a twittering noise often intermittent Accessory drive belt chirp Pulley misalignment usually evident at idle CHECK that the accessory drive belt is running centrally on the flat pulleys TEST the system for normal operation CHECK the pulleys for excessive end float and bent flanges With the engine running at idle use a stethoscope to identify the source of the n...

Page 1056: ...of rotation and alignment INSTALL a new accessory drive belt tensioner as necessary REFER to Accessory Drive Belt Tensioner 1 8L Duratec DOHC 85kW 115PS Zetec 303 05 Accessory Drive Removal and Installation Accessory Drive Belt Tensioner 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation TEST the system for normal operation 5 5 If the acce...

Page 1057: ...to Accessory Drive Belt 1 8L Duratec DOHC 85kW 115PS Zetec 303 05 Accessory Drive Removal and Installation Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation TEST the system for normal operation Generator Decoupler 1 1 Remove the accessory drive belt REFER to Accessory Drive Belt 1 8L Duratec DOHC 85kW 115PS Zetec 303 ...

Page 1058: ...he battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 3 Remove the splash shield 4 Remove the accessory drive belt 1 Rotate the accessory drive belt tensioner clockwise 2 Remove the accessory drive belt 1 To install reverse the removal procedure ht...

Page 1059: ...Vehicles without air conditioning 2 To install reverse the removal procedure http vnx su ...

Page 1060: ...http vnx su ...

Page 1061: ...1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 3 Remove the splash shield 4 Remove the accessory drive belt 1 Rotate the accessory drive belt tensioner clockwise 2 Remove the accessory drive belt 1 To install reverse the remova...

Page 1062: ...Vehicles without air conditioning 2 To install reverse the removal procedure http vnx su ...

Page 1063: ...http vnx su ...

Page 1064: ...in the following illustration s and table s Description Accessory drive belt tensioner retaining bolts Accessory drive belt tensioner 5 To install reverse the removal procedure 1 Remove the accessory drive belt For additional information refer to Accessory Drive Belt in this section 2 Lower the vehicle 3 Detach the coolant expansion tank and position it to one side Item 1 2 Part Number http vnx su...

Page 1065: ... Removal and Installation 1 NOTE Make a note of the position of the charge air cooler outlet pipe retaining clamps Remove the charge air cooler outlet pipe 2 Detach the coolant expansion tank and position it to one side 3 Detach the power steering fluid reservoir and position it to one side 4 Detach the power steering pipe retaining bracket http vnx su ...

Page 1066: ...ction may result in failure of the accessory drive belt tensioner 5 Detach the fuel filter and the fuel filter retaining bracket and position it to one side Press the fuel filter retaining clip Detach the fuel filter and the fuel filter retaining bracket from the fuel filter support bracket 6 Remove the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDC...

Page 1067: ...cessory drive belt tensioner retaining nuts Accessory drive belt tensioner 8 To install reverse the removal procedure Item 1 2 3 4 5 6 9 CAUTION The charge air cooler outlet pipe retaining clamps must be installed in the same position as removed Failure to follow this instruction may cause premature failure of adjacent components Install the charge air cooler outlet pipe retaining clamps Part Numb...

Page 1068: ...steering pump retaining bolts Item 4 Power steering pump Installation Details Item 3 Power steering pump retaining bolts 1 Lower the vehicle 1 Detach the power steering pump and position to one side 1 Raise the vehicle http vnx su ...

Page 1069: ...ect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Starter motor retaining bolts 35 26 Starter motor power connection 12 9 Starter solenoid connection 6 53 Valve cover oil separator retaining bolt 2 0L Duretec RS 25 18 http vnx su ...

Page 1070: ... BJB Switch es Battery Starter motor Symptom Possible Sources Action The engine does not crank the relay does click Battery REFER to Section 414 00 Charging System General Information Relay CARRY OUT the relay Component Test REFER to the wiring diagrams Circuit s GO to Pinpoint Test A Starter motor CARRY OUT the starter motor Component Test using WDS The engine does not crank the relay does not cl...

Page 1071: ... INSTALL a new starter motor as necessary Flywheel ring gear INSPECT the flywheel for damage REFER to Section 303 00 Engine System General Information PINPOINT TEST A THE ENGINE DOES NOT CRANK THE RELAY DOES CLICK TEST CONDITIONS DETAILS RESULTS ACTIONS A1 CHECK VOLTAGE TO STARTER SOLENOID Ignition switch in position III 1 Measure the voltage between starter motor terminal 50 harness side and grou...

Page 1072: ...OUND CIRCUIT FOR OPEN Measure the resistance between the starter motor casing and battery ground terminal 1 Is the resistance less than 0 5 ohms Yes INSTALL a new starter motor REFER to Starter Motor 1 8L Starter Motor 1 8L Diesel in this section TEST the system for normal operation No CLEAN and TIGHTEN all battery and engine ground cable connections TEST the system for normal operation PINPOINT T...

Page 1073: ...STALL a new ignition switch REFER to Section 211 05 Steering Column Switches TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation B3 CHECK CIRCUIT 31S BB16 BK RD FOR OPEN Ignition switch in position II 1 Measure the resistance between the starter relay C1017 pin 2 circuit 31S BB16 BK RD harness side and ground 2 Is the resistance between 20 and 25 ohms Ye...

Page 1074: ...OPEN Ignition switch in position 0 1 Disconnect PCM C414 2 Measure the resistance between the starter relay C1017 pin 2 circuit 31S BB16 BK RD harness side and PCM C414 pin 21 31S BB16 BK RD harness side 3 Is the resistance less than 5 ohms Yes CHECK the PCM REFER to WDS No REPAIR the circuit TEST the system for normal operation B6 CHECK CIRCUIT 31S BB16 BK RD FOR OPEN Ignition switch in position ...

Page 1075: ... to starter motor solenoid cable REFER to Section 414 01 Battery Mounting and Cables Test the system for normal operation C2 CHECK FOR GROUND CONNECTION Ignition switch in position III 1 Measure the voltage between the starter motor case and the battery ground terminal 2 Is the voltage less than 0 5 volts Yes INSTALL a new starter motor REFER to Starter Motor 1 8L Starter Motor 1 8L Diesel in this...

Page 1076: ... Symptom Possible Sources Action The engine does not crank the relay does click Battery REFER to Battery 414 01 Battery Mounting and Cables Diagnosis and Testing Relay CARRY OUT the relay Component Test REFER to the wiring diagrams Circuit s GO to Pinpoint Test A Starter motor CARRY OUT the starter motor Component Test using the WDS The engine does not crank the relay does not click Battery REFER ...

Page 1077: ...8 2006 1 8L Duratorq TDCi Kent Diesel 303 06 Removal and Installation INSPECT the starter motor gear for damage INSTALL a new starter motor as necessary Flywheel ring gear INSPECT the flywheel for damage REFER to Flywheel Inspection 303 00 Engine System General Information General Procedures PINPOINT TEST A THE ENGINE DOES NOT CRANK THE RELAY DOES CLICK TEST CONDITIONS DETAILS RESULTS ACTIONS A1 C...

Page 1078: ... REPAIR circuit 50 BB12 GY TEST the system for normal operation No REPAIR circuit 30 BB12 RD TEST the system for normal operation A4 CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN Measure the resistance between the starter motor casing and the battery ground terminal 1 Is the resistance less than 0 5 ohms Yes INSTALL a new starter motor REFER to Starter Motor Vehicles Built From 08 2006 1 8L Dura...

Page 1079: ...6 GY BK harness side 3 Is the resistance less than 1 ohm Yes INSTALL a new ignition switch REFER to Ignition Switch 211 05 Steering Column Switches Removal and Installation TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation B3 CHECK CIRCUIT 31S BB16 BK RD FOR OPEN Ignition switch in position II 1 Measure the resistance between the starter relay R13 pin ...

Page 1080: ...etween the starter motor terminal 30 component side and the battery positive terminal 2 Is the voltage less than 0 5 volts Yes GO to C2 No CLEAN and TIGHTEN all battery positive cable connections TEST the system for normal operation If the concern persists INSTALL a new battery to starter motor solenoid cable REFER to Battery Cables 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 414...

Page 1081: ...3 06 Removal and Installation TEST the system for normal operation No CLEAN and TIGHTEN all battery ground cable connections starter motor mounting and body to ground straps TEST the system for normal operation If the concern persists INSTALL a new battery ground cable Test the system for normal operation http vnx su ...

Page 1082: ...tallation 3 Remove the components in the order indicated in the following illustration s and table s Description Starter motor retaining bolts 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Remove the air cleaner outlet pipe Item 1 Part Number http vnx su ...

Page 1083: ...ails Item 3 Ignition switch and battery to starter motor solenoid cable electrical connector Installation Details Item 3 Ignition switch and battery to starter motor solenoid cable electrical connector 2 3 4 5 1 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 2 Disconnect the ignition switch and battery to starter motor solenoid cable electrical...

Page 1084: ...illustration s and table s Description Ignition switch and battery to starter motor solenoid cable electrical connector See Removal Detail Starter motor retaining bolts Battery to transaxle ground cable 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Raise and support the vehicle For additional information refer to Section 100 ...

Page 1085: ...r 4 5 1 Disconnect and detach the ignition switch and battery to starter motor solenoid cable electrical connector 1 Detach the ignition switch and battery to starter motor cable retaining clip 2 Remove the ignition switch to starter motor solenoid cable electrical connector retaining nut 3 Remove the battery to starter motor solenoid cable electrical connector retaining nut http vnx su ...

Page 1086: ...n installation details Installation 1 Disconnect the battery ground cable Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Raise and support the vehicle Refer to Lifting 100 02 Jacking and Lifting Description and Operation 3 1 Torque 12 Nm 2 Torque 6 Nm 3 Torque 35 Nm 4 Torque 35 Nm 1 To install reverse the removal procedure http vnx su ...

Page 1087: ... 85kW 115PS Zetec Specifications Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Ignition coil retaining bolts 6 53 Ignition coil bracket retaining bolts 20 15 Spark plugs 15 11 http vnx su ...

Page 1088: ...y evident verify the symptom and refer to the Symptom Chart Symptom Chart Symptom Chart Worldwide Diagnostic System WDS Electrical Wiring harness Electrical connector s Spark plug s Spark plug wire s Ignition coil pack Powertrain control module PCM Symptom Possible Sources Action Engine misfire Spark plug s Spark plug wire s CARRY OUT a KV test using WDS Ignition coil pack PCM PCM calibration REFE...

Page 1089: ...ansit Tourneo Connect 2002 5 06 2002 Print Item Nm lb ft lb in Glow plug 15 11 Glow plug electrical connector retaining nut 2 18 Glow plug relay to glow plug wire terminal block cable electrical connector retaining nut 4 35 http vnx su ...

Page 1090: ...al or electrical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the cause is not visually evident verify the symptom and refer to WDS to diagnose the system Electrical Fuse s Relay Wiring harness Electrical connector s Glow plug s Glow plug wire Powertrain control module PCM...

Page 1091: ...s and table s Description Glow plug relay to glow plug wire terminal block cable electrical connector retaining nut Remover Installer Hose Clamp 303 397 24 003 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Remove the charge air cooler For additional information refer to Section 303 12 Intake Air Distribution and Filtering Ite...

Page 1092: ...ose retaining clamp See Removal Detail PCV hose Glow plug wire electrical connector retaining nut Glow plug wire 4 To install reverse the removal procedure Removal Details Item 5 Oil level indicator tube Item 6 Positive crankcase ventilation PCV hose retaining clamp 2 3 4 5 6 7 8 9 1 Detach the oil level indicator tube and position it to one side 1 Using the special tool detach the PCV hose retain...

Page 1093: ...s procedure may contain installation details CAUTION Make sure that all openings are sealed Installation Hose clamp remover installer 1 Disconnect the battery ground cable Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 General Equipment Hose clamp remover installer 3 1 Torque 4 Nm 2 Torque 7 Nm 3 Torque 2 Nm 4 Torque 15 Nm 1 To install reverse the r...

Page 1094: ...C 85kW 115PS Zetec Specifications Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Positive crankcase ventilation PCV pipe retaining bolt 10 89 Thermostat housing retaining bolts 20 15 http vnx su ...

Page 1095: ...ceeding to the next step 4 4 If the concern is not visually evident verify the symptom and refer to the Symptom Chart Symptom Chart Symptom Chart Electrical Vacuum line s Hose s hose joints Gasket s Positive crankcase ventilation PCV valve Crankcase vent oil separator Symptom Possible Sources Action Excessive crankcase pressure Blocked or damaged PCV pipe s hose s Blocked PCV valve Blocked crankca...

Page 1096: ...le s Description PCV hose to intake manifold retaining clip PCV hose to intake manifold Thermostat housing retaining bolts See Removal Detail See Installation Detail Thermostat housing Thermostat housing seal 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Drain the cooling system For additional information refer to Section 303...

Page 1097: ...val procedure Removal Details Item 3 Thermostat housing retaining bolts Item 5 Thermostat housing seal NOTE Discard the thermostat housing seal Installation Details Item 5 Thermostat housing seal NOTE Install a new thermostat housing seal Item 3 Thermostat housing retaining bolts 6 7 8 1 Lower the vehicle 1 Raise the vehicle http vnx su ...

Page 1098: ... EGR cooler to EGR valve bolts 20 15 Charge air cooler intake pipe support bracket nut 23 17 Positive crankcase ventilation PCV oil separator bolt 23 17 EGR cooler bolt 23 17 Intake manifold bolts 25 18 Intake manifold nuts 25 18 Description Nm lb ft lb in Charge air cooler hose clamps 4 35 EGR cooler clamp 4 35 Charge air cooler intake pipe nut 9 80 Charge air cooler outlet pipe nut 9 80 EGR cool...

Page 1099: ...ng charge air in the intake manifold where it mixes with the air fuel mixture and lowers the peak gas temperature reducing nitrogen oxide NOx exhaust emissions The EGR valve is electrically operated and is controlled through an input from the powertrain control module PCM The EGR valve must not be disassembled or removed from the intake manifold The EGR system is fitted with an EGR cooler The EGR ...

Page 1100: ...ventilation PCV hose Crankcase vent oil separator to valve cover PCV hose Crankcase vent oil separator Crankcase vent oil separator to crankcase PCV hose Description PCV valve cover PCV valve diaphragm PCV valve bush Valve cover Item 1 2 3 4 Item 1 2 3 4 Part Number Part Number http vnx su ...

Page 1101: ...gm operated PCV valve built into the valve cover and cannot be removed As the pressure in the crankcase vent oil separator reduces the diaphragm valve closes against the force of the PCV valve spring so closing the PCV valve As the crankcase pressure rises the PCV valve is pushed open assisted by the PCV valve spring This allows the positive crankcase gasses to be scavenged by the air intake syste...

Page 1102: ...point Tests Hand Vacuum Pressure Pump 416 D001 23 036A Mechanical Exhaust gas recirculation EGR valve EGR tube EGR tube clamps Gaskets seals Positive crankcase ventilation PCV hoses Crankcase vent oil separator EGR vacuum regulator valve Symptom Possible Sources Action Excessive exhaust black smoke EGR valve EGR vacuum regulator valve GO to Pinpoint Test A Excessive crankcase pressure Blocked or d...

Page 1103: ...cuum gauge Yes GO to A2 No Using WDS CHECK the Exhaust Gas Recerculation Valve Duty Cycle input signal to the EGR vacuum regulator valve If the result is 0 INSTALL a new vacuum regulator valve TEST the system for normal operation If the result is not 0 continue the diagnostic with WDS A2 CHECK THE EGR VALVE Remove the charge air cooler outlet pipe 1 Detach the power steering fluid reservoir and po...

Page 1104: ...ngine TEST the system for normal operation A3 CHECK THE EGR VALVE Using the special tool apply a vacuum to the EGR valve 1 Inspect the EGR valve and valve seat for damage 2 Is the EGR valve and valve seat undamaged Yes REFER to Section 303 04A Fuel Charging and Controls 303 04B Fuel Charging and Controls 303 04C Fuel Charging and Controls Turbocharger 303 04D Fuel Charging and Controls No INSTALL ...

Page 1105: ...l from the EGR valve position sensor allows for the precise control of the timing and the quantity of exhaust gas to be recirculated If the EGR valve becomes inoperative or fails to close completely the PCM will raise a diagnostic trouble code DTC and the instrument cluster malfunction indicator lamp MIL will be illuminated The EGR system is fitted with an EGR cooler The EGR cooler reduces the tem...

Page 1106: ... 4 4 If the cause is not visually evident verify the symptom and refer to the diagnostic trouble code DTC Index Chart Diagnostic Trouble Code DTC Index Chart 1 1 If no DTCs are retrieved verify the symptom and refer to the Symptom Chart Symptom Chart Pinpoint Tests Mechanical Electrical EGR valve EGR cooler Gasket s PCV hoses Crankcase vent oil separator Electrical connector Wiring harness DTC Des...

Page 1107: ...TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK THE PCV HOSES FOR BLOCKAGE Remove the PCV hoses 1 Inspect the PCV hoses and connections for blockage 2 Are the PCV hoses and connections free from blockage Yes INSTALL a new valve cover REFER to Valve Cover 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair No CLEAN or INSTALL new PCV hoses as necessary TE...

Page 1108: ...er to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Remove the air cleaner For additional information refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 3 NOTE Make note of the positions of the charge air cooler intake hose retaining clamp to make sure it is positioned in exactly the same position when installing Remo...

Page 1109: ...ensor electrical connector CHT sensor electrical connector retaining clip PCV hose retaining clamp PCV hose Charge air cooler intake pipe support bracket retaining nut Charge air cooler intake pipe support bracket Crankcase ventilation oil separator retaining bolt Crankcase ventilation oil separator See Removal Detail 5 To install reverse the removal procedure Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Pa...

Page 1110: ...er pipe hose clamp in the same position as when removed 7 CAUTION The charge air cooler intake hose retaining clamp must be installed in the same position as removed Failure to follow this instruction may cause premature failure of adjacent components NOTE Make sure that the inside of the charge air cooler intake hose is clean and free from any oil residue as this will reduce the installation grip...

Page 1111: ...http vnx su ...

Page 1112: ...lation General Equipment Removal NOTE Removal steps in this procedure may contain installation details Installation Hose clamp remover installer 1 CAUTION Make sure that the inside of the pipe ends are clean and free of oil residue 1 Torque 4 Nm 2 Torque 9 Nm 3 General Equipment Hose clamp remover installer 2 General Equipment Hose clamp remover installer 3 Torque 23 Nm 1 To install reverse the re...

Page 1113: ...Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Remove the air cleaner For additional information refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 3 Remove the air cleaner outlet pipe 4 NOTE Make note of the position of the charge air cooler intake hose retaining clamp to make sure it is positioned in exactly the same positio...

Page 1114: ...olt See Removal Detail See Installation Detail EGR cooler outlet hose retaining clamp See Removal Detail EGR cooler outlet hose EGR cooler inlet hose retaining clamp EGR cooler inlet hose EGR cooler 6 To install reverse the removal procedure Item 1 2 3 4 5 6 7 8 7 Raise the vehicle 8 Tighten the EGR cooler retaining bolt Part Number http vnx su ...

Page 1115: ...o charge air cooler pipe hose clamp in the same position as when removed 11 CAUTION The charge air cooler intake hose retaining clamp must be installed in the same position as removed Failure to follow this instruction may cause premature failure of adjacent components NOTE Make sure that the inside of the charge air cooler intake hose is clean and free from any oil residue as this will reduce the...

Page 1116: ...e sure the clamp is installed in the same position as removed The hinge of the clamp should be obscured by the EGR cooler when viewed from the top of the engine This is to allow access to the catalytic convertor retaining nuts 1 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling General Procedures 1 Lower the vehicle 1 Us...

Page 1117: ...mover installer 1 Remove the fuel filter Refer to Fuel Filter 1 8L Duratorq TDCi Lynx Diesel 310 01A Fuel Tank and Lines Removal and Installation 2 CAUTION Make sure that the inside of the pipe ends are clean and free of oil residue NOTE Make a note of the orientation of the charger air cooler clamp 1 Torque 4 Nm 2 Torque 9 Nm 3 NOTE The gaskets are to be reused unless damaged General Equipment Ho...

Page 1118: ...3 To install reverse the removal procedure http vnx su ...

Page 1119: ... retaining clamp Remove the charge air cooler outlet pipe 1 Loosen the retaining clamps 2 Remove the retaining nuts Discard the hose retaining clamp 2 Disconnect the EGR valve electrical connector 3 Disconnect the intake manifold and EGR valve vacuum lines 4 Remove the turbocharger For additional information refer to Turbocharger 1 8L Duratorq TDCi FGT 55kW 75PS Lynx 1 8L Duratorq TDCi FGT 66kW 90...

Page 1120: ...ature failure of adjacent components Install a new intake manifold to charge air cooler pipe hose and clamp Remove and discard the intake manifold to charge air cooler pipe hose and clamp Install a new intake manifold to charge air cooler pipe hose Install a new turbocharger to charge air cooler pipe hose clamp in the same position as when removed 8 CAUTION The charge air cooler outlet hose retain...

Page 1121: ... Install a new intake manifold gasket Item 1 Intake manifold retaining nuts NOTE Install new intake manifold retaining nuts from any oil residue as this will reduce the installation grip of the hose to the charge air cooler Install the charge air cooler outlet pipe Clean the inside of the charge air cooler outlet hose Install a new charge air cooler outlet hose retaining clamp in the same position...

Page 1122: ...tails Installation 1 Remove the exhaust manifold Refer to Exhaust Manifold 303 01B Engine 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel In vehicle Repair 2 Remove the EGR cooler Refer to Exhaust Gas Recirculation EGR Cooler 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 08B Engine Emission Control 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Install...

Page 1123: ...1 To install reverse the removal procedure http vnx su ...

Page 1124: ...ressure gauge with a vacuum piston which acts as a display and indicates the condition of the air cleaner element The air cleaner condition indicator is mounted on the air cleaner directly behind the air cleaner element It uses the available vacuum in the air intake system to continuously measure the air permeability of the air cleaner element The measurement of the air permeability of the air cle...

Page 1125: ...one air cleaner element should be replaced Red zone air cleaner element must be replaced NOTE Under the effects of extreme humidity it is possible for the air cleaner condition indicator to give an incorrect reading If the air cleaner element has only recently been replaced but the vacuum piston is in the clear zone or the red zone then press the reset button The air cleaner element does not need ...

Page 1126: ...scription and Operation Description Charge air cooler outlet pipe Intake air temperature IAT sensor Charge air cooler intake pipe Air cleaner outlet pipe Mass air flow MAF sensor Air cleaner cover Air cleaner element Air cleaner intake pipe Air cleaner housing Positive crankcase ventilation PCV hose Charge air cooler Item 1 2 3 4 5 6 7 8 9 10 11 Part Number http vnx su ...

Page 1127: ...ve intake air noise Detached air cleaner intake pipe Detached air cleaner outlet pipe Detached charge air cooler intake pipe vehicles with diesel engines Detached charge air cooler outlet pipe vehicles with diesel engines CHECK the pipe s for security and leaks to atmosphere INSTALL new intake air system components as necessary TEST the system for normal operation Oil in the air intake system Bloc...

Page 1128: ...r 75 PS 90 PS 303 04C Diagnosis and Testing Turbocharger 110 PS Vehicles With Fixed Vane Turbocharger 303 04C Diagnosis and Testing Turbocharger 110 PS Vehicles With Variable Vane Turbocharger 303 04C Diagnosis and Testing http vnx su ...

Page 1129: ... s and table s Description Air cleaner outlet pipe retaining clamp See Removal Detail Intake air temperature IAT sensor electrical connector See Removal Detail Engine breather pipe See Removal Detail Air cleaner See Removal Detail See Installation Detail 2 To install reverse the removal procedure Removal Details Item 1 Air cleaner outlet pipe retaining clamp Item 1 2 3 4 Part Number http vnx su ...

Page 1130: ...ther pipe Installation Details Item 4 Air cleaner NOTE Make sure the three locating pegs on the air cleaner housing are located into the rubber grommets on the support bracket 1 Vehicles with 1 8L petrol engine disconnect the mass air flow MAF sensor electrical connector 1 Vehicles with 1 8L petrol engine disconnect the breather pipe http vnx su ...

Page 1131: ...tion s and table s Description Charge air cooler air duct retaining screws Charge air cooler air duct Charge air cooler intake hose retaining clamp See Removal Detail See Installation Detail Charge air cooler intake hose Charge air cooler outlet hose retaining clamp See Removal Detail See Installation Detail Charge air cooler outlet hose Intake air temperature IAT sensor electrical connector Charg...

Page 1132: ...s removed Failure to follow this instruction may cause premature failure of adjacent components NOTE Make sure that the inside of the charge air cooler outlet hose is clean and free from any oil residue as this will reduce the installation grip of the hose to the charge air cooler Item 3 Charge air cooler intake hose retaining clamp CAUTION The charge air cooler intake hose retaining clamp must be...

Page 1133: ...sit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details Installation 1 Torque 3 Nm 2 CAUTION Make sure that the inside of the pipe ends are clean and free of oil residue 1 Torque 4 Nm 2 Torque 9 Nm 1 To install reverse the removal procedure http vnx su ...

Page 1134: ... Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the cause is not visually evident verify the symptom and refer to WDS to diagnose the system Mechanical Electrical Vacuum line s Evaporative emission EVAP system canister EVAP system hose s EVAP system canister purge valve Fuse s Wiri...

Page 1135: ...ining clip See Removal Detail Evaporative emission canister 3 To install reverse the removal procedure Removal Details Item 1 Evaporative emission canister outlet pipe quick release coupling Item 3 Evaporative emission canister retaining clip 1 Remove the fuel tank For additional information refer to Section 310 01A Fuel Tank and Lines 310 01B Fuel Tank and Lines Item 1 2 3 4 1 Disconnect the evap...

Page 1136: ...ve the evaporative emission canister 1 Release the evaporative emission canister retaining clip 2 Slide the evaporative emission canister off of the evaporative emission canister retaining bracket http vnx su ...

Page 1137: ...mshaft position CMP sensor retaining bolt 20 15 Power steering pressure switch 20 15 Heated oxygen sensor HO2S 48 35 Description Nm lb ft lb in Powertrain control module PCM electrical connector retaining bolt 4 35 Crankshaft position CKP sensor retaining bolt 6 53 Fuel temperature sensor 15 11 Knock sensor KS retaining bolt 20 15 Cylinder head temperature CHT sensor 20 15 Heated oxygen sensor HO2...

Page 1138: ...n and Operation Components of the engine management system Description Mass Air Flow MAF sensor with integrated Intake Air Temperature IAT sensor Throttle Position TP sensor Cylinder Head Temperature CHT sensor Crankshaft position CKP sensor Camshaft Position CMP Sensor Pre cat Heated Oxygen Sensor HO2S Item 1 2 3 4 5 6 Part Number http vnx su ...

Page 1139: ...ompressor clutch radiator fan circuit Coil Electronic Ignition EI Instrument cluster communicates with the PCM via the SCP data bus Malfunction Indicator Lamp MIL Locations of PCM and inertia fuel cut off switch The PCM is located under a cover on the right hand A pillar RHD vehicle shown The inertia fuel cut off switch is located on the driver s side underneath a cover on the A pillar The inertia...

Page 1140: ...Description PCM Inertia fuel cut off switch Item 1 2 http vnx su ...

Page 1141: ... 06 2002 Print Description and Operation Components of the engine management system Description Crankshaft position CKP sensor Cylinder Head Temperature CHT sensor Intake Air Temperature IAT sensor in the intercooler IAT sensor in front of the turbocharger Ignition lock Battery Item 1 2 3 4 5 6 Part Number http vnx su ...

Page 1142: ... Gas Recirculation EGR valve VP 30 distributor injection pump with pump control unit Generator control EEC V Powertrain Control Module PCM Data Link Connector DLC A C compressor and radiator fan control Pre glow module EGR solenoid valve Instrument cluster Pre glow indicator lamp fault lamp 7 8 9 10 11 12 13 14 15 16 17 18 19 http vnx su ...

Page 1143: ...Duratorq TDCi VNT 66kW 90PS Lynx 1 8L Duratorq TDCi VNT 55kW 75PS Lynx 1 8L Duratorq TDCi 81kW 110PS Lynx 1 8L Duratorq TDCi Lynx Diesel Transit Tourneo Connect 2002 5 06 2002 Print Description and Operation Components of the engine management system Description Manifold Absolute Pressure MAP sensor Cylinder Head Temperature CHT sensor Item 1 2 Part Number http vnx su ...

Page 1144: ...DCi installed in the 2002 5 onward Transit Connect is now only regulated by one PCM In this PCM the functions of the PCM and the functions of the Injector Driver Module IDM are combined This is referred to as the so called One Box System The strategies for engine management and for actuation of the injectors are very similar to those found on the system with a PCM and an IDM the so called Two Box ...

Page 1145: ...Description Conventional PCM IDM PCM for the 1 8L Duratorq TDCi engine in the 2002 5 onward Transit Connect Item 1 2 3 Part Number http vnx su ...

Page 1146: ...Petroleum Gas LPG Transit Tourneo Connect 2002 5 06 2002 Print Description and Operation Vehicles with LPG fuel system Description Powertrain control module PCM Clutch pedal position CPP switch Throttle position TP sensor Fuel vaporizer coolant temperature sensor Item 1 2 3 4 Part Number http vnx su ...

Page 1147: ... MAF sensor Idle air control IAC valve Vehicle speed sensor VSS Camshaft position CMP sensor Crankshaft position CKP sensor Catalyst monitor sensor Heated oxygen HO2S sensor Power steering pressure PSP switch Cylinder head temperature CHT sensor 5 6 7 8 9 10 11 12 13 14 15 http vnx su ...

Page 1148: ...el Concern display must be possible using a generic scan tool EOBD consists of the following elements Drive Cycle A drive cycle commences when the engine is started cold or warm and ends when the engine is switched off Trip A trip begins when the engine is started and is complete when all the EOBD monitors have completed a self test This may take place over a number of drive cycles On diesel varia...

Page 1149: ...le driving conditions exist and potential faults are accumulated and compared with acceptance criteria Examples of this type are the turbocharger boost pressure and Exhaust gas recirculation EGR monitors on vehicles with common rail fuel injection Comprehensive Component Monitor CCM When the CCM detects a component operating out of tolerance it sets a Diagnostic Trouble Code DTC which is stored in...

Page 1150: ...ecks if the upstream HO2S is able to switch fast enough and whether the voltage output is correct The operation of the sensor heating element is also checked This test is carried out under closed loop control Downstream HO2S test This test is only started when the upstream HO2S test has been successfully completed To protect the downstream HO2S it is only switched on when it has reached a pre dete...

Page 1151: ...normal operation it should illuminate at key on and go out almost as soon as the engine is started Diagnostic Trouble Codes DTCs The DTCs given by the PCM are standardized which means that generic scan tools can read results from all vehicles The DTC is always a 5 digit alphanumerical code for example P0100 The first digit of a code letter identifies the system which has set the code Provision has...

Page 1152: ...reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the cause is not visually evident verify the symptom and refer to WDS or equivalent scan tool for further diagnostics Mechanical Electrical Sensors Actuators Fuse s Wiring harness Electrical connector s Powertrain control module PCM http vnx su ...

Page 1153: ...ion using the programmable modules installation routine prior to commencing the removal of the PCM 2 Remove the components in the order indicated in the following illustration s and table s Description Glovebox retaining bolts Glovebox Passenger side instrument panel lower footwell trim panel retaining clips Passenger side instrument panel lower footwell trim panel 1 Disconnect the battery ground ...

Page 1154: ...lled connect WDS Download the PCM configuration information using the programmable modules installation routine after the installation of the PCM Removal Details Item 6 PCM security bracket shear bolt CAUTION When removing the PCM security bracket do not place excessive strain on the wiring harness NOTE Make sure the floor covering is protected before drilling is started Item 5 6 7 8 9 Part Number...

Page 1155: ...e PCM security bracket shear bolt Drill a 3mm pilot hole in the center of the security bracket welded nut Drill a 8mm hole in the security bracket welded nut and remove the security bracket shear bolt http vnx su ...

Page 1156: ...rmation using the programmable modules installation routine prior to commencing the removal of the PCM 2 Remove the components in the order indicated in the following illustration s and table s Description Instrument panel lower panel retaining screws Instrument panel lower panel retaining clips Headlamp switch electrical connector Instrument panel lower panel 1 Disconnect the battery ground cable...

Page 1157: ...lled connect WDS Download the PCM configuration information using the programmable modules installation routine after the installation of the PCM Removal Details Item 6 PCM security bracket shear bolt CAUTION When removing the PCM security bracket do not place excessive strain on the wiring harness NOTE Make sure the floor covering is protected before drilling is started Item 5 6 7 8 9 Part Number...

Page 1158: ...e PCM security bracket shear bolt Drill a 3mm pilot hole in the center of the security bracket welded nut Drill a 8mm hole in the security bracket welded nut and remove the security bracket shear bolt http vnx su ...

Page 1159: ...mable modules installation routine prior to commencing the removal of the PCM 2 Remove the components in the order indicated in the following illustration s and table s Description Glovebox retaining bolts Glovebox Passenger side instrument panel lower footwell trim panel retaining clips Passenger side instrument panel lower footwell trim panel 1 Disconnect the battery ground cable For additional ...

Page 1160: ... PCM configuration information using the programmable modules installation routine after the installation of the PCM Removal Details Item 6 PCM security bracket shear bolt CAUTION When removing the PCM security bracket do not place excessive strain on the wiring harness NOTE Make sure the floor covering is protected before drilling is started Item 5 6 7 8 9 1 File a flat across the PCM security br...

Page 1161: ...hear bolt Drill a 2mm pilot hole 3mm from the outer edge of the security bracket welded nut at an angle inwards of approximately 2 Drill a 5mm hole in the security bracket welded nut and remove the security bracket shear bolt http vnx su ...

Page 1162: ...rogrammable modules installation routine prior to commencing the removal of the PCM 2 Remove the components in the order indicated in the following illustration s and table s Description Instrument panel lower panel retaining screws Instrument panel lower panel retaining clips Headlamp switch electrical connector Instrument panel lower panel 1 Disconnect the battery ground cable For additional inf...

Page 1163: ... PCM configuration information using the programmable modules installation routine after the installation of the PCM Removal Details Item 6 PCM security bracket shear bolt CAUTION When removing the PCM security bracket do not place excessive strain on the wiring harness NOTE Make sure the floor covering is protected before drilling is started Item 5 6 7 8 9 1 File a flat across the PCM security br...

Page 1164: ...hear bolt Drill a 2mm pilot hole 3mm from the outer edge of the security bracket welded nut at an angle inwards of approximately 2 Drill a 5mm hole in the security bracket welded nut and remove the security bracket shear bolt http vnx su ...

Page 1165: ... necessary when installing a new component Upload the PCM configuration information using the Programmable Modules Installation routine General Equipment Worldwide Diagnostic System WDS 2 Disconnect the battery ground cable Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 3 Remove the right hand side wheel and tire Refer to Wheel and Tire 204 04 Wheels ...

Page 1166: ...se the removal procedure 2 NOTE This step is only necessary when installing a new component Download the PCM configuration information using the Programmable Modules Installation routine General Equipment Worldwide Diagnostic System WDS http vnx su ...

Page 1167: ...lowing illustration s and table s Description Mass air flow MAF sensor electrical connector See Installation Detail Air cleaner outlet pipe to throttle body retaining clamp Air cleaner outlet pipe to throttle body Engine breather pipe Air cleaner and outlet pipe 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables Item 1 2 3 4 5 Part ...

Page 1168: ...lve IAC valve seal See Removal Detail See Installation Detail 3 To install reverse the removal procedure Removal Details Item 9 IAC valve seal NOTE Discard the IAC seal Installation Details Item 9 IAC valve seal NOTE Install a new IAC seal Item 6 7 8 9 Part Number http vnx su ...

Page 1169: ...s routed and secured in such a way that it cannot be damaged by heat or moving components and will not cause a noise vibration or harshness NVH issue 1 Remove the components in the order indicated in the following illustration s and table s Description Expansion tank coolant pipe retaining clips Bypass tube retaining clips Bypass tube HO2S electrical connector HO2S See Removal Detail 2 To install ...

Page 1170: ...1 Using the special tool remove the HO2S http vnx su ...

Page 1171: ...components in the order indicated in the following illustration s and table s Description CHT sensor electrical connector See Removal Detail CHT sensor See Removal Detail 3 To install reverse the removal procedure Socket Cylinder Head Temperature Sensor 303 680 21 239 1 Remove the generator For additional information refer to Section 414 02 Generator and Regulator Item 1 2 Part Number http vnx su ...

Page 1172: ...Removal Details Item 1 CHT sensor electrical connector Item 2 CHT sensor 1 Detach and disconnect the CHT sensor electrical connector 1 Using the special tool remove the CHT sensor http vnx su ...

Page 1173: ...that a new component is installed Socket Cylinder Head Temperature Sensor 303 680 21 239 1 Remove the positive crankcase ventilation PCV oil separator For additional information refer to Crankcase Vent Oil Separator 75 PS 90 PS 303 08B Engine Emission Control 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Removal and Installation 2 Using the special tool remove the CHT sensor 1 To i...

Page 1174: ...the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Disconnect the CKP sensor electrical connector 3 Remove the CKP sensor retaining bolt 4 Remove the CKP sensor Discard the CKP sensor 1 If the new CKP sensor has a raised feature on the tip follow steps 2 through to 4 If the new CKP sensor has a flat ti...

Page 1175: ...or electrical connector 5 Install the CKP sensor against the flywheel 6 Using suitable feeler gauges take note of the measurement of the gap between the CKP sensor and the CKP sensor housing 7 Set the CKP sensor gap to the flywheel 1 Add 1 2 mm to the measurement recorded in step 11 Using suitable feeler gauges set to the calculated figure set the gap between the CKP sensor and the CKP sensor hous...

Page 1176: ...etaining bolt 9 Connect the CKP sensor electrical connector 10 Connect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures http vnx su ...

Page 1177: ...ilure to follow this instruction may result in personal injury CAUTIONS Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible Foreign matter from work on clutches brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction Always carry out the cleaning process before carrying out any repai...

Page 1178: ...rotected from contamination Failure to follow this instruction may cause premature failure of the generator Protect the generator with lint free material to prevent contamination 5 CAUTION Protect the fuel metering valve and fuel temperature sensor electrical connectors to prevent contamination with the cleaning fluid Clean the fuel pump and surrounding areas For additional information refer to Fu...

Page 1179: ... ring seal and fuel temperature sensor 1 Remove and discard the blanking plug from the fuel pump 2 Using the Pneumatic vacuum gun vacuum foreign material from the fuel pump open port 3 Using a suitable multipurpose lubricant spray lubricate the new fuel temperature sensor O ring seal 4 Install the O ring seal and fuel temperature sensor fuel pump shown removed for clarity 5 Connect the fuel temper...

Page 1180: ...q TDDi Lynx Diesel 309 00 Exhaust System Removal and Installation 2 Torque 23 Nm 3 NOTE Note the position of the component before removal Torque 20 Nm 1 CAUTION A new component may be supplied with a longer cable than the one removed Make sure that the cable cannot be damaged or cause a noise vibration or harshness NVH concern NOTE Make sure that the sensor is installed in the same location as whe...

Page 1181: ...l Installation 1 Clean the fuel temperature sensor and surrounding areas Refer to Fuel Injection Component Cleaning Vehicles With Common Rail Fuel Injection 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel General Procedures 2 1 NOTE Make sure that the sensor housing is clean and free of foreign material To install reverse the removal procedure http ...

Page 1182: ...ption CMP sensor electrical connector CMP sensor retaining bolt CMP sensor See Installation Detail 2 To install reverse the removal procedure Installation Details Item 3 CMP sensor CAUTION Make sure that the CMP sensor locating hole is free from foreign matter before installing the CMP sensor Failure to follow this instruction may result in incorrect installation of the CMP sensor and will not all...

Page 1183: ...ties Clutch Torque specifications Parts Specification Manual transmission fluid WSD M2C200 C High temperature grease ESD M1C220 A Super DOT 4 brake fluid ESD M6C57 A Liters MTX 75 manual transaxle 0 5 mm below the lower edge of the oil level check bore 1 9 Decription mm Pedal travel 133 3 Description Nm lb ft lb in Clutch slave cylinder bleed nipple 21 15 http vnx su ...

Page 1184: ...s 1 1 Check the operation of the clutch Lay a block of wood approximately 25 mm thick under the clutch pedal and depress the clutch pedal as far as the stop If first or second gear can be selected with the engine running and the parking brake applied without any concerns the clutch is OK 2 2 If the gear s cannot be selected REFER to Symptom Chart Transaxle noise concerns 1 1 Check the engine and t...

Page 1185: ...the brake and clutch hydraulic systems for leaks REPAIR as necessary Air in the clutch hydraulic system BLEED the system REFER to Clutch System Bleeding 308 00 Manual Transmission Transaxle and Clutch General Information General Procedures Clutch pedal free travel Clutch pressure plate Clutch disc Crankshaft end play GO to Pinpoint Test C Clutch pedal pulsation Clutch pressure plate Clutch disc IN...

Page 1186: ...bearings DISASSEMBLE the transaxle REFER to Transaxle 308 03 Manual Transmission Transaxle Vehicles With Manual Transaxle Vehicles With MTX 75 Disassembly INSTALL new components as necessary Clutch pedal Clutch release bearing GO to Pinpoint Test D Fluid leakage Clutch master cylinder Clutch slave cylinder Clutch hydraulic lines INSPECT the brake and clutch hydraulic systems for leaks REPAIR as ne...

Page 1187: ... slave cylinder REFER to Clutch Slave Cylinder 308 02 Clutch Controls Removal and Installation TEST the system for normal operation No INSTALL a new clutch master cylinder REFER to Clutch Master Cylinder 308 02 Clutch Controls Removal and Installation TEST the system for normal operation PINPOINT TEST B CLUTCH CHATTER OR SHUDDER TEST CONDITIONS DETAILS RESULTS ACTIONS B1 TEST FOR CLUTCH SHUDDER St...

Page 1188: ...late REFER to Clutch Disc and Pressure Plate 308 01 Clutch Removal and Installation 1 Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid Yes CHECK the engine and transaxle for leaks INSTALL new components as necessary TEST the system for normal operation No GO to C3 C3 CHECK THE CLUTCH DISC AND PRESSURE PLATE Visually check the clutch disc and pressure plate 1 Is the cl...

Page 1189: ...CTIONS D1 STATIC CHECK Depress and release the clutch pedal 1 Is the noise apparent when the clutch is operated Yes LUBRICATE the clutch and brake pedal shaft TEST the system for normal operation No GO to D2 D2 DYNAMIC CHECK Start the engine 1 Depress the clutch pedal 2 Is the noise apparent when the clutch pedal is depressed Yes REFER to Engine 303 00 Engine System General Information Diagnosis a...

Page 1190: ...ansaxle and Clutch General Information Clutch Slave Cylinder Check Transit Tourneo Connect 2002 5 06 2002 Print General Procedures 1 Check the clutch slave cylinder and release bearing assembly For leaks Bellows http vnx su ...

Page 1191: ...utch control system is self venting The components are arranged in such a way that small amounts of air trapped in the system are removed automatically Vehicles built up to 10 2004 Hand Vacuum Pressure Pump 416 001D 23 036A Name Super DOT 4 brake fluid 1 Extract brake fluid from the brake fluid reservoir until the level is at the MIN mark 2 Fill the reservoir of the special tool with approx 100 ml...

Page 1192: ... In order to remove any small amounts of trapped air remaining in the system operate the clutch pedal several times max 4 5 times using the full clutch pedal travel 9 Check the brake fluid level The brake fluid level must be between the MIN and MAX marks If the level drops below the MIN mark the brake warning light comes on If necessary top up the brake fluid reservoir with Super DOT 4 brake fluid...

Page 1193: ...ng reverse gear If gear engagement is excessively noisy remove the small amounts of trapped air remaining in the system by operating the clutch pedal several times max 4 5 times using the full clutch pedal travel After waiting approx 30 seconds check the operation of the clutch again If gear engagement is still excessively noisy repeat the previous steps http vnx su ...

Page 1194: ...tional information refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 3 Using the special tool lock the gearshift lever 1 Pull the reverse gear release 2 Install the special tool 4 Rotate the special tool approximately 45 degrees clockwise to lock the gearshift mechanism 5 Detach the gearshift cables from the transaxle 1 Detach the gearshift cable from the g...

Page 1195: ...ransaxle into 3rd gear 8 NOTE The selector cable is colored black Attach the selector cable to the selector lever 9 Adjust the selector cable Press the locking tab 10 Shift the transaxle into neutral 11 NOTE The gearshift cable is colored white Attach the gearshift cable to the gearshift linkage http vnx su ...

Page 1196: ...egrees counterclockwise to unlock the gearshift mechanism 14 Remove the special tool 1 Pull the reverse gear release 2 Remove the special tool 15 Using the special tool lock the gearshift lever 16 Detach the selector cable from the selector lever 1 Release the selector cable adjuster 2 Press the selector cable catch http vnx su ...

Page 1197: ...lector cable 1 Press the selector cable catch and attach the selector cable to the selector lever 2 Lock the selector cable adjuster 20 Attach the gearshift cable to the gearshift lever 1 Shift the transmission into neutral 2 Press the gearshift cable catch and attach the gearshift cable to the gear lever 21 Remove the special tool http vnx su ...

Page 1198: ...tall the air cleaner For additional information refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 23 Attach the gearshift lever boot and trim panel to the floor console http vnx su ...

Page 1199: ...02 Print Clutch Torque Specifications Type Single plate dry clutch Operation Hydraulic External diameter 1 8L Zetec E 1 8L Endura DI 228 mm Pedal travel not adjustable 133 3 mm Description Nm lb ft lb in Clutch pressure plate retaining bolts 29 21 http vnx su ...

Page 1200: ...utch Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Manual Transaxle and Clutch 308 00 Manual Transmission Transaxle and Clutch General Information Diagnosis and Testing http vnx su ...

Page 1201: ...m spring is no longer under pressure about two turns Detach the clutch from the flywheel Remove the bolts and lift the clutch pressure plate and disc from the guide pegs Discard the bolts 1 Centre the clutch disc on the pressure plate 2 CAUTION Tighten the bolts evenly working diagonally until the pressure plate is fully in contact with the flywheel NOTE Install new clutch pressure plate bolts Ins...

Page 1202: ...3 Remove the special tools 4 Install the transmission For additional information refer to Section 308 03 Manual Transmission Transaxle http vnx su ...

Page 1203: ...sives Clutch Controls Torque Specifications Item Specification Slave cylinder sealer ESK M4G269 A Brake fluid Super DOT 4 ESD M6C57 A Operation Hydraulic Adjustment Automatic Pedal travel not adjustable 133 3 mm Description Nm lb ft lb in Clutch master cylinder bolts 9 80 Clutch slave cylinder 10 89 http vnx su ...

Page 1204: ...utch Controls Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Manual Transaxle and Clutch 308 00 Manual Transmission Transaxle and Clutch General Information Diagnosis and Testing http vnx su ...

Page 1205: ...e brake fluid reservoir cap 5 CAUTION If brake fluid is spilt on the paintwork the affected area must be immediately washed down with cold water Using a suitable syringe remove brake fluid from the brake fluid reservoir until the brake fluid level is at MIN mark 6 Install the brake fluid reservoir cap 7 CAUTION Cap the clutch slave cylinder supply line to prevent fluid loss and dirt ingress NOTE R...

Page 1206: ...inder actuating rod from the clutch pedal 1 Install the clutch master cylinder Attach the clutch master cylinder actuating rod to the clutch pedal Lock the clutch master cylinder to the pedal assembly 2 Install the clutch master cylinder retaining bolts 3 NOTE Make sure that the locking plates are correctly seated Connect the clutch master cylinder hoses 1 Connect the clutch master cylinder supply...

Page 1207: ...nd Filtering Removal and Installation 6 Install the battery For additional information refer to Battery 414 01 Battery Mounting and Cables Removal and Installation 7 Bleed the clutch system For additional information refer to Clutch System Bleeding 308 00 Manual Transmission Transaxle and Clutch General Information General Procedures http vnx su ...

Page 1208: ... Transmission 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Vehicles Built From 04 2009 308 03 Manual Transmission Transaxle Vehicles With Manual Transaxle Vehicles With MTX 75 Removal Transaxle 1 8L Duratec DOHC 85kW 115PS Zetec 308 03 Manual Transmission Transaxle Vehicles With Manual Transaxle Vehicles With MTX 75 Removal 2 Degrease the input shaft splines 3 CAUTION Wrap the inp...

Page 1209: ...esel 1 8L Duratorq TDDi Lynx Diesel Vehicles Built Up To 03 2009 308 03 Manual Transmission Transaxle Vehicles With Manual Transaxle Vehicles With MTX 75 Installation Transmission 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Vehicles Built From 04 2009 308 03 Manual Transmission Transaxle Vehicles With Manual Transaxle Vehicles With MTX 75 Installation Transaxle 1 8L Duratec DOHC ...

Page 1210: ...rive 4 060 4 060 Type Input Shaft mm Output Shaft mm Differential mm Measuring shims 1 00 1 00 1 10 Determined end float 0 22 0 33 0 36 Preload figure 0 13 0 33 End float 0 05 Required shim thickness 1 17 1 46 1 79 Shims available 1 15 1 71 in 0 01 mm steps 1 31 1 91 in 0 02 mm steps 1 40 2 20 in 0 05 mm steps Description Nm lb ft lb in Lower arm to wheel knuckle retaining bolt 150 111 Intermediat...

Page 1211: ...ission fluid filler plug 45 33 Subframe front retaining bolts 200 148 Subframe rear retaining bolts 115 85 Starter motor to transaxle housing 35 26 Cooling fluid tube bracket retaining nuts 25 18 http vnx su ...

Page 1212: ... 3rd gear The output shaft and output pinion are made as one component Synchronised reverse gear Bearing bracket for reverse gear idler shaft for all engine variants High mounted transmission breather for the prevention of water ingress when driving through water up to 450 mm deep The final drive is integrated into the transmission housing Gearshift mechanism Modified shift mechanism for improved ...

Page 1213: ...g transmission housing side 3rd gear needle roller bearing 3rd gear wheel 3rd gear synchroniser ring Complete synchroniser assembly for 3rd 4th gear Snap ring 4th gear synchroniser ring 4th gear needle roller bearing 4th gear wheel 5th gear wheel Snap ring Taper roller bearing clutch housing side Output shaft 3rd gear 1 258 1 258 1 448 4th gear 0 921 0 921 1 028 5th gear 0 705 0 705 0 767 Reverse ...

Page 1214: ...ngs on the clutch housing side and the transmission housing side halves of the housing Description Taper roller bearing clutch housing side Output pinion inseparable Output shaft 1st gear needle roller bearing 1st gear wheel Inner synchroniser ring 1st gear Synchroniser cone 1st gear Outer synchroniser ring 1st gear Complete synchroniser assembly for 1st 2nd gear Snap ring Outer synchroniser ring ...

Page 1215: ...on housing side Bearing bracket for reverse gear idler Description Reverse gear idler Reverse gear idler shaft Bearing bracket for reverse gear idler shaft The MTX 75 is equipped with a bearing bracket for the reverse gear idler The provides significant additional strength for the reverse gear idler allowing it to absorb even the high torque peaks particularly on the 1 8L Duratorq TDCi engine with...

Page 1216: ...positioning of the transmission breather Description Retaining clip Transmission breather Transmission breather hose Retaining clip NOTE During service repairs it is important to ensure that the transmission breather hose is routed according to the instructions and is therefore securely clipped in place refer to the current service literature The transmission breather is connected via a hose to th...

Page 1217: ...Transaxle Vehicles With MTX 75 Manual Transaxle Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Manual Transaxle and Clutch 308 00 Manual Transmission Transaxle and Clutch General Information Diagnosis and Testing http vnx su ...

Page 1218: ...ion or overheating possibly through excessive pre load Install a new bearing and new seals if necessary Check the bearing is correctly lubricated 3 Check whether the ends of the taper rollers are worn away due to incorrect installation excessive pre load or faulty bearing seating Install a new bearing and new seals if necessary Check the bearing is correctly lubricated 4 Check whether the bearing ...

Page 1219: ...heating yellow or brown is normal due to excessive pre load or inadequate lubrication Install a new bearing new seals and check other components as necessary 7 Check the surfaces for abrasion due to metal fatigue Install a new bearing and clean all other affected components as necessary http vnx su ...

Page 1220: ...nsmission Oil 75W FE WSS M2C200 D2 7U7J M2C200 BA 1 NOTE Make sure that the vehicle is standing on a level surface Refer to Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Lifting 100 02 Jacking and Lifting Description and Operation 3 1 WARNING Be prepared to collect escaping fluid 2 Torque 35 Nm 4 5 Material Transmission Oil 75W FE WSS M2C200 D2 7U7J ...

Page 1221: ...6 Torque 35 Nm http vnx su ...

Page 1222: ...nsmission Oil 75W FE WSS M2C200 D2 7U7J M2C200 BA 1 NOTE Make sure that the vehicle is standing on a level surface Refer to Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Lifting 100 02 Jacking and Lifting Description and Operation 3 WARNING Be prepared to collect escaping fluid 4 Material Transmission Oil 75W FE WSS M2C200 D2 7U7J M2C200 BA 5 Torque ...

Page 1223: ...http vnx su ...

Page 1224: ...mer 205 047 15 011 Installer Front Halfshaft Oil Seal 205 115 15 058 Separator Ball Joint 211 020 13 006 Extractor Front Halfshaft Oil Seal 308 208 16 074 Name Manual transmission fluid 1 Loosen the strut top mount retaining nuts by four turns 2 Remove the wheel For additional information refer to Section 204 04 Wheels and Tires 3 CAUTION Do not unscrew the track rod end retaining nut from the bal...

Page 1225: ... to protect the thread Protect the ball joint gaiter using a soft cloth to prevent damage Protect the heat shield using a soft cloth to prevent damage Using a suitable two legged puller detach the lower suspension arm from the spindle carrier 1 Use a soft faced hammer to strike the lower suspension arm 2 Remove and discard the retaining nut 7 CAUTIONS Secure the halfshaft to prevent damage to the ...

Page 1226: ...e the halfshaft to prevent damage to the constant velocity joints The inner constant velocity joint must not be bent more than 18 degrees The outer constant velocity joint must not be bent more than 45 degrees Ensure that the halfshaft oil seal is not damaged Ensure that the snap ring is correctly located in the groove NOTE Fit a new halfshaft snap ring Attach the halfshaft to the transmission 3 W...

Page 1227: ... mm Allen key Attach the track rod end to the spindle carrier 5 Check the transmission fluid level and top up the manual transmission fluid if necessary For additional information refer to Section 308 03 Manual Transmission Transaxle 6 Install the wheel For additional information refer to Section 204 04 Wheels and Tires 7 Tighten the strut top mount retaining nut http vnx su ...

Page 1228: ...cles with diesel engine 1 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 2 Remove the vehicle speed sensor VSS Disconnect the VSS electrical connector Remove the retaining bolt 3 Remove the VSS 1 Remove the retaining pin 2 Disconnect the VSS electrical connector 1 Install the vehicle speed sensor VSS 1 Connect the VSS electrical connector 2 Ins...

Page 1229: ...All vehicles 3 Lower the vehicle http vnx su ...

Page 1230: ...303 290A 303 290 01 21 140 01 Adapter for 303 290A 303 290 02 21 140 02 Adapter for 303 290A 303 290 03A 21 140 03A Transmission jack Retaining straps Syringe 1 Remove the battery For additional information refer to Section 414 01 Battery Mounting and Cables 2 Remove the battery tray For additional information refer to Section 414 01 Battery Mounting and Cables 3 Remove the air cleaner For additio...

Page 1231: ... the reversing lamp switch electrical connector 7 Disconnect the transaxle breather tube from the transaxle Unclip the breather tube 8 Detach the engine wiring harness from the support bracket 9 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 10 Remove the accessory drive belt cover http vnx su ...

Page 1232: ...le to prevent oil loss or dirt ingress Detach the right hand halfshaft and the intermediate shaft from the transaxle and secure it to one side Allow the oil to drain into a suitable container 14 CAUTIONS Support the halfshaft The inner joint must not be bent more than 18 degrees The outer joint must not be bent more than 45 degrees Do not damage the halfshaft seal Plug the transaxle to prevent oil...

Page 1233: ...bles from the bracket 16 Disconnect the vehicle speed sensor VSS electrical connector 17 Lower the vehicle 18 NOTE Do not disconnect the starter motor electrical connector Remove the starter motor upper retaining bolts 19 Remove the transaxle upper retaining studs 20 Install the special tools 21 Remove the engine rear mount center retaining nut Discard the nut http vnx su ...

Page 1234: ...d retaining bolts 24 Using the special tools lower the engine and transaxle assembly 25 Remove the engine rear mount bracket 26 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 27 CAUTION If brake fluid is spilt on the http vnx su ...

Page 1235: ...tach the starter motor from the transaxle and position it to one side 29 NOTE Support the transaxle with wooden blocks NOTE Use suitable retaining straps to secure the transaxle on the transmission jack Using a suitable transmission jack support the transaxle 30 Remove the transaxle left hand retaining bolts 31 Remove the transaxle right hand lower retaining bolt 32 Using a suitable transmission j...

Page 1236: ...33 Remove the transaxle http vnx su ...

Page 1237: ...26 16 092 Adapter for 204 226 204 226 01 16 092 01 Slide Hammer 205 047 15 011 Support Bar Engine 303 290A 21 140 Adapter for 303 290 303 290 02 21 140 02 Adapter for 303 290 303 290 03 21 140 03 Adapter for 303 290 303 290 01 21 140 01 Remover Installer cooling hose clamp 303 397 24 003 Transmission jack Securing straps 1 Shift the gearshift lever to the neutral position 2 Disconnect the battery ...

Page 1238: ...ir temperature IAT sensor electrical connector 6 CAUTION If brake fluid is spilt on the paintwork the affected area must be immediately washed down with cold water NOTE Plug the clutch slave cylinder supply line Disconnect the clutch slave cylinder supply line from the clutch slave cylinder Remove the spring clip 7 Detach the vehicle speed sensor VSS electrical wiring harness from the transaxle 8 ...

Page 1239: ...ntral electrical connector bracket from the transaxle 11 Detach the power steering line bracket from the transaxle 12 Remove the PCV unit upper retaining nut Detach the PCV unit from the transaxle and secure it to one side Detach the cooling fluid tube bracket from the transaxle and secure it to one side 13 Remove the transaxle upper retaining studs http vnx su ...

Page 1240: ...ting 100 02 Jacking and Lifting Description and Operation 17 Remove the crossmember For additional information refer to Crossmember 502 00 Uni Body Subframe and Mounting System Removal and Installation 18 Detach the gearshift cables from the transaxle 1 Detach the gearshift cables from the gearshift and selector lever 2 Turn the abutment sleeves clockwise and detach the cables from the bracket 19 ...

Page 1241: ...r bearing cap and locknuts 21 CAUTIONS Support the halfshaft The inner joint must not be bent more than 18 degrees The outer joint must not be bent more than 45 degrees Do not damage the halfshaft oil seal NOTE Plug the transaxle to prevent oil loss or dirt ingress Detach the right hand halfshaft and the intermediate shaft from the transaxle and secure it to one side Allow the oil to drain into a ...

Page 1242: ...ear mount 27 Using the special tools lower the engine and transaxle assembly 28 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 29 Remove the engine rear mount bracket retaining bolts 30 Remove the transaxle left hand retaining bolts http vnx su ...

Page 1243: ...ter motor cable bracket from the transaxle Detach the starter and secure it to one side 32 Remove the transaxle right hand lower retaining bolt 33 Using suitable securing straps secure the transaxle on a transmission jack 34 Remove the transaxle right hand upper retaining bolts 35 Remove the transaxle http vnx su ...

Page 1244: ...6 2002 Print Removal Special Tool s General Equipment 204 226 Remover Halfshaft 204 226 01 Adapter for 204 266 204 605 Separator Lower Arm Ball Joint 205 047 Slide Hammer 211 020 Separator Ball Joint 303 290 01 Adapter for 303 290A 303 290 02 Adapter for 303 290A 303 290 06 Adapter for 303 290A 303 290A Support Bar Engine Cable ties Retaining Strap Tire lever Transmission jack Two leg puller Woode...

Page 1245: ...cription and Operation 2 Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 3 On both sides Loosen 3 turn s 4 If equipped 5 6 Refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 7 http vnx su ...

Page 1246: ...8 9 10 http vnx su ...

Page 1247: ...11 Install the Special Tool s 303 290A 303 290 01 303 290 02 303 290 06 12 Refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 13 http vnx su ...

Page 1248: ...14 15 16 http vnx su ...

Page 1249: ...17 18 CAUTION Make sure that the ball joint ball does not rotate On both sides 19 CAUTION Make sure that the ball joint ball does not rotate On both sides Special Tool s 211 020 http vnx su ...

Page 1250: ...ure that the ball joint ball does not rotate On both sides 21 CAUTION Make sure that the ball joint ball does not rotate On both sides General Equipment Two leg puller 22 On both sides Special Tool s 204 605 http vnx su ...

Page 1251: ...23 WARNING Be prepared to collect escaping fluid Special Tool s 204 226 204 226 01 205 047 24 Secure to one side 25 WARNING Be prepared to collect escaping fluid 26 Secure to one side http vnx su ...

Page 1252: ...27 28 29 30 Secure to one side http vnx su ...

Page 1253: ...e is not forcibly bent General Equipment Cable ties 33 CAUTION Make sure that the exhaust flexible pipe is not forcibly bent General Equipment Tire lever 34 Lower the Vehicle 35 WARNING Be prepared to collect escaping fluid CAUTION Make sure that all openings are sealed http vnx su ...

Page 1254: ...36 37 38 Special Tool s 303 290A 39 Refer to Lifting 100 02 Jacking and Lifting Description and Operation 40 http vnx su ...

Page 1255: ...all the following items 1 General Equipment Wooden Block 42 Install the following items 1 General Equipment Wooden Block General Equipment Transmission jack General Equipment Retaining Strap 43 44 http vnx su ...

Page 1256: ...45 WARNING This step requires the aid of another technician General Equipment Transmission jack http vnx su ...

Page 1257: ...ring Outer Races 205 078 15 048 Adapter 205 078 01 15 048 01 Remover Bearing Outer Races 205 176 15 074 Mounting Bracket Engine Differential 205 329 15 105A Transmission Mounting Bracket in conjunction with 303 435 303 435 06 21 031B Remover Halfshaft Oil Seal 308 208 16 074 1 Install the special tools 2 NOTE Make sure the gearshift mechanism is in neutral Remove the gearshift mechanism http vnx s...

Page 1258: ...e special tool remove the front halfshaft oil seals 4 NOTE Only required for sealing repairs Remove the speedometer drive pinion 5 NOTE Only required for sealing repairs Remove the vehicle speed sensor VSS 6 NOTE Do not remove the locating dowels Undo the transmission housing bolts http vnx su ...

Page 1259: ...agnetic disc 9 Remove the selector rods and the first and second gear selector fork 10 Remove the selector forks 1 Swivel the fifth and reverse gear selector fork to the side and remove it 2 Turn the third and fourth gear selector fork and remove it 11 Remove the snap ring from the reverse gear idler 12 Remove the input shaft and the output shaft Lever the input and output shafts together out of t...

Page 1260: ...t shaft splines 16 CAUTIONS Do not allow brake fluid to come into contact with the skin or eyes If brake fluid contacts the skin or eyes rinse the affected area immediately with water Failure to observe these instructions can lead to personal injury Wrap the input shaft splines with adhesive tape to protect the input shaft oil seal from damage NOTE Discard the clutch slave cylinder Remove the clut...

Page 1261: ... special tool in the recesses in the housing 19 Remove the output shaft bearing outer race with the shim Locate the special tool in the recesses in the housing 20 NOTE Only when damaged or leaking Remove the reverse gear idler shaft 21 NOTE Only when damaged or leaking Remove the reverse gear idler shaft Drive it out using a block of hard wood http vnx su ...

Page 1262: ...1 Support Plate Gear Removal 308 198 16 063 Support Plate Gear Removal Dia 85 1 mm 308 230 16 077 Press Name Transmission fluid 1 CAUTION The inner synchronizer ring and the synchronizer cone must be handled very carefully General note Graphical overview of the input shaft For additional information refer to Manual Transaxle 308 03 Manual Transmission Transaxle Vehicles With Manual Transaxle Vehic...

Page 1263: ...e taper roller bearing on the transmission housing side 5 NOTE Remove the gear wheels using a suitable press NOTE Discard the snap ring Remove the fifth gear wheel 1 Remove the snap ring 2 Remove the gear wheel using the special tool 6 NOTE Remove the gear wheels using a http vnx su ...

Page 1264: ... 1 Remove the snap ring 2 Remove the synchronizer assembly 9 NOTE Mark the position of the selector ring with respect to the synchronizer hub for installation Components are paired NOTE Carefully pull the selector ring off the synchronizer hub The detent balls are spring loaded Disassemble the third and fourth gear synchronizer 1 Pull off the selector ring 2 Synchronizer hub 3 Compression spring 4...

Page 1265: ...zer 1 Insert the compression springs 2 Insert the blocker bar with the detent balls against the spring pressure 3 Push on the selector ring 5 NOTE Renew the snap ring use a snap ring with a collar height of 2 5 mm NOTE Fit the synchronizer hub with the large collar towards the outside and the ring groove facing the small collar Attach the complete 3rd 4th gear synchronizer assembly 1 Fit the compl...

Page 1266: ...eel Press on the fifth gear wheel using a suitable tube and a press Install a new snap ring 8 Press on the transmission side taper roller bearing Press the taper roller bearing on using a suitable tube and a press http vnx su ...

Page 1267: ...on housing roller bearing together with the reverse gear gearwheel using the special tool 2 Remove the reverse gear synchronizer ring 1 Remove the needle roller bearing 2 Remove the synchronizer ring 3 NOTE If gear changes are difficult carefully remove the synchronizer hub assembly and the fifth gear gearwheel Remove the fifth and reverse gear synchronizer hub assembly 1 Remove the circlip 2 Remo...

Page 1268: ...r ring and the synchronizer cone Remove the second gear synchronizer rings 1 Remove the needle roller bearing 2 Remove the synchronizer inner ring 3 Remove the synchronizer cone 4 Remove the synchronizer outer ring 8 Remove the first and second gear synchronizer hub assembly 1 Remove the circlip 2 Remove the synchronizer hub assembly 9 CAUTION Be careful when handling the inner synchronizer ring a...

Page 1269: ...rings 4 Remove the blocker bars 5 Remove the check balls 1 CAUTION Be careful when handling the inner synchronizer ring and the synchronizer cone Lubricate the synchronizer rings with transmission fluid prior to installation NOTE If installing new roller bearings do not lubricate the bearings Carefully clean and check all parts and coat sliding surfaces with transmission fluid before reassembly 2 ...

Page 1270: ...bly 1 Install the synchronizer hub assembly 2 Install the snap ring 5 Install the second gear gearwheel 1 Install the needle roller bearing 2 Install the synchronizer outer ring 3 Install the synchronizer cone 4 Install the synchronizer inner ring 5 Install the second gear gearwheel 6 Install the third gear gearwheel using the special tool 7 NOTE Install a new snap ring Install the fourth gear gea...

Page 1271: ...d the annular groove facing outwards Install the fifth and reverse gear synchronizer hub assembly 1 Install the synchronizer hub assembly 2 Install a new snap ring 11 Install the reverse gear gearwheel 1 Install the synchronizer ring 2 Install the needle roller bearing 3 Install the reverse gear gearwheel 12 Install the transmission housing roller bearing using a suitable tube 13 Install the clutc...

Page 1272: ...http vnx su ...

Page 1273: ...oller Bearing 205 081 15 032 Remover Taper Roller Bearing Main Tool 205 295 15 050A Collet for 205 295 308 197 16 062 Press Name Transmission fluid 1 Pull off the taper roller bearings from the differential illustration shows 1 8L diesel engine 1 Fit the special tool 2 Pull off the taper roller bearings Take off the speedometer worm gear 1 8L diesel engine or vehicle speed sensor ring VSS ring 1 8...

Page 1274: ...ng for the vehicle speed sensor must engage in the recess on the housing Press on the taper roller bearing illustration shows 1 8L diesel engine 1 Attach the speedometer worm gear 1 8L diesel engine or VSS ring 1 8L engine 2 Press on the taper roller bearing using a press and the special tool 4 CAUTION Do not use the taper roller bearing as a support Install the taper roller bearing spur gear end ...

Page 1275: ...special tool and a press http vnx su ...

Page 1276: ...204 050 14 024 Preload Gauge 205 067 15 041 Installer Rear Hub Oil Seal 205 075 15 036 Installer Drive Pinion Oil Seal 205 115 15 058 Socket Drive Pinion Nut 205 175 15 073 Compressor Valve Spring 303 060 21 024 Adapter for 303 060 303 060 02 21 024 02 Adapter for 303 060 303 060 07 21 024 07 Mounting Plate for 303 435 06 303 435 14A 21 212A Installer Input Shaft Oil Seal 307 210 17 041 Holding Fi...

Page 1277: ...3 CAUTION The press force must not exceed 15kN Fit the bearing races on the transmission housing side Heat up the transmission housing locally to approximately 80 C using a hot air blower Cool the bearing races with temperature reduction spray and fit them Fit the bearing races using the press 1 Input shaft using 307 210 17 041 2 Output shaft using 205 075 15 036 3 Differential using 204 050 14 02...

Page 1278: ...ear Fit the input shaft and the output shaft together in the transmission housing 7 NOTE Do not oil taper roller bearings which are to be used again Install new taper roller bearings untreated Install the differential illustration shows 1 8L diesel engine 8 NOTE Check that the mating surface is clean Position the clutch end housing section Attach the special tool to the transmission housing flange...

Page 1279: ... Attach the special tool to the transmission 2 Set up the magnetic dial indicator gauge base 3 Set the dial indicator to 0 13 NOTE Carry out both the previous and this step three times and calculate the average measurement Measure the input shaft end float 1 Lift the input shaft with a lever 2 Note the resulting measurement e g 0 22mm Example 0 22 mm 0 23 mm 0 21 mm divided by three 0 22 mm http v...

Page 1280: ...owing step three times and calculate the average measurement Measure the output shaft end float Lift the output shaft with a lever and note the resulting measurement e g 0 32mm Example 0 32 mm 0 34 mm 0 33 mm divided by three 0 33mm 16 Prepare the differential for measuring Turn the input shaft backwards and forwards 20 times and at the same time press down the differential Set up the dial indicat...

Page 1281: ...e previous step 0 22 mm End float dimension 0 05 mm Required shim 0 22 mm 0 05 mm 1 00 mm 1 17 mm 19 Calculate the required output shaft shim thickness Required shim thickness 1 00 mm Measured end float see previous step 0 33 mm Preload dimension 0 13 mm Required shim 1 00 mm 0 33 mm 0 13 mm 1 46 mm 20 Calculate the required differential shim thickness Required shim thickness 1 10mm Measured end f...

Page 1282: ...Reverse gear idler wheel smaller collar faces downwards 4 Upper thrust washer 5 Snap ring 24 Install the input and output shafts together Coat the taper roller bearing with transmission fluid 25 Install selector fork Move the fourth gear selector ring to the neutral position Insert the fifth and reverse gear selector fork and swivel it to the side 26 Install the third and fourth gear selector fork...

Page 1283: ...ting surface must be dry and free of oil Apply sealant evenly to the inside of the mating surface even 2 mm bead of sealant 30 NOTE The transmission housing must not be turned over to tighten the bolts Fit the clutch end housing section Tighten the 16 flange bolts within 15minutes working diagonally 31 NOTE Make sure the transmission is in neutral the gearshift lever and selector lever must be ver...

Page 1284: ...g torque Engage fourth gear Measure the turning torque If the turning torque is too high all the measurements to establish the required shim thickness must be repeated 33 Fit the speedometer drive pinion Insert the drive pinion Carefully drive in the roll pin 34 Install the vehicle speed sensor VSS 35 Install the front driveshaft oil seals http vnx su ...

Page 1285: ...ead to injury CAUTIONS Wrap the input shaft splines with adhesive tape to protect the input shaft oil seal Do not oil clutch slave cylinder NOTE Install a new clutch slave cylinder Install the clutch slave cylinder with a new oil seal and with slave cylinder sealer 37 Remove the adhesive tape from the input shaft splines 38 Apply a thin film of high temperature grease to the input shaft splines ht...

Page 1286: ...3 290A 21 140 Adapter for 303 290A 303 290 02 21 140 02 Adapter for 303 290A 303 290 03A 21 140 03A Adapter for 303 290A 303 290 01 21 140 01 Transmission jack Securing straps Name Manual transmission fluid 1 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 Using suitable securing straps secure the transaxle to a trans...

Page 1287: ...he starter motor to the transaxle Attach the starter motor cable bracket to the transaxle Attach the engine ground cable to the transaxle 9 Install the transaxle left hand retaining bolts 10 Install the engine rear mount bracket 11 Lower the vehicle 12 Using the special tools raise the engine and transaxle assembly http vnx su ...

Page 1288: ...ender retaining bolts 2 Remove the special tools 3 Tighten the fender retaining bolts 4 Install the fender retaining bolts 15 Connect the transaxle breather tube to the transaxle Clip the breather tube 16 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 17 Install the accessory drive belt cover 18 Connect the vehicle spe...

Page 1289: ...mage the halfshaft oil seal Make sure the snap ring is correctly seated NOTE Install a new snap ring Attach the left hand halfshaft to the transaxle 21 Attach the gearshift cables to the transaxle 1 Attach the gearshift cable to the bracket and turn the abutment sleeve counterclockwise 2 Attach the selector cable to the bracket and turn the abutment sleeve counterclockwise 22 Adjust the gearshift ...

Page 1290: ... bracket retaining nuts Attach the central electrical connector bracket to the transaxle 28 Install the positive crankcase ventilation PCV unit upper retaining nut Attach the PCV unit to the transaxle 29 Tighten the strut and spring assembly top mount retaining nuts on both sides 30 Connect the reversing lamp switch electrical connector http vnx su ...

Page 1291: ...inder Install the spring clip 33 Install the air cleaner For additional information refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 75 PS 90 PS 303 12 Intake Air Distribution and Filtering Removal and Installation Connect the intake air temperature IAT sensor electrical connector 34 Attach the air cleaner outlet pipe and the PCV hose to the engine 35 Instal...

Page 1292: ... General Information General Procedures 38 Connect the battery ground cable to the battery terminal clamp For additional information refer to Battery Cables 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 414 01 Battery Mounting and Cables Removal and Installation 39 Check the transmission fluid level and top up with manual transmission fluid if necessary http vnx su ...

Page 1293: ...140A Adapter for 303 290A 303 290 01 21 140 01 Adapter for 303 290A 303 290 02 21 140 02 Adapter for 303 290A 303 290 03A 21 140 03A Transmission jack Retaining straps Name Manual transmission fluid 1 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 2 NOTE Use suitable retaining straps secure the transaxle on a transmission jack Using a suitable ...

Page 1294: ...uid is spilt on the paintwork the affected area must be immediately washed down with cold water NOTE Make sure the spring clip is correctly seated Connect the clutch slave cylinder supply line to the transaxle Install the spring clip 8 Install the transaxle right hand retaining bolts 9 Attach the starter motor to the transaxle http vnx su ...

Page 1295: ...ear mount bracket 13 Using the special tools raise the engine and transaxle assembly 14 NOTE Install a new engine rear mount center retaining nut NOTE Do not fully tighten the engine rear mount retaining nuts at this stage Install the engine rear mount 15 Remove the special tools http vnx su ...

Page 1296: ...t the vehicle For additional information refer to Section 100 02 Jacking and Lifting 20 Attach the gearshift cables to the transaxle 1 Attach the gearshift cable to the bracket and turn the abutment sleeve counterclockwise 2 Attach the selector cable to the bracket and turn the abutment sleeve counterclockwise 21 Adjust the gearshift cables For additional information refer to Section 308 00 Manual...

Page 1297: ...le 24 CAUTIONS Support the halfshaft The inner joint must not be bent more than 18 degrees The outer joint must not be bent more than 45 degrees Do not damage the halfshaft seal NOTE Install a new center bearing cap and locknuts Attach the right hand halfshaft and the intermediate shaft to the transaxle Install the center bearing cap and locknuts 25 Install the crossmember For additional informati...

Page 1298: ...nsaxle with manual transmission fluid until the oil level is just below the bottom of the filler hole 33 Bleed the hydraulic clutch system For additional information refer to Section 308 00 Manual Transmission Transaxle and Clutch General Information 34 Fill and bleed the power steering system For additional information refer to Section 211 00 Steering System General Information 35 Install the air...

Page 1299: ...ector Halfshaft Seal 303 290 01 Adapter for 303 290A 303 290 02 Adapter for 303 290A 303 290 06 Adapter for 303 290A 303 290A Support Bar Engine Name Specification Grease K HT ESD M1C220 A A88SX1C220AA Grease KS PS SA M1C9107 A YS5J M1C9107 AA Cable ties Retaining Strap Tire lever Transmission jack Wooden Block 1 Refer to Health and Safety Precautions 100 00 General Information Description and Ope...

Page 1300: ...uipment Transmission jack 4 Perform this and the following operation simultaneously Torque 47 Nm 5 Torque 47 Nm 6 Remove the following items 1 General Equipment Wooden Block General Equipment Transmission jack General Equipment Retaining Strap 7 Remove the following items 1 General Equipment Wooden Block http vnx su ...

Page 1301: ...8 Torque 80 Nm 9 Lower the Vehicle 10 Special Tool s 303 290A 11 Torque 80 Nm http vnx su ...

Page 1302: ... 2 Torque 48 Nm 14 Refer to Clutch System Bleeding 308 00 Manual Transmission Transaxle and Clutch General Information General Procedures 15 Refer to Lifting 100 02 Jacking and Lifting Description and Operation http vnx su ...

Page 1303: ...E Make sure that a new component is installed 3 CAUTION Make sure that the exhaust flexible pipe is not forcibly bent General Equipment Tire lever Torque 48 Nm 17 Remove the following items General Equipment Cable ties 18 Torque 47 Nm 19 Torque 35 Nm http vnx su ...

Page 1304: ...20 Torque 47 Nm 21 Torque 47 Nm 22 Remove the special tool before completely installing the halfshaft Special Tool s 205 775 http vnx su ...

Page 1305: ...nt is installed Remove the special tool before completely installing the halfshaft Special Tool s 205 775 25 26 On both sides Special Tool s 204 605 27 CAUTIONS Make sure that a new nut is installed Make sure that the ball joint ball does not rotate On both sides Torque 150 Nm 28 CAUTIONS http vnx su ...

Page 1306: ... installed Make sure that the ball joint ball does not rotate On both sides Torque 47 Nm 29 CAUTION Make sure that the ball joint ball does not rotate On both sides Torque 50 Nm 30 31 1 Torque 47 Nm 2 Torque 80 Nm 32 http vnx su ...

Page 1307: ...saxle and Clutch General Information General Procedures 34 35 Refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 36 Lower the Vehicle 37 Remove the Special Tool s 303 290A 303 290 01 303 290 02 303 290 06 38 1 Torque 47 Nm 2 Torque 25 Nm http vnx su ...

Page 1308: ...39 40 41 http vnx su ...

Page 1309: ... Air Distribution and Filtering Removal and Installation 43 Torque 10 Nm 44 If equipped 45 On both sides Torque 25 Nm 46 Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures Torque 8 Nm http vnx su ...

Page 1310: ...Jacking and Lifting Description and Operation 48 Refer to Transmission Fluid Level Check 308 03 Manual Transmission Transaxle Vehicles With Manual Transaxle Vehicles With MTX 75 General Procedures 49 Lower the Vehicle http vnx su ...

Page 1311: ...ransit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Shift and selector cable bushing 9 80 Gearshift mechanism to floor assembly 9 80 Shift lever bearing housing to gearshift housing 9 80 Exhaust flange bolts 47 35 http vnx su ...

Page 1312: ...of which the gearshift action was noticeably improved At the same time this also requires a modified internal gearshift mechanism which can transfer the direct gearshift action accordingly to the shift forks The ends of the gearshift cables are different in design to prevent them being confused with each other Furthermore the selector cable is marked black and the shift cable is marked white Descr...

Page 1313: ...Gearshift cable mounting point on the selector lever shaft Selector shaft lever 12 13 http vnx su ...

Page 1314: ...s Gearshift lever damaged Transaxle selector mechanism damaged GO to Pinpoint Test A PINPOINT TEST A STIFF GEARSHIFT TEST CONDITIONS DETAILS RESULTS ACTIONS A1 CHECK THE GEARSHIFT LEVER Detach the gearshift cables from the gearshift lever 1 Is the gearshift lever difficult to operate Yes Install a new gearshift lever REFER to Gearshift Lever 308 06 Manual Transmission Transaxle External Controls R...

Page 1315: ...Instrument Panel and Console Floor Console Removal and Installation Floor Console Vehicles Built From 04 2009 Removal and Installation 2 Remove the air duct 3 Detach the gearshift cables from the retaining bracket Turn the abutment sleeves clockwise and detach the cable from the bracket 4 Detach the gearshift cables from the gearshift lever 5 Remove the gearshift lever 1 To install reverse the rem...

Page 1316: ...2 Adjust the gearshift cables For additional information refer to Gearshift Cable Adjustment 308 00 Manual Transmission Transaxle and Clutch General Information General Procedures http vnx su ...

Page 1317: ...suitable splint 3 Remove the exhaust flange retaining bolts Detach the exhaust flexible pipe from the support insulators 4 Detach the exhaust heat shield from the floor panel and push it backwards Unclip the shift and selector cables from the floor panel 5 Lower the vehicle 6 Remove the air cleaner For additional information refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal...

Page 1318: ... Remove the air distribution channel 10 Cut the carpet and the insulation pad to gain access to the gearshift cables 11 Detach the gearshift cables from the retaining bracket Turn the abutment sleeves clockwise and detach the cable from the bracket 12 Detach the gearshift cables from the gearshift lever 13 Remove the gearshift cables 1 Remove the nuts 2 Pull the cables through to the interior http...

Page 1319: ...arshift cables To install reverse the removal procedure 2 Adjust the gearshift cables For additional information refer to Gearshift Cable Adjustment 308 00 Manual Transmission Transaxle and Clutch General Information General Procedures http vnx su ...

Page 1320: ...rint Disassembly and Assembly Disassembly Assembly 1 NOTE Location of the spring Remove the bracket lever Remove the snap ring 2 Dismantle the bracket lever 1 Retaining clip 2 Spring 3 Sleeve 4 Bracket lever 3 Detach the bearing housing and bearing shell 1 Reassemble the parts in reverse order http vnx su ...

Page 1321: ...cles with M10 nuts 47 35 Catalytic converter to turbocharger nuts vehicles with M8 nuts 25 18 Catalytic converter to turbocharger nuts vehicles with variable vane turbocharger 25 18 Flexible pipe flange nuts 47 35 Muffler assembly flange nuts 47 35 Clamp nuts 47 35 HO2S 47 35 Support bracket nuts 22 16 Catalytic converter support bolt diesel 25 18 Manifold heatshield bolts 10 89 Catalytic converte...

Page 1322: ...ame Anti seize grease 1 Remove the exhaust manifold heat shield 2 Disconnect the heated oxygen sensor H02S electrical connector 3 Remove the H20S 4 Detach the catalytic converter from the exhaust manifold Discard the nuts 5 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 6 Disconnect the catalyst monitor sensor electrical http vnx su ...

Page 1323: ...flexible pipe with a suitable support wrap or suitable splint 9 Detach the exhaust flexible pipe from the catalytic converter Discard the gasket and nuts 10 CAUTION The catalytic converter must be supported while the support strap is removed Remove the catalytic converter support bracket 11 Remove the catalytic converter 1 CAUTION Never use jointing compound http vnx su ...

Page 1324: ...ard of the catalytic converter NOTE Coat the catalytic converter and exhaust flexible pipe studs with anti seize grease NOTE Install new gaskets and nuts To install reverse the removal procedure http vnx su ...

Page 1325: ... discard the catalytic converter to turbocharger nuts 2 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 3 Remove and discard the catalytic converter to turbocharger nuts 4 CAUTION Over bending of the exhaust flexible pipe may cause damage resulting in failure Support the exhaust flexible pipe with a suitable support wra...

Page 1326: ... catalytic converter to the cylinder block 2 NOTE Only tighten the nuts finger tight at this stage Attach the exhaust flexible pipe to the tailpipe and muffler assembly Coat the studs with grease Install new nuts 3 CAUTION Jointing compound must not be used forward of the catalytic converter NOTE Only tighten the nuts finger tight at this stage NOTE Make sure that the exhaust flanges are correctly...

Page 1327: ...led Tighten the catalytic converter to turbcharger nuts Vehicles with M8 nuts tighten to 25 Nm Vehicles with M10 nuts tighten to 47 Nm 7 Raise and support the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 8 Tighten the catalytic converter to cylinder block bolt 9 Tighten the exhaust flexible pipe to the tailpipe and muffler assembly nuts 1...

Page 1328: ...11 Lower the vehicle http vnx su ...

Page 1329: ...ipment 1 1 CAUTION If the component is loose a new component must be installed Torque 48 Nm 1 To install reverse the removal procedure 2 Carry out the powertrain control module PCM Reset the Diesel Particulate Filter Learned Values service function Carry out the powertrain control module PCM Reset the Diesel Particulate Filter Differential Pressure Sensor Learned Values service function General Eq...

Page 1330: ...bending of the exhaust flexible pipe may cause damage resulting in failure Support the exhaust flexible pipe with a suitable support wrap or suitable splint 3 CAUTION Using suitable cable ties support the exhaust tailpipe and muffler assembly to prevent damage to the exhaust hanger insulators Detach the exhaust flexible pipe from the exhaust tailpipe and muffler assembly Discard the gasket and nut...

Page 1331: ...ifting Description and Operation 2 CAUTION Over bending of the exhaust flexible pipe may cause damage resulting in failure Support the exhaust flexible pipe with a support wrap or splint 3 Loosen the exhaust flexible pipe to catalytic converter clamp retaining nut 4 CAUTION Using cable ties support the muffler and tailpipe assembly to prevent damage to the exhaust hanger insulators Detach the exha...

Page 1332: ...muffler and tailpipe assembly studs with grease NOTE Install a new exhaust flexible pipe to muffler and tailpipe assembly gasket and retaining nuts NOTE Remove the cable ties Attach the exhaust flexible pipe to the muffler and tailpipe assembly 3 Tighten the exhaust flexible pipe to catalytic converter clamp retaining nut 4 CAUTION Over bending of the exhaust flexible pipe may cause damage resulti...

Page 1333: ... the catalytic converter in the position shown 1 CAUTION Never use jointing compound forward of the catalytic converter NOTE Do not fully tighten the catalytic converter to cylinder block retaining bolt at this stage Install the catalytic converter 2 NOTE Do not fully tighten the exhaust flexible pipe to catalytic converter clamp retaining nut at this stage NOTE Make sure that the exhaust flexible...

Page 1334: ... manifold 6 Raise and support the vehicle For additional information refer to 100 02 Jacking and Lifting Jacking Description and Operation Lifting Description and Operation 7 Tighten the catalytic converter to cylinder block retaining bolt 8 NOTE Remove the cable ties Tighten the exhaust flexible pipe to muffler and tailpipe assembly retaining nuts 9 Tighten the exhaust flexible pipe to catalytic ...

Page 1335: ...10 CAUTION Over bending of the exhaust flexible pipe may cause damage resulting in failure Remove the exhaust flexible pipe support wrap or splint 11 Lower the vehicle http vnx su ...

Page 1336: ...spect for obvious signs of mechanical or electrical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the cause is not visually evident verify the symptom and refer to the Symptom Chart Symptom Chart Symptom Chart Hand Vacuum Pressure Pump 416 D001 23 036A Mechanical Electrical...

Page 1337: ...ne Fuel charging and controls REFER to Section 303 04A Fuel Charging and Controls 303 04B Fuel Charging and Controls 303 04C Fuel Charging and Controls Turbocharger 303 04D Fuel Charging and Controls Air ingress into the fuel lines GO to Pinpoint Test A Engine starts but immediately stops all except vehicles with diesel engine Fuel charging and controls REFER to WDS Poor idling vehicles with diese...

Page 1338: ...el Charging and Controls Turbocharger 303 04D Fuel Charging and Controls Air ingress into the fuel lines GO to Pinpoint Test A Engine misfire all except vehicles with diesel engine Ignition system REFER to Section 303 07A Engine Ignition 303 07B Glow Plug System Fuel charging and controls REFER to WDS Excessive fuel consumption vehicles with diesel engine Fuel charging and controls REFER to Sectio...

Page 1339: ... Fuel Tank and Lines Fuel tank ventilation pipe or hose leaking CHECK the fuel tank ventilation pipe and hose for evidence of a fuel leak If a fuel leak is evident INSTALL a new fuel tank ventilation pipe and hose For additional information REFER to Section 310 01A Fuel Tank and Lines 310 01B Fuel Tank and Lines PINPOINT TEST A AIR INGRESS INTO THE FUEL LINES TEST CONDITIONS DETAILS RESULTS ACTION...

Page 1340: ... amount of air in the clear plastic pipe decrease when any of the connectors unions or joints were oiled Yes INSTALL a new fuel pipe s as necessary Test the system for normal operation No REMOVE the clear plastic pipe from between the fuel injection pump and the fuel injection pump to fuel filter fuel return line GO to A3 A3 CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS Drain the fuel tank REFER to ...

Page 1341: ... of air ingress 7 Are any signs of air present in the clear plastic pipe Yes INSTALL a new fuel level sensor or fuel tank to fuel filter supply pipe as necessary REFER to Section 310 01A Fuel Tank and Lines 310 01B Fuel Tank and Lines No INSTALL a new fuel filter REFER to Section 310 01A Fuel Tank and Lines 310 01B Fuel Tank and Lines http vnx su ...

Page 1342: ... Fuel leak s Fuel line s Fuel filler cap Fuel filter Fuel tank Fuel tank ventilation hose Fuel tank filler hose Wiring harness Electrical connector s Fuel level sensor Symptom Possible Sources Action Engine cranks but does not start Fuel charging and controls REFER to Fuel Charging and Controls 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lyn...

Page 1343: ...uel tank to fuel filter fuel supply line blocked CHECK the fuel supply lines for damage INSTALL a new fuel filter fuel supply line as necessary GO to Pinpoint Test B Fuel filter blocked INSTALL a new fuel filter REFER to Fuel Filter 1 8L Duratorq TDCi Lynx Diesel 310 01A Fuel Tank and Lines Removal and Installation Fuel charging and controls REFER to Fuel Charging and Controls 75 PS 90 PS 110 PS V...

Page 1344: ...g CHECK the fuel tank filler pipe and hose for evidence of a fuel leak If a fuel leak is evident INSTALL a new fuel tank filler pipe or hose as necessary Fuel tank leaking CHECK the fuel tank for evidence of a fuel leak If a fuel leak is evident INSTALL a new fuel tank REFER to Fuel Tank 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 310 01A Fuel Tank and Lines Removal and Installat...

Page 1345: ...ilt From 08 2006 303 04B Fuel Charging and Controls 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Diagnosis and Testing A2 CHECK WHERE AIR IS ENTERING THE SYSTEM Using suitable clean engine oil apply the oil to each of the fuel supply line and fuel return line connections unions and joints in turn and observe the clear plastic pipe for visible signs of air after each oil applicatio...

Page 1346: ... any type when working on or near any fuel related components Highly flammable mixtures are always present and may ignite Failure to follow these instructions may result in personal injury This procedure involves fuel handling Be prepared for fuel spillage at all times and always observe fuel handling precautions Failure to follow this instruction may result in personal injury CAUTIONS Diesel fuel...

Page 1347: ...d pressure pump at least 30 times 3 Disconnect the fuel pump fuel return line quick release coupling REFER to Quick Release Coupling 310 00A Fuel System General Information General Procedures 4 Using a suitable piece of clear plastic pipe manufacture and install a pipe between the fuel pump fuel return line and the fuel return line union 5 Observe the flow of fuel in the clear plastic pipe 6 Does ...

Page 1348: ...to follow these instructions may result in personal injury The fuel system remains pressurized for a long time after the ignition is switched off The fuel pressure must be released before attempting any repairs Failure to follow this instruction may result in personal injury Remove the fuel pump fuse 2 Start the engine and allow to idle until the engine stalls 3 Crank the engine for approximately ...

Page 1349: ... when working with these components Always install blanking plugs to any open orifices or lines NOTE Fuel supply line connectors are white or are identified by a white band Fuel return line connectors are red or are identified by a red band Flat bladed screwdriver 1 Release the fuel system pressure For additional information refer to Fuel System Pressure Release 310 00A Fuel System General Informa...

Page 1350: ...fuel tank vent line quick release coupling Press the fuel tank vent line quick release coupling locking release collar 7 Disconnect the fuel tank vent line quick release coupling 8 Release the fuel line quick release coupling Press the fuel line quick release coupling locking release collar 9 Disconnect the fuel line quick release coupling http vnx su ...

Page 1351: ... screwdriver release the fuel line quick release coupling secondary locking tang 11 Operate the fuel line quick release coupling primary locking tang Push the fuel line quick release coupling primary locking tang into from the fuel line quick release coupling 12 Disconnect the fuel line from the fuel line quick release coupling 13 Disconnect the fuel line from the fuel filter 1 Press the collar in...

Page 1352: ...fied by a white band Fuel return line connectors are red or are identified by a red band 1 Push the connector on to the fuel filter 2 Install the fuel line to the fuel line quick release coupling 3 CAUTION Make sure the quick release coupling primary locking tang clicks into place when installing Insert the fuel line quick release coupling secondary locking tang into the fuel line quick release co...

Page 1353: ...s inserted fully into the fuel line quick release coupling before the locking tang is locked Install the fuel line quick release coupling 1 Install the fuel line quick release coupling locking tang 2 Rotate the fuel line quick release coupling locking tang into position 9 NOTE Make sure the collar on the fuel line is inserted fully into the fuel line quick release coupling before the locking tang ...

Page 1354: ...rsonal injury This procedure involves fuel handling Be prepared for fuel spillage at all times and always observe fuel handling precautions Failure to follow these instructions may result in personal injury Disconnect Tool Spring Lock Coupling 3 8 yellow 310 D004 23 039 Disconnect Tool Spring Lock Coupling 1 2 green 310 D005 23 040 Disconnect Tool Spring Lock Coupling 5 8 black 412 038 34 003 Disc...

Page 1355: ... the special tool to release the spring lock coupling locking tangs Slide the special tool into the spring lock coupling to release the locking tangs 5 Disconnect the fuel line from the spring lock coupling Allow the fuel to drain into a suitable container 6 Remove the safety clips from the fuel line spring lock couplings http vnx su ...

Page 1356: ...e Failure to follow these instructions may result in personal injury The fuel system remains pressurized for a long time after the ignition is switched off 7 Install the special tool onto the fuel line spring lock coupling 8 Close and push the fuel line spring lock coupling tool into the open side of the cage 9 Separate the fuel line spring lock coupling 10 Remove the special tool http vnx su ...

Page 1357: ...th fuel line spring lock coupling ends Install new O rings and garter springs if necessary 2 NOTE Lubricate the O rings seals with clean engine oil Insert the male fitting into the female end and push until the garter spring snaps over the flared end of the female fitting 3 Make sure the fuel line spring lock coupling is engaged by pulling on the lines 4 NOTE Make sure the collar on the fuel line ...

Page 1358: ...resent and may ignite Failure to follow these instructions may result in personal injury Always disconnect the vehicle battery ground cable before commencing any service or repair procedure Failure to follow this instruction may result in personal injury Disconnect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General...

Page 1359: ...result in personal injury Drain the fuel tank 6 Remove the pipe and disconnect the fuel tank drainer ground cable 7 Connect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 8 Initialize the door window motors For additional information refer to in this section http vnx su ...

Page 1360: ...injecting LPG in dry gas form through the fuel injection supply manifold to the injectors which are located on the outside of the intake manifold When the vehicle is operating on LPG the petrol system is disabled LPG Leak Test There are two methods that are used to identify leaks in the fuel system Electronic leak detector Liquid leak test Electronic Leak Detector This type of equipment is very se...

Page 1361: ...ls 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Diagnosis and Testing Poor starting Fuel charging and controls REFER to Fuel Charging and Controls 303 04D Fuel Charging and Controls 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Diagnosis and Testing Air ingress into the fuel lines REFER to Fuel System 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW...

Page 1362: ... REFER to Fuel System 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Diagnosis and Testing Excessive fuel consumption running on LPG LPG Fuel injector s are inoperative REFER to Fuel Charging and Controls 303 04D Fuel Charging and Controls 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Diagnosis and Testing Faulty spark plug o...

Page 1363: ...rry lighted tobacco or any open flame of any type Flammable gases may be present and ignite Failure to follow these instructions may result in personal injury Eye hand and ear protection are required to be worn during depressurizing or removal and installation of fuel system components Failure to follow this instruction may result in personal injury Always ground the vehicle and alternative fuel s...

Page 1364: ...CAUTION If the alternative fuel system is being disconnected for an extended length of time cover all open hose fittings and electrical connections to avoid contamination http vnx su ...

Page 1365: ...orrect use of parts or materials can produce an untested configuration that could result in fire or cause engine damage Failure to follow these instructions may result in personal injury The fuel tank and lines must be evacuated before attempting any repairs Failure to follow this instruction may result in personal injury Never attempt to tighten or adjust fittings while the system is pressurized ...

Page 1366: ...ection gloves and eye protection must be worn at all times Failure to follow these instructions may result in personal injury Always disconnect the vehicle battery ground cable before commencing any service or repair procedure Failure to follow this instruction may result in personal injury All gas lines must be installed prior to reconnecting the battery Failure to follow this instruction may res...

Page 1367: ... fuel line connector and PRV special tool must be checked for leaks Failure to follow this instruction may result in personal injury Check the fuel system for leaks For additional information refer to Fuel System Leak Test 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG General Procedures 7 WARNINGS The LPG recovery and transfer unit should no...

Page 1368: ... may result in personal injury Turn off the LPG recovery and transfer unit equipment 10 WARNING Always disconnect the recovery equipment fuel line from the vehicle before proceeding to the next step Failure to follow this instruction may result in personal injury Disconnect the LPG recovery and transfer unit from the fuel line connector special tool Disconnect the LPG recovery and transfer unit gr...

Page 1369: ...t in personal injury Never attempt to tighten or adjust fittings while the system is pressurized Failure to follow this instruction may result in personal injury All gas lines must be installed prior to reconnecting the battery Failure to follow this instruction may result in personal injury The fuel lines must be evacuated before attempting any repairs Failure to follow these instructions may res...

Page 1370: ...detector 5 Repair the detected leak Test the system for normal operation http vnx su ...

Page 1371: ...structions may result in personal injury The fuel tank and lines must be evacuated before attempting any repairs Failure to follow this instruction may result in personal injury Never attempt to tighten or adjust fittings while system is pressurized Failure to follow this instruction may result in personal injury All gas lines must be installed prior to reconnecting the battery Failure to follow t...

Page 1372: ...idle for approximately 3 to 4 minutes until the engine stops 5 Switch the engine off for approximately 1 to 2 minutes 6 Start the engine and allow it to idle until the engine stops or switches to petrol operation http vnx su ...

Page 1373: ...ecially designed the materials components and system configuration for alternative fuel vehicles and each particular system is precisely calibrated for efficient operation The use of incorrect parts or materials can produce an untested configuration that could result in fire or cause engine damage Failure to follow these instructions may result in personal injury Eye hand and ear protection are re...

Page 1374: ...ed length of time cover all open hose fittings and electrical connections to avoid contamination Disconnect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Remove the air cleaner For additional information refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 3 W...

Page 1375: ... the fuel vaporizer actuator cable special tool to the actuator cable special tool 11 Connect the actuator cable special tool to an independent 12 volt battery supply and energize the fuel vaporizer solenoid 12 WARNING Before the LPG fuel tank is evacuated the fuel line and special tools must be checked for leaks Failure to follow this instruction may result in personal injury Check the fuel syste...

Page 1376: ...onal injury Disconnect the LPG recovery and transfer unit from the fuel line connector special tool 15 Disconnect the actuator cable special tool from the independent 12 volt battery supply 16 Disconnect the fuel vaporizer evacuation hose special tool from the fuel line connector special tool 17 Disconnect the fuel vaporizer evacuation hose special tool from the fuel vaporizer 18 Install the blank...

Page 1377: ... system differential pressure setting in the fuel vaporizer may have been affected by this procedure Before the vehicle is tested for normal operation carry out the fuel system differential pressure check Failure to follow this instruction may cause premature failure of the fuel vaporizer Check the fuel system differential pressure settings For additional information refer to Fuel System Different...

Page 1378: ...on The use of incorrect parts or materials can produce an untested configuration that could result in fire or cause engine damage Failure to follow these instructions may result in personal injury Eye hand and ear protection are required to be worn during evacuation or removal and installation of fuel system components Failure to follow this instruction may result in personal injury CAUTION If the...

Page 1379: ... meter 6 Disconnect the manifold absolute pressure MAP sensor vacuum hose from the MAP sensor 7 Connect the differential pressure meter T piece connector to the MAP sensor vacuum hose 8 Connect the differential pressure meter hose to the differential pressure meter T piece connector 9 Connect the differential pressure meter hose between the T piece connector and the MAP sensor http vnx su ...

Page 1380: ...0 rpm for 5 seconds and then allow it to return to idle before checking the pressure settings If the pressure settings are incorrect repeat step 12 14 Turn the ignition to position 0 15 NOTE Leave the differential pressure testing equipment connected Evacuate the fuel lines For additional information refer to Fuel Line Evacuation Without Using Recovery Equipment 310 00B Fuel System General Informa...

Page 1381: ...isconnect the fuel injection supply manifold fuel supply line from the fuel filter Discard the fuel line retaining clip 21 Install the special tool between the fuel injection supply manifold fuel supply line and the fuel filter 22 Connect the differential pressure meter to the differential pressure meter hose on the special tool http vnx su ...

Page 1382: ...ferential pressure meter to 1000 10 millibar 26 Raise the engine speed to 2 000 rpm for 5 seconds and then allow it to return to idle before checking the pressure settings If the pressure settings are incorrect repeat step 25 27 Turn the ignition to position 0 28 NOTE Leave the differential pressure testing equipment connected Evacuate the fuel lines For additional information refer to Fuel Line E...

Page 1383: ...refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 33 Disconnect the differential pressure meter hose from the differential pressure meter T piece connector and the MAP sensor 34 Disconnect the differential pressure meter hose from the differential pressure meter T piece connector 35 Disconnect the differential pressure meter T piece connector from the MAP s...

Page 1384: ...he system is tested for normal operation carry out the fuel system leak test Failure to follow this instruction may result in personal injury Check the fuel system for leaks For additional information refer to Fuel System Leak Test 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG General Procedures http vnx su ...

Page 1385: ...ipe vent hose retaining clamp 4 35 Fuel tank filler pipe filler hose retaining clamp 4 35 Fuel filter retaining bolt 9 80 Fuel pump module locking ring 92 68 Wheel retaining nuts 120 89 Description Nm lb ft lb in Fuel tank support strap retaining bolts 25 18 Fuel tank filler pipe vent hose retaining clamp 4 35 Fuel tank filler pipe filler hose retaining clamp 4 35 Fuel filter bracket retaining bol...

Page 1386: ...ank support straps Fuel tank Fuel tank vent valves Fuel Tank Vent Valves Fuel tank ventilation is achieved by two fuel tank vent valves The fuel tank vent valves are integral to the fuel tank and will prevent fuel loss from the fuel tank if the vehicle becomes inverted Under normal working conditions the pressure within the fuel tank is controlled by allowing the fuel vapor to vent through the fue...

Page 1387: ... the information from the fuel level sensor to the instrument cluster and the powertrain control module PCM using the controller area network CAN circuits The fuel level sensor resistor card can be susceptible to contaminated fuel which can affect electrical continuity This condition is normally temporary and self rectifying If the fuel level sensor has been removed moving the rigid wire lever fro...

Page 1388: ...lve Vehicles with petrol engine Description Fuel supply and return lines Fuel filter Fuel tank vent valve to evaporative emission canister fuel vapor line Fuel pump and sender unit locking ring Fuel pump and sender unit Fuel tank filler pipe breather pipe Fuel tank filler pipe Evaporative emission canister Fuel tank support straps Vent valves Item 1 2 Item 1 2 3 4 5 6 7 8 9 10 Part Number Part Num...

Page 1389: ...led by a fuel pressure regulator mounted in the fuel return system Fuel is pumped from the fuel tank to the fuel filter From the fuel filter fuel is delivered to the fuel rail A T piece is fitted into the fuel injector fuel supply line above the fuel tank This T piece acts as the fuel return line and has a fuel pressure regulator fitted in the circuit By allowing excess fuel pressure to return to ...

Page 1390: ...r become restricted vehicle performance will become impaired The inability of the fuel tank to substitute the fuel demanded by the fuel pump with air will create a negative pressure in the fuel tank which could result in deformation of the fuel tank Fuel Pump and Sender Unit Description Fuel level sensor locking ring Fuel level sensor sealing ring Fuel level sensor resistor card Fuel jet pump and ...

Page 1391: ...r card resistance is continuously outside the permitted range for more than 33 seconds a DTC will be set in the CJB and the fuel gauge pointer will fall to its key off position In all cases where the fuel pump and sender is suspected of being inoperative worn or damaged the Worldwide Diagnostic System WDS diagnostic procedures must be followed before any parts are dismantled The fuel pump supplies...

Page 1392: ...ws the displaced air above the fuel in the fuel tank to escape without pushing the fuel entering the fuel tank during refill back up the fuel tank filler pipe Fuel Filler Cap This vehicle uses a lockable fuel filler cap The fuel filler cap is sealed to the fuel filler neck This is to prevent the escape of fuel vapor during normal operation and to prevent fuel loss in the event of a vehicle acciden...

Page 1393: ...and Testing For additional information REFER to Fuel System 75 PS 90 PS 310 00A Fuel System General Information Diagnosis and Testing Fuel System 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 310 00A Fuel System General Information Diagnosis and Testing http vnx su ...

Page 1394: ...e released before attempting any repairs Failure to follow these instructions may result in personal injury 6 Remove the components in the order indicated in the following illustration s and table s Wrench Fuel Tank Sender Unit 310 069 23 055 Transmission jack Name Grease 1 Release the fuel system pressure For additional information refer to Section 310 00A Fuel System General Information 310 00B ...

Page 1395: ...Description Muffler Description Item 1 Item Part Number Part Number http vnx su ...

Page 1396: ...ler hose See Removal Detail See Installation Detail Fuel tank vent hose Evaporative emissions canister line quick release coupling See Removal Detail Fuel return line See Removal Detail Fuel tank to fuel filter fuel supply line quick release coupling See Removal Detail Fuel tank support straps See Removal Detail See Installation Detail Fuel tank 2 3 4 5 6 Item 7 8 9 10 11 12 Part Number http vnx s...

Page 1397: ...ons canister line See Removal Detail Evaporative emissions canister See Removal Detail Fuel pump module supply line See Removal Detail Fuel pump module return line See Removal Detail Fuel tank vent pipe See Removal Detail Fuel pump module locking ring See Removal Detail Fuel pump module seal Fuel pump module 13 14 Item 15 16 17 18 19 20 21 22 23 24 Part Number http vnx su ...

Page 1398: ...l filter fuel supply line quick release coupling Item 10 Fuel return line Item 12 Fuel tank support straps CAUTION When supporting the fuel tank use a suitable packing material to prevent damage to the underside of the fuel tank Item 13 Fuel tank 25 1 Detach the exhaust pipe center heat shield 1 For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System...

Page 1399: ... module electrical connector 1 Disconnect the quick release couplings For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 Remove the evaporative emission canister 1 Release the evaporative emission canister retaining clip 2 Slide the evaporative emission canister off of the evaporative emission canister retaining bracket 1 D...

Page 1400: ...uel tank make sure the fuel lines do not get kinked or trapped Item 12 Fuel tank support straps 2 Press in the four fuel tank vent fuel separator clips and remove the fuel separator and vent pipes 1 Using the special tool remove the fuel pump module locking ring 1 Remove the fuel pump module 1 Rotate the fuel pump module counterclockwise 2 Remove the fuel pump module from the fuel tank 1 Raise the...

Page 1401: ... tank filler hose NOTE The fuel tank filler hose retaining clamp must be installed in the same position as removed 1 Install the fuel tank support strap retaining bolt and remove the transmission jack http vnx su ...

Page 1402: ...ollow these instructions may result in personal injury 5 Remove the components in the order indicated in the following illustration s and table s Wrench Fuel Tank Sender Unit 310 069 23 055 Transmission jack Name Grease 1 Disconnect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 Drain the fuel tank...

Page 1403: ...Description Muffler Description Item 1 Item Part Number Part Number http vnx su ...

Page 1404: ...ion Fuel tank filler hose See Removal Detail See Installation Detail Fuel tank vent hose Fuel return line See Removal Detail Fuel tank to fuel filter fuel supply line quick release coupling See Removal Detail Fuel tank support straps See Removal Detail See Installation Detail Fuel tank See Removal Detail See Installation Detail 2 3 4 5 6 Item 7 8 9 10 11 12 Part Number http vnx su ...

Page 1405: ... return line See Removal Detail Fuel tank vent pipe See Removal Detail Fuel tank level sensor locking ring See Removal Detail Fuel tank level sensor seal See Removal Detail Fuel tank level sensor See Removal Detail See Installation Detail Fuel tank 6 To install reverse the removal procedure Removal Details Item 3 Exhaust pipe center heat shield 13 Item 14 15 16 17 18 19 20 21 22 Part Number http v...

Page 1406: ... of the fuel tank Item 12 Fuel tank CAUTION When lowering the fuel tank do not place excessive strain on the fuel lines and wiring harness Item 13 Fuel tank level sensor electrical connector 1 Detach the exhaust pipe center heat shield 1 Detach the fuel return line quick release coupling For additional information refer to Quick Release Coupling 310 00A Fuel System General Information General Proc...

Page 1407: ...ion refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures 1 Disconnect the quick release couplings For additional information refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures 1 Remove the fuel tank vent pipe and vent pipe filter 1 Remove the fuel tank vent pipe filter 2 Press in the four fuel tank vent fuel separator cl...

Page 1408: ...he fuel tank level sensor 1 Rotate the fuel tank level sensor counterclockwise 2 Remove the fuel tank level sensor from the fuel tank 1 Install the fuel tank level sensor to the fuel tank Align the larger arrow 1 on the fuel pump and sender unit with the align mark center of 3 dashes 2 on the fuel tank The smaller arrow 3 on the fuel pump and sender unit must be automatically aligned to the align ...

Page 1409: ...traps Item 7 Fuel tank filler hose NOTE The fuel tank filler hose retaining clamp must be installed in the same position as removed 1 Install the fuel tank support strap retaining bolt and remove the transmission jack http vnx su ...

Page 1410: ...lves fuel handling Be prepared for fuel spillage at all times and always observe fuel handling precautions Failure to follow these instructions may result in personal injury 3 Remove the components in the order indicated in the following illustration s and table s Description Fender splash shield 1 Drain the fuel tank For additional information refer to Section 310 00A Fuel System General Informat...

Page 1411: ...ON When removing the fuel tank filler hose or fuel tank vent hose do not use any sharp edged tools to lever off the hoses Failure to follow this instruction may cause damage to the filler hose or vent hose NOTE Make a note of the position of the fuel tank filler hose retaining clamp Installation Details Item 5 Fuel tank filler hose NOTE The fuel tank filler hose retaining clamp must be installed i...

Page 1412: ...instructions may result in personal injury The fuel system remains pressurized for a long time after the ignition is switched off The fuel pressure must be released before attempting any repairs Failure to follow these instructions may result in personal injury 4 Remove the components in the order indicated in the following illustration s and table s 1 Depressurize the fuel system For additional i...

Page 1413: ...el filter retaining bracket Fuel filter 5 To install reverse the removal procedure Removal Details Item 2 Fuel filter to fuel supply manifold fuel supply line quick release coupling Item 3 Fuel tank to fuel filter fuel supply line quick release coupling Item 1 2 3 4 5 1 For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information Part ...

Page 1414: ...all times and always observe fuel handling precautions Failure to follow these instructions may result in personal injury CAUTION Diesel fuel injection equipment is manufactured to very precise tolerances and clearances It is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices or lines 1 Remove the components i...

Page 1415: ...Item 6 Fuel filter Item 4 Fuel filter support bracket and fuel filter CAUTION The fuel filter support bracket is the ground connection for the fuel filter Make sure that the mating surfaces are clean and free from foreign material 3 4 5 6 1 For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 Press in the fuel filter support ...

Page 1416: ...1 Install the fuel filter and the fuel filter support bracket until an audible click is heard http vnx su ...

Page 1417: ...andling Be prepared for fuel spillage at all times and always observe fuel handling precautions Failure to follow these instructions may result in personal injury CAUTION Diesel fuel injection equipment is manufactured to very precise tolerances and clearances It is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open or...

Page 1418: ...ply line quick release coupling See Removal Detail See Installation Detail Fuel filter support bracket and fuel filter See Removal Detail See Installation Detail Fuel filter retaining screw Fuel filter See Installation Detail 3 To install reverse the removal procedure Item 1 2 3 4 5 6 4 CAUTION Make sure that the fuel filter connection is not damaged with the installation of the special tool as th...

Page 1419: ... Operate the fuel hand pressure pump special tool until fuel starts to flow through the fuel filter and fuel pump and the hand pressure pump becomes firm 8 CAUTION Do not operate the starter motor for longer than 10 seconds at a time After 10 seconds turn the ignition to position 0 and allow the starter motor to cool for 30 seconds before attempting to start the engine again Start the engine and a...

Page 1420: ... fuel filter For additional information refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures 1 For additional information refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures 2 Install a blanking plug to the fuel pump fuel supply line 1 For additional information refer to Quick Release Coupling 310 00A Fuel System General ...

Page 1421: ...water in fuel sensor electrical connector 1 NOTE Make sure that the locating arrows on the fuel filter and the fuel filter support bracket are correctly aligned Fill the fuel filter with clean diesel 1 Install the fuel filter and the fuel filter support bracket until an audible click is heard 1 Clean the area around the fuel filter fuel line connections 2 Do not connect the fuel tank to fuel filte...

Page 1422: ...e blanking plug from the fuel filter fuel pump fuel supply line 2 Remove and discard the blanking plug from the fuel filter to fuel pump fuel supply line connection 3 For additional information refer to Quick Release Coupling 310 00A Fuel System General Information General Procedures http vnx su ...

Page 1423: ...S switch electrical connector IFS switch retaining bolts IFS switch See Installation Detail 4 To install reverse the removal procedure Installation Details Item 3 IFS switch NOTE Make sure the IFS switch is in the reset position 1 Remove the passenger side instrument panel lower footwell trim panel 2 Remove the right hand side cowl side trim panel For additional information refer to Section 501 05...

Page 1424: ...al injury The fuel system remains pressurized for a long time after the ignition is switched off The fuel pressure must be released before attempting any repairs Failure to follow these instructions may result in personal injury Alignment Pins Subframe 205 316 15 097A Disconnect Tool Fuel Line 5 16 310 040 23 041 Transmission jack 1 Depressurize the fuel system For additional information refer to ...

Page 1425: ... 6 Disconnect the fuel supply and return spring lock couplings For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 7 Detach the fuel supply and fuel return lines from the retaining clip 8 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 9 Install the crossmember alignment pin...

Page 1426: ...11 Remove the components in the order indicated in the following illustration s and table s 10 Using a suitable transmission jack support the crossmember http vnx su ...

Page 1427: ...val procedure Removal Details Item 1 Crossmember suspension and steering gear Item 3 Fuel supply line to fuel filter fuel line quick release coupling Item 6 Fuel supply line Item 1 2 3 4 5 6 1 NOTE Take care not to place excessive strain on the power steering pipes Lower the crossmember 75mm 1 Disconnect the quick release coupling For additional information refer to Section 310 00A Fuel System Gen...

Page 1428: ...retaining clip fuel line retaining clip Make a note of the routing of the existing fuel supply line to assist with the installation 1 The fuel pipe retaining clip acts as the fuel line earthing connection and must be clean and secure http vnx su ...

Page 1429: ...ructions may result in personal injury Diesel fuel injection equipment is manufactured to very precise tolerances and clearances It is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices or lines Alignment Pins Subframe 205 316 15 097A Transmission jack 1 Disconnect the battery ground cable For additional infor...

Page 1430: ...7 Remove the components in the order indicated in the following illustration s and table s 6 Using a suitable transmission jack support the crossmember http vnx su ...

Page 1431: ...Fuel supply line See Removal Detail 8 To install reverse the removal procedure Removal Details Item 1 Crossmember suspension and steering gear Item 3 Fuel supply line to fuel level sensor fuel line quick release coupling Item 1 2 3 4 5 6 7 1 NOTE Take care not to place excessive strain on the power steering pipes Lower the crossmember 75mm 1 Clean the area around the fuel supply line quick release...

Page 1432: ...se coupling For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 2 Disconnect the quick release coupling For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 Detach the fuel supply line from the bulkhead fuel line retaining clip Make a note of the routing ...

Page 1433: ...ure Removal Details Item 1 Fuel return line to fuel pump module fuel line quick release coupling Item 2 Fuel return line 1 Remove the fuel supply line For additional information refer to Fuel Supply Line 1 8L in this section Item 1 2 1 Disconnect the quick release coupling For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 ...

Page 1434: ...http vnx su ...

Page 1435: ... to follow these instructions may result in personal injury Diesel fuel injection equipment is manufactured to very precise tolerances and clearances It is therefore essential that absolute cleanliness is observed when working with these components Always fit blanking plugs to any open orifices or lines 4 Remove the components in the order indicated in the following illustration s and table s 1 Di...

Page 1436: ...fuel line quick release coupling Item 2 Fuel return pipe Item 1 2 1 Disconnect the quick release coupling For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 Detach the fuel return line from the fuel line retaining clip and the brake pipe retaining clip Make a note of the routing of the existing fuel return line to assist wi...

Page 1437: ...Duratec DOHC 85kW 115PS Zetec Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 For additional information refer to Fuel Tank 1 8L in this section 1 To install reverse the removal procedure http vnx su ...

Page 1438: ...x Diesel 1 8L Duratorq TDDi Lynx Diesel Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 For additional information refer to Fuel Tank 1 8L Diesel in this section 1 To install reverse the removal procedure http vnx su ...

Page 1439: ...ect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Fuel tank retaining bolts 48 35 Fuel filler pipe to fuel filler valve union 48 35 Fuel tank air tight housing retaining bolts 10 89 Fuel level sensor retaining bolts 10 89 Fuel tank one way valve 100 74 Fuel tank solenoid valve 100 74 http vnx su ...

Page 1440: ...OHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Fuel Tank and Lines Transit Tourneo Connect 2002 5 06 2002 Print Description and Operation Description Fuel tank and hoses Fuel filler valve Fuel filter Item 1 2 3 Part Number http vnx su ...

Page 1441: ...he vehicle in the spare wheel area Fuel Filter The fuel filter comprises of a paper element sealed within a canister and is located next to the battery tray Fuel Tank Solenoid Valve The fuel tank solenoid valve is controlled by the LPG select switch when the ignition is switched ON and LPG operation is selected the solenoid valve opens and pressurizes the fuel line to the fuel vaporizer Item 1 2 3...

Page 1442: ... used to measure LPG fuel quantity Fuel Tank One Way Valve The fuel tank one way valve opens when LPG fuel is pressurized into the fuel tank supply line When the fuel tank reaches 80 full the mechanical float closes the one way valve This is to allow expansion of the LPG in various temperatures http vnx su ...

Page 1443: ...d Petroleum Gas LPG Fuel Tank and Lines Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Fuel System 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Diagnosis and Testing http vnx su ...

Page 1444: ...uel filler pipe dry break connector 3 Lower the vehicle 4 Remove the luggage compartment left hand side trim panel 5 Remove the fuel filler pipe protective cover retaining clip Discard the retaining clip Slide the protective cover down the fuel filler pipe to expose the fuel filler pipe union 6 Disconnect the fuel filler pipe union from the fuel filler valve 7 NOTE Support the fuel filler valve ho...

Page 1445: ...l reverse the removal procedure 2 WARNING Before the vehicle is tested for normal operation carry out the fuel system leak test Failure to follow this instruction may result in personal injury Check the fuel system for leaks For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information http vnx su ...

Page 1446: ...For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 2 Remove the loadspace floor covering 3 Remove the fuel tank upper retaining bolts 4 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 5 Disconnect the fuel tank electrical connector 6 Remove the air tight housing cover from ...

Page 1447: ...sconnect the fuel tank to fuel vaporizer fuel supply line dry break connector Push the dry break connector forward and then pull back on the dry break connector collar to release 9 Using a suitable Transmission stand support the fuel tank 10 Remove the fuel tank lower retaining bolts and lower the fuel tank 11 Evacuate the fuel tank For additional information refer to Section 310 00A Fuel System G...

Page 1448: ...Remove the fuel tank level sensor Discard the fuel tank level sensor gasket 16 Disconnect the fuel tank fuel hose union from the fuel tank solenoid valve Remove the retaining clip 17 Disconnect the fuel tank fuel hose union from the fuel tank one way valve Remove the retaining clip http vnx su ...

Page 1449: ...nk 1 NOTE Install a new fuel tank level sensor gasket To install reverse the removal procedure 2 WARNING Before the vehicle is tested for normal operation carry out the fuel system leak test Failure to follow this instruction may result in personal injury Check the fuel system for leaks For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General ...

Page 1450: ...ilter Discard the fuel supply line retaining clips 3 NOTE Direction of flow indicated by the arrow on the fuel filter Loosen the clamp bolt and remove the fuel filter 1 NOTE Install new fuel supply line retaining clips To install reverse the removal procedure 2 WARNING Before the vehicle is tested for normal operation carry out the fuel system leak test Failure to follow this instruction may resul...

Page 1451: ...ing Description and Operation 2 Disconnect the fuel tank wiring harness electrical connector 3 Remove the air tight housing cover from the air tight housing 4 Evacuate the fuel tank For additional information refer to Fuel Tank Evacuation 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG General Procedures 5 Disconnect the fuel level sensor gaug...

Page 1452: ... procedure 2 WARNING Before the vehicle is tested for normal operation carry out the fuel system leak test Failure to follow this instruction may result in personal injury Check the fuel system for leaks For additional information refer to Fuel System Leak Test 310 00B Fuel System General Information 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG General Procedures http vnx su ...

Page 1453: ...Acceleration Control Specifications Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Accelerator pedal retaining nuts 9 80 http vnx su ...

Page 1454: ...accelerator cable Accelerator cable incorrectly installed CHECK the accelerator cable for the correct installation Worn or damaged throttle body INSTALL a new throttle body REFER to Throttle Body 303 04A Fuel Charging and Controls 1 8L Duratec DOHC 85kW 115PS Zetec Removal and Installation Worn or damaged accelerator pedal INSTALL a new accelerator pedal Accelerator pedal is hard to depress or has...

Page 1455: ...ll except vehicles with diesel engines Damaged accelerator cable INSTALL a new accelerator cable Accelerator cable incorrectly installed CHECK the accelerator cable for the correct installation High engine idle speed Vehicles with diesel engine Damaged accelerator pedal INSTALL a new accelerator pedal PCM calibration Refer to the WDS to diagnose the system http vnx su ...

Page 1456: ...ccelerator Pedal Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details 1 2 3 4 Torque 9 Nm http vnx su ...

Page 1457: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 1458: ...ion Passenger compartment footwell air duct retaining clip Passenger compartment footwell air duct Accelerator cable to accelerator pedal Accelerator pedal retaining nuts See Installation Detail Accelerator pedal 2 To install reverse the removal procedure Installation Details Item 4 Accelerator pedal retaining nuts NOTE The accelerator pedal retaining nuts must be tightened evenly to prevent disto...

Page 1459: ...scription Passenger compartment footwell air duct retaining clip Passenger compartment footwell air duct Accelerator pedal position sensor electrical connector Accelerator pedal retaining nuts See Installation Detail Accelerator pedal 2 To install reverse the removal procedure Installation Details Item 4 Accelerator pedal retaining nuts NOTE The accelerator pedal retaining nuts must be tightened e...

Page 1460: ...Accelerator cable retaining clip See Removal Detail Accelerator cable to coolant expansion tank hose retaining clips Accelerator cable retaining clip See Removal Detail Accelerator cable inner cable See Removal Detail Accelerator cable to bulkhead grommet See Removal Detail See Installation Detail Accelerator cable See Removal Detail See Installation Detail 2 To install reverse the removal procedu...

Page 1461: ...etach the accelerator cable from the throttle body accelerator cable retaining bracket 1 For right hand drive vehicles detach the accelerator cable to engine lifting eye retaining clip 1 For right hand drive vehicles detach the accelerator cable to power steering fluid return pipe retaining clip 1 Detach the accelerator cable inner cable from the accelerator pedal http vnx su ...

Page 1462: ...erator cable grommet 2 Detach the accelerator cable grommet from the bulkhead 1 Attach a suitable draw cord to the accelerator cable to assist with installation 1 Using the draw cord install the accelerator cable Remove the draw cord 1 Install the accelerator cable and grommet 1 Install the accelerator cable grommet into the bulkhead 2 Push the accelerator cable into the accelerator cable grommet ...

Page 1463: ...A C Clutch Tightening torques Material Specification Refrigerant R134a WSH M17B19 A Refrigerant oil WSH M1C231 B Grams Air conditioning 905 15 Milliliters Air conditioning 200 Milliliters When all lines and components are replaced add 200 Air conditioning A C compressor if the quantity of refrigerant oil drained from the faulty compressor is less than 150 ml add 150 Air conditioning compressor if ...

Page 1464: ...ion CHECK the operation of the system 5 5 If no fault is stored in the fault memory PROCEED with the symptom chart according to the fault symptom 6 6 Following checking or elimination of the fault and after completion of operations the fault memories of all vehicle modules must be READ OUT and any stored faults must be DELETED READ OUT all fault memories again following a road test Refrigerant Cir...

Page 1465: ... outlet line must be measured To do this the following preconditions must be met Open all windows Set the air distribution to the defrost dashboard position and open all the ventilation nozzles DO NOT switch on recirculated air Select lowest blower switch setting Select lowest temperature setting NOTE The temperature measurement cannot be done with a thermometer which makes no contact The surface ...

Page 1466: ...d Charging 412 00 Climate Control System General Information General Procedures Symptom Chart Symptom Chart Symptom Possible Sources Action Blower motor inoperative partly inoperative Fuse s Circuit s Blower motor Blower switch Blower resistor assembly GO to Pinpoint Test A Blower motor running continuously Blower switch Circuit s GO to Pinpoint Test B Air conditioning inoperative blower function ...

Page 1467: ... A3 No RENEW fuse F64 30 A CHECK the operation of the system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams A3 CHECK THE VOLTAGE AT FUSE F64 Connect fuse F64 BJB 1 Ignition switch in position II 2 Measure voltage between fuse F64 30 A and ground 3 Does the meter display battery voltage Yes GO to A4 No REPAIR the voltage supply to fuse F64 using the Wiring Diagrams CH...

Page 1468: ...RCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH Disconnect connector C469 of heater blower switch 1 Measure the resistance between the blower motor connector C789 pin 2 circuit 31S FA18 BK RD wiring harness side and the blower switch connector C469 pin 6 circuit 31S FA33 BK OG wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes GO to A7 No LOCATE and RECTIFY the open circu...

Page 1469: ...tance of less than 2 Ohm registered Yes INSTALL A NEW blower switch CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31S FA33 BK OG between the blower switch and soldered connection S24 using the Wiring Diagrams CHECK the operation of the system A9 CHECK THE HEATER BLOWER SWITCH Ignition switch in position 0 1 Disconnect connector C469 of heater blower switch 2 Ignition ...

Page 1470: ...N THE BLOWER RESISTOR AND THE BLOWER SWITCH Ignition switch in position 0 1 Measure the resistance between the blower resistor assembly connector C470 pin 4 circuit 31S FA32 BK BU wiring harness side and the blower switch connector C469 pin 5 circuit 31S FA32 BK BU wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes GO to A12 No LOCATE and REPAIR the break in circuit 31S FA32 B...

Page 1471: ...tor assembly CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31S FA30 BK WH between the blower resistor assembly and the blower switch using the Wiring Diagrams CHECK the operation of the system PINPOINT TEST B BLOWER MOTOR RUNNING CONTINUOUSLY TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK THE HEATER BLOWER SWITCH Ignition switch in position 0 1 Disconnect connector ...

Page 1472: ...ing the service units When recovering the refrigerant do not allow it to enter the atmosphere under any circumstances Connect the R 134a refrigerant center or the set of R134a pressure gauges to the refrigerant circuit and measure the refrigerant pressure in the refrigerant circuit 2 Is a refrigerant pressure of more than 3 2 bar measured Yes Vehicles built up to 07 2006 GO to C2 Vehicles built fr...

Page 1473: ...e F34 7 5 A and ground 3 Does the meter display battery voltage Yes GO to C10 No REPAIR the voltage supply to fuse F34 using the Wiring Diagrams CHECK the operation of the system C6 CHECK FUSE F48 Ignition switch in position 0 1 CHECK Fuse F48 CJB 2 Is the fuse OK Yes GO to C7 No INSTALL a new fuse F48 7 5 A CHECK the operation of the system If the fuse blows again LOCATE and REPAIR the short usin...

Page 1474: ...he system If the fuse blows again after switching the air conditioning on CHECK the refrigerant compressor clutch diode and RENEW as necessary If the refrigerant compressor clutch diode is OK LOCATE and RECTIFY the short circuit with the aid of the Wiring Diagrams C11 CHECK THE VOLTAGE AT FUSE F26 Connect fuse F26 BJB 1 Measure the voltage between fuse F26 10 A and ground 2 Does the meter display ...

Page 1475: ... soldered connection S117 vehicles built from 07 2006 soldered connection S54 with the aid of the Wiring Diagrams CHECK the operation of the system C14 CHECK THE A C CLUTCH ELECTRICAL CIRCUIT Ignition switch in position 0 1 Use a fused test cable 10 A to bridge the air conditioning clutch relay socket C1011 pin 3 and pin 5 wiring harness side 2 Check that the A C system clutch operates correctly 3...

Page 1476: ...ing harness side and ground 1 Is a resistance of less than 2 Ohm registered Yes INSTALL A NEW air conditioning clutch CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31 FA6 BK between the A C clutch and soldered connection S109 using the Wiring Diagrams CHECK the operation of the system C17 CHECK THE VOLTAGE AT THE REFRIGERANT LOW PRESSURE SWITCH Disconnect connector C6...

Page 1477: ... engine except vehicles with LPG fuel system GO to C23 Vehicles built from 07 2006 GO to C37 No RENEW the refrigerant low pressure switch CHECK the operation of the system C19 CHECK ELECTRICAL CIRCUIT BETWEEN A C LOW PRESSURE SWITCH AND POWERTRAIN CONTROL MODULE PCM FOR OPEN CIRCUIT VEHICLES WITH 1 8L 55 KW DIESEL ENGINE AND VEHICLES WITH LPG FUEL SYSTEM Disconnect connector C415 from PCM 1 Measur...

Page 1478: ...CAL CIRCUIT BETWEEN A C LOW PRESSURE SWITCH AND POWERTRAIN CONTROL MODULE PCM FOR OPEN CIRCUIT VEHICLES WITH 1 8L 66 KW DIESEL ENGINE Disconnect connector C414 of PCM 1 Measure the resistance between PCM connector C414 pin 19 circuit 15S RE8 GN YE wiring harness side and A C low pressure switch connector C692 pin 1 circuit 15S RE8 GN YE wiring harness side 2 Is a resistance of less than 2 Ohm regi...

Page 1479: ...S RE8 GN YE between the A C low pressure switch and the PCM using the Wiring Diagrams CHECK the operation of the system C24 CHECK ELECTRICAL CIRCUIT BETWEEN A C CLUTCH RELAY AND PCM FOR OPEN CIRCUIT VEHICLES WITH 85 KW ENGINE EXCEPT VEHICLES WITH LPG FUEL SYSTEM Measure the resistance between the PCM connector C416 pin 54 circuit 31S FA11 BK YE wiring harness side and the A C clutch relay socket C...

Page 1480: ... the break in circuit 91 FA38 BK OG between the refrigerant high pressure switch and soldered connection S118 using the Wiring Diagrams CHECK the operation of the system C27 CHECK REFRIGERANT HIGH PRESSURE SWITCH Ignition switch in position 0 1 Measure the resistance at the A C high pressure switch connector C882 between pin 1 and pin 4 component side 2 Is a resistance of less than 2 Ohm registere...

Page 1481: ... CJB connector C16 pin 9 circuit 29 FA13 OG wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes CHECK the CJB and RENEW as necessary CHECK the operation of the system No LOCATE and RECTIFY the break in circuit 29 FA13 OG between the control panel for the climate control system and the CJB using the Wiring Diagrams CHECK the operation of the system C30 CHECK THE CIRCUIT BETWEEN ...

Page 1482: ...m CJB 1 Measure the resistance between the control panel for the climate control system connector C380 pin 10 circuit 15 FA13 GN RD wiring harness side and the CJB connector C10 pin 8 circuit 15 FA13 GN RD wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes CHECK the CJB and RENEW as necessary CHECK the operation of the system No LOCATE and RECTIFY the break in circuit 15 FA13 ...

Page 1483: ... pin 12 circuit 91 FA13 BK OG wiring harness side and ground 2 Is a resistance of less than 2 Ohm registered Yes GO to C35 No LOCATE and RECTIFY the open circuit in circuit 91 FA13 BK OG between the control panel for the climate control system and soldered connection S12 with the aid of the Wiring Diagrams CHECK the operation of the system C35 CHECK GROUND CONNECTION THROUGH BLOWER SWITCH Set the ...

Page 1484: ...tem CHECK the operation of the system No LOCATE and REPAIR the break in circuit 15S FA38 GN RD between the control panel for the climate control system and the refrigerant high pressure switch with the aid of the Wiring Diagrams CHECK the operation of the system C37 CHECK THE A C REQUEST SIGNAL IN THE POWERTRAIN CONTROL MODULE PCM Connect the diagnostic tool 1 Switch on the blower 2 Switch on the ...

Page 1485: ... 31S FA11 BK YE between the refrigerant low pressure switch and the PCM using the Wiring Diagrams CHECK the operation of the system C40 CHECK THE A C REQUEST SIGNAL IN THE CENTRAL TIMER MODULE CTM NOTE The central timer module CTM is integrated in the instrument cluster Switch on the blower 1 Switch on the air conditioning system 2 Using the diagnostic unit select the CTM and check in the data log...

Page 1486: ... of less than 2 Ohm registered Yes GO to C28 No LOCATE and REPAIR the break in circuit 15S FA38 GN RD between the control panel for the climate control system and the instrument cluster with the aid of the Wiring Diagrams CHECK the operation of the system PINPOINT TEST D MALFUNCTION OF THE RECIRCULATED AIR FLAP NOTE The recirculated air flap is actuated by means of a DC motor This is activated for...

Page 1487: ... the climate control system 2 Measure the resistance between the air recirculation flap actuator connector C375 pin 2 RHD vehicles pin 4 circuit 32 FA76 WH BU wiring harness side and the control panel for the climate control system connector C380 pin 14 circuit 32 FA76 WH BU wiring harness side 3 Is a resistance of less than 2 Ohm registered Yes GO to D3 No LOCATE and REPAIR the break in circuit 3...

Page 1488: ...e and the control panel for the climate control system connector C380 pin 14 circuit 32 FA76 WH BU wiring harness side 3 Is a resistance of less than 2 Ohm registered Yes GO to D5 No LOCATE and REPAIR the break in circuit 32 FA76 WH BU between the air recirculation flap actuator and the control panel for the climate control system with the aid of the Wiring Diagrams CHECK the operation of the syst...

Page 1489: ...rol system with the aid of the Wiring Diagrams CHECK the operation of the system D7 CHECK THE CIRCUIT BETWEEN THE AIR RECIRCULATION FLAP ACTUATOR AND THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR OPEN CIRCUIT RHD VEHICLES BUILT FROM 08 2004 Measure the resistance between the recirculated air flap actuator connector C375 pin 4 circuit 32 FA76R WH BU wiring harness side and the control panel ...

Page 1490: ...n the control panel for the climate control system connector C380 pin 16 circuit 33 FA76 YE BU RHD vehicles circuit 33 FA76R YE BU wiring harness side and ground 2 Measure the resistance between the control panel for the climate control system connector C380 pin 14 circuit 32 FA76 WH BU RHD vehicles circuit 32 FA76R WH BU wiring harness side and ground 3 Is a resistance greater than 10 000 Ohms me...

Page 1491: ...e short to ground in circuit 91S FA20 BK YE between the dehumidification switch and the control panel for the climate control system using the Wiring Diagrams CHECK the operation of the system PINPOINT TEST E REFRIGERANT COMPRESSOR INOPERATIVE WHEN SWITCH SET TO DEFROST DEMIST WINDSHIELD OTHER FUNCTIONS OF THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM OK NOTE If the temperature outside is less ...

Page 1492: ...esistance of less than 2 Ohm registered Yes GO to E3 No LOCATE and RECTIFY the open circuit in circuit 91S FA20 BK YE between the control panel for the climate control system and the dehumidification switch with the aid of the Wiring Diagrams CHECK the operation of the system E3 CHECK THE GROUND CONNECTION OF THE DEHUMIDIFICATION SWITCH Measure the resistance between the dehumidification switch co...

Page 1493: ...en contact in the switched state Use a fused test cable 1 A to connect pin 1 of the air conditioning clutch relay component side to the battery positive terminal Use a test cable to connect pin 2 of the air conditioning clutch relay component side to the battery negative terminal Measure the resistance at the air conditioning clutch relay between pin 3 and pin 5 component side Is a resistance of l...

Page 1494: ...the clamping spring 2 Press the special tool into the clamping spring 3 Disconnect the refrigerant line Discard the O ring seals 4 Connect the refrigerant line Check the clamping spring for damage Carefully pull out any damaged clamping springs using a thin piece of wire and install new one 5 NOTE Clean the connections using refrigerant oil and a lint free cloth Press the indicator ring into the c...

Page 1495: ...seals NOTE Coat the refrigerant line O ring seals in clean refrigerant oil prior to installation Connect the refrigerant lines Check that the clamping spring engages correctly http vnx su ...

Page 1496: ...ound For additional information refer to Specifications in this section 1 Belt pulley 2 Drive plate Air gap A the difference measured between the A C clutch engaged and disengaged 2 Measurement for non recessed pulley Check the air gap A between the drive plate and the pulley at 60 degrees intervals around the circumference For additional information refer to Specifications in this section 1 Belt ...

Page 1497: ...ion to aid in assembly When a spring lock coupler is suspected of leaking always wipe the fitting clean and verify the leak with R 134a Automatic Calibration Halogen Leak Detector NOTE The exact location of leaks can be pinpointed by the bright yellow green glow of the tracer dye Since more than one leak may exist always inspect each component UV Spot Lamp Manifold Gauge Set Fluorescent Dye Inject...

Page 1498: ...e the manifold gauge may become contaminated Contaminated refrigerant must be disposed of as special waste The manufacturer s instructions must be followed when working with the service unit NOTE Both manifold gauges should indicate 4 1 5 5 bar at 24 C with the engine off Attach the manifold gauge set to the service gauge port valves 1 For the leak test close the manual valves on the gauge set 2 I...

Page 1499: ...s waste Always follow the manufacturer s instructions when using the refrigerant center and the refrigerant analyzer Remove the protective cap from the A C high pressure charging connection 2 Detach the right hand wheel arch trim panel shown with wheel removed for clarity 3 Remove the protective cap from the A C low pressure charging connection 4 Pull back the catches of the quick fit unions on th...

Page 1500: ...r conditioning system that was filled with refrigerant is being evacuated some refrigerant will still be in the refrigerant oil in the compressor This remaining refrigerant may evaporate causing a slight increase in pressure during the leak test The system is leak free provided that this pressure increase does not exceed 20 mbar 2 kPa 0 29 psi Perform the leak test 1 For the leak test close the ha...

Page 1501: ...rigerant 3 Top up with the remaining amount of refrigerant whilst the air conditioning is switched on For this purpose run the engine at approx 1200 1500 rpm Switch the air conditioning to maximum cooling power and fresh air mode Set the blower to maximum speed Fill with the remainder of the prescribed fill capacity 12 WARNING Do not detach the high pressure hose when the air conditioning is switc...

Page 1502: ...osed and sealed container to prevent ingress of moisture NOTE The refrigerant oil from the new A C compressor needs to be drained because the fill capacities at the factory are not always the same NOTE Rotate the compressor shaft at least 6 to 8 turns when draining the refrigerant oil Drain the refrigerant oil from the new A C compressor 3 CAUTIONS The amount of refrigerant oil topped up must not ...

Page 1503: ...d only by means of a suitable servicing unit designed for the purpose of collecting and storing contaminated refrigerant so that the spread to other vehicles can be prevented 1 Use refrigerant identification equipment to check that there is contaminated refrigerant in the air conditioning system 2 Inform the customer about the additional cost to repairing the system caused by the contamination 3 E...

Page 1504: ...ed room Keep all vehicle doors and windows open for the duration of the operation Do not inhale vapors under any circumstances Do not smoke and avoid open fire and unprotected light sources Failure to observe this instruction can lead to injuries NOTE The odour eliminating agent can remove deposits in the heater housing but cannot prevent odours that are distributed by the ventilation system for e...

Page 1505: ...ay gun as far as possible into the opening created by removal of the above component and point it in the direction of the evaporator 18 By moving the hose spray the odour eliminating agent over the entire surface of the evaporator 19 Spray all of the odour eliminating agent into the opening Allow the odour eliminating agent to take effect for 10 minutes 20 Install the components in reverse order 2...

Page 1506: ...uum Leak Detection Transit Tourneo Connect 2002 5 06 2002 Print General Procedures 1 Drain the air conditioning A C system For additional information refer to Air Conditioning A C System Recovery Evacuation and Charging in this section http vnx su ...

Page 1507: ...gain by forced air extraction above the tailgate or the rear doors Pollen filter The pollen filter is located under the wind cowl grille on the right hand side on LHD vehicles and on the left hand side on RHD vehicles as seen looking from the driver s seat Protective screens to trap large particles are installed on the left and right hand sides of the pollen filter Description Protective screen Po...

Page 1508: ... Distribution and Filtering Air Distribution and Filtering Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 412 00 Climate Control System General Information http vnx su ...

Page 1509: ...oval 1 NOTE The pollen filter is situated on the passenger side NOTE Position the wipers in vertical position Remove the hood rubber seal 2 Remove the cowl panel on the passenger side 3 Remove the water collection tray of the pollen filter 4 Remove the pollen filter retaining flap 5 Remove the pollen filter http vnx su ...

Page 1510: ...Installation 1 NOTE Note the direction of flow of the pollen filter Refit the components in reverse order http vnx su ...

Page 1511: ...s Item Nm lb ft lb in Passenger compartment side nut for heat exchanger evaporator housing 9 80 Engine compartment side nut for heat exchanger evaporator housing 7 62 Bolts reinforcing element 20 15 Bolts reinforcing element bracket 16 12 Bolt steering column 17 13 Nut steering column 16 12 http vnx su ...

Page 1512: ...Heating and Ventilation Heating and Ventilation Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 412 00 Climate Control System General Information http vnx su ...

Page 1513: ...5 06 2002 Print Removal and Installation Removal Installation 1 Remove the footwell lower trim panel 2 Remove the footwell vent air duct 3 Disconnect the blower motor electrical connector 4 Remove the blower motor 1 To install reverse the removal procedure http vnx su ...

Page 1514: ... 03 Engine Cooling 2 NOTE Seal off the coolant lines and the heater core to prevent the entry of dirt Using the special tool detach the coolant hoses from the heater core 3 Lower the vehicle 4 Remove the center console For additional information refer to Section 501 12 Instrument Panel and Console 5 Remove the rear footwell air guide 1 Remove the bolt 2 Pull out the air guide 6 Remove the passenge...

Page 1515: ...e driver side fascia crash padding lower trim Pull off the light switch connector 10 Remove the driver side air guide 11 Detach the accelerator pedal with bracket from the bulkhead and lay it to one side 12 Remove the right and left hand reinforcing element brackets right hand side shown http vnx su ...

Page 1516: ...the right hand air guide housing half 14 Remove the left hand air guide housing half 15 Remove the heater core housing with heater core 16 Remove the heater core bolt 17 Remove the heater core housing http vnx su ...

Page 1517: ...Installation 1 Install the components in the reverse order http vnx su ...

Page 1518: ...OTE Removal steps in this procedure may contain installation details Hose clamp s 1 Refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 CAUTION Make sure that all openings are sealed General Equipment Hose clamp s 3 Refer to Floor Console Vehicles Built From 04 2009 501 12 Instrument Panel and Console Removal and Installation 4 5 http vnx su ...

Page 1519: ...Left hand drive vehicles 6 7 8 Torque 9 Nm http vnx su ...

Page 1520: ...All vehicles 9 10 11 http vnx su ...

Page 1521: ...12 13 http vnx su ...

Page 1522: ...Installation 14 1 To install reverse the removal procedure http vnx su ...

Page 1523: ...2 Bleed the cooling system Refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling General Procedures http vnx su ...

Page 1524: ...tional information refer to Air Conditioning A C System Recovery Evacuation and Charging 412 00 Climate Control System General Information General Procedures 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling General Procedures 3 NOTE Seal off the coolant line and the heater core to prevent the entry of dirt Using the s...

Page 1525: ...et 7 Remove the trim from the engine main wiring harness connector 8 Detach the engine wiring harness electrical connector from the wheelhouse assembly 9 Lower the vehicle 10 Remove the engine upper cover 11 Detach the charge air cooler outlet pipe from the intake manifold http vnx su ...

Page 1526: ...arge air cooler outlet pipe 1 Release the hose clip 2 Remove the nuts 13 Detach the rear coolant hose from the fuel fired booster heater using the special tool and lay it to one side 14 Remove the air cleaner outlet pipe 15 Remove the retaining clips of the spring lock couplings on the refrigerant lines http vnx su ...

Page 1527: ... 2006 415 01A Audio Unit Removal and Installation Audio Unit Vehicles Built From 08 2008 415 01A Audio Unit Removal and Installation 18 Remove the gearshift lever For additional information refer to Gearshift Lever 308 06 Manual Transmission Transaxle External Controls Removal and Installation 19 Remove the glove compartment 20 Remove the lower dashboard trim on the passenger side 21 Disconnect th...

Page 1528: ... right hand A pillar trim For additional information refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 26 Detach the right hand dashboard wiring harness connector from the socket Remove the ground cable bolt 27 Detach the lower dashboard trim on the driver s side from the fascia crash padding 28 Remove the lower dashboard trim on the driver s side Pull of...

Page 1529: ...quipped 31 Remove the steering column lower trim 1 Release the steering column locking lever 2 Unscrew the bolts 32 Disconnect the passive anti theft system PATS transceiver windshield washer system switch and airbag sliding contact connectors 33 Disconnect the ignition switch and turn signal switch connectors http vnx su ...

Page 1530: ...ion switch if equipped 2 Stoplamp switch 3 Clutch position switch 36 Detach the wiring harness from the steering column 1 Release the retaining pin 2 Detach the wiring harness 37 Detach the steering column from the dashboard crossmember 38 Disconnect the left hand dashboard wiring harness connector from the socket Remove the ground cable bolt http vnx su ...

Page 1531: ... system connector 40 Remove the shift cable bracket 41 Disconnect the connector of the handbrake warning lamp switch 42 Disconnect the airbag module connector 43 Remove the airbag module Unclip the wiring harness http vnx su ...

Page 1532: ...rom the heater core evaporator core housing 46 Detach the adjusting mechanism of the temperature flap from the heater core evaporator core housing 47 Detach the airbag module wiring harness from the dashboard crossmember bracket 48 Remove the left and right hand dashboard crossmember brackets right hand side shown http vnx su ...

Page 1533: ...e A pillars left hand side shown 51 Remove the upper bolt of the dashboard crossmember on the the left and right hand side left hand side shown 52 Remove the dashboard upper bolts 53 Remove the side bolt of the dashboard crossmember on the the left and right hand side left hand side shown 1 Remove the cover 2 Remove the bolt http vnx su ...

Page 1534: ...ve the right hand engine compartment side nut for heater core evaporator core housing 57 Remove the left hand engine compartment side nut for heater core evaporator core housing 58 Remove the right hand passenger compartment side nut for heater core evaporator core housing 59 Remove the left hand passenger compartment side nut for heater core evaporator core housing http vnx su ...

Page 1535: ...juries NOTE Install new refrigerant line O rings NOTE Coat the refrigerant line O ring with clean refrigerant oil prior to installation 60 Remove the heater core evaporator core housing 1 Check the position of the dashboard crossmember in relation to the A pillars left hand side shown 2 Install the components in the reverse order http vnx su ...

Page 1536: ...ed NOTE Removal steps in this procedure may contain installation details 412 038 Disconnect Tool Spring Lock Coupling 5 8 black 4 mm drill bit Blind rivet gun Electric drill Hose clamp s 1 Refer to Supplemental Restraint System SRS Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Air Conditioning A C System Recovery Evacuation and Charging 412 00 Climat...

Page 1537: ...8 9 General Equipment Electric drill General Equipment 4 mm drill bit General Equipment Blind rivet gun 10 11 12 http vnx su ...

Page 1538: ... 412 038 14 Remove the driver door 15 Remove the driver seat Refer to Front Seat Vehicles Built From 04 2009 501 10 Seating Removal and Installation 16 On both sides Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 17 18 http vnx su ...

Page 1539: ...19 20 Refer to Gearshift Lever 308 06 Manual Transmission Transaxle External Controls Removal and Installation 21 Torque 9 Nm 22 Torque 8 Nm 23 http vnx su ...

Page 1540: ...24 Torque 25 Nm 25 26 27 http vnx su ...

Page 1541: ...r to Audio Unit Vehicles Built From 04 2009 415 01A Audio Unit Removal and Installation Refer to Audio Unit Vehicles Built From 04 2009 Vehicles With Navigation System 415 01A Audio Unit Removal and Installation 32 33 Torque 10 Nm 34 Torque 10 Nm http vnx su ...

Page 1542: ...35 36 Torque 28 Nm 37 Torque 25 Nm 38 http vnx su ...

Page 1543: ...Installation 1 To install reverse the removal procedure 2 Bleed the cooling system Refer to Cooling System Draining Filling and Bleeding 303 03 Engine Cooling General Procedures http vnx su ...

Page 1544: ...nect 2002 5 06 2002 Print Disassembly and Assembly Disassembly 1 Detach the footwell vent hose 2 Remove the driver side air guide 3 Remove the right hand air guide housing half 4 Remove the left hand air guide housing half 5 Remove the heater core housing with heater core http vnx su ...

Page 1545: ...ts 1 Remove the two screws 2 Release four retaining tangs 9 Separate the blower recirculated air housing parts Release nine retaining tangs 10 CAUTION Cut through the foam seal at the housing separation points in order to prevent damage to the foam seal Dismantle the recirculated air housing http vnx su ...

Page 1546: ...rder to prevent damage to the foam seal Separate the heater core evaporator core housing Release 11 retaining tangs 1 CAUTIONS Cut foam seals can be reused torn or otherwise damaged foam seals must be replaced Check that the guide pins are seated correctly when assembling Replacement steel clips must be used if the housing is not properly sealed after assembly or the retaining tangs are broken Ass...

Page 1547: ...ct 2002 5 06 2002 Print Tightening torques Description Nm lb ft lb in Nuts booster heater to bulkhead 6 53 Band clamp booster heater muffler 7 62 Bolts bracket to booster heater 6 53 Nut booster heater muffler 6 53 Booster heater glow plug 6 53 http vnx su ...

Page 1548: ...or countries with a cold climate a fuel operated booster heater is installed and this can also be ordered as an option The electrically operated glowplug booster heater is integral with the cooling system and is switched on and off depending on certain pre conditions The glowplugs are controlled through 3 relays by the PCM and are switched in three different stages depending on demand 1st stage gl...

Page 1549: ...r I R 13 Relay glowplug booster heater II R 10 The relays are located in the fuse box in the engine compartment Fuel fired additional heater Description Fuel return line Fuel supply line to engine Fuel supply line to fuel filter Fuel supply line to booster heater Metering pump Additional heater Item 1 2 3 Item 1 2 3 4 5 6 Part Number Part Number http vnx su ...

Page 1550: ...tion of the booster heater in all weather conditions The booster heater has its own exhaust system which vents safely into the atmosphere The external temperature sensor prevents boost heating when the ambient temperature is above 8 C no boost heating needed The ambient temperature sensor is located at the right on the radiator bracket Coolant flow Description Vehicle engine Booster heater Heat ex...

Page 1551: ...k Flame sensor Control sensor Overheating sensor Glow plug Fuel pump Blower motor The booster heater will only start after the self test of the heating unit is successful Should a fault be detected a fault notification will be output through the vehicle diagnosis The ceramic glowplug starts to heat the combustion chamber After a delay the blower switches on During the start procedure the blower co...

Page 1552: ...rst start second start one after the other all further start attempts are stopped by the control unit This inhibit state can only be released by clearing the fault memory Run on mode 120 seconds After the coolant has reached a temperature of 85 C or the switch on conditions are no longer satisfied the heater passes into run on mode In run on mode the combustion chamber is cooled and prepared for a...

Page 1553: ... remains below 10 2 V for a time 40 seconds a Low voltage shutdown is notified A fault during self test causes the start process to interrupt and generates a fault notification corresponding to the fault which occurred Block circuit diagram Description Relay voltage supply R 8 EEC Power Booster heater Data Link Connector DLC Ambient temperature switch PCM Ignition lock Central fuse box below instr...

Page 1554: ...nd to those of the fuel operated booster heater Like the booster heater the parking heater is built into the cooling circuit Coolant flow Description Coolant pump Parking heater Vehicle heat exchanger Vehicle engine First of all the parking heater warms the coolant for the vehicle engine After the engine has been heated by the coolant the heat is passed to the vehicle interior depending on the blo...

Page 1555: ...just heating time 10 to 120 minutes using buttons 5 and 7 Press button 6 current time is shown colon symbol flashes Set preset time By pressing button 6 once twice or three times preset time 1 2 or 3 is called up Shown in display e g preset time 1 Set preset time with buttons 5 and 7 The preset time is activated or deactivated using button 4 When preset time is activated the symbol ON 2 is display...

Page 1556: ... switch Blower motor Mini clock operating controls PCM Ignition lock Central fuse box below instrument panel Engine running relay R24 Blower motor relay Fuse box for parking heater Fuse box in the engine compartment Ignition relay R1 Battery Ambient temperature switch Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number http vnx su ...

Page 1557: ... the powertrain control module PCM using the WDS tester and RECTIFY any displayed faults according to the fault description CHECK the operation of the system 5 5 If no fault is stored in the fault memory PROCEED with the symptom chart according to the fault symptom 6 6 Following checking or elimination of the fault and after completion of operations the fault memories of all vehicle modules must b...

Page 1558: ...Check the combustion air blower motor according to the component check at the end of this section B2456 Temperature sensor circuit short to ground Check the temperature sensor according to the component check at the end of this section B2457 Temperature sensor circuit open circuit Check the temperature sensor according to the component check at the end of this section B2458 Overheating sensor circ...

Page 1559: ... Vehicles with programmable fuel fired booster heater Check the operation of the fuel fired booster heater coolant pump B2467 Blower cooling time limit exceeded Check exhaust and combustion air pipes A temperature exceeding 70 C is measured by the flame sensor for longer than 240 seconds when the booster heater is switched on Check the flame sensor according to the component check at the end of th...

Page 1560: ... 8 C and the coolant temperature has not yet exceeded 75 C TEST CONDITIONS DETAILS RESULTS ACTIONS A1 CHECK FUSE F11 Ignition switch in position 0 1 CHECK fuse F11 BJB 2 Is the fuse OK Yes GO to A2 No RENEW fuse F11 20 A CHECK the operation of the system If the fuse blows again LOCATE and REPAIR the short to ground using the Wiring Diagrams A2 CHECK THE VOLTAGE AT FUSE F11 Connect fuse F11 BJB 1 M...

Page 1561: ...he Wiring Diagrams CHECK the operation of the system A6 CHECK VOLTAGE AT FUEL FIRED BOOSTER HEATER Ignition switch in position II 1 Measure the voltage between the fuel fired booster heater connector C878 pin 4 circuit 15 RD18 GN RD wiring harness side and ground 2 Does the meter display battery voltage Yes GO to A7 No LOCATE and REPAIR the break in circuit 15 RD18 GN RD between the fuel fired boo...

Page 1562: ...ENEW if necessary CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31 RD18 BK between the fuel fired booster heater and soldered connection S121 using the Wiring Diagrams CHECK the operation of the system A9 CHECK VOLTAGE AT AMBIENT TEMPERATURE THERMO SWITCH Ignition switch in position 0 1 Disconnect ambient temperature thermo switch C875 2 Ignition switch in position II...

Page 1563: ... RD18 BU WH between the ambient temperature thermo switch and the fuel fired booster heater using the Wiring Diagrams CHECK the operation of the system A11 CHECK VOLTAGE AT ENGINE RUN RELAY Ignition switch in position 0 1 Disconnect engine run relay C1024 CJB 2 Ignition switch in position II 3 Measure the voltage between the engine run relay socket C1024 pin 3 wiring harness side and ground 4 Does...

Page 1564: ...ring harness side and the ambient temperature thermo switch connector C875 pin 1 circuit 64 RD18 BU WH wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes CHECK the CJB and RENEW as necessary CHECK the operation of the system No LOCATE and REPAIR the break in the circuit between the CJB and the ambient temperature thermo switch with the aid of the Wiring Diagrams CHECK the oper...

Page 1565: ...2 Is a resistance of less than 2 Ohm registered Yes CHECK the CJB and RENEW as necessary CHECK the operation of the system No LOCATE and REPAIR the open circuit between the CJB and the PCM with the aid of the Wiring Diagrams CHECK the operation of the system A18 CHECK THE CIRCUIT BETWEEN THE ENGINE RUN RELAY AND THE POWERTRAIN CONTROL MODULE PCM FOR OPEN CIRCUIT VEHICLES WITH A 1 8L 75 PS DIESEL E...

Page 1566: ...checks ensure that the vehicle battery is OK and that the charge state is sufficient NOTE The fuel fired booster heater only works in booster heater mode if the engine is running the battery is being charged by the generator the ambient temperature is below 8 C and the coolant temperature has not yet exceeded 75 C TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK THE BOOSTER HEATER FUNCTION Ignitio...

Page 1567: ...rcuit C30 RD18 RD wiring harness side and ground 2 Does the meter display battery voltage Yes GO to B9 No LOCATE and RECTIFY the break in circuit 30 RD18 RD between the fuel fired additional heater and fuse F11 with the aid of the Wiring Diagrams CHECK the operation of the system B6 CHECK FUSE FB Ignition switch in position 0 1 CHECK Fuse FB auxiliary fuse box vehicles built from 02 2004 fuse hold...

Page 1568: ...off the fuel fired booster heater via the parking heater control unit 1 Measure the resistance between the fuel fired booster heater connector C501 pin 2 circuit 31 RD18A BK wiring harness side and ground 2 Is a resistance of less than 2 Ohm registered Yes CHECK the fuel fired booster heater using WDS and RECTIFY the fault s displayed according to the fault code table CHECK the operation of the sy...

Page 1569: ...Diagrams CHECK the operation of the system B13 CHECK FOR OPEN CIRCUIT BETWEEN THE PARKING HEATER CONTROLS AND THE FUEL FIRED BOOSTER HEATER Measure the resistance between the parking heater control unit connector C505 pin 2 circuit 8 FC14 WH BK wiring harness side and the fuel fired booster heater connector C501 pin 7 circuit 8 FC14 WH BK wiring harness side 1 Is a resistance of less than 2 Ohm re...

Page 1570: ...e resistance between the ambient temperature thermo switch connector C875 pin 2 circuit 64S RD18 BU WH wiring harness side and the fuel fired booster heater connector C501 pin 6 circuit 64S RD18 BU WH wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes RENEW the ambient temperature thermo switch CHECK the operation of the system No LOCATE and REPAIR the break in circuit 64S RD1...

Page 1571: ...he engine run relay socket C1024 pin 5 wiring harness side and the ambient temperature thermo switch connector C875 pin 1 circuit 64 RD18 BU WH wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes GO to B21 No GO to B20 B20 CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE AMBIENT TEMPERATURE THERMO SWITCH Disconnect connector C14 from CJB 1 Measure the resistance between the CJB c...

Page 1572: ...d PCM connector C414 pin 23 circuit 31S PA19 BK GN wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes CHECK the PCM and RENEW as necessary CHECK the operation of the system No GO to B23 B23 CHECK THE CIRCUIT BETWEEN THE CJB AND THE PCM FOR CONTINUITY Disconnect connector C10 from CJB 1 Measure the resistance between the CJB connector C10 pin 3 circuit 31S PA19 BK GN wiring har...

Page 1573: ...g harness side 2 Is a resistance of less than 2 Ohm registered Yes CHECK the CJB and RENEW as necessary CHECK the operation of the system No LOCATE and REPAIR the open circuit between the CJB and the PCM with the aid of the Wiring Diagrams CHECK the operation of the system PINPOINT TEST C BLOWER MOTOR INOPERATIVE WHEN FUEL FIRED BOOSTER HEATER SWITCHED ON VEHICLES WITH PROGRAMMABLE FUEL FIRED BOOS...

Page 1574: ...elay socket C503 pin 1 circuit 30S FA23 RD BU wiring harness side and ground 2 Does the meter display battery voltage Yes GO to C8 No GO to C5 C5 CHECK FOR OPEN CIRCUIT BETWEEN THE FUEL FIRED BOOSTER HEATER AND THE ADDITIONAL HEATER BLOWER RELAY CAUTION In order to prevent damage to the control module always wait for the run on time of the fuel fired booster heater to end before disconnecting Swit...

Page 1575: ...ween the additional heater blower relay and ground connection G1 with the aid of the wiring diagrams CHECK the operation of the system PINPOINT TEST D AUXILIARY HEATER METERING PUMP INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS D1 CHECK FOR OPEN CIRCUIT BETWEEN THE CONTROL MODULE AND THE AUXILIARY HEATER METERING PUMP Ignition switch in position 0 1 Disconnect Connector C501 from the fuel fi...

Page 1576: ...und 2 Is a resistance of more than 10 000 ohms measured Yes RENEW the auxiliary heater metering pump CHECK the operation of the system If the system is still inoperative CHECK the wiring harness between the additional heater metering pump and the control unit for damage and REPAIR as necessary If the wiring harness is OK RENEW the control unit of the additional heater No LOCATE and REPAIR the shor...

Page 1577: ...dule and the glow plug using the Wiring Diagrams CHECK the operation of the system PINPOINT TEST F FUEL FIRED BOOSTER HEATER COOLANT PUMP INOPERATIVE VEHICLES WITH PROGRAMMABLE FUEL FIRED BOOSTER HEATER TEST CONDITIONS DETAILS RESULTS ACTIONS F1 CHECK THE CIRCUIT BETWEEN THE FUEL FIRED BOOSTER HEATER COOLANT PUMP AND THE CONTROL MODULE FOR SHORT CIRCUIT Disconnect Connector C1066 from control modu...

Page 1578: ... CONTROL MODULE FOR OPEN CIRCUIT Measure the resistance between the control module connector C1066 pin 10 BN wiring harness side and the fuel fired booster heater coolant pump connector C1069 BN wiring harness side 1 Measure the resistance between the control module connector C1066 pin 11 VT wiring harness side and the fuel fired booster heater coolant pump connector C1069 VT wiring harness side 2...

Page 1579: ...for ease of movement and soiling Check for moisture which can freeze at temperatures below 0 C Ensure correct routing of the wiring harness ELIMINATE stiffness or blockage RENEW the combustion air blower motor if necessary 2 2 Combustion air blower motor open short circuit CHECK and REPAIR the combustion air blower motor for damage RENEW the combustion air blower motor if necessary Measure the res...

Page 1580: ...ness side Compare the resistance value with the following table Does the resistance measured correspond to the required value 1 If yes the temperature sensor is OK 2 If no RENEW the temperature sensor Overheating sensor 1 1 CHECK both cables RD leading to the overheating sensor for damage and RENEW the overheating sensor if necessary 2 2 Check the overheating sensor for a short to ground Measure t...

Page 1581: ... sensor for damage and RENEW the flame sensor if necessary 2 2 Check the flame sensor for short to ground Measure the resistance between the control module connector C1066 pin 1 BU wiring harness side and the flame sensor housing Measure the resistance between the control module connector C1066 pin 2 BN wiring harness side and the flame sensor housing Is a resistance greater than 10 000 Ohms measu...

Page 1582: ...er heater via the parking heater controls or for vehicles with non programmable fuel fired booster heater start the engine and run it at idle speed Note the switch on conditions of the fuel fired booster heater REFER to Auxiliary Heater 412 02B Auxiliary Heating Description and Operation If necessary bridge the ambient temperature thermo switch Fuel delivery begins 45 seconds after the fuel fired ...

Page 1583: ...f the fuel fired booster heater The fuel quantity delivered should be between 7 8 cm and 9 0 cm If the fuel quantity is outside this range check the additional heater fuel line and repair as required Check that the connections are correct Where fuel lines are joined by a length of hose ensure that the ends of the fuel lines abut completely to prevent air bubbles from forming Description Correct li...

Page 1584: ...the charging system with WDS and RECTIFY any displayed faults in accordance with the fault description CHECK the operation of the system 5 5 For vehicles without any stored faults PROCEED in accordance with the Symptom Chart 6 6 Following checking or elimination of the fault and after completion of operations the fault memories of all vehicle modules must be READ OUT and any stored faults must be ...

Page 1585: ...E ELECTRIC BOOSTER HEATER Ignition switch in position III 1 Measure the current in circuits 15 RD23 GN BK and 15 RD22 GN RD at the electric booster heater using the clip on ammeter 2 Is a current measured Yes GO to A2 No GO to A3 A2 CHECK 1ST STAGE OF ELECTRIC BOOSTER HEATER CIRCUIT Measure the current in circuit 15 RD22 GN RD at the electric booster heater using the clip on ammeter 1 Is a current...

Page 1586: ...grams CHECK the operation of the system A5 CHECK THE SIGNAL FROM THE INTAKE AIR TEMPERATURE SENSOR NOTE The intake air temperature sensor is integrated in the mass air flow sensor engine management Connect the diagnostic tool 1 Ignition switch in position II 2 Check the intake air temperature signal using the WDS 3 Is the intake air temperature signal OK i e is the indicated temperature value plau...

Page 1587: ...rness side and ground 2 Does the meter display battery voltage Yes GO to A9 No LOCATE and REPAIR the break in circuit 30 RH24 RD between the glow plug heating relay stage 1 and fuse F11 using the Wiring Diagrams CHECK the operation of the system A9 CHECK CONTROL VOLTAGE AT GLOW PLUG HEATING RELAY STAGE 1 Ignition switch in position II 1 Measure the voltage between glow plug heating relay stage 1 s...

Page 1588: ... the Wiring Diagrams CHECK the operation of the system No RENEW the electric booster heater CHECK the operation of the system A12 CHECK GLOW PLUG HEATING RELAY STAGE 1 Check glow plug heating relay 1 in accordance with the component test at the end of this section 1 Is the glow plug heating relay stage 1 OK Yes Vehicles with 104 pin EEC GO to A13 Vehicles with 121 pin EEC GO to A14 No RENEW glow p...

Page 1589: ...4 pin 61 circuit 31S RH23 BK OG wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes CHECK the PCM and RENEW as necessary CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31S RH23 BK OG between the PCM and the glow plug heating relay stage 1 using the Wiring Diagrams CHECK the operation of the system A15 CHECK FUSE F18 Ignition switch in position 0 1 C...

Page 1590: ...f the system A18 CHECK CONTROL VOLTAGE AT GLOW PLUG HEATING RELAY STAGE 2 Ignition switch in position II 1 Measure the voltage between glow plug heating relay stage 2 socket C1010 pin 1 circuit 15 RH25 GN BK wiring harness side and ground 2 Does the meter display battery voltage Yes GO to A19 No LOCATE and REPAIR the break in circuit 15 RH25 GN BK between glow plug heating relay stage 2 and solder...

Page 1591: ...the system A21 CHECK THE ELECTRIC BOOSTER HEATER Measure the resistance between electric booster heater connector C967 component side and ground 1 Is a resistance of less than 1 2 Ohm registered Yes LOCATE and REPAIR the break in circuit 15 RD23 GN BK between glow plug heating relay stage 2 and the electric booster heater or bridge at electric booster heater using the Wiring Diagrams CHECK the ope...

Page 1592: ...ance of less than 2 Ohm registered Yes CHECK the PCM and RENEW as necessary CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31S RH25 BK GN between the PCM and the glow plug heating relay stage 2 using the Wiring Diagrams CHECK the operation of the system A24 CHECK FOR OPEN CIRCUIT BETWEEN PCM AND GLOW PLUG HEATING RELAY STAGE 2 VEHICLES WITH 121 PIN EEC Disconnect PCM C...

Page 1593: ...tery negative terminal Measure the resistance at the relay between pin 3 and pin 5 component side Is a resistance of less than 2 Ohm registered 1 If yes then the relay is OK 2 If no RENEW the relay Glow plug heating relay stage 2 1 1 Check the normally open contact in the unswitched state Measure the resistance at the relay between pin 3 and pin 5 component side Is a resistance of more than 10 kOh...

Page 1594: ...ive terminal Using a test cable connect pin 2 of the relay component side to the battery negative terminal Measure the resistance at the relay between pin 3 and pin 5 component side Is a resistance of less than 2 Ohm registered 1 If yes then the relay is OK 2 If no RENEW the relay http vnx su ...

Page 1595: ...the charging system with WDS and RECTIFY any displayed faults in accordance with the fault description CHECK the operation of the system 5 5 For vehicles without any stored faults PROCEED in accordance with the Symptom Chart 6 6 Following checking or elimination of the fault and after completion of operations the fault memories of all vehicle modules must be READ OUT and any stored faults must be ...

Page 1596: ...E ELECTRIC BOOSTER HEATER Ignition switch in position III 1 Measure the current in circuits 15 RD23 GN BK and 15 RD22 GN RD at the electric booster heater using the clip on ammeter 2 Is a current measured Yes GO to A2 No GO to A3 A2 CHECK 1ST STAGE OF ELECTRIC BOOSTER HEATER CIRCUIT Measure the current in circuit 15 RD22 GN RD at the electric booster heater using the clip on ammeter 1 Is a current...

Page 1597: ...grams CHECK the operation of the system A5 CHECK THE SIGNAL FROM THE INTAKE AIR TEMPERATURE SENSOR NOTE The intake air temperature sensor is integrated in the mass air flow sensor engine management Connect the diagnostic tool 1 Ignition switch in position II 2 Check the intake air temperature signal using the WDS 3 Is the intake air temperature signal OK i e is the indicated temperature value plau...

Page 1598: ...rness side and ground 2 Does the meter display battery voltage Yes GO to A9 No LOCATE and REPAIR the break in circuit 30 RH24 RD between the glow plug heating relay stage 1 and fuse F11 using the Wiring Diagrams CHECK the operation of the system A9 CHECK CONTROL VOLTAGE AT GLOW PLUG HEATING RELAY STAGE 1 Ignition switch in position II 1 Measure the voltage between glow plug heating relay stage 1 s...

Page 1599: ... the Wiring Diagrams CHECK the operation of the system No RENEW the electric booster heater CHECK the operation of the system A12 CHECK GLOW PLUG HEATING RELAY STAGE 1 Check glow plug heating relay 1 in accordance with the component test at the end of this section 1 Is the glow plug heating relay stage 1 OK Yes Vehicles with 104 pin EEC GO to A13 Vehicles with 121 pin EEC GO to A14 No RENEW glow p...

Page 1600: ...4 pin 61 circuit 31S RH23 BK OG wiring harness side 2 Is a resistance of less than 2 Ohm registered Yes CHECK the PCM and RENEW as necessary CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31S RH23 BK OG between the PCM and the glow plug heating relay stage 1 using the Wiring Diagrams CHECK the operation of the system A15 CHECK FUSE F18 Ignition switch in position 0 1 C...

Page 1601: ...f the system A18 CHECK CONTROL VOLTAGE AT GLOW PLUG HEATING RELAY STAGE 2 Ignition switch in position II 1 Measure the voltage between glow plug heating relay stage 2 socket C1010 pin 1 circuit 15 RH25 GN BK wiring harness side and ground 2 Does the meter display battery voltage Yes GO to A19 No LOCATE and REPAIR the break in circuit 15 RH25 GN BK between glow plug heating relay stage 2 and solder...

Page 1602: ...the system A21 CHECK THE ELECTRIC BOOSTER HEATER Measure the resistance between electric booster heater connector C967 component side and ground 1 Is a resistance of less than 1 2 Ohm registered Yes LOCATE and REPAIR the break in circuit 15 RD23 GN BK between glow plug heating relay stage 2 and the electric booster heater or bridge at electric booster heater using the Wiring Diagrams CHECK the ope...

Page 1603: ...ance of less than 2 Ohm registered Yes CHECK the PCM and RENEW as necessary CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31S RH25 BK GN between the PCM and the glow plug heating relay stage 2 using the Wiring Diagrams CHECK the operation of the system A24 CHECK FOR OPEN CIRCUIT BETWEEN PCM AND GLOW PLUG HEATING RELAY STAGE 2 VEHICLES WITH 121 PIN EEC Disconnect PCM C...

Page 1604: ...tery negative terminal Measure the resistance at the relay between pin 3 and pin 5 component side Is a resistance of less than 2 Ohm registered 1 If yes then the relay is OK 2 If no RENEW the relay Glow plug heating relay stage 2 1 1 Check the normally open contact in the unswitched state Measure the resistance at the relay between pin 3 and pin 5 component side Is a resistance of more than 10 kOh...

Page 1605: ...ive terminal Using a test cable connect pin 2 of the relay component side to the battery negative terminal Measure the resistance at the relay between pin 3 and pin 5 component side Is a resistance of less than 2 Ohm registered 1 If yes then the relay is OK 2 If no RENEW the relay http vnx su ...

Page 1606: ...ir cooler outlet pipe from the intake manifold 4 Remove the charge air cooler outlet pipe 1 Release the hose clip 2 Remove the nuts 5 CAUTION Seal off the coolant hose and the fuel fired booster heater to prevent the entry of dirt Using the special tool detach the front coolant hose from the fuel fired booster heater 6 NOTE Seal off the coolant hose and the fuel fired booster heater to prevent the...

Page 1607: ...d booster heater fuel pump 8 Pull off the fuel fired booster heater connector 9 Unscrew the fuel fired booster heater upper nut 10 Raise the vehicle For additional information refer to Section 100 02 Jacking and Lifting 11 Unscrew the fuel fired booster heater exhaust system nut 12 Remove the fuel fired booster heater exhaust system http vnx su ...

Page 1608: ...nd the heater core to prevent the entry of dirt Using the special tool detach the coolant hoses from the heater core 15 Unscrew the fuel fired booster heater left lower nut 16 Unscrew the fuel fired booster heater right lower nut 17 Guide the fuel fired booster heater downwards http vnx su ...

Page 1609: ...h bracket 19 Pull off the fuel fired booster heater fuel pump connector 20 Detach the fuel hose from the fuel fired booster heater 21 Remove the fuel fired booster heater fuel pump with bracket 22 Remove the fuel fired booster heater http vnx su ...

Page 1610: ...Installation 1 Install the components in the reverse order http vnx su ...

Page 1611: ...fired booster heater Vehicles with programmable fuel fired booster heater 1 Remove the water cooling jacket cover 2 Remove the combustion air blower motor cover 3 Remove the fuel metering pump cover 4 Detach the auxiliary coolant flow pump from the booster heater 5 Remove the auxiliary coolant flow pump Disconnect the electrical connector http vnx su ...

Page 1612: ...rommets 7 CAUTION Cap the fuel lines to prevent dirt ingress Disconnect the fuel metering pump hose 8 Remove the fuel metering pump 9 Remove the combustion air blower motor cover 10 Detach the overheat sensor and the temperature sensor from the water cooling jacket Discard the O ring seals http vnx su ...

Page 1613: ...ining bolts 12 Remove the combustion air blower motor cover 13 Remove the fuel fired booster heater module Disconnect the internal electrical connector 14 Disconnect the glow plug wire from the glow plug 15 Disconnect the cables from the fuel fired booster heater electrical connector glow plug shown http vnx su ...

Page 1614: ...d wrench to hold the pre ignition chamber by the hexagon to prevent damages of the pre ignition chamber Remove the glow plug 18 Remove the flame sensor Remove the support 19 Remove the pre ignition chamber 1 Turn the pre ignition chamber clockwise 2 Pull out the pre ignition chamber 1 Discard the O ring seals 20 Remove the combustion air blower motor Discard the seal http vnx su ...

Page 1615: ...ble screwdriver remove the heat exchanger Discard the O ring seal 1 NOTE Install new O ring seals and gaskets NOTE Coat the O ring seals in coolant prior to installation To assemble reverse the disassembly procedure http vnx su ...

Page 1616: ...or crossmember 24 18 Dehydrator 7 62 Bolt A C compressor 24 18 Refrigerant line to dehydrator 8 71 Refrigerant line bracket to radiator crossmember 10 89 Bolt refrigerant line to A C compressor 20 15 Nut refrigerant line to condenser 8 71 A C charging connection 10 89 Orifice connection 8 71 Bolt A C compressor drive plate 13 10 High pressure switch 10 89 Low pressure switch 2 5 23 http vnx su ...

Page 1617: ...or Clutch cycling switch Heater air conditioning blower Evaporator Orifice tube valve with variable aperture High pressure switch double pressure switch Engine cooling fans High pressure liquid and warm Low pressure liquid and cold Low pressure gas and cold High pressure gas and hot Cold air Warm air Installed locations Item 1 2 3 4 5 6 7 8 9 A B C D E F Part Number http vnx su ...

Page 1618: ...ube valve with variable aperture Evaporator High pressure charge valve High pressure switch double pressure switch Condenser Compressor Accumulator dehydrator Orifice tube valve with variable aperture Item 1 2 3 4 5 6 7 8 Part Number http vnx su ...

Page 1619: ...a valve with a variable aperture is installed Because of this valve with variable aperture the air conditioning system uses less power Idle speed emissions are reduced Fuel consumption is reduced The pressure in the high pressure line pushes the metering pin against a spring with a force which depends on the type of driving idle town or motorway highway The aperture of the valve is increased or de...

Page 1620: ...Air Conditioning Air Conditioning Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 412 00 Climate Control System General Information http vnx su ...

Page 1621: ...ehicle For additional information refer to Section 100 02 Jacking and Lifting 3 Remove the drive belt cover 4 Turn the drive belt tensioner counter clockwise and remove the drive belt 5 CAUTION Cap the refrigerant lines and the A C compressor to prevent dirt ingress Detach the refrigerant lines from the A C compressor Discard the O rings 6 Detach the A C compressor clutch connector 7 Remove the A ...

Page 1622: ...e A C compressor pulley Remove the spacer washers Discard the pulley snap ring 10 Remove the solenoid coil snap ring 11 NOTE Mark the installation position of the A C compressor clutch connector in relation to the compressor housing Remove the solenoid coil 1 CAUTION Do not tilt the solenoid coil when installing in the A C compressor http vnx su ...

Page 1623: ...ressor pulley snap ring NOTE Install new refrigerant line O rings NOTE Coat the refrigerant line O rings with clean refrigerant oil before installation Install the components in the reverse order 2 Check the A C clutch air gap For additional information refer to Section 412 00 Climate Control System General Information http vnx su ...

Page 1624: ... lines Vehicles with 1 6L engine CAUTION Support the A C compressor before removing the retaining bolts and secure it to prevent load being placed on the refrigerant lines Two leg puller Name M6 x 30 mm bolt Washer 1 Remove the accessory drive belt For additional information refer to Section 303 05 Accessory Drive 2 Disconnect the air conditioning A C compressor clutch electrical connector 3 Detac...

Page 1625: ...essor drive plate 6 Remove the A C compressor pulley Remove the spacer shims 7 NOTE Mark the position of the A C compressor clutch electrical connector in relation to the compressor housing Using a suitable two leg puller remove the clutch field coil http vnx su ...

Page 1626: ...emove the M6 x 30 mm bolt washer and A C compressor drive plate Install the spacer shims 3 NOTE Install a new A C compressor pulley snap ring Install the A C compressor pulley Install the snap ring 4 Install the A C compressor drive plate 5 Check the A C clutch air gap For additional information refer to Section 412 00 Climate Control System General Information 6 Attach the A C compressor to the A...

Page 1627: ...h the A C compressor to the A C compressor bracket 8 Connect the A C compressor clutch electrical connector 9 Install the accessory drive belt For additional information refer to Section 303 05 Accessory Drive http vnx su ...

Page 1628: ...eral Information 2 Raise the vehicle For additional information refer to Section 100 02 Jacking and Lifting 3 Remove the right hand wheel arch trim panel shown with the wheel removed for clarity 4 CAUTION Close off the refrigerant lines and the dehydrator to prevent contamination Remove the dehydrator 1 Disconnect the refrigerant line from the dehydrator using the special tool 2 Disconnect the ref...

Page 1629: ...uring low pressure cutoff switch removal Connect a 20 A fuse rated jumper wire between Pin 1 and Pin 4 harness side of the low pressure cutoff switch electrical connector 5 WARNING Make sure that the low pressure cutoff switch valve closes completely after removal of the low pressure cutoff switch to prevent loss of refrigerant Failure to follow this instruction may result in personal injury Remov...

Page 1630: ...To install reverse the removal procedure http vnx su ...

Page 1631: ...itioning A C System Recovery Evacuation and Charging 412 00 Climate Control System General Information General Procedures 2 Detach the A C charging connection holder from the fender 3 Raise the vehicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 4 Remove the lower radiator cover Discard the retaining clips 5 Detach the refrigerant line bracket f...

Page 1632: ...er core to prevent the entry of dirt Detach the lower refrigerant line from the condenser core 8 CAUTION Seal off the refrigerant lines and the condenser core to prevent the entry of dirt Detach the upper refrigerant line from the condenser core 9 Remove the lower wheelhouse cover 10 CAUTION Support the cooler with a transmission jack Remove the cooler traverse http vnx su ...

Page 1633: ...enser core 1 Push the condenser core to one side 2 Pull out the condenser core downwards 1 NOTE Install new refrigerant line O rings NOTE Coat the refrigerant line O rings with clean refrigerant oil before installation NOTE Install new lower radiator cover retaining clips http vnx su ...

Page 1634: ...Install the components in the reverse order http vnx su ...

Page 1635: ...cutoff switch electrical connector 3 NOTE Make sure that the high pressure cutoff switch valve closes completely after removal of the high pressure cutoff switch to prevent loss of refrigerant Remove the high pressure cutoff switch Discard the O ring seals 1 NOTE Install new high pressure cutoff switch O ring seals NOTE Coat the high pressure cutoff switch O ring seals in clean refrigerant oil pri...

Page 1636: ...oupling 5 8 black 412 081 34 003 1 Drain the air conditioning A C system For additional information refer to Section 412 00 Climate Control System General Information 2 Raise the vehicle For additional information refer to Section 100 02 Jacking and Lifting 3 Remove the right hand wheel arch trim panel shown with wheel removed for clarity 4 CAUTION Seal off the refrigerant line to prevent entry of...

Page 1637: ...om the intake manifold 8 Remove the charge air cooler outlet pipe 1 Release the hose clip 2 Remove the nuts 9 Drain the cooling system For additional information refer to Section 303 03 Engine Cooling 10 Detach the rear coolant hose from the fuel fired booster heater using the special tool and lay it to one side 11 Remove the air cleaner outlet pipe http vnx su ...

Page 1638: ... O rings 14 CAUTION Seal off the refrigerant line to prevent entry of dirt Remove the evaporator core orifice refrigerant line Discard the O rings 15 Hook the special tool into the evaporator core orifice 1 Insert the special tool together with the adapter into the evaporator core orifice 2 Engage the adapter in the evaporator core orifice by means of a turn 16 Remove the evaporator core orifice T...

Page 1639: ...re orifice is faulty Remove faulty evaporator core orifice using special tools 1 NOTE Install new refrigerant line O rings NOTE Coat the refrigerant line O ring seals with clean refrigerant oil prior to installation Install the components in the reverse order http vnx su ...

Page 1640: ...Coupling 1 2 blue 412 038 Disconnect Tool Spring Lock Coupling 5 8 black Name Specification Compressor Oil Air Conditioning WSH M1C231 B 6U7J M1C231 AA 1 Carry out the air conditioning A C system recovery procedure Refer to Air Conditioning A C System Recovery Evacuation and Charging 412 00 Climate Control System General Information General Procedures 2 3 4 Carry out the cooling system drain proce...

Page 1641: ...gs are sealed 6 7 CAUTION Make sure that all openings are sealed Special Tool s 412 038 8 Remove the right hand front road wheel Refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 9 10 CAUTION Make sure that all openings are sealed Special Tool s 412 027 http vnx su ...

Page 1642: ...ation 1 Follow the disassembly procedure in reverse order 2 Coat the O rings for the refrigerant line with clean refrigerant oil Material Compressor Oil Air Conditioning WSH M1C231 B 6U7J M1C231 AA http vnx su ...

Page 1643: ...8 Disconnect Tool Spring Lock Coupling 5 8 black Name Specification Compressor Oil Air Conditioning WSH M1C231 B 6U7J M1C231 AA 1 Carry out the air conditioning A C system recovery procedure Refer to Air Conditioning A C System Recovery Evacuation and Charging 412 00 Climate Control System General Information General Procedures 2 3 4 Carry out the cooling system drain procedure Refer to Cooling Sy...

Page 1644: ...o Wheel and Tire 204 04 Wheels and Tires Removal and Installation 9 10 CAUTION Make sure that all openings are sealed 1 Torque 8 Nm 1 Follow the disassembly procedure in reverse order 2 Coat the O rings for the refrigerant line with clean refrigerant oil Material Compressor Oil Air Conditioning WSH M1C231 B 6U7J M1C231 AA http vnx su ...

Page 1645: ...efer to Air Conditioning A C System Recovery Evacuation and Charging 412 00 Climate Control System General Information General Procedures 2 CAUTION Make sure that all openings are sealed Torque 10 Nm 3 Raise the vehicle Refer to Lifting 100 02 Jacking and Lifting Description and Operation 4 CAUTION Make sure that all openings are sealed 1 Torque 8 Nm 2 Torque 20 Nm 1 Follow the disassembly procedu...

Page 1646: ...Control Components Control Components Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 412 00 Climate Control System General Information http vnx su ...

Page 1647: ...y open the glove compartment 2 Disconnect the air inlet blend door actuator connector 3 Remove the air inlet blend door actuator heater core evaporator core housing removed for clarity 1 CAUTION Ensure that the air inlet blend door actuator shaft correctly engages in the air inlet blend door Install the components in the reverse order http vnx su ...

Page 1648: ... Information and Entertainment System 2 Unscrew and remove the upper bolts from the fascia crash padding console 3 Remove the ashtray 4 Unscrew and remove the lower bolts from the fascia crash padding console 5 Pull the fascia crash padding console forwards and disconnect the plug s 6 Detach the temperature flap actuation cables and the air distribution flap from the heater air conditioning contro...

Page 1649: ...emove the heater air conditioning control unit 1 NOTE To install the cables turn the air distribution control and the temperature control counter clockwise to the stop Refit the components in reverse order http vnx su ...

Page 1650: ... 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 Refer to Floor Console Vehicles Built From 04 2009 501 12 Instrument Panel and Console Removal and Installation 2 1 To install reverse the removal procedure http vnx su ...

Page 1651: ...ol Cable Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 Refer to Floor Console Vehicles Built From 04 2009 501 12 Instrument Panel and Console Removal and Installation 2 3 4 5 http vnx su ...

Page 1652: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 1653: ...415 01B Information and Entertainment System 2 Unscrew and remove the upper bolts from the fascia crash padding console 3 Remove the ashtray 4 Unscrew and remove the lower bolts from the fascia crash padding console 5 Pull the fascia crash padding console forwards and disconnect the plug s 6 Detach the temperature flap actuation cables and the air distribution flap from the heater air conditioning...

Page 1654: ...connect the headlamp switch electrical connector 9 Remove the actuation cable for the air distribution flap 10 Remove the actuation cable for the temperature flap 1 NOTE To install the cables turn the air distribution control and the temperature control counter clockwise to the stop http vnx su ...

Page 1655: ...Refit the components in reverse order http vnx su ...

Page 1656: ...l Assembly Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 Refer to Floor Console Vehicles Built From 04 2009 501 12 Instrument Panel and Console Removal and Installation 2 3 4 5 http vnx su ...

Page 1657: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 1658: ...ations on the blower motor resistor before the blower motor resistor has cooled to ambient temperature Failure to observe this instruction can lead to injury Installation 1 Fully open the glove compartment 2 Disconnect the blower motor resistor connector 3 Remove the blower motor resistor 1 Install the components in the reverse order http vnx su ...

Page 1659: ...009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 Refer to Floor Console Vehicles Built From 04 2009 501 12 Instrument Panel and Console Removal and Installation 2 1 To install reverse the removal procedure http vnx su ...

Page 1660: ...erature Sensor Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 Refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 3 1 To install reverse the removal procedure http vnx su ...

Page 1661: ...Headlamp switch GO to Pinpoint Test A The Instrument cluster illumination is inoperative Circuit s Instrument cluster GO to Pinpoint Test B The climate control illumination is inoperative Circuit s Climate control panel GO to Pinpoint Test C The audio system illumination is inoperative Circuit s Audio unit GO to Pinpoint Test D The hazard lamps switch illumination is inoperative Circuit s Hazard l...

Page 1662: ...ration PINPOINT TEST B THE INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK CIRCUIT 29S GG14 OG FOR VOLTAGE Ignition switch in position 0 1 Disconnect Instrument cluster C809 2 Place the headlamp switch in the headlamp ON position 3 Measure the voltage between the instrument cluster C809 pin 3 circuit 29S GG14 OG harness side and ground 4 Is the volta...

Page 1663: ...he headlamp switch in the headlamp ON position 3 Measure the voltage between the climate control unit C493 pin 2 circuit 29S LH27 OG GN harness side and ground 4 Is the voltage greater than 10 volts Yes GO to C2 No REPAIR the circuit TEST the system for normal operation C2 CHECK CIRCUIT 31 LH27 BK FOR OPEN Place the headlamp switch in the OFF position 1 Measure the resistance between the climate c...

Page 1664: ...tion D2 CHECK CIRCUIT 91 MD34 BK YE FOR OPEN Place the headlamp switch in the OFF position 1 Measure the resistance between the audio C443 pin 2 circuit 91 MD34 BK YE harness side and ground 2 Is the resistance less than 5 ohms Yes INSTALL a new audio unit TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation PINPOINT TEST E THE HAZARD LAMPS SWITCH ILLUMIN...

Page 1665: ...r normal operation No REPAIR the circuit TEST the system for normal operation PINPOINT TEST F THE PASSENGER SIDE WINDOW CONTROL SWITCH ILLUMINATION IS INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS F1 CHECK CIRCUIT 31 LH31 BK FOR OPEN Ignition switch in position 0 1 Disconnect Passenger side window control switch C489 2 Ignition switch in position II 3 Measure the resistance between the passe...

Page 1666: ...REPAIR the circuit TEST the system for normal operation PINPOINT TEST H THE PARKING AID SWITCH ILLUMINATION IS INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS H1 CHECK CIRCUIT 29S LH49 OG BK FOR VOLTAGE Ignition switch in position 0 1 Disconnect Parking aid switch C620 2 Place the headlamp switch in the headlamp ON position 3 Measure the voltage between the parking aid switch C620 pin 3 circui...

Page 1667: ...side and ground Is the resistance less than 5 ohms Yes INSTALL a new parking aid switch TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation http vnx su ...

Page 1668: ...bly Symptom Possible Sources Action The headlamp switch illumination is inoperative Fuse Circuit s Headlamp switch GO to Pinpoint Test A The instrument cluster illumination is inoperative Circuit s Instrument cluster GO to Pinpoint Test B The climate control assembly illumination is inoperative Circuit s Climate control assembly GO to Pinpoint Test C The audio system illumination is inoperative Ci...

Page 1669: ...TEST the system for normal operation PINPOINT TEST B THE INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK CIRCUIT 29S GG14 OG FOR VOLTAGE Ignition switch in position 0 1 Disconnect Instrument Cluster C809 2 Place the headlamp switch in the headlamp ON position 3 Measure the voltage between the instrument cluster C809 pin 24 circuit 29S GG14 OG harness...

Page 1670: ...UIT 29S LH27 OG GN FOR VOLTAGE Ignition switch in position 0 1 Disconnect Climate Control Assembly C493 2 Place the headlamp switch in the headlamp ON position 3 Measure the voltage between the climate control assembly C493 pin 2 circuit 29S LH27 OG GN harness side and ground 4 Is the voltage greater than 10 volts Yes GO to C2 No REPAIR the circuit TEST the system for normal operation C2 CHECK CIR...

Page 1671: ... REPAIR the circuit TEST the system for normal operation D2 CHECK CIRCUITS 91 MD15 BK GN AND 91 MD34 BK YE FOR OPEN Place the headlamp switch in the OFF position 1 Measure the resistance between the audio unit C443 pin 12 circuit 91 MD15 BK GN harness side and ground and between the audio unit C443 pin 11 circuit 91 MD34 BK YE harness side and ground 2 Are the resistances less than 1 ohm Yes INSTA...

Page 1672: ...circuit 91 LG7 BK BU harness side and ground 2 Is the resistance less than 1 ohm Yes INSTALL a new hazard lamps switch TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation PINPOINT TEST F THE PASSENGER SIDE WINDOW CONTROL SWITCH ILLUMINATION IS INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS F1 CHECK CIRCUIT 31 LH31 BK FOR OPEN Ignition switch in posi...

Page 1673: ...ONS G1 CHECK CIRCUIT 29S LH15 OG FOR VOLTAGE Ignition switch in position 0 1 Disconnect Cigar Lighter C911 2 Place the headlamp switch in the headlamp ON position 3 Measure the voltage between the cigar lighter C911 pin 1 circuit 29S LK15 OG harness side and ground 4 Is the voltage greater than 10 volts Yes INSTALL a new cigar lighter socket TEST the system for normal operation No REPAIR the circu...

Page 1674: ...ription and Operation Overview Description Windshield wiper relay Rear window wiper relay Heated rear window and mirror heating relay Interior lighting relay Interior lighting relay Instrument cluster with timer functions Data Link Connector DLC Item 1 2 3 4 5 6 7 Part Number http vnx su ...

Page 1675: ...re transmitted to the instrument cluster via the SCP databus Engine speed for the tachometer Generator failure for the generator charging lamp Coolant temperature for the coolant temperature display Fault in the engine management system for Malfunction Indicator Light MIL and engine control system only on petrol engines Pre glow for the pre glow indicator on diesel vehicles only Vehicle speed for ...

Page 1676: ...ue Right hand turn signal indicator green ABS warning indicator yellow Charge control lamp red Oil pressure warning indicator red Brake system warning indicator red Traction Control System TCS warning indicator yellow Passive anti theft system PATS LED red Glow plug indicator diesel engines yellow Second function if it flashes while driving then it serves as a fault lamp and provides the driver wi...

Page 1677: ...tem warning indicator red TCS warning indicator yellow Passive anti theft system PATS LED red Water in fuel warning indicator yellow Timer functions Depending on the equipment level of the vehicle the following functions are controlled by the timer module of the instrument cluster Battery protection function Exterior lighting on warning Switching on the interior lighting when entering the vehicle ...

Page 1678: ...en entering the vehicle The interior lighting is switched ON as a person enters the vehicle if the ignition is off and a signal to unlock the vehicle is sent from the remote control or the lock cylinder is turned The interior lighting goes out again approx 25 seconds after switching on the ignition or after receipt of a signal to lock the central locking from the remote control or lock cylinder In...

Page 1679: ...erior lighting switch is in the door switch position and not in the continuous operation or Off position The reading lamps in the interior lighting optional are switched on and off with separate switches Control of the heated windshield When the button for the windshield heating is pressed the windshield is heated for approx 4 minutes The requirement for this function is that the engine must be ru...

Page 1680: ...for this function is that the engine must be running An LED in the switch lights up while the rear window and the rear view mirrors are being heated The rear window heating is switched via a relay in the central fuse box underneath the instrument cluster The rear window heating and the heating for the rear view mirrors are switched off after the 10 minute time period has elapsed by pressing the bu...

Page 1681: ...er has no influence on the Slow and Fast functions With the intermittent function the timer module controls the windshield wiper and repeats the wipe cycle every 8 seconds The wiper returns to the park position when switched off Washer fluid is sprayed onto the windshield when the windshield washer button is pressed Two wipes are performed when the spraying is finished and after 100 milliseconds T...

Page 1682: ...hen the wiper runs on continuously for four seconds Description Rear window wiper relay Modelling of the warning tones and signal tones plus the management of their priorities The timer module generates the warning tones and signal tones and determines their priorities The following warning tones and signal tones are currently generated by the timer module listed in order of priority Airbag system...

Page 1683: ... warning light switch is switched off again Turn signal when the turn signal switch is operated a clicking tone sounds 70 to 110 times a minute or 140 to 250 times a minute if the bulb is faulty as long as the turn signal switch is switched on http vnx su ...

Page 1684: ...e warning indicator LPG select indicator Parking brake Brake warning indicator Fuel gauge LPG gauge Traction Control System TCS Speedometer Odometer Tachometer Temperature gauge The LPG and petrol fuel systems share the same fuel gauge When LPG running is selected the fuel gauge will move to the empty position and then move back up the gauge until it settles to show the LPG fuel level At the same ...

Page 1685: ...ot all will be illuminated The gauges and warning indicators may use the outputs from common sensors to carry out their respective functions This should always be considered when looking at any system which may not be functioning correctly for example The electronic speedometer receives its signal from the vehicle speed sensor VSS mounted on the transaxle Other systems which require input include ...

Page 1686: ...must be released within 3 seconds of tESt being displayed in the tripmeter LCD or the Self Diagnostic Mode will exit 3 3 The Self Diagnostic Mode will enter the gauge sweep test 4 4 To navigate through or skip any of the instrument cluster Self Diagnostic Mode tests press the tripmeter RESET button If the reset button is pressed and held for more than 3 seconds between tests the instrument cluster...

Page 1687: ...d type as stored in the non volatile memory 6 Diagnostic trouble code DTC dtc then XXXX or nonE DTCs To list the DTCs stored press the RESET button REFER to the instrument cluster DTC index A new DTC code will be displayed with each press of the reset button 7 Vehicle speed m p h XXX X Speedometer Displays the speed signal input in m p h 000 0 will be displayed in odometer display if no signal rec...

Page 1688: ... input 27 Fuel sender 1XXX Fuel sender input Displays the raw input from the fuel level sender unit 28 Intermittent front wiper 2L or 2H Intermittent front wiper switch input Displays L for intermittent front wiper switch not pressed and H for intermittent front wiper switch pressed 29 Drivers door courtesy switch 3H or 2L Drivers door courtesy switch position input Displays H for door closed and ...

Page 1689: ...uit 8 GA7 WH RD C809 pin 15 circuit 9 GA7 BN RD and C732 pin 4 circuit 9 GA7 YE VT 3 Are the resistances less than 1 ohm Yes GO to A2 No REPAIR circuit 8 GA7 WH RD or 9 GA7 BN RD as necessary TEST the system for normal operation A2 CHECK THE OPERATION OF THE FUEL PUMP AND SENDER UNIT FUEL LEVEL SENSOR Remove the fuel pump and sender unit fuel level sensor REFER to Fuel Level Sensor 1 8L Duratorq T...

Page 1690: ...in fuel sensor No Vehicles built up to 06 2004GO to B2 Vehicles built 06 2004 onwardsGO to B6 B2 CHECK CIRCUIT 15 PE23 GN RD FOR POWER Ignition switch in position 0 1 Disconnect Water in Fuel Sensor C724 2 Ignition switch in position II 3 Measure the voltage between water in fuel sensor C724 pin 2 circuit 15 PE23 GN RD harness side and ground 4 Is the voltage greater than 10 volts Yes GO to B3 No ...

Page 1691: ...stance between water in fuel sensor C724 pin 1 circuit 15S PE23 GN RD harness side and instrument cluster C809 pin 17 circuit 15S PE23 GN RD harness side 3 Is the resistance less than 5 ohms Yes INSTALL a new instrument cluster REFER to Instrument Cluster 413 01 Instrument Cluster Removal and Installation TEST the system for normal operation No REPAIR the circuit TEST the system for normal operati...

Page 1692: ...r C724 pin 2 circuit 91 PE23 BK OG harness side and water in fuel sensor C724 pin 1 circuit 91S PE23 BK OG harness side 2 Ignition switch in position II 3 Does the water in fuel lamp illuminate Yes INSTALL a new water in fuel sensor TEST the system for normal operation No GO to B9 B9 CHECK CIRCUIT 91S PE23 BK OG FOR OPEN Ignition switch in position 0 1 Disconnect Instrument Cluster C813 2 Measure ...

Page 1693: ... to C3 C2 CHECK THE LPG FUEL GAUGE FOR RETURN Install a 10 amp fused jumper wire between the LPG fuel tank C907 pin 3 circuit 91 XL31 BK BU harness side and the LPG fuel tank C907 pin 1 circuit 8 GA6 WH harness side 1 Does the LPG fuel indicator in the instrument cluster return to empty Yes GO to C5 No GO to C7 C3 CHECK CIRCUIT 8 GA6 FOR POWER Measure the voltage between the LPG fuel tank C907 pin...

Page 1694: ...ORRECT OPERATION Remove the LPG fuel level sensor gauge 1 NOTE Place the magnet underneath the fuel level sensor gauge Using a suitable magnet check the fuel level sensor gauge for movement by twisting the magnet clockwise and counterclockwise 2 Does the fuel level sensor gauge move freely Yes INSTALL a new fuel level sensor REFER to Fuel Level Sensor 310 01B Fuel Tank and Lines 1 8L Duratec DOHC ...

Page 1695: ...t 5 EG8 BU WH harness side 3 Is the resistance less than 5 ohms Yes GO to C9 No REPAIR the circuit TEST the system for normal operation C9 CHECK CIRCUIT 4 EG9C GY OG AND CIRCUIT 5 EG8 GY VT FOR OPEN Measure the resistance between the PCM C415 pin 16 circuit 4 EG9C GY OG harness side and the instrument cluster C809 pin 13 circuit 5 EG8 GY VT harness side 1 Is the resistance less than 5 ohms Yes GO ...

Page 1696: ...on information installed Yes INSTALL a new AFCM REFER to Gas Control Module 303 04D Fuel Charging and Controls 1 8L Duratec DOHC 85kW 115PS Zetec Liquefied Petroleum Gas LPG Removal and Installation TEST the system for normal operation No Reprogram the AFCM using the Ford approved diagnostic tool TEST the system for normal operation C13 CHECK CIRCUIT 30 XL35 RD AND CIRCUIT 30 XL35A RD FOR POWER Ig...

Page 1697: ... EBD indicator Is the voltage greater than 10 volts Yes GO to C15 No REPAIR the circuit TEST the system for normal operation C15 CHECK THE AFCM GROUND CIRCUIT FOR OPEN Ignition switch in position 0 1 Measure the resistance between the AFCM C406 pin 37 circuit 91 XL35 BK harness side and ground and the AFCM pin 38 circuit 91 XL35A BK harness side and ground and the AFCM pin 39 circuit 91 XL35B BK h...

Page 1698: ...ove the components in the order indicated in the following illustration s and table s Description Instrument panel lower panel retaining screws Instrument panel lower panel retaining clips Headlamp switch electrical connector Instrument panel lower panel Steering column upper shroud retaining clips See Removal Detail 1 Disconnect the battery ground cable For additional information refer to Section...

Page 1699: ... shroud retaining clips Item 9 Instrument cluster electrical connectors CAUTION Make sure the instrument cluster lens is protected by a clean soft cloth Failure to follow this instruction may result in damage to the instrument cluster lens 6 7 8 9 10 1 Using a thin bladed screwdriver release the steering column upper shroud retaining clips 1 To disconnect the instrument cluster electrical connecto...

Page 1700: ...ponent Upload the instrument cluster configuration information using the Programmable Modules Installation Routine General Equipment Ford diagnostic equipment 2 NOTE This step is only necessary when installing a new component Record the odometer value from the original instrument cluster If the odometer value cannot be obtained from the instrument cluster display failure the customer should supply...

Page 1701: ...oval procedure 2 NOTE This step is only necessary when installing a new component Download the instrument cluster configuration information to the newly installed instrument cluster using the programmable modules installation routine http vnx su ...

Page 1702: ...Horn Specifications Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Horn bracket retaining bolt 12 9 http vnx su ...

Page 1703: ...ident verify the symptom and refer to the Symptom Chart Symptom Chart Symptom Chart Pinpoint Tests Electrical Fuse s Wiring harness Electrical connector s Horn switch Horn Clockspring Relay Symptom Possible Sources Action The horn is inoperative Fuse s Circuit s Horn Relay Clockspring Horn switch GO to Pinpoint Test A The horn is always on Relay Horn switch Circuit s Clockspring GO to Pinpoint Tes...

Page 1704: ...system for normal operation A3 CHECK POWER TO THE HORN RELAY Disconnect Horn Relay C1014 1 Measure the voltage between the horn relay C1014 pin 1 harness side and ground and horn relay C1014 pin 3 harness side and ground 2 Are the voltages greater than 10 volts Yes GO to A4 No INSTALL a new BJB TEST the system for normal operation A4 CHECK HORN SWITCH CIRCUIT FOR OPEN Measure the resistance betwee...

Page 1705: ...CIRCUIT 91S GJ7 BK BU FOR OPEN WARNING To deactivate the driver air bag refer to the procedure in section 501 20B for the correct air bag deactivation procedure Failure to follow this instruction may result in personal injury Disconnect Clockspring C896 1 Measure the resistance between the clockspring C896 pin 6 circuit 91S GJ7 BK BU harness side and horn relay C1014 pin 2 circuit 91S GJ7 BK BU ha...

Page 1706: ...int System TEST the system for normal operation No INSTALL a new driver air bag module REFER to Section 501 20A Safety Belt System 501 20B Supplemental Restraint System TEST the system for normal operation PINPOINT TEST B THE HORN IS ALWAYS ON TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK CIRCUIT 29S GJ7 OG YE FOR SHORT TO BATTERY POSITIVE Disconnect Horn Relay C1014 1 Does the horn stop soundi...

Page 1707: ...B Supplemental Restraint System TEST the system for normal operation B3 CHECK HORN SWITCH CIRCUIT FOR SHORT TO GROUND Measure the resistance between the clockspring C896 pin 6 circuit 91S GJ7 BK BU component side and ground 1 Is the resistance greater than 10 000 ohms Yes REPAIR circuit 91S GJ7 BK BU TEST the system for normal operation No INSTALL a new driver air bag module REFER to Section 501 2...

Page 1708: ...Installation Removal NOTE The horn switch and driver air bag module are one component and cannot be serviced separately 1 Remove the driver air bag module For additional information refer to Section 501 20A Safety Belt System 501 20B Supplemental Restraint System http vnx su ...

Page 1709: ... 2 2 Visually inspect for obvious signs of electrical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the cause is not visually evident verify the symptom and refer to WDS to diagnose the system Electrical Instrument cluster http vnx su ...

Page 1710: ...Oil message in the information and message center if equipped If the oil change reminder indicator is still illuminated or the Service Oil message is still displayed turn the ignition key to position 0 and repeat the procedure from Step 1 If it has turned off or the Service Oil message has disappeared proceed to Step 5 5 Turn the ignition key to position 0 and leave it there for at least 2 minutes...

Page 1711: ...002 Print Description and Operation Overview Description Parking aid control unit LED parking aid switch Data Link Connector DLC Backup lamp switch Ignition lock Parking aid switch Ultrasonic sensors Fitting locations Item 1 2 3 4 5 6 7 Part Number http vnx su ...

Page 1712: ...ts of four ultrasonic sensors in the rear bumper a control unit onto which the speaker is positioned and a switch with LED for switching the system off The ultrasonic sensors emit ultrasonic sound waves which they then receive back after they are reflected by the obstacle The ignition must be switched on and reverse gear must be engaged for this function to work A speaker on the right hand side RH...

Page 1713: ...g to indicate the distance to an obstacle Ultrasonic sensors The ultrasonic sensor produces the ultrasound signal and receives the reflected echo signal All of the sensors are identical in form and electrical function The sensors are connected to the system by a 3 pole wiring harness connector Switch and indication of operation The parking aid can be deactivated by pressing the switch while revers...

Page 1714: ...nsor left outer Ultrasonic sensor left Rear bumper Speaker located on the control unit Reverse gear switch DLC Control unit Parking aid switch with LED Central fuse box Ignition lock Fuse box engine compartment Battery Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number http vnx su ...

Page 1715: ...on and Verification 1 1 Verify the customer concern 2 2 Visually inspect for obvious signs of electrical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the cause is not visually evident connect the Worldwide Diagnostic System the Ford diagnostic equipment to the data link co...

Page 1716: ...he system for normal operation C1703 Outer right sensor signal circuit open or short to ground Parking aid sensor signal circuit Parking aid sensor Parking aid module GO to Pinpoint Test D C1704 Concern with outer right parking aid sensor Outer right parking aid sensor INSTALL a new parking aid sensor TEST the system for normal operation C1705 Inner left sensor signal circuit short to battery Park...

Page 1717: ...OG for open If the circuit is OK INSTALL a new parking aid module TEST the system for normal operation C1920 Parking aid disable switch LED circuit short to ground Parking aid disable switch circuit Parking aid module CHECK the circuit 15S GN23 GN OG for short to battery If the circuit is OK INSTALL a new parking aid module TEST the system for normal operation C1748 Parking aid disable switch shor...

Page 1718: ...on A3 CHECK THE REVERSE LAMP VOLTAGE INPUT Select REVERSE 1 Measure the voltage between the parking aid module C622 pin 9 circuit 15S LG3B GN YE harness side and ground 2 Is the voltage greater than 10 volts Yes INSTALL a new parking aid module REFER to Parking Aid Module 413 13 Parking Aid Removal and Installation TEST the system for normal operation No REPAIR the circuit 15S GN11 15S LG3B TEST t...

Page 1719: ...or normal operation No REPAIR the circuit TEST the system for normal operation PINPOINT TEST C DTC C1700 REAR OUTER LEFT SENSOR SIGNAL CIRCUIT OPEN OR SHORT TO GROUND TEST CONDITIONS DETAILS RESULTS ACTIONS C1 CHECK CIRCUIT 8 GN22 WH GN FOR OPEN CIRCUIT Disconnect Parking Aid Module C622 1 Disconnect Parking Aid Sensor C607 2 Measure the resistance between the parking aid module C622 pin 11 circui...

Page 1720: ...nect Parking Aid Module C622 1 Disconnect Parking Aid Sensor C604 2 Measure the resistance between the parking aid module C622 pin 24 circuit 8 GN19 WH harness side and the parking aid sensor C604 pin 2 circuit 8 GN19 WH harness side 3 Is the resistance less than 1 Ohm Yes GO to D2 No REPAIR the circuit TEST the system for normal operation D2 CHECK CIRCUIT 8 GN19 WH FOR SHORT TO GROUND Measure the...

Page 1721: ...normal operation E2 CHECK CIRCUIT 8 GN21 WH BU FOR SHORT TO GROUND Measure the resistance between the parking aid module C622 pin 10 circuit 8 GN21 WH BU harness side and ground 1 Is the resistance greater than 10 000 Ohms Yes INSTALL a new parking aid sensor If the concern persists INSTALL a new parking aid module REFER to Parking Aid Module 413 13 Parking Aid Removal and Installation TEST the sy...

Page 1722: ...n persists INSTALL a new parking aid module REFER to Parking Aid Module 413 13 Parking Aid Removal and Installation TEST the system for normal operation No REPAIR the short to ground TEST the system for normal operation PINPOINT TEST G DTC B1299 SENSOR VOLTAGE SUPPLY SHORT TO GROUND TEST CONDITIONS DETAILS RESULTS ACTIONS G1 CHECK THE CIRCUIT 7 GN2 YE RD FOR SHORT TO GROUND Disconnect Parking Aid ...

Page 1723: ...CONDITIONS DETAILS RESULTS ACTIONS H1 CHECK CIRCUIT 8 GN26 WH FOR SHORT TO GROUND Disconnect Parking Aid Module C622 1 Disconnect Parking Aid Speaker C627 2 Measure the resistance between the parking aid module C622 pin 14 circuit 8 GN26 WH harness side and the parking aid speaker C627 pin 1 circuit 8 GN26 WH harness side 3 Is the resistance less than 1 ohm Yes GO to H2 No REPAIR the circuit TEST ...

Page 1724: ...id module C622 pin 14 circuit 8 GN26 WH harness side and ground 4 Is a voltage present Yes REPAIR the circuit TEST the system for normal operation No GO to I2 I2 CHECK CIRCUIT 9 GN26 BN FOR SHORT TO BATTERY Measure the voltage between the parking aid module C622 pin 17 circuit 9 GN26 BN harness side and ground 1 Is a voltage present Yes REPAIR the circuit TEST the system for normal operation No IN...

Page 1725: ...h C620 2 Measure the resistance between the parking aid module C622 pin 7 circuit 31S GN12 BK OG harness side and ground 3 Is the resistance greater than 10 000 Ohms Yes INSTALL a new parking aid disable switch TEST the system for normal operation No REPAIR the short to ground TEST the system for normal operation http vnx su ...

Page 1726: ...ystem check should be carried out with the vehicle on a level surface NOTE The parking aid system will switch on when the ignition is turned from position 0 to position II Turn the ignition switch to position II 2 Apply the parking brake 3 Place the gear shift in reverse 4 Verify the parking aid system detects the object 7 62 cm diameter pipe 99 06 cm high when placed in the five specified locatio...

Page 1727: ...ed out with the vehicle on a 4 8 metres wide by 3 00 metres deep smooth concrete surface free of all obstacles The area should be free of noise from fans and pneumatic tools 4 Turn the ignition switch to position II 5 Apply the parking brake 6 Place the gear shift in reverse 7 NOTE No audible tones should be heard If audible alerts are heard check to make sure the bumper is properly installed and ...

Page 1728: ...ollowing illustration s and table s Description Instrument panel lower panel retaining screws Instrument panel lower panel retaining clips Headlamp switch electrical connector Instrument panel lower panel 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables Item 1 2 3 4 Part Number http vnx su ...

Page 1729: ...aid module retaining bolts Parking aid module 3 To install reverse the removal procedure Removal Details Item 6 Parking aid module electrical connector Item 5 6 7 8 1 To disconnect the parking aid module electrical connector 1 Press the locking tang 2 Detach the self locating electrical connector Part Number http vnx su ...

Page 1730: ...ing Aid Parking Aid Module Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 2 3 1 To install reverse the removal procedure http vnx su ...

Page 1731: ...vantageous to match the battery charging voltage to the temperature of the battery To do this the PCM needs the vehicle battery electrolyte temperature information Measuring the electrolyte temperature The heat radiated by the vehicle engine must be taken into account when the electrolyte temperature is considered In order to calculate the electrolyte temperature the Intake Air Temperature IAT is ...

Page 1732: ...rator is working The PCM actuates the charge warning lamp in the instrument cluster Starting the generator during engine starting In the smart charge current supply system the generator is not activated during engine starting The generator is only switched on after the engine has started Switching on is done electronically by the PCM The generator power is then increased smoothly to the value requ...

Page 1733: ...ce and protect your eyes Always provide ventilation Failure to follow these instructions may result in personal injury 1 1 Verify the customer concern 2 2 Visually inspect for obvious signs of mechanical or electrical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 Check the ope...

Page 1734: ...ER to the WDS The generator is noisy Accessory drive belt REFER to Accessory Drive 303 05 Accessory Drive Diagnosis and Testing Loose generator mounting bolts TIGHTEN the generator mounting bolts Generator INSTALL a new generator REFER to Generator 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel Vehicles Built From 05 2003 414 02 Generator and Regulator Removal and Installation Gener...

Page 1735: ...Test 1 1 With the engine running turn on the air conditioning if equipped turn the blower motor to high speed and the headlamps to high beam 2 2 Increase the engine speed to 2000 rpm The voltage should increase a minimum of 0 5 volts above the base voltage If the voltage does not increase as specified REFER to the WDS If the voltage increases as specified the charging system is charging correctly ...

Page 1736: ...cles electrical systems It also removes the variability in the process and makes sure that the actual dissipation of the surface charge is qualified prior to testing 1 1 Connect the black lead to the battery negative terminal and the red lead to the battery positive terminal 2 2 The red indicator A illuminates and the green indicator B flashes 3 3 Wait until the green indicator B fully illuminates...

Page 1737: ...ent on the test battery Therefore if the Micro390 does not operate when connected to a test battery then a charge of less than 5 5 volts is present In this instance the battery must be charged in line with the battery charging instructions prior to testing In the event of a conflict of results between the charge eye indicator and the battery tester the battery tester result must always be used The...

Page 1738: ...Test result 3 Battery voltage 5 5 Press the information button and carefully note the six digit Test Code on the job card for claim submission and audit purposes graphic shows an example of the code only Battery tester results and required actions Tester Reading Action GOOD BATTERY Return to service GOOD RECHARGE Fully charge the battery and return to service CHARGE RETEST Fully charge the battery...

Page 1739: ...correctly and that all key off loads luggage compartment lamps glove compartment lamp and interior lamps are not staying on battery from the vehicle and retest If the result remains after surface charge removal install a new battery UNABLE TO TEST Disconnect the battery from the vehicle and retest http vnx su ...

Page 1740: ... overcharging The Midtronics GR 590 Battery Management Center also incorporates a software program that has the capability to assist in the recovery of deeply discharged sulphated batteries NOTE Charging methods and types of battery chargers vary widely Whichever method is utilized it must be carried out carefully to avoid damage to the battery and possible personal injury Specific instructions ac...

Page 1741: ...t manufacturer s instructions A charge of 30 amps for up to 30 minutes is the most common fast charging application If the battery is very discharged and requires additional restoration an additional charge of 20 amps for a period up to one and a half hours should be applied Fast charging for a period in excess of two hours significantly increases the risk of causing damage to the battery NOTE Whe...

Page 1742: ...it Silver Calcium Ca 08 1994 60 Focus Silver Calcium Ca All 60 Transit Silver Calcium Ca 08 1994 70 Focus diesel Silver Calcium Ca All 70 Transit diesel Silver Calcium Ca 08 1994 Description Nm lb ft lb in Battery clamp nuts to battery terminal 5 44 Battery tray bolts 12 9 Battery hold down clamp 12 9 Auxiliary connections on battery clamps 5 44 Ground cable to engine bolt 35 26 Generator electric...

Page 1743: ...attery Mounting and Cables Battery Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Charging System 414 00 Charging System General Information Diagnosis and Testing http vnx su ...

Page 1744: ...ing the battery make sure that no data is required from the powertrain control module PCM as battery cable disconnection will erase any fault codes and idle drive values held in the keep alive memory KAM It is not necessary to disconnect or remove electronic control modules NOTE This procedure should be used to disconnect the battery while carrying out repairs that refer to the battery being disco...

Page 1745: ... to the correct time 5 NOTE When the battery has been disconnected and connected the stored idle and drive values contained within the powertrain control module PCM will have been erased The following steps must be carried out to allow the PCM to relearn its idle and drive values Start and run the engine at idle for three minutes 6 When the engine reaches normal operating temperature increase the ...

Page 1746: ... positive terminal cover Battery positive terminal clamp Battery hold down clamp retaining bolt Battery hold down strap Battery hold down clamp Battery See Installation Detail 3 To install reverse the removal procedure 1 Disconnect the battery ground cable For additional information refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures Item 1 2 3 4 5 6 Part ...

Page 1747: ...pe For additional information refer to Specifications 414 01 Battery Mounting and Cables Specifications Installation Details Item 6 Battery CAUTION Make sure the battery is positioned as close as possible to the left hand side front fender within the battery tray http vnx su ...

Page 1748: ...ation s and table s Description Battery to starter motor solenoid cable retaining clips Engine wiring harness retaining clips Fuel injection supply wiring harness retaining clips Battery tray retaining bolts Battery tray 3 To install reverse the removal procedure 1 Remove the battery For additional information refer to Battery in this section Item 1 2 3 4 5 Part Number http vnx su ...

Page 1749: ... attention If swallowed call a physician immediately Failure to follow these instructions may result in personal injury Audio unit key code saving devices must not be used when working on supplemental restraint or fuel systems When using these devices the vehicle electrical system is still live but with a reduced current flow Failure to follow this instruction may result in personal injury CAUTION...

Page 1750: ...power cable retaining nut Auxiliary power cable Battery positive terminal clamp Auxiliary power cable retaining clip Battery ground cable retaining bolt Battery hold down clamp retaining bolt Battery hold down clamp Starter motor solenoid electrical connector Battery cable retaining clip Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part Number http vnx su ...

Page 1751: ...ing the battery ground cable to avoid damage to the vehicle electrical system Item 14 15 16 17 18 19 20 21 4 Enter the audio unit keycode and preset radio frequencies 5 Reset the clock to the correct time 6 NOTE When the battery has been disconnected and connected the stored idle and drive values contained within the powertrain control module PCM will have been erased The following steps must be c...

Page 1752: ...ining bolt Installation Details Item 14 Starter motor retaining bolt miles eight kilometers of varied driving 1 Raise and support the vehicle For additional information refer to Section 100 02 Jacking and Lifting 1 Lower the vehicle http vnx su ...

Page 1753: ...rompt medical attention If swallowed call a physician immediately Failure to follow these instructions may result in personal injury Audio unit key code saving devices must not be used when working on supplemental restraint or fuel systems When using these devices the vehicle electrical system is still live but with a reduced current flow Failure to follow this instruction may result in personal i...

Page 1754: ...power cable retaining nut Auxiliary power cable Auxiliary power cable retaining clip Battery positive terminal clamp Battery ground cable retaining bolt Battery hold down clamp retaining bolt Battery hold down strap Starter motor solenoid electrical connector Battery cable retaining clips Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part Number http vnx su ...

Page 1755: ...ector retaining nut Battery cable 3 To install reverse the removal procedure CAUTION Make sure all electrical systems are switched OFF before connecting the battery ground cable to avoid damage to the vehicle electrical system Item 14 15 16 17 18 19 20 4 Enter the audio unit keycode and preset radio frequencies 5 Reset the clock to the correct time 6 NOTE When the battery has been disconnected and...

Page 1756: ...have been erased The following steps must be carried out to allow the PCM to relearn its idle and drive values Start and run the engine at idle for three minutes 7 When the engine reaches normal operating temperature increase the engine speed to 1200 rpm and maintain for approximately two minutes 8 Drive the vehicle for approximately five miles eight kilometers of varied driving http vnx su ...

Page 1757: ...ining bolts 25 18 Generator electrical connector retaining nut 8 71 Generator decoupler retaining bolts 12 9 Generator decoupler pulley bracket retaining bolts 25 18 Air conditioning A C compressor retaining bolts 25 18 Description Nm lb ft lb in Generator retaining bolts 48 35 Generator electrical connector retaining nut 8 71 Engine roll restrictor retaining bolts 48 35 Front engine mounting to b...

Page 1758: ...Generator and Regulator Generator Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 414 00 Charging System General Information http vnx su ...

Page 1759: ...system remains pressurised for a long time after the ignition is switched off The fuel pressure must be released before attempting any repairs Failure to follow these instructions may result in personal injury 6 Remove the components in the order indicated in the following illustration s and table s Disconnect Tool Fuel Line 5 16 310 040 23 041 1 Depressurise the fuel system For additional informa...

Page 1760: ...l connector retaining bolt Fuel charging wiring harness electrical connector See Removal Detail Engine ground cable to body retaining bolt Engine ground cable Fuel return line to fuel pressure regulator spring release coupling See Removal Detail Fuel supply line to fuel injection supply manifold fuel supply pipe quick release coupling See Removal Detail Engine front mounting to body retaining bolt...

Page 1761: ...ant expansion tank Item 4 Power steering reservoir Item 6 EVAP canister purge valve Item 8 Fuel charging wiring harness electrical connector Item 11 Fuel return line to fuel pressure regulator spring release coupling Item 15 16 17 18 19 20 1 Secure the coolant expansion tank to one side 1 Detach the power steering reservoir and secure it to one side 1 Secure the EVAP canister purge valve to one si...

Page 1762: ...onal information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 Disconnect the fuel supply line from the fuel injection supply manifold fuel supply pipe For additional information refer to Section 310 00A Fuel System General Information 310 00B Fuel System General Information 1 Reposition the engine Slide the engine forward Secure in position usi...

Page 1763: ...ional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 Remove the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 3 Detach the air conditioning A C compressor and secure it to one side 4 Disconnect the generator electrical co...

Page 1764: ...age Install the generator and the generator retaining bolts finger tight 2 Install the generator decoupler and the generator decoupler pulley bracket retaining bolts 3 Tighten the generator retaining bolts generator decoupler shown removed for clarity 4 Install the generator decoupler retaining bolts http vnx su ...

Page 1765: ...tors 6 Install the A C compressor and the A C compressor retaining bolts 7 Install the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation http vnx su ...

Page 1766: ...hicle For additional information refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 Remove the accessory drive belt For additional information refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 3 Detach the air conditioning A C compressor and secure it to one side 4 Disconnect the generato...

Page 1767: ...tioning 7 Remove the generator 8 Remove the generator 1 Install the generator and generator retaining bolts 2 NOTE Do not tighten the generator retaining bolts at this stage Install the generator and the generator retaining bolts finger tight 3 Install the generator decoupler and the generator http vnx su ...

Page 1768: ...or retaining bolts generator decoupler shown removed for clarity 5 Install the generator decoupler retaining bolts 6 Connect the generator electrical connectors 7 Install the A C compressor and the A C compressor retaining bolts 8 Install the accessory drive belt For additional information refer to Accessory http vnx su ...

Page 1769: ...Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation http vnx su ...

Page 1770: ...neo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 Refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation 2 2 if equipped 3 1 Torque 25 Nm 2 2 if equipped Torque 8 Nm 3 Torque 8 Nm http vnx su ...

Page 1771: ...3 Refer to Accessory Drive Belt 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 303 05 Accessory Drive Removal and Installation http vnx su ...

Page 1772: ...stem General Information Specifications Transit Tourneo Connect 2002 5 06 2002 Print Lubricants Fluids Sealers and Adhesives Item Specification Cassette head cleaning fluid from cassette head cleaner kit Isopropyl alcohol http vnx su ...

Page 1773: ... Mode Self Diagnostic Mode 2 Channel System NOTE The audio unit must be in radio mode before entering the Self Diagnostic Mode 1 1 To enter the audio unit Self Diagnostic Mode switch the audio unit ON Within four seconds depress the preset buttons 3 and 6 together 2 2 Release the preset buttons 3 and 6 and the audio unit will enter the Self Diagnostic Mode 3 3 To exit the Self Diagnostic Mode swit...

Page 1774: ...nnel system 2CH LF for two channel system Left hand front speaker circuit 2 4CH RF for four channel system 2CH RF for two channel system Right hand front speaker circuit 3 4CH LR for four channel system Left hand rear speaker circuit 4 4CH RR for four channel system Right hand rear speaker circuit 5 FM frequency received Antenna cable DTC Description Condition Possible Source Action B1342 Audio un...

Page 1775: ...na cable Audio unit GO to Pinpoint Test B Poor quality distorted sound from one or more speakers not all speakers Speaker s Circuit Audio unit GO to Pinpoint Test C No sound from all speakers Audio unit INSTALL a new audio unit TEST the system for normal operation No sound from one or more of the speakers not all speakers Speaker s Circuit Audio unit GO to Pinpoint Test D The auxiliary audio contr...

Page 1776: ... BK GN or 91 MD34 BK YE TEST the system for normal operation PINPOINT TEST B POOR RECEPTION TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK THE ANTENNA CABLE SHIELD Ignition switch in position 0 1 Disconnect the antenna cable from the audio unit 2 Measure the resistance between the antenna cable ground connector shield and ground 3 Is the resistance less than 1 ohm Yes GO to B2 No CLEAN and TIGHT...

Page 1777: ...ersists INSTALL a new audio unit REFER to Audio Unit Vehicles Built From 08 2008 415 01A Audio Unit Removal and Installation TEST the system for normal operation No INSTALL a new antenna cable REFER to Antenna Cable Vehicles Built Up To 04 2009 415 02 Antenna Removal and Installation TEST the system for normal operation If the concern persists INSTALL a new audio unit REFER to Audio Unit Vehicles ...

Page 1778: ...uit Yes GO to C3 No REPAIR speaker input circuit TEST the system for normal operation C3 CHECK SPEAKER RETURN FOR SHORT TO GROUND Measure the resistance between the inoperative speaker connector pin 2 harness side and ground 1 Is the resistance greater than 10 000 ohms open circuit Yes SUBSTITUTE a known good speaker TEST the system for normal operation If the concern persists INSTALL a new audio ...

Page 1779: ...udio Unit C442 1 Measure the resistance between the following audio unit C442 pins harness side and the inoperative speaker s connector pin 1 harness side Left front speaker C937 pin 1 WH to C442 pin 3 WH BK Right front speaker C938 pin 1 WH to C442 pin 2 WH RD Left rear speaker C939 pin 1 WH VT to C442 pin 4 WH VT Right rear speaker C940 pin 1 WH to C442 pin 1 WH 2 Is the resistance less than 1 o...

Page 1780: ...939 pin 2 GY WH to ground Right rear speaker C940 pin 2 GY to ground 1 Is the resistance greater than 10 000 ohms open circuit Yes SUBSTITUTE a known good speaker TEST the system for normal operation If the concern persists INSTALL a new audio unit REFER to Audio Unit Vehicles Built From 08 2008 415 01A Audio Unit Removal and Installation No REPAIR the circuit in question TEST the system for norma...

Page 1781: ...s GO to E3 No REPAIR the circuit TEST the system for normal operation E3 CHECK CIRCUIT 9 MD26 FOR OPEN Measure the resistance between the audio unit C445 pin 8 circuit 9 MD26 BN YE harness side and the audio control switch C437 pin 2 circuit 9 MD26 BN YE harness side 1 Is the resistance less than 1 ohm Yes INSTALL a new audio control switch TEST the system for normal operation If the concern persi...

Page 1782: ...Audio Unit Audio System Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 415 00 Information and Entertainment System General Information http vnx su ...

Page 1783: ...ts Using the audio unit removal tools remove the audio unit 1 Insert the audio unit removal tools 2 Pull the audio unit removal tools gently outwards 3 Detach the audio unit 4 Disconnect the electrical connectors 5 Disconnect the antenna cable s 6 Remove the audio unit 2 Remove the audio unit removal tools 1 CAUTION The audio unit wiring harness must not become trapped when installing the audio un...

Page 1784: ...3 If a new audio unit is to be installed connect the diagnostic tool and upload the audio unit configuration information using the Programmable Module Installation Routine prior to commencing the removal of the audio unit General Equipment Ford diagnostic equipment 4 CAUTION Take care not to damage the wiring harnesses General Equipment Audio unit removal tools GV3301 5 Remove the audio unit remov...

Page 1785: ...ny media is ejected from the unit Ford diagnostic equipment 1 NOTE This step is only necessary when installing a new component Connect the diagnostic tool and upload the audio unit configuration information using the Programmable Modules Installation Routine prior to commencing the removal of the audio unit General Equipment Ford diagnostic equipment 2 3 http vnx su ...

Page 1786: ...Installation 4 1 NOTE New units must be configured using the Programmable Module Installation Routine in the diagnostic tool To install reverse the removal procedure http vnx su ...

Page 1787: ...NOTE This step is only necessary when installing a new component Connect the diagnostic tool and upload the audio unit configuration information using the Programmable Modules Installation Routine prior to commencing the removal of the audio unit General Equipment Ford diagnostic equipment 2 3 General Equipment Audio unit removal tools GV3301 1 NOTE New units must be configured using the Programma...

Page 1788: ...t the vehicle electrical system is fully depowered and no other power source is connected NOTE Removal steps in this procedure may contain installation details 4 mm drill bit Blind rivet gun Electric drill 1 Refer to Supplemental Restraint System SRS Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Battery Disconnect and Connect 414 01 Battery Mounting ...

Page 1789: ...ove the driver seat Refer to Front Seat Vehicles Built From 04 2009 501 10 Seating Removal and Installation 10 On both sides Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 11 12 http vnx su ...

Page 1790: ...13 14 Refer to Gearshift Lever 308 06 Manual Transmission Transaxle External Controls Removal and Installation 15 Torque 9 Nm 16 Torque 8 Nm 17 http vnx su ...

Page 1791: ...18 Torque 25 Nm 19 20 http vnx su ...

Page 1792: ...21 22 Torque 25 Nm 23 On both sides http vnx su ...

Page 1793: ...io Unit Vehicles Built From 08 2008 415 01A Audio Unit Removal and Installation Refer to Audio Unit Vehicles Built From 04 2009 Vehicles With Navigation System 415 01A Audio Unit Removal and Installation 26 27 Torque 10 Nm http vnx su ...

Page 1794: ...28 Torque 10 Nm 29 30 Torque 28 Nm 31 Torque 25 Nm http vnx su ...

Page 1795: ...Installation 32 1 To install reverse the removal procedure http vnx su ...

Page 1796: ...Antenna Antenna Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 415 00 Information and Entertainment System General Information http vnx su ...

Page 1797: ... 06 2002 Print Removal and Installation Removal Vehicles with overhead console All vehicles 1 2 Refer to Front Headliner Short Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 3 Torque 10 Nm 4 Torque 3 Nm http vnx su ...

Page 1798: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 1799: ...nel removed for clarity Description Glove compartment retaining screws Glove compartment Antenna cable to heater core housing retaining clip Antenna cable to instrument panel bulkhead retaining clips Antenna cable to A pillar retaining clips Antenna base and antenna See Removal Detail 1 Remove the headliner For additional information refer to Section 501 05 Interior Trim and Ornamentation Item 1 2...

Page 1800: ...and antenna Item 8 Audio unit Item 9 Antenna cable NOTE Make a note of the routing of the antenna cable Installation Details Item 9 Antenna cable NOTE The antenna cable must be installed to the same routing as when removed 7 8 9 1 Disconnect the antenna cable electrical connector 1 Remove the audio unit For additional information refer to Section 415 01A Audio Unit 415 01B Information and Entertai...

Page 1801: ...cal system is fully depowered and no other power source is connected NOTE Removal steps in this procedure may contain installation details 4 mm drill bit Blind rivet gun Electric drill 1 Refer to Supplemental Restraint System SRS Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Pr...

Page 1802: ...ove the driver seat Refer to Front Seat Vehicles Built From 04 2009 501 10 Seating Removal and Installation 10 On both sides Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 11 12 http vnx su ...

Page 1803: ...13 14 Refer to Gearshift Lever 308 06 Manual Transmission Transaxle External Controls Removal and Installation 15 Torque 9 Nm 16 Torque 8 Nm 17 http vnx su ...

Page 1804: ...18 Torque 25 Nm 19 20 http vnx su ...

Page 1805: ...21 22 Torque 25 Nm 23 On both sides http vnx su ...

Page 1806: ...io Unit Vehicles Built From 08 2008 415 01A Audio Unit Removal and Installation Refer to Audio Unit Vehicles Built From 04 2009 Vehicles With Navigation System 415 01A Audio Unit Removal and Installation 26 27 Torque 10 Nm http vnx su ...

Page 1807: ...28 Torque 10 Nm 29 30 Torque 28 Nm 31 Torque 25 Nm http vnx su ...

Page 1808: ...amentation Removal and Installation Refer to Front Headliner Short Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation Refer to Front Headliner Long Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 33 Torque 10 Nm 34 Torque 3 Nm http vnx su ...

Page 1809: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 1810: ...Speakers Speakers Transit Tourneo Connect 2002 5 06 2002 Print Diagnosis and Testing REFER to Section 415 00 Information and Entertainment System General Information http vnx su ...

Page 1811: ...nsit Tourneo Connect 2002 5 06 2002 Print Headlamp alignment Tightening torques Item X value Headlamp X 12 cm 10 m 0 degrees 41 minutes 1 2 Fog lamp X 22 cm 10 m 1 degree 16 minutes 2 2 Parts Nm lb ft lb in Bolt headlamp 5 44 http vnx su ...

Page 1812: ... for the headlamp levelling system cannot be exchanged The main headlamp is retained with three bolts The bulbs can be replaced without removing the headlamp The reflectors are free shape reflectors The free shape technology allows the full reflector to be utilised In this technology every point of the freely calculated reflector is allocated to lighting a particular part of the road in front of t...

Page 1813: ...arness connector H11 halogen bulbs with a power rating of 55W are used The fog lights are mounted in the lower part of the front bumper To change the bulbs grasp behind the bumper unlatch the wiring harness connector and disconnect it The bulb holder can now be turned anti clockwise and pulled out Side turn signal lamp Item 1 2 3 Item 1 2 3 Part Number Part Number http vnx su ...

Page 1814: ...sing light 5W brake light 21W Turn signal light 21W Reversing light 21W Rear fog light 21W Bulb holder rear view Securing nuts As well as the rear lamps the rear lamp clusters incorporate all rearward facing lights with exception of the license plate lamp and the additional high mounted stoplamp The relevant rear lamp must be removed to change the bulbs To do this remove the two retaining nuts on ...

Page 1815: ...nted third stop lamp is mounted in the middle above the tailgate To change a bulb the brake light unit must be removed To do this remove the nuts on the inside Number plate lamp Description 10W bulb Cover To change the bulb unclip and open the cover Item 1 2 3 Item 1 2 Part Number Part Number http vnx su ...

Page 1816: ...ing Anti Lock Control Traction Control 206 09B Anti Lock Control Traction Control Diagnosis and Testing NOTE Before reading out the vehicle specific data remake all the electrical connections which were separated in the vehicle so that communication between the module and WDS is ensured 1 1 Verify the customer concern 2 2 Visually inspect for obvious signs of electrical or mechanical damage Visual...

Page 1817: ...THE VOLTAGE SUPPLY TO FUSE F42 15 A CJB FOR OPEN CIRCUIT Connect Fuse F42 15 A CJB 1 Ignition switch in position II 2 Measure the voltage between F42 15 A CJB and ground 3 Is battery voltage measured Yes GO to A3 No LOCATE AND RECTIFY the break in the voltage supply of fuse F42 15 A CJB using the Wiring Diagrams If necessary RENEW the CJB CHECK the operation of the system A3 CHECK VOLTAGE SUPPLY T...

Page 1818: ... pin 1 circuit 15S LG14 A B GN RD 15S CF58 GN OG 15S RN2A GN BU wiring harness side 3 Vehicles built from 08 2005 to 08 2006 4 Using a fused bridging cable 15 A at the brake light switch connect between connector C444 pin 2 circuit 15 LG23 GN WH and pin 1 circuit 15S LG14 A B GN RD 15S CF58 GN OG 15S RN2A GN BU wiring harness side 5 Vehicles built from 08 2006 6 Connect a fused jumper wire 15 A to...

Page 1819: ...and pin 1 circuit 15S LG14 A B GN RD 15S CF58 GN OG 15S RN2A GN BU wiring harness side 4 Vehicles built from 08 2005 to 08 2006 5 Using a fused bridging cable 15 A at the brake light switch connect between connector C444 pin 2 circuit 15 LG23 GN WH and pin 1 circuit 15S LG14 A B GN RD 15S CF58 GN OG 15S RN2A GN BU wiring harness side 6 Vehicles built from 08 2006 7 Connect a fused jumper wire 15 A...

Page 1820: ...en soldered connection S212 and the high mounted stoplamp using the Wiring Diagrams CHECK the operation of the system B3 CHECK THE VOLTAGE SUPPLY TO THE LEFT HAND REAR LAMP ASSEMBLY STOPLAMP FOR OPEN CIRCUIT NOTE The fused jumper lead used in the previous step is still connected to the stop lamp switch Ignition switch in position 0 1 Disconnect Left hand rear lamp assembly from connector Vehicles ...

Page 1821: ...nd ground Vehicles with trailer socket Connector C475a pin 6 circuit GN wiring harness side and ground 4 Is battery voltage measured Yes LOCATE and RECTIFY the break in the circuit between the right hand rear lamp assembly and ground connection G47 using the Wiring Diagrams If necessary RENEW the rear lamp assembly CHECK the operation of the system No LOCATE and RECTIFY the break in the circuit be...

Page 1822: ...tion control Yes GO to C5 No GO to C6 C5 ELIMINATE THE ABS CONTROL MODULE TRACTION CONTROL SYSTEM AS CAUSE FOR THE SHORT TO BATTERY VOLTAGE Disconnect Fuse F13 30 A BJB 1 Disconnect Fuse F23 20 A BJB 2 Disconnect Fuse F36 7 5 A CJB 3 Ignition switch in position II 4 CHECK the stop lamps 5 Do the stoplamps illuminate continuously Yes Vehicles built up to 08 2006 GO to C6 Vehicles built from 08 2006...

Page 1823: ...tion II 4 CHECK the stop lamps 5 Do the stoplamps illuminate continuously Yes LOCATE and RECTIFY the short to battery voltage in the circuits connected to soldered connection S212 using the Wiring Diagrams CHECK the operation of the system No INSTALL a new PCM CHECK the operation of the system C9 RULE OUT THE POWERTRAIN CONTROL MODULE PCM AS POSSIBLE CAUSE FOR A SHORT TO BATTERY VOLTAGE Ignition s...

Page 1824: ...isual inspection before carrying out any further tests 4 4 If the concern is not visually evident PERFORM a fault diagnosis on the central timer module CTM with Ford diagnostic equipment and RECTIFY any displayed faults in accordance with the displayed fault description CHECK operation of system 5 5 On a vehicle without stored fault s continue according to the Symptom Chart and the corresponding s...

Page 1825: ... REFER to Daytime Running Lamps DRL 417 04 Daytime Running Lamps DRL Diagnosis and Testing One or more parking rear or license lamp s is are inoperative Fuse s Circuit s Headlamp Rear lamp assembly License plate lamps Headlight switch Central junction box CJB GO to Pinpoint Test B Parking lamps rear lamps and license plate lamps lit continuously Circuit s Headlight switch Central junction box CJB ...

Page 1826: ...tery voltage measured Yes GO to A3 No CHECK CJB and if necessary RENEW CHECK operation of system A3 CHECK THE VOLTAGE SUPPLY TO THE LIGHT SWITCH FOR OPEN CIRCUIT Disconnect Headlight switch from connector C320 1 Measure the voltage between the headlight switch connector C320 pin 11 circuit 29 LE29 OG BK wiring harness side and ground 2 Does the meter display battery voltage Yes RENEW headlight swi...

Page 1827: ... license plate lamp is inoperative GO to B16 B2 CHECK FUSE F57 F56 7 5 A CJB Ignition switch in position 0 1 Disconnect Fuse Vehicles built up to 08 2006 F57 7 5 A CJB Vehicles built from 08 2006 F56 7 5 A CJB 2 CHECK Fuse Vehicles built up to 08 2006 F57 7 5 A CJB Vehicles built from 08 2006 F56 7 5 A CJB 3 Is the fuse OK Yes CHECK CJB and if necessary RENEW CHECK the operation of the system No R...

Page 1828: ...p and soldered connection S109 using the Wiring Diagrams CHECK the operation of the system B5 CHECK THE VOLTAGE SUPPLY OF THE RIGHT HAND HEADLAMP PARKING LAMP FOR OPEN CIRCUIT SWITCH ON side light 1 Measure voltage between right hand headlamp connector C834 pin 3 circuit 29S LF16 OG GN wiring harness side and ground 2 Is battery voltage measured Yes CHECK and if necessary RENEW the headlamp CHECK ...

Page 1829: ...e measured Yes CHECK and if necessary RENEW the headlamp CHECK the operation of the system No LOCATE and RECTIFY the break in the circuit between fuse F58 F55 CJB and the left headlamp using the Wiring Diagrams CHECK the operation of the system B8 CHECK RIGHT HAND REAR LAMP ASSEMBLY Ignition switch in position II 1 SWITCH ON right hand turn signal 2 Check rear right hand turn signal 3 Does the rig...

Page 1830: ...UIT Ignition switch in position 0 1 Disconnect Right hand rear lamp assembly from connector Vehicles without trailer socket C475 Vehicles with trailer socket C475a 2 SWITCH ON side light 3 Measure voltage between right hand rear lamp assembly Vehicles without trailer socket connector C475 pin 2 circuit 29S LF20 OG wiring harness side and ground Vehicles with trailer socket Connector C475a pin 2 ci...

Page 1831: ...o LOCATE and RECTIFY the break in the circuit between the left hand rear lamp assembly and ground connection G46 using the Wiring Diagrams CHECK the operation of the system B13 CHECK THE VOLTAGE SUPPLY TO THE LEFT HAND REAR LAMP ASSEMBLY REAR LAMP FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect Left hand rear lamp assembly from connector Vehicles without trailer socket C474 Vehicles wi...

Page 1832: ...TE LAMP FOR OPEN CIRCUIT SWITCH OFF side light 1 Measure resistance between right hand license lamp connector C496 pin 1 circuit 31 LF22 BK wiring harness side and ground 2 Is a resistance of less than 2 Ohms registered Yes LOCATE and REPAIR the break in circuit 29S LF22 OG BK between the left hand license plate lamp and the right hand license plate lamp using the Wiring Diagrams CHECK the operati...

Page 1833: ...o 08 2006 F62 7 5 A CJB Vehicles built from 08 2006 F57 7 5 A CJB 3 Is the fuse OK Yes GO to B18 No RENEW fuse F62 F57 7 5 A CJB and CHECK the operation of the system If the fuse blows again LOCATE and RECTIFY the short using the Wiring Diagrams CHECK the operation of the system B18 CHECK THE VOLTAGE SUPPLY TO FUSE F62 F57 7 5 A CJB FOR OPEN CIRCUIT Connect Fuse Vehicles built up to 08 2006 F62 7 ...

Page 1834: ...dlamp switch and fuse F62 F57 CJB using the Wiring Diagrams If necessary RENEW the CJB CHECK operation of system B20 CHECK HEADLIGHT SWITCH Disconnect Headlight switch from connector C320 1 Connect a fused jumper wire 10 A to the headlight switch connector C320 between pin 11 circuit 29 LE29 OG BK and pin 13 circuit 29S LF1 OG YE wiring harness side 2 Check parking lamps and rear lamps 3 Do the pa...

Page 1835: ...S FOR SHORT CIRCUIT TO BATTERY VOLTAGE Ignition switch in position 0 1 Disconnect Fuse Vehicles built up to 08 2006 F58 7 5 A CJB Vehicles built from 08 2006 F55 7 5 A CJB 2 Ignition switch in position II 3 Check left hand parking lamps and rear lamps 4 Are the left hand parking lamp rear lamp lit continuously Yes LOCATE and RECTIFY the short to battery voltage in the circuits connected to fuse F5...

Page 1836: ... on Yes LOCATE and RECTIFY the short to battery voltage in the circuit between the headlight switch and fuse F62 F57 7 5 A CJB using the Wiring Diagrams If necessary RENEW the CJB CHECK the operation of the system No Parking and rear lamps illuminate continuously vehicles built up to 08 2006 LOCATE and RECTIFY the short to battery voltage in the circuit between the headlight switch and fuses F57 F...

Page 1837: ...5 circuit 15S LE29 GN BK wiring harness side and ground 2 Is battery voltage measured Yes REFER to Daytime Running Lamps DRL 417 04 Daytime Running Lamps DRL Diagnosis and Testing No RENEW headlight switch CHECK the operation of the system C7 NARROW DOWN THE CONDITIONS UNDER WHICH THE FAULT OCCURS NOTE Ignition should be switched off when carrying out the measurement Ignition switch in position 0 ...

Page 1838: ...cigarette lighter CHECK operation of system C9 ELIMINATE THE HEATER CONTROL MODULE AS CAUSE FOR THE SHORT TO BATTERY VOLTAGE Ignition switch in position 0 1 Disconnect Fuse Vehicles built up to 08 2006 F34 7 5 A CJB Vehicles built from 08 2006 F60 7 5 A CJB 2 Disconnect Fuse Vehicles built up to 08 2006 F59 7 5 A CJB Vehicles built from 08 2006 F48 7 5 A CJB 3 Ignition switch in position II 4 Meas...

Page 1839: ...witch in position II 6 Measure voltage between headlamp switch connector C320 pin 9 circuit 29S DA2 OG BU wiring harness side and ground 7 Is battery voltage measured Yes GO to C11 No RENEW radio CHECK operation of system C11 ELIMINATE THE INSTRUMENT CLUSTER AS CAUSE FOR THE SHORT TO BATTERY VOLTAGE Ignition switch in position 0 1 Connect Fuse Vehicles built up to 08 2006 F31 15 A CJB Vehicles bui...

Page 1840: ...DA2 OG BU wiring harness side and ground 6 Is battery voltage measured Yes LOCATE and RECTIFY the short to battery voltage in the circuits connected to soldered connection S5 using the Wiring Diagrams CHECK the operation of the system No RENEW instrument cluster CHECK the operation of the system http vnx su ...

Page 1841: ...timeter for all electrical measurements Terminal probe kit 29 011 A Electrical Fuse s Bulb s Electrical connector s Wiring harness Symptom Possible Sources Action Fog lamps inoperative Fuse Circuit s Headlight switch Rear fog lamp cut off relay Cut off relay rear fog lamp parking aid Trailer socket GO to Pinpoint Test A Individual fog lamp inoperative Circuit s Fog lamp Left right hand rear lamp a...

Page 1842: ...ion II 2 CHECK the voltage between F28 20 A BJB and ground 3 Is battery voltage measured Yes GO to A4 No Vehicles built before 08 2006 LOCATE and RECTIFY the break in circuit 15 DC28 GN BU between ignition relay 1 without front fog lamps or ignition relay 2 with front fog lamps and fuse F28 BJB using the Wiring Diagrams CHECK the operation of the system Vehicles built from 08 2006 LOCATE and RECTI...

Page 1843: ...circuit 15S LD6 GN YE between the headlight switch and intermediate connector C61b pin 16 using the Wiring Diagrams CHECK the operation of the system Vehicles without trailer socket Vehicles built from 02 2004 to 8 2006 LOCATE and RECTIFY the break in circuit 15S LD6 GN YE between the headlight switch and intermediate connector C54 pin 10 using the Wiring Diagrams CHECK the operation of the system...

Page 1844: ...s without parking aid rear fog lamp cut off relay socket C1103 circuit BN wiring harness side and ground Vehicles with parking aid rear fog lamp parking aid cut off relay socket C1110 circuit BN wiring harness side and ground 2 Is a resistance of less than 2 Ohms registered Yes GO to A8 No LOCATE and RECTIFY the break in the circuit between the cut off relay and soldered connection S1001 using the...

Page 1845: ...switch and soldered connection S110 using the Wiring Diagrams CHECK the operation of the system PINPOINT TEST B INDIVIDUAL FOG LAMP INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS B1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position II 1 Switch on DIPPED BEAM 2 SWITCH ON the front and rear fog lamps 3 CHECK fog lamps 4 Is a single fog lamp inoperative Yes Left f...

Page 1846: ...Wiring Diagrams CHECK the operation of the system B3 CHECK GROUND CONNECTION OF LEFT HAND FRONT FOG LAMP FOR OPEN CIRCUIT Ignition switch in position 0 1 Vehicles built up to 08 2005 2 Measure the resistance between left hand front fog lamp connector C302 pin 1 circuit 31 LD11 BK wiring harness side and ground 3 Vehicles built from 08 2005 4 Measure the resistance between the left hand front fog l...

Page 1847: ...and front fog lamp connector C304 pin 2 circuit 15S LD17 GN WH wiring harness side and ground 6 Vehicles built from 08 2005 7 Measure the voltage between right hand front fog lamp connector C304 pin 1 circuit 15S LD17 GN WH wiring harness side and ground 8 Is battery voltage measured Yes GO to B5 No LOCATE and RECTIFY the break in the circuit between soldered connection S110 and the right hand fro...

Page 1848: ...TAGE SUPPLY TO THE LEFT HAND REAR LAMP ASSEMBLY REAR FOG LAMP FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect left hand rear lamp assembly Vehicles without trailer socket from connector C474 Vehicles with trailer socket from connector C474a 2 Ignition switch in position II 3 SWITCH ON the rear fog lamps 4 Measure the voltage between left hand rear lamp assembly Vehicles without trailer...

Page 1849: ...N AT THE LEFT HAND REAR LAMP ASSEMBLY FOR OPEN CIRCUIT Ignition switch in position 0 1 Measure the resistance between the left hand rear lamp assembly Vehicles without trailer socket Connector C474 pin 5 circuit 31 LF23 BK wiring harness side and ground Vehicles with trailer socket Connector C474a pin 5 circuit BN wiring harness side and ground 2 Is the resistance less than 2 ohm Yes CHECK and if ...

Page 1850: ...hand rear lamp assembly using the Wiring Diagrams CHECK the operation of the system Vehicles without trailer socket Vehicles built from 08 2006 LOCATE and RECTIFY the break in the circuit between intermediate connector C61 pin 1 and the right hand rear lamp assembly using the Wiring Diagrams CHECK the operation of the system Vehicles with trailer socket LOCATE and RECTIFY the break in the circuit ...

Page 1851: ... to battery voltage in the circuits connected to the headlamp switch connector C320 pin 2 using the Wiring Diagrams CHECK the operation of the system Rear fog lamps permanently on Vehicles with trailer socket GO to C2 No INSTALL A NEW headlight switch CHECK the operation of the system C2 NARROW DOWN THE CAUSE OF THE SHORT TO BATTERY VOLTAGE Ignition switch in position 0 1 Disconnect Corresponding ...

Page 1852: ... Wiring Diagrams CHECK the operation of the system No LOCATE and RECTIFY short to battery voltage in the circuits VT YE connected to the cut off relay with the aid of the wiring diagrams CHECK the operation of the system http vnx su ...

Page 1853: ...ion between the module and WDS is ensured 1 1 Verify the customer concern 2 2 Visually inspect for obvious signs of electrical or mechanical damage NOTE Ensure correct locking of wiring harness connector Visual Inspection Chart 3 3 Resolve any obvious causes or concerns found during the visual inspection before carrying out any further tests 4 4 If the cause of the concern cannot be determined wit...

Page 1854: ...relay Headlight switch Turn signal switch Instrument cluster GO to Pinpoint Test F The headlamp flasher is inoperative Circuit s Turn signal switch GO to Pinpoint Test G PINPOINT TEST A HEADLAMPS INOPERATIVE DIPPED BEAM AND MAIN BEAM TEST CONDITIONS DETAILS RESULTS ACTIONS A1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position II 1 SWITCH ON dipped beam 2 SWITCH ON ma...

Page 1855: ...splay battery voltage Yes Vehicles without daytime running lights GO to A4 Vehicles with daytime running lights LOCATE and REPAIR break in circuit 91 DA3 BK OG between soldered connection S118 and ground G37 with the aid of the Wiring Diagrams CHECK the operation of the system No Vehicles before 08 2006 LOCATE AND RECTIFY the break in the voltage supply of fuse F37 7 5 A CJB using the Wiring Diagr...

Page 1856: ...connector C835 2 Measure the resistance between left hand headlamp connector C835 pin 4 circuit 31 LE31 BK wiring harness side and ground 3 Is a resistance of less than 2 Ohms registered Yes CHECK and if necessary RENEW the headlamp CHECK the operation of the system No LOCATE and RECTIFY break in circuit s between headlamp and ground connection G37 with the aid of the wiring diagrams CHECK the ope...

Page 1857: ...cles without daytime running lights LOCATE and RECTIFY the break in the circuit 30 LE20 RD between soldered connection S102 and the dipped beam relay using the Wiring Diagrams CHECK the operation of the system Vehicles with daytime running lights GO to B2 B2 CHECK FUSE F22 20 A BJB Ignition switch in position 0 1 Disconnect Fuse F22 20 A BJB 2 CHECK Fuse F22 20 A BJB 3 Is the fuse OK Yes GO to B3 ...

Page 1858: ...IRCUIT Ignition switch in position 0 1 Measure the resistance between the dipped beam relay socket C1006 pin 2 circuit 91 LE19 BK BU BJB side and ground 2 Is a resistance of less than 2 Ohms registered Yes Vehicles without daytime running lights RENEW the dipped beam relay CHECK the operation of the system Vehicles with daytime running lights GO to B6 No LOCATE and RECTIFY the break in the circuit...

Page 1859: ...o Vehicles built before 08 2006 LOCATE and RECTIFY the break in the circuit between fuse F37 20A CJB and the headlamp switch using the Wiring Diagrams CHECK the operation of the system Vehicles built from 08 2006 LOCATE and RECTIFY the break in the circuit between fuse F58 20A CJB and the headlamp switch using the Wiring Diagrams CHECK the operation of the system B8 CHECK THE HEADLIGHT SWITCH Igni...

Page 1860: ...lay from socket C1006 2 Measure resistance between the turn signal switch connector C459 pin 9 circuit 15S LE19 GN BU wiring harness side and the dipped beam relay socket C1006 pin 1 circuit 15S LE19 GN BU wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes RENEW the turn signal switch CHECK the operation of the system No LOCATE and RECTIFY the break in the circuit s between t...

Page 1861: ...es GO to C3 No GO to C4 C3 CHECK THE GROUND CONNECTION OF THE MAIN BEAM RELAY Ignition switch in position 0 1 Measure the resistance between the main beam relay socket C1005 pin 2 circuit 91 LE12 BK YE BJB side and ground 2 Is a resistance of less than 2 Ohms registered Yes RENEW the main beam relay CHECK the operation of the system No LOCATE and RECTIFY the break in the circuit between the main b...

Page 1862: ... position 0 1 Connect Main beam relay to socket C1005 2 Connect a fused bridging cable 7 5 A at the turn signal switch connector C459 between pin 6 circuit 15 LE14 GN RD wiring harness side and pin 7 circuit 15S LE12 GN YE wiring harness side 3 Ignition switch in position II 4 CHECK the main beam 5 Are the main beam headlamps lit up Yes RENEW the turn signal switch CHECK the operation of the syste...

Page 1863: ...les without daytime running lights LOCATE and RECTIFY the break in circuit 15S DC16 GN BU between the dipped beam relay and fuse F16 10 A BJB using the Wiring Diagrams CHECK the operation of the system Vehicles with daytime running lights LOCATE and RECTIFY the break in circuit 15S DC16A GN BU between the soldered connection S120 and fuse F16 10 A BJB using the Wiring Diagrams CHECK the operation ...

Page 1864: ...attery voltage Yes GO to D7 No Vehicles without daytime running lights LOCATE and RECTIFY the break in circuit 15S DC17 GN BU between the dipped beam relay and fuse F17 10 A BJB using the Wiring Diagrams CHECK the operation of the system Vehicles with daytime running lights LOCATE and RECTIFY the break in circuit 15S DC17A GN BU between soldered connection S120 and fuse F17 10 A BJB using the Wiri...

Page 1865: ... the operation of the system If the fuse blows again LOCATE and RECTIFY the short to ground using the Wiring Diagrams CHECK the operation of the system E3 CHECK THE VOLTAGE SUPPLY TO FUSE F15 10 A BJB Connect fuse F15 10 A BJB 1 Ignition switch in position II 2 SWITCH ON main beam 3 Measure voltage between fuse F15 10 A BJB and ground 4 Does the meter display battery voltage Yes GO to E4 No LOCATE...

Page 1866: ...ration of the system E6 CHECK THE VOLTAGE SUPPLY TO FUSE F25 10 A BJB Connect fuse F25 10 A BJB 1 Ignition switch in position II 2 SWITCH ON main beam 3 Measure voltage between fuse F25 10 A BJB and ground 4 Does the meter display battery voltage Yes GO to E7 No LOCATE and RECTIFY the break in circuit 15S DC25 GN BU between the main beam relay and fuse F25 10 A BJB using the Wiring Diagrams CHECK ...

Page 1867: ... on GO to F2 F2 CHECK POWER SUPPLY CIRCUIT FOR SHORT TO BATTERY VOLTAGE Ignition switch in position 0 1 Disconnect fuse F16 10 A BJB 2 Disconnect fuse F17 10 A BJB 3 Ignition switch in position II 4 CHECK the dipped beam 5 Is one of the dipped beam headlamps on Yes Left hand dipped beam lit LOCATE and RECTIFY the short to battery voltage in circuit 15S LE16 GN OG between fuse F16 10 A BJB and the ...

Page 1868: ...and RECTIFY short to battery voltage in the circuits connected to soldered connection S120 with the aid of the wiring diagrams CHECK the operation of the system If necessary CHECK and RENEW the BJB CHECK the operation of the system If the concern persists REFER to Daytime Running Lamps DRL 417 04 Daytime Running Lamps DRL Diagnosis and Testing No GO to F4 F4 CHECK THE CONTROL CIRCUIT OF THE DIPPED...

Page 1869: ...eter display battery voltage Yes LOCATE and RECTIFY the short to battery voltage in the circuit s between the turn signal switch and the headlamp switch using the Wiring Diagrams CHECK the operation of the system No CHECK and if necessary RENEW the turn signal switch CHECK the operation of the system If the concern persists vehicles with daytime running lamps REFER to Daytime Running Lamps DRL 417...

Page 1870: ...AIN BEAM RELAY FOR A SHORT TO BATTERY VOLTAGE Measure the voltage between the main beam relay socket C1005 pin 1 circuit 15S LE12 GN YE BJB side and ground 1 Does the meter display battery voltage Yes GO to F11 No RENEW the main beam relay CHECK the operation of the system F11 RULE OUT THE TURN SIGNAL SWITCH AS THE CAUSE OF THE FAULT Ignition switch in position 0 1 Connect Main beam relay with soc...

Page 1871: ...agrams CHECK the operation of the system If necessary CHECK and RENEW the BJB CHECK the operation of the system No CHECK and if necessary RENEW the instrument cluster CHECK the operation of the system PINPOINT TEST G HEADLAMP FLASHER INOPERATIVE DIPPED BEAM OK TEST CONDITIONS DETAILS RESULTS ACTIONS G1 DETERMINE THE CAUSE OF THE FAULT Ignition switch in position II 1 SWITCH ON dipped beam 2 SWITCH...

Page 1872: ... 15 LE14 GN RD between fuse F37 7 5 A CJB and the turn signal switch using the wiring diagrams CHECK the operation of the system Vehicles built from 08 2006 LOCATE and RECTIFY the break in circuit 15 LE14 GN RD between fuse F58 7 5 A CJB and the turn signal switch using the wiring diagrams CHECK the operation of the system http vnx su ...

Page 1873: ...t Symptom Chart Symptom Chart Pinpoint Tests NOTE Use a digital multimeter for all electrical measurements Terminal probe kit 29 011 A Electrical Fuse Electrical connector s Headlight switch Wiring harness Symptom Possible Sources Action Headlamp levelling system inoperative malfunctioning Fuse Circuit s Headlight switch Headlamp positioning motor GO to Pinpoint Test A PINPOINT TEST A HEADLAMP LEV...

Page 1874: ... the SETTING of the headlamp leveling system during the measurement UP DOWN 6 Measure the voltage between left hand headlamp connector C835 pin 2 circuit 64 LE45 BU wiring harness side and ground 7 Does the registered voltage vary proportionally with the adjustment of the variable resistor Yes GO to A4 No LOCATE and RECTIFY the break in the circuit between the headlamp and soldered connection S106...

Page 1875: ...C834 2 Ignition switch in position II 3 SWITCH ON dipped beam 4 CHANGE the SETTING of the headlamp leveling system during the measurement UP DOWN 5 Measure the voltage between right hand headlamp connector C834 pin 2 circuit 64 LE46 BU RD wiring harness side and ground 6 Does the registered voltage vary proportionally with the adjustment of the variable resistor Yes GO to A7 No LOCATE and RECTIFY ...

Page 1876: ...the operation of the system If the fuse blows again LOCATE and RECTIFY short using the Wiring Diagrams CHECK the operation of the system Vehicles built from 08 2006 RENEW fuse F58 7 5 A CJB and CHECK the operation of the system If the fuse blows again LOCATE and RECTIFY short using the Wiring Diagrams CHECK the operation of the system A9 CHECK THE VOLTAGE SUPPLY TO FUSE F37 F58 7 5 A CJB FOR OPEN ...

Page 1877: ...hicles built before 08 2006 LOCATE and RECTIFY the break in the circuit between fuse F37 7 5 A CJB and the headlamp switch using the Wiring Diagrams CHECK the operation of the system Vehicles built from 08 2006 LOCATE and RECTIFY the break in the circuit between fuse F58 7 5 A CJB and the headlamp switch using the Wiring Diagrams CHECK the operation of the system A11 EXCLUDE THE HEADLAMP AS THE CA...

Page 1878: ... between left hand headlamp connector C835 pin 2 circuit 64 LE45 BU wiring harness side and ground 7 Does the registered voltage vary proportionally with the adjustment of the variable resistor Yes CHECK and if necessary INSTALL A NEW left hand headlamp CHECK the operation of the system No CHECK and if necessary INSTALL A NEW right hand headlamp CHECK the operation of the system A13 CHECK COMMON C...

Page 1879: ...the aid of the wiring diagrams CHECK the operation of the system A15 CHECK CONTROL CIRCUIT FOR SHORT TO BATTERY VOLTAGE Ignition switch in position 0 1 Disconnect Headlight switch from connector C320 2 Ignition switch in position II 3 Measure the voltage between the headlamp switch connector C320 pin 1 circuit 64 LE1 BU wiring harness side and ground 4 Does the meter display battery voltage Yes LO...

Page 1880: ...ed Yes INSTALL A NEW headlight switch CHECK the operation of the system No LOCATE and RECTIFY the break in the circuit between the headlight switch and soldered connection S6 using the wiring diagrams CHECK the operation of the system http vnx su ...

Page 1881: ...onnections in the vehicle so that communication between the module and WDS is ensured 1 1 Verify the customer concern 2 2 Visually inspect for obvious signs of electrical damage NOTE Ensure correct locking of wiring harness connector Visual Inspection Chart 3 3 Resolve any obvious causes or concerns found during the visual inspection before carrying out any further tests 4 4 If the cause of the co...

Page 1882: ...her relay RENEW the flasher relay CHECK operation of system PINPOINT TEST A TURN INDICATORS INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS A1 CHECK FUSE F48 F44 7 5 A CJB Ignition switch in position 0 1 Disconnect Fuse Vehicles built before 08 2006 F48 7 5 A CJB Vehicles built from 08 2006 F44 7 5 A CJB 2 CHECK Fuse Vehicles built before 08 2006 F48 7 5 A CJB Vehicles built from 08 2006 F44 7...

Page 1883: ...sary RENEW the CJB CHECK operation of system A3 CHECK FUSE F61 F30 15 A CJB Ignition switch in position 0 1 Disconnect Fuse Vehicles built before 08 2006 F61 15 A CJB Vehicles built from 08 2006 F30 15 A CJB 2 CHECK Fuse Vehicles built before 08 2006 F61 15 A CJB Vehicles built from 08 2006 F30 15 A CJB 3 Is the fuse OK Yes GO to A4 No Vehicles built before 08 2006 RENEW fuse F61 15 A CHECK system...

Page 1884: ...IT Ignition switch in position 0 1 Disconnect flasher relay from socket C457 2 Ignition switch in position II 3 Measure the voltage between the flasher relay socket C457 pin 2 circuit 15 LG25 A GN BU socket side and ground 4 Does the meter display battery voltage Yes GO to A6 No Vehicles built before 08 2006 LOCATE and RECTIFY the break in the circuit s between fuse F48 7 5 A CJB and the turn sign...

Page 1885: ...7 CHECK GROUND SUPPLY TO FLASHER RELAY FOR OPEN CIRCUIT Ignition switch in position 0 1 Measure the resistance between the turn signal relay socket C457 pin 5 circuit 91 LG25 BK BU socket side and ground 2 Is a resistance of less than 2 Ohms registered Yes GO to A8 No LOCATE and RECTIFY the break in the circuit s between the turn signal relay and ground connection G41 with the aid of the wiring di...

Page 1886: ...HECK the turn signal lamps 5 Are the left hand turn signal lamps flashing Yes RENEW the turn signal switch CHECK system operates correctly No RENEW the flasher relay CHECK system operates correctly PINPOINT TEST B TURN SIGNAL LAMPS ILLUMINATE OR FLASH CONTINUOUSLY TEST CONDITIONS DETAILS RESULTS ACTIONS B1 DETERMINE THE FAULT CONDITION Ignition switch in position II 1 CHECK the turn signal lamps a...

Page 1887: ...JB Vehicles built from 08 2006 F37 7 5 A CJB 3 Disconnect Fuse Vehicles built before 08 2006 F48 7 5 A CJB Vehicles built from 08 2006 F59 7 5 A CJB 4 Ignition switch in position II 5 CHECK the turn signal lamps 6 Are the turn signal lamps lit up permanently Yes vehicles with anti theft warning system central locking module with trailer socket GO to B3 vehicles without anti theft warning system ce...

Page 1888: ...on of system No CHECK the anti theft warning system central locking module using WDS RENEW if necessary CHECK system operates correctly B4 CHECK THE HAZARD WARNING LIGHT SWITCH Ignition switch in position 0 1 Disconnect Hazard warning light switch from connector C458 2 Ignition switch in position II 3 CHECK the turn signal lamps 4 Are the turn signal lamps flashing continuously Yes CHECK the anti ...

Page 1889: ... built from 08 2006 F44 7 5 A CJB 1 Ignition switch in position II 2 Measure the voltage between fuse Vehicles built before 08 2006 F48 7 5 A CJB and ground Vehicles built from 08 2006 F44 7 5 A CJB and ground 3 Does the meter display battery voltage Yes GO to B7 No LOCATE AND RECTIFY the break in the voltage supply of fuse F48 7 5 A CJB using the Wiring Diagrams If necessary RENEW the CJB CHECK s...

Page 1890: ...06 F61 15 A CJB and ground Vehicles built from 08 2006 F30 15 A CJB and ground 3 Does the meter display battery voltage Yes GO to B9 No Vehicles built before 08 2006 LOCATE AND RECTIFY the break in the voltage supply of fuse F61 15 A CJB using the Wiring Diagrams CHECK the operation of the system CHECK and INSTALL A NEW CJB if necessary CHECK system operates correctly Vehicles built from 08 2006 L...

Page 1891: ... LG26 OG wiring harness side and ground 1 Does meter display battery voltage Yes GO to B11 No Vehicles built before 08 2006 LOCATE and RECTIFY the break in the circuit s between fuse F61 15 A CJB and the turn signal relay using the wiring diagrams CHECK the operation of the system CHECK and INSTALL A NEW CJB if necessary CHECK operation of system Vehicles built from 08 2006 LOCATE and RECTIFY the ...

Page 1892: ...gnition switch in position II 3 Measure the voltage between the turn signal lamp relay connector C457 pin 4 circuit 49 LG8 BU WH wiring harness side and ground 4 Does the meter display battery voltage Yes LOCATE and RECTIFY the short to battery voltage in the circuit between the turn signal relay and the hazard warning switch using the wiring diagrams CHECK operation of system No RENEW the hazard ...

Page 1893: ...ENEW the flasher relay CHECK operation of system No LOCATE and RECTIFY the break in the circuit between the turn signal relay and the hazard warning light switch using the wiring diagrams CHECK operation of system PINPOINT TEST D ONE OR MORE TURN INDICATORS ARE INOPERATIVE OR LIT ALL THE TIME TEST CONDITIONS DETAILS RESULTS ACTIONS D1 DETERMINE THE FAULT CONDITION Ignition switch in position II 1 ...

Page 1894: ... lamp inoperative GO to D15 Right hand rear turn signal lamp inoperative GO to D18 All turn signal lamps inoperative on the left hand side when the turn signal switch is operated GO to D21 All turn signal lamps inoperative on the left hand side when the hazard light switch is operated GO to D22 All turn signal lamps inoperative on the right hand side when the turn signal switch is operated GO to D...

Page 1895: ...2006 F48 7 5 A CJB 2 Disconnect Fuse Vehicles built before 08 2006 F40 7 5 A CJB Vehicles built from 08 2006 F37 7 5 A CJB 3 Disconnect Fuse Vehicles built before 08 2006 F48 7 5 A CJB Vehicles built from 08 2006 F59 7 5 A CJB 4 Ignition switch in position II 5 CHECK the turn signal lamps 6 Are the turn signals lit continuously on one side Yes vehicles with anti theft warning system central lockin...

Page 1896: ... system central locking module using WDS RENEW if necessary CHECK operation of system D7 DETERMINE THE FAULT CONDITION CHECK the turn signal lamps 1 Are the turn signal lamps permanently lit on the left hand side Yes LOCATE and RECTIFY short to battery voltage in the circuits connected to soldered connection S3 with the aid of the wiring diagrams CHECK operation of system No LOCATE and RECTIFY sho...

Page 1897: ...mps on the left hand side permanently lit LOCATE and RECTIFY short to battery voltage in the circuits connected to soldered connection S3 with the aid of the wiring diagrams CHECK operation of system All turn signal lamps on the right hand side permanently lit LOCATE and RECTIFY short to battery voltage in the circuits connected to soldered connection S4 with the aid of the wiring diagrams CHECK s...

Page 1898: ...L SIDE REPEATER LAMP FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect Front right hand turn signal side repeater lamp from connector C754 2 Measure the resistance between right hand indicator side repeater lamp connector C754 pin 1 1 8L Duratorq TDCi Kent diesel built from 02 2004 circuit 91 LG20 BK OG wiring harness side and ground All other models circuit 31 LG20 BK wiring harness sid...

Page 1899: ...G11 BK wiring harness side and ground 3 Is a resistance of less than 2 Ohms registered Yes LOCATE and REPAIR break in circuit 49S LG11 BU OG between solder point S104 and headlamp using the wiring diagrams CHECK operation of system If the concern persists CHECK and if necessary RENEW the headlamp CHECK operation of system No LOCATE and RECTIFY the break in the circuit between the headlamp and sold...

Page 1900: ...er socket C474a 2 Measure resistance between left hand rear lamp assembly Vehicles without trailer socket Connector C474 pin 5 circuit 31 LF23 BK wiring harness side and ground Vehicles with trailer socket Connector C474a pin 5 circuit BN wiring harness side and ground 3 Is a resistance of less than 2 Ohms registered Yes Vehicles without trailer socket LOCATE and REPAIR break in circuit 49S LG12 B...

Page 1901: ...signal flash Yes INSTALL A NEW trailer module switch interface SI CHECK operation of system No LOCATE and RECTIFY the break in the circuit s between the trailer module switch interface SI and the left hand rear lamp cluster using the Wiring Diagrams CHECK operation of system If the concern persists CHECK and if necessary RENEW the left hand rear lamp cluster CHECK operation of system D18 CHECK GRO...

Page 1902: ...ldered connection S4 and trailer switch interface SI using the Wiring Diagrams CHECK operation of system D20 CHECK VOLTAGE SUPPLY OF THE RIGHT HAND REAR LAMP CLUSTER TURN SIGNAL FOR OPEN CIRCUIT Ignition switch in position 0 1 Connect Right hand rear lamp cluster to connector C475a 2 Use a fused bridging cable 5 A at the trailer module switch interface SI connector C1102 to bridge between circuit ...

Page 1903: ...tor C458 2 Use a fused jumper lead 7 5 A at the hazard warning switch connector C458 to connect between pin 6 circuit 49 LG8 BU WH and pin 5 circuit 49S LG3 BU wiring harness side 3 Ignition switch in position II 4 CHECK the turn signal lamps 5 Do the turn signal lamps flash on the left hand side Yes RENEW the hazard warning light switch CHECK system operates correctly No LOCATE and RECTIFY the br...

Page 1904: ... A at the hazard warning lights switch connector C458 to connect between pin 6 circuit 49 LG8 BU WH and pin 7 circuit 49S LG4 BU RD wiring harness side 3 Ignition switch in position II 4 CHECK the turn signal lamps 5 Do the turn signal lamps flash on the right hand side Yes RENEW the hazard warning light switch CHECK system operates correctly No LOCATE and RECTIFY the break in the circuit between ...

Page 1905: ...tion switch in position II 2 Measure the voltage between fuse Vehicles built before 08 2006 F48 7 5 A CJB and ground Vehicles built from 08 2006 F44 7 5 A CJB and ground 3 Does the meter display battery voltage Yes GO to D27 No LOCATE AND RECTIFY the break in the voltage supply of fuse F48 7 5 A CJB using the Wiring Diagrams If necessary RENEW the CJB CHECK system operates correctly LOCATE AND REC...

Page 1906: ...08 2006 F30 15 A CJB and ground 3 Does the meter display battery voltage Yes GO to D29 No Vehicles built before 08 2006 LOCATE AND RECTIFY the break in the voltage supply of fuse F61 15 A CJB using the Wiring Diagrams CHECK system operates correctly CHECK and INSTALL A NEW CJB if necessary CHECK system operates correctly Vehicles built from 08 2006 LOCATE AND RECTIFY the break in the voltage suppl...

Page 1907: ... No Vehicles built before 08 2006 LOCATE and RECTIFY the break in the circuit s between fuse F61 15 A CJB and the turn signal relay using the wiring diagrams CHECK system operates correctly CHECK and INSTALL A NEW CJB if necessary CHECK system operates correctly Vehicles built from 08 2006 LOCATE and RECTIFY the break in the circuit s between fuse F30 15 A CJB and the turn signal relay using the w...

Page 1908: ...itch in position 0 1 Disconnect Turn signal switch from connector C459 2 Ignition switch in position II 3 CHECK the turn signal lamps 4 Do the turn signals flash continuously on one side Yes vehicles with anti theft warning system central locking module GO to E2 vehicles without anti theft warning system central locking module RENEW the hazard warning light switch CHECK operation of system No RENE...

Page 1909: ...ith petrol engine GO to F3 turn signal warning lamp inoperative for right turn signal vehicles with diesel engine LOCATE and REPAIR the break in the circuit s between soldered connection S4 and soldered connection S7 using the Wiring Diagrams CHECK operation of system turn signal warning lamp inoperative for both sides vehicles with petrol engine GO to F5 Turn signal warning lamp inoperative for b...

Page 1910: ...hicles built before 08 2006 Measure the voltage between the instrument cluster connector C809 pin 17 circuit 49S LG22 BU YE wiring harness side and ground 5 Vehicles built from 08 2006 Measure the voltage between the instrument cluster connector C809 pin 3 circuit 49S LG22 BU YE wiring harness side and ground 6 Is fluctuating battery voltage measured Yes CHECK the instrument cluster using WDS RENE...

Page 1911: ...OPEN CIRCUIT Ignition switch in position 0 1 Disconnect Instrument cluster from connector Vehicles built before 08 2006 C809 Vehicles built from 08 2006 C813 2 Measure the resistance between the instrument cluster connector Vehicles built before 08 2006 C809 pin 2 circuit 91 GG14 BK OG wiring harness side and ground Vehicles built from 08 2006 C813 pin 2 circuit 91 GG14 BK OG wiring harness side a...

Page 1912: ...for obvious signs of electrical damage NOTE Ensure correct locking of wiring harness connector Visual Inspection Chart 3 3 Resolve any obvious causes or concerns found during the visual inspection before carrying out any further tests 4 4 If the concern persists after the visual inspection PERFORM a fault diagnosis on the central timer module CTM using WDS and RESOLVE the fault s displayed accordi...

Page 1913: ...Pinpoint Test D PINPOINT TEST A BACK UP LAMP INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS A1 CHECK FUSE F53 41 10 A CJB Ignition switch in position 0 1 Disconnect Fuse Vehicles built before 08 2006 F53 10 A CJB Vehicles built from 08 2006 F41 10 A CJB 2 CHECK Fuse Vehicles built before 08 2006 F53 10 A CJB Vehicles built from 08 2006 F41 10 A CJB 3 Is the fuse OK Yes GO to A2 No RENEW fuse ...

Page 1914: ...en reversing lamp switch Vehicles built before 08 2006 with 1 8L Duratorq TDCi Kent diesel engine Connector C862 pin 2 circuit 15 LG28 GN WH wiring harness side and ground All other vehicles Connector C863 pin 2 circuit 15 LG28 B GN WH wiring harness side and ground 4 Is battery voltage measured Yes GO to A4 No LOCATE and RECTIFY the break in the circuit between fuse F53 41 CJB and the reversing l...

Page 1915: ...he backup lamps 3 Is the left hand back up lamp inoperative Yes GO to B2 No Right hand reversing lamp inoperative GO to B4 B2 CHECK VOLTAGE SUPPLY TO LEFT HAND REAR LAMP ASSEMBLY FOR OPEN CIRCUIT NOTE Reverse gear is still engaged Ignition switch in position 0 1 Disconnect Left hand rear lamp assembly from connector Vehicles without trailer socket C474 Vehicles with trailer socket C474a 2 Ignition...

Page 1916: ...TO RIGHT HAND REAR LAMP ASSEMBLY FOR OPEN CIRCUIT NOTE Reverse gear is still engaged Ignition switch in position 0 1 Disconnect Right hand rear lamp assembly from connector Vehicles without trailer socket C475 Vehicles with trailer socket C475a 2 Ignition switch in position II 3 Measure the voltage between the right hand rear lamp assembly Vehicles without trailer socket Connector C475 pin 4 circu...

Page 1917: ...0 1 Disconnect Reversing lamp switch from connector Vehicles built before 08 2006 with 1 8L Duratorq TDCi Kent diesel engine C862 All other vehicles C863 2 Ignition switch in position II 3 CHECK the backup lamps 4 Do the reversing lamps illuminate continuously Yes Vehicles built before 08 2006 without parking aid LOCATE and RECTIFY the short to battery voltage in the circuits connected to soldered...

Page 1918: ... connected to soldered connection S92 using the Wiring Diagrams Vehicles with trailer coupling check trailer socket and RENEW if necessary CHECK the operation of the system No INSTALL a new instrument cluster CHECK the operation of the system PINPOINT TEST D CIRCUIT OF REVERSING LAMP SWITCH FAULTY OPEN CIRCUIT TEST CONDITIONS DETAILS RESULTS ACTIONS D1 NARROW DOWN THE CAUSE OF THE FAULT Ignition s...

Page 1919: ...between soldered connection S91 and the instrument cluster using the Wiring Diagrams CHECK the operation of the system http vnx su ...

Page 1920: ...mptom Chart Symptom Chart System Checks NOTE Use a digital multimeter for all electrical measurements Terminal Probe Kit 29 011A Electrical Fuse s Bulb s Connectors Trailer socket Trailer lamps Wiring harness Symptom Possible Sources Action Trailer lamps inoperative Fuse s Circuit s in vehicle Circuit s in trailer Trailer socket Trailer switch interface SI module Rear fog lamp cut off relay GO to ...

Page 1921: ...ECK the operation of the system A2 CHECK GROUND CONNECTION OF TRAILER SOCKET FOR OPEN CIRCUIT Ignition switch in position 0 1 Measure the resistance between 7 pin trailer socket Connector C1109 pin 3 circuit BN WH and ground 13 pin trailer socket connector C1104 pin 3 circuit BN WH and ground and between pin 13 circuit BN and ground 2 Is the resistance less than 2 Ohm Yes Continue fault finding on...

Page 1922: ...rface SI module connector C1102 circuit RD wiring harness side and ground 4 Does the meter display battery voltage Yes GO to A6 No LOCATE and RECTIFY break in circuit between fuse FC fuse holder 1 and trailer module switch interface SI using the wiring diagrams CHECK the operation of the system A6 CHECK THE GROUND SUPPLY TO THE TRAILER SWITCH INTERFACE SI MODULE FOR OPEN CIRCUIT Ignition switch in...

Page 1923: ...15 LG23 GN WH and pin 1 circuit 15S LG14 A B GN RD 15S CF58 GN OG 15S RN2A GN BU wiring harness side 6 Vehicles built from 08 2006 7 Connect a fused jumper wire 15 A to the stop lamp switch connector C444 between pin 2 circuit 15 LG23 GN WH and pin 1 circuit 15S LG14 GN RD 15S LG5 GN RD wiring harness side 8 Ignition switch in position II 9 Measure the voltage between the trailer socket 7 pin sock...

Page 1924: ...nd the trailer module switch interface SI using the Wiring Diagrams CHECK the operation of the system A9 CHECK THE TRAILER SWITCH INTERFACE SI MODULE NOTE The jumper lead used in the previous step is still connected Ignition switch in position 0 1 Use a fused bridging cable 15 A at the trailer switch interface SI module to bridge between connector C1102 circuit BK RD and circuit VT wiring harness ...

Page 1925: ...ween soldered connection S1004 and the trailer socket using the Wiring Diagrams CHECK the operation of the system A11 CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE REAR FOG LAMPS SWITCHED ON Ignition switch in position II 1 Switch on the REAR FOG LAMP 2 Measure the voltage between the trailer socket 7 pin socket connector C1109 pin 2 circuit RD YE and ground 13 pin socket connector C1104 pin 2 ...

Page 1926: ... between the cut off relay and soldered connection S1001 using the Wiring Diagrams CHECK the operation of the system A13 CHECK THE REAR FOG LAMP CUT OFF RELAY Fused bridging cable 20A at Vehicles without parking aid rear fog lamp cut off relay connected between socket C1103 circuit RD WH and circuit RD YE wiring harness side Vehicles with parking aid rear fog lamp cut off relay parking aid connect...

Page 1927: ...s 2 Is one of the rear lamps on the trailer inoperative Yes Left hand trailer rear lamp inoperative GO to B2 Right hand trailer rear lamp inoperative GO to B3 No Trailer stop lamps inoperative GO to Pinpoint Test A Trailer reversing lamp s inoperative GO to Pinpoint Test A Trailer rear fog lamp s inoperative GO to Pinpoint Test A Left hand trailer turn signal lamp inoperative GO to B4 Right hand t...

Page 1928: ...and the trailer socket using the Wiring Diagrams CHECK the operation of the system B3 CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE SIDE LIGHTS SWITCHED ON Switch on SIDE LIGHTS 1 Measure the voltage between the trailer socket 7 pin socket connector C1109 pin 5 circuit OG and ground 13 pin socket connector C1104 pin 5 circuit OG and ground 2 Does the meter display battery voltage Yes Continue f...

Page 1929: ...fault finding on the trailer No GO to B5 B5 CHECK THE CIRCUIT BETWEEN THE TRAILER SWITCH INTERFACE SI MODULE AND THE TRAILER SOCKET FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect trailer switch interface SI module from connector C1102 2 Measure the resistance between the trailer switch interface SI module connector C1102 circuit BU wiring harness side and the trailer socket 7 pin sock...

Page 1930: ...ND THE TRAILER SOCKET FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect trailer switch interface SI module from connector C1102 2 Measure the resistance between the trailer switch interface SI module connector C1102 circuit BU RD wiring harness side and the trailer socket 7 pin socket connector C1109 pin 4 circuit BU RD 13 pin socket connector C1104 pin 4 circuit BU RD 3 Is the resistanc...

Page 1931: ...es continuously GO to C7 Trailer stop lamps and flashers illuminate continuously RENEW the trailer switch interface SI module CHECK the operation of the system C2 CHECK FOR SHORT TO BATTERY VOLTAGE AT THE TRAILER SOCKET REAR FOG LAMP Measure the voltage between the trailer socket 7 pin socket connector C1109 pin 2 circuit RD YE and ground 13 pin socket connector C1104 pin 2 circuit RD YE and groun...

Page 1932: ... SI MODULE AS CAUSE FOR THE SHORT TO BATTERY VOLTAGE NOTE Fuse holder 1 is located near the trailer module switch interface SI Ignition switch in position 0 1 Disconnect Fuse FC 10 A fuse holder 1 2 Ignition switch in position II 3 Measure the voltage between the trailer socket 7 pin socket connector C1109 pin 6 circuit VT and ground 13 pin socket connector C1104 pin 6 circuit VT and ground 4 Does...

Page 1933: ...in 1 circuit BU and ground 13 pin socket connector C1104 pin 1 circuit BU and ground 1 Does the meter display battery voltage Yes GO to C6 No Continue fault finding on the trailer C6 EXCLUDE THE TRAILER SWITCH INTERFACE SI MODULE AS CAUSE FOR THE SHORT TO BATTERY VOLTAGE NOTE Fuse holder 1 is located near the trailer module switch interface SI Ignition switch in position 0 1 Disconnect Fuse FC 10 ...

Page 1934: ...et CHECK the operation of the system No RENEW the trailer switch interface SI module CHECK the operation of the system C7 CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE RIGHT HAND TURN SIGNAL LAMP Measure the voltage between the trailer socket 7 pin socket connector C1109 pin 4 circuit BU RD and ground 13 pin socket connector C1104 pin 4 circuit BU RD and ground 1 Does the meter display batte...

Page 1935: ...oltage between the trailer socket 7 pin socket connector C1109 pin 4 circuit BU RD and ground 13 pin socket connector C1104 pin 4 circuit BU RD and ground 4 Does the meter display battery voltage Yes LOCATE and RECTIFY the short to battery voltage in the circuit between the trailer switch interface SI module and the trailer socket using the Wiring Diagrams If necessary RENEW the trailer socket CHE...

Page 1936: ...ut of the template in mm Y enlargement reduction factor in Z original dimension in mm 25 4 Enlarge reduce the printout with a photocopier by the calculated percentage Compare dimension X on the photocopy with the original dimension 5 Cut out the prepared template for the headlamp 6 Cut out the hatched areas 7 NOTE Right headlamp only Align the template on the lens of the headlamp 1 Alignment edge ...

Page 1937: ...e lamp surface Copy the outline of the template with a suitable pen onto the headlamp lens 12 Remove the template 13 NOTE Make sure not to go past the marked area Mask the marked area with opaque black adhesive tape 14 Repeat operations 11 to 13 for the other headlamp 15 Template for LHD vehicles right hand headlamp 1 Alignment edge on the headlamp lens 2 Reference point http vnx su ...

Page 1938: ...16 Template for LHD vehicles left hand headlamp 1 Alignment edge on the headlamp lens 2 Reference point http vnx su ...

Page 1939: ...17 Template for RHD vehicles right hand headlamp 1 Alignment edge on the headlamp lens 2 Reference point http vnx su ...

Page 1940: ...18 Template for RHD vehicles left hand headlamp 1 Alignment edge on the headlamp lens 2 Reference point http vnx su ...

Page 1941: ...http vnx su ...

Page 1942: ...ipped beam 4 Repeatedly operate the headlamp levelling switch through its range then set it to 0 5 Set up the measuring screen of the beam setting device to the correct headlamp setting value 6 Adjust the headlamps so that the boundary line touches the horizontal line 7 NOTE A stray portion of the dipped beam may cross the 15 degree line Adjust the dipped beam so that the rising line of the light ...

Page 1943: ...http vnx su ...

Page 1944: ... vehicle on a level surface 2 Make sure that the tire pressures are to specification and that the vehicle is not abnormally laden 3 Switch on front fog lamps 4 Set up the measuring screen of the beam setting device to the correct setting value for the front fog lamps 5 Adjust the front fog lamps so that the boundary line touches the horizontal line http vnx su ...

Page 1945: ...llation Vehicles with diesel engine All vehicles 3 Remove the components in the order indicated in the following illustration s and table s Description Lower headlamp bolts See Removal Detail Upper headlamp bolts See Removal Detail 1 Remove the intercooler air scoop 2 Remove the radiator grille Item 1 2 Part Number http vnx su ...

Page 1946: ...lts Item 2 Upper headlamp bolts Item 4 Headlamp connector 3 4 5 Headlamp Adjustment For additional information refer to 417 01 in this section 1 NOTE Raise the vehicle For additional information refer to Section 100 02 Jacking and Lifting Unscrew and remove the lower headlamp bolts 1 Lower the vehicle 1 Disconnect the headlamp connector http vnx su ...

Page 1947: ... Removal and Installation 1 Remove the components in the order indicated in the following illustration s and table s Description Bolts lower fascia crash padding cover Lower fascia crash padding cover Connector headlamp switch See Removal Detail Item 1 2 3 Part Number http vnx su ...

Page 1948: ...ion Bolts headlamp switch Headlamp switch 2 To install reverse the removal procedure Removal Details Item 3 Connector headlamp switch Item 4 5 1 Disconnect the headlamp switch connector Part Number http vnx su ...

Page 1949: ...rior Lighting Headlamp Switch Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 1 To install reverse the removal procedure http vnx su ...

Page 1950: ...5 06 2002 Print Removal and Installation 1 Remove the components in the order indicated in the following illustration s and table s Description Connector fog lamp Bolt fog lamp Fog lamp 2 To install reverse the removal procedure Item 1 2 3 Part Number http vnx su ...

Page 1951: ...5 06 2002 Print Removal and Installation Removal Installation 1 Refer to Front Bumper Cover Vehicles Built From 04 2009 501 19 Bumpers Removal and Installation 2 3 1 1 To install reverse the removal procedure 2 Refer to Headlamp Adjustment 417 01 Exterior Lighting General Procedures http vnx su ...

Page 1952: ...e symptom and refer to the Symptom Chart Symptom Chart Symptom Chart Electrical Fuse s Bulb s Switch es Relay s Wiring harness Central junction box CJB Instrument cluster Symptom Possible Sources Action The interior lamps are inoperative Circuit s Battery saver relay Interior lamp CJB Instrument cluster GO to Pinpoint Test A The interior center lamp is inoperative Circuit s Interior center lamp GO...

Page 1953: ...7B OG BU FOR OPEN Disconnect CJB C14 1 Measure the resistance between the interior front lamp C899 pin 1 circuit 29 LC7B OG BU harness side and CJB C14 pin 7 circuit 29 LC7 OG BU harness side 2 Is the resistance less than 5 ohms Yes GO to A3 No REPAIR the circuit TEST the system for normal operation A3 BATTERY SAVER RELAY COMPONENT TEST Disconnect Battery saver relay K115 1 CARRY OUT a relay compo...

Page 1954: ...tem for normal operation A6 CHECK THE CJB C1023 PIN 2 CIRUIT FOR AN OPEN Disconnect CJB C13 1 Measure the resistance between the CJB C1023 pin 2 component side and CJB C13 pin 3 component side 2 Is the resistance less than 5 ohms Yes GO to A7 No INSTALL a new CJB TEST the system for normal operation A7 CHECK CIRCUIT 31S LC22 FOR OPEN Disconnect Instrument cluster C809 1 Measure the resistance betw...

Page 1955: ...20 pin 2 circuit 29 LB25A OG BU harness side and ground 2 Is the voltage greater than 10 volts Yes GO to B2 No REPAIR the circuit TEST the system for normal operation B2 CHECK CIRCUIT 31S LB25A BK BU FOR OPEN Disconnect Interior center lamp C819 1 Disconnect Interior front lamp C892 2 Measure the resistance between the interior center lamp C819 pin 1 circuit 31S LB25A BK BU harness side and interi...

Page 1956: ...ont lamp C892 2 Measure the resistance between the interior rear lamp C821 pin 1 circuit 31S LB25B BK BU harness side and interior front lamp C892 pin 1 circuit 31S LB25B BK BU harness side 3 Is the resistance less than 5 ohms Yes INSTALL a new interior rear lamp TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation PINPOINT TEST D THE INTERIOR LAMPS DO NO...

Page 1957: ...ween the CJB C14 pin 3 circuit 31 DA1 BK harness side and ground 1 Is the resistance less than 5 ohms Yes GO to D4 No REPAIR the circuit TEST the system for normal operation D4 INTERIOR LAMP RELAY COMPONENT TEST Disconnect Interior lamp relay K142 1 CARRY OUT a relay component test REFER to the wiring diagrams in this section 2 Is the relay OK Yes GO to D5 No INSTALL a new interior lamp relay TEST...

Page 1958: ...ter REFER to Instrument Cluster 413 01 Instrument Cluster Removal and Installation TEST the system for normal operation If the concern persists install a new CJB TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation http vnx su ...

Page 1959: ...mptom Chart Pinpoint Test Worldwide Diagnostic System WDS Electrical Fuse s Bulb s Switch es Relay s Wiring harness Central junction box CJB Instrument cluster Lamp s Symptom Possible Sources Action The interior lamps are inoperative Circuit s Battery saver relay Interior lamp CJB Instrument cluster GO to Pinpoint Test A The centre interior lamp is inoperative Circuit s Centre interior lamp GO to ...

Page 1960: ... between the front interior lamp C899 pin 1 circuit 29 LC7B OG BU harness side and the CJB C14 pin 9 circuit 29 LC7 OG BU harness side 1 Is the resistance less than 1 ohm Yes GO to A3 No REPAIR the circuit TEST the system for normal operation A3 CJB INPUT AND TIMER FUNCTION TESTS Using the WDS carry out a CJB test 1 Does the CJB pass the WDS test Yes GO to A4 No INSTALL a new CJB TEST the system f...

Page 1961: ...entre Interior Lamp C820 1 Measure the voltage between the centre interior lamp C820 pin 2 circuit 29 LB25A OG BU harness side and ground 2 Is the voltage greater than 10 volts Yes GO to B2 No REPAIR the circuit TEST the system for normal operation B2 CHECK CIRCUIT 31S LB25A BK BU FOR OPEN CIRCUIT Disconnect Centre Interior Lamp C819 1 Disconnect Front Interior Lamp C892 2 Measure the resistance b...

Page 1962: ...amp C821 1 Disconnect Front Interior Lamp C892 2 Measure the resistance between the rear interior lamp C821 pin 1 circuit 31S LB25B BK BU harness side and the front interior lamp C892 pin 1 circuit 31S LB25B BK BU harness side 3 Is the resistance less than 1 ohm Yes INSTALL a new rear interior lamp TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation PINP...

Page 1963: ...14 pin 5 circuit 31S LC7 BK BU harness side 1 Is the resistance less than 1 ohm Yes GO to D3 No REPAIR the circuit TEST the system for normal operation D3 CHECK CIRCUIT 31 DA1 FOR OPEN CIRCUIT CAUTION Take care not to damage the CJB electrical connector when back probing the pin Measure the resistance between the CJB C14 pin 1 circuit 31 DA1 BK harness side and ground 1 Is the resistance less than...

Page 1964: ...l connector when back probing the pin Disconnect Instrument Cluster C809 1 Measure the resistance between the instrument cluster C809 pin 12 circuit 31S LC18 BK BU harness side and the CJB C11 pin 11 circuit 31S LC18 BK BU harness side 2 Is the resistance less than 1 ohm Yes INSTALL a new CJB TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation http vnx s...

Page 1965: ...t Symptom Chart Symptom Chart Pinpoint Test NOTE Perform all measurements using a digital multimeter Terminal probe kit 29 011 A Electrical Fuse s Bulb s Electrical connector s Switch es Wiring harness Symptom Possible Sources Action Daytime running lamps DRL inoperative Fuse Circuit s Daytime running lamp relay Headlight switch GO to Pinpoint Test A Parking lamps rear lamps and license plate lamp...

Page 1966: ...ing lamp relay socket C1012 and soldered connection S120 with the aid of the Wiring Diagrams CHECK the operation of the system Parking lamps rear lamps and license plate lamps are inoperative GO to Pinpoint Test B A3 CHECK FUSE F22 20 A BJB Ignition switch in position 0 1 CHECK Fuse F22 20 A BJB 2 Is the fuse OK Yes GO to A4 No RENEW fuse F22 20 A BJB and CHECK the operation of the system If the f...

Page 1967: ...lt from 08 2006 F58 7 5 A CJB 1 Ignition switch in position II 2 Measure the voltage between fuse Vehicles built before 08 2006 F37 7 5 A CJB and ground Vehicles built from 08 2006 F58 7 5 A CJB and ground 3 Does the meter display battery voltage Yes GO to A7 No Vehicles built before 08 2006 LOCATE AND RECTIFY the break in the voltage supply of fuse F37 7 5 A CJB using the Wiring Diagrams CHECK th...

Page 1968: ...CHECK GROUND CONNECTION OF DAYTIME RUNNING LAMP RELAY Ignition switch in position 0 1 Measure resistance between daytime running lamp relay socket C1012 pin 2 circuit 91 LE6 BK YE BJB side and ground 2 Is a resistance of less than 2 ohms registered Yes RENEW daytime running lamp relay CHECK the operation of the system No LOCATE and RECTIFY break in circuit between daytime running lamp relay and so...

Page 1969: ...et C1012 2 Connect a fused jumper wire 7 5 A to the headlight switch connector C320 pin 4 circuit 15S LE6 GN YE and pin 8 circuit 15 LE29 GN BK wiring harness side 3 Ignition switch in position II 4 Check the daytime running lamps 5 Are the daytime running lamps on Yes RENEW headlight switch CHECK the operation of the system No LOCATE and RECTIFY break in circuit 15S LE6 GN YE between headlight sw...

Page 1970: ...ak in circuit 15S DC19 GN BU between the daytime running lamp relay and fuse F19 10 A BJB using the Wiring Diagrams CHECK the operation of the system B4 CHECK VOLTAGE SUPPLY TO HEADLIGHT SWITCH DAYTIME RUNNING LAMPS PARKING LAMP Ignition switch in position 0 1 Disconnect Headlight switch from connector C320 2 Ignition switch in position II 3 Measure voltage between headlight switch connector C320 ...

Page 1971: ...HE SHORT TO BATTERY VOLTAGE Connect DRL relay to socket C1012 1 Disconnect Fuse Vehicles built before 08 2006 F37 7 5 A CJB Vehicles built from 08 2006 F58 7 5 A CJB 2 CHECK the daytime running lamps 3 Are the daytime running lamps permanently on Yes GO to C5 No GO to C4 C4 CHECK THE IGNITION SWITCH Connect Fuse Vehicles built before 08 2006 F37 7 5 A CJB Vehicles built from 08 2006 F58 7 5 A CJB ...

Page 1972: ...t switch connector C320 pin 8 circuit 15 LE29 GN BK wiring harness side and ground 1 Does the meter display battery voltage Yes LOCATE and RECTIFY the short to battery voltage in the circuit s connected to the headlamp switch C320 pin 8 using the Wiring Diagrams If necessary RENEW the CJB CHECK the operation of the system No RENEW headlight switch CHECK the operation of the system C7 NARROW DOWN T...

Page 1973: ...C9 C9 NARROW DOWN THE LOCATION OF THE SHORT TO BATTERY VOLTAGE Connect fuse F16 10 A BJB 1 Connect fuse F17 10 A BJB 2 Connect Fuse F19 10 A BJB 3 Disconnect Headlight switch from connector C320 4 CHECK the daytime running lamps 5 Are the daytime running lamps dipped beam permanently on Yes LOCATE and RECTIFY the short to battery voltage in the circuit between fuse F19 10 A BJB and the headlamp sw...

Page 1974: ...2 CHECK the daytime running lamps 3 Are the left hand daytime running lamps parking lamps rear lamps permanently on Yes Vehicles built before 08 2006 LOCATE and RECTIFY the short to battery voltage in the circuit s between fuse F58 7 5 A CJB and the parking lamps rear lamps with the aid of the wiring diagrams CHECK the operation of the system Vehicles built from 08 2006 LOCATE and RECTIFY the shor...

Page 1975: ...F58 7 5 A CJB using the Wiring Diagrams CHECK the operation of the system No daytime running lamps parking lamps rear lamps permanently on vehicles built from 08 2006 LOCATE and RECTIFY the short to battery voltage in the circuits between headlight switch and fuses F55 F56 7 5 A CJB using the Wiring Diagrams CHECK the operation of the system http vnx su ...

Page 1976: ...fferent data bus systems Depending upon model and equipment level all four data bus systems may be used Each of these data bus systems has its own protocol Data bus systems Standard Corporate Protocol SCP bus This consists of two twisted wires It is used for communication between the Powertrain Control Module PCM and the WDS via the DLC Depending upon engine version and year of manufacture a third...

Page 1977: ...ee of error protection two 120 Ohm terminating resistors are installed in the CAN These are integrated in the first module connected to the CAN and in the last module connected to the CAN respectively and are used for suppression as well as the elimination of voltage peaks In order to ensure correct functioning of the data bus system the modules must always be connected with an integral terminatin...

Page 1978: ...he fault memories of the modules connected to the data bus The ISO 9141 bus connects the various modules to the WDS via the DLC CAN vehicles built from 07 2006 Depending upon equipment level two data bus systems are used in the Transit Tourneo Connect built from MY 2007 The number of modules connected to the two data bus systems depends upon the equipment level of the vehicle Description High spee...

Page 1979: ...the electronic instrument cluster The modules connected to the two CAN data bus systems depend upon the equipment level of the vehicle One 120 Ohm terminating resistor of the HS CAN bus is installed in the PCM and in the electronic instrument cluster respectively One 120 Ohm terminating resistor of the MS CAN bus is installed in the audio module and one in the electronic instrument cluster respect...

Page 1980: ...The SCP bus connects only the PCM and the electronic instrument cluster to the DLC It is only responsible for communication between the PCM electronic instrument cluster and WDS http vnx su ...

Page 1981: ... the displayed fault description CHECK operation of system 5 5 For vehicles with no stored fault s PROCEED in accordance with the symptom chart according to the fault symptom 6 6 Following checking or elimination of the fault and after completion of operations the fault memories of all vehicle modules must be READ OUT and any stored faults must be DELETED READ OUT the fault memory of all modules a...

Page 1982: ... restraint control module RCM GO to Pinpoint Test H No communications possible via the SCP bus Fuse s Circuitry Instrument cluster PCM GO to Pinpoint Test I PINPOINT TEST A SAFETY RESTRAINT CONTROL MODULE RCM NOT COMMUNICATING WITH THE DIAGNOSTIC UNIT WARNINGS The stored voltage must be discharged in order to prevent unintentional deployment of the airbag belt pretensioner After disconnecting the ...

Page 1983: ...and ground 1 Is battery voltage measured Yes GO to A4 No LOCATE and REPAIR the break in the circuit between the DLC and fuse F10 using the Wiring Diagrams CHECK operation of system A4 CHECK THE GROUND CONNECTION OF THE DLC PIN 4 Measure the resistance between the DLC connector C200 pin 4 circuit 31 RA1 BK wiring harness side and ground 1 Is a resistance of less than 2 Ohms registered Yes GO to A5 ...

Page 1984: ...the voltage between fuse F63 20 A and ground 2 Is battery voltage measured Yes GO to A8 No REPAIR the voltage supply to fuse F63 with the aid of the Wiring Diagrams CHECK operation of system A8 CHECK FUSE F38 CHECK fuse F38 CJB 1 Is the fuse OK Yes GO to A9 No INSTALL A NEW fuse F38 7 5 A CHECK system operates correctly If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams ...

Page 1985: ...CM Disconnect connector C13 from CJB 1 Measure the resistance between the CJB connector C13 pin 4 circuit 29 AA17 OG WH wiring harness side and the RCM connector C451 pin 5 circuit 29 AA17 OG WH wiring harness side 2 Is a resistance of less than 2 Ohms registered Yes CHECK the CJB and RENEW as necessary CHECK operation of system No LOCATE and REPAIR the open circuit in 29 AA17 OG WH between the RC...

Page 1986: ...GROUND CONNECTION OF THE RCM Ignition switch in position 0 1 Measure the resistance between the RCM connector C424 pin 9 circuit 91 JA10 BK RD wiring harness side and ground 2 Is a resistance of less than 2 Ohms registered Yes GO to A15 No LOCATE and RECTIFY the break in circuit 91 JA10 BK RD between the RCM and ground connection G59 with the aid of the Wiring Diagrams CHECK system operates correc...

Page 1987: ...to B2 No GO to Pinpoint Test A B2 CHECK FUSE F23 CHECK fuse F23 BJB 1 Is the fuse OK Yes GO to B3 No INSTALL a new fuse F23 20 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams B3 CHECK THE VOLTAGE AT FUSE F23 Connect fuse F23 BJB 1 Measure the voltage between fuse F23 20 A and ground 2 Is battery voltage measured Yes GO to B4 No REPAIR the v...

Page 1988: ... the voltage supply to fuse F36 using the Wiring Diagrams CHECK operation of system B8 CHECK THE VOLTAGE AT THE ABS MODULE Ignition switch in position 0 1 Disconnect Connector C830 of the ABS module 2 Measure voltage between the ABS module connector C830 pin 32 circuit 30 CF6A RD wiring harness side and ground 3 Is battery voltage measured Yes GO to B9 No LOCATE and REPAIR the break in the circuit...

Page 1989: ...BS module connector C830 pin 4 circuit 15 CF6A GN YE wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes CHECK the CJB and RENEW as necessary CHECK operation of system No LOCATE and REPAIR the break in the circuit between the ABS module and CJB using the wiring diagrams CHECK operation of system B12 CHECK THE GROUND CONNECTION OF THE ABS MODULE Ignition switch in position 0 1 ...

Page 1990: ...ess than 2 Ohms registered Yes CHECK the ABS module and if necessary INSTALL a new one CHECK operation of system No LOCATE and REPAIR the break in the circuit between the ABS module and solder point S10 using the wiring diagrams CHECK operation of system PINPOINT TEST C POWERTRAIN CONTROL MODULE PCM NOT COMMUNICATING WITH THE DIAGNOSTIC UNIT TEST CONDITIONS DETAILS RESULTS ACTIONS C1 CHECK FUSE F1...

Page 1991: ...C5 No LOCATE and RECTIFY the break in the circuit between the DLC and ground connection G14 with the aid of the Wiring Diagrams CHECK operation of system C5 CHECK THE GROUND CONNECTION OF THE DLC PIN 5 Measure the resistance between the DLC connector C200 pin 5 circuit 91 RA1 BK OG wiring harness side and ground 1 Is a resistance of less than 2 Ohms registered Yes Vehicles with common rail fuel in...

Page 1992: ... Is the fuse OK Yes GO to C9 No RENEW fuse F18 10 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams C9 CHECK THE VOLTAGE AT FUSE F18 Connect Fuse F18 BJB 1 Ignition switch in position II 2 Measure the voltage between fuse F18 10 A and ground 3 Is battery voltage measured Yes GO to C12 No GO to C10 C10 CHECK FUSE F9 Ignition switch in position...

Page 1993: ...osition II 1 Measure the voltage between PCM connector C416 pin 37 circuit 15 RE8M GN YE wiring harness side and ground 2 Measure the voltage between PCM connector C416 pin 57 circuit 15 RE8N GN YE wiring harness side and ground 3 Is battery voltage measured in both cases Yes GO to C28 No If battery voltage is not measured during one measurement LOCATE and RECTIFY the break in the corresponding ci...

Page 1994: ...iring harness side and ground 2 Is battery voltage measured Yes GO to C16 No LOCATE and REPAIR the break in the circuit between the PCM and fuse F20 using the Wiring Diagrams CHECK operation of system C16 CHECK THE VOLTAGE AT THE PCM Ignition switch in position 0 1 Use a fused test lead 1 A at the PCM connector C415 pin 96 to bridge circuit 31S RH10 BK OG wiring harness side and ground 2 Measure t...

Page 1995: ... Ignition switch in position 0 1 Use a fused test lead 1 A at the PCM connector C414 pin 9 to bridge circuit 31S RH10A BK OG wiring harness side and ground 2 Measure the voltage between PCM connector C414 pin 3 circuit 15 RE8G GN YE wiring harness side and ground 3 Measure the voltage between PCM connector C414 pin 4 circuit 15 RE8H GN YE wiring harness side and ground 4 Measure the voltage betwee...

Page 1996: ...CATE and REPAIR the break in circuit 30 RH10 RD between the power supply relay and fuse F9 using the Wiring Diagrams CHECK operation of system C20 CHECK THE VOLTAGE AT THE POWER SUPPLY RELAY Ignition switch in position II 1 Measure the voltage between the power supply relay socket C1008 pin 1 circuit 15 RH9 GN BU wiring harness side and ground 2 Is battery voltage measured Yes GO to C21 No LOCATE ...

Page 1997: ...R the open circuit between the engine management relay and the PCM using the Wiring Diagrams CHECK operation of system C23 CHECK THE VOLTAGE AT THE POWER SUPPLY RELAY Measure the voltage between the power supply relay socket C1008 pin 1 circuit 30 RH9 RD wiring harness side and ground 1 Is battery voltage measured Yes Vehicles with common rail fuel injection system GO to C26 Vehicles with direct i...

Page 1998: ...R the open circuit between the engine management relay and the PCM using the Wiring Diagrams CHECK operation of system C26 CHECK FOR OPEN CIRCUIT BETWEEN THE POWER SUPPLY RELAY AND THE PCM Measure the resistance between the power supply relay socket C1008 pin 2 circuit 31S RH10 BK OG wiring harness side and the PCM connector C414 pin 9 circuit 31S RH10A BK OG wiring harness side 1 Is a resistance ...

Page 1999: ...PCM connector C416 pin 40 circuit 91 RE8N BK YE wiring harness side and ground 3 Measure the resistance between the PCM connector C416 pin 60 circuit 91 RE8P BK YE wiring harness side and ground 4 Is a resistance of less than 2 Ohms measured in all of the cases Yes GO to C29 No If a resistance of more than 2 Ohms is measured in one or two of the measurements LOCATE and REPAIR the break in the rele...

Page 2000: ...re the resistance between the PCM connector C416 pin 19 circuit 4 EG9 vehicles built from 02 2004 4 EG9C GY OG wiring harness side and DLC connector C200 pin 2 circuit 4 EG7 GY RD wiring harness side 1 Measure the resistance between the PCM connector C416 pin 18 circuit 5 EG9 vehicles built from 02 2004 5 EG9C BU BK wiring harness side and DLC connector C200 pin 10 circuit 5 EG7 BU RD wiring harne...

Page 2001: ...s CHECK operation of system Is a resistance of more than 2 Ohms measured in all of the measurements LOCATE and RECTIFY the break in the circuit between solder point S53 and ground connection G27 with the aid of the Wiring Diagrams CHECK operation of system C32 CHECK THE GROUND CONNECTION OF THE PCM PIN 25 Measure the resistance between the PCM connector C415 pin 25 circuit 31 RE8 BK wiring harness...

Page 2002: ... the relevant circuit between the PCM and the DLC using the Wiring Diagrams CHECK operation of system C34 CHECK THE GROUND CONNECTION OF THE PCM Measure the resistance between the PCM connector C414 pin 1 circuit 91 RE8G BK YE wiring harness side and ground 1 Measure the resistance between the PCM connector C414 pin 2 circuit 91 RE8H BK YE wiring harness side and ground 2 Measure the resistance be...

Page 2003: ...etween the PCM connector C414 pin 74 circuit 5 EG9B BU BK wiring harness side and the DLC connector C200 pin 10 circuit 5 EG7 BU RD wiring harness side 2 Is a resistance of less than 2 Ohms measured in both cases Yes GO to Pinpoint Test I No LOCATE and REPAIR the break in the relevant circuit between the PCM and the DLC using the Wiring Diagrams CHECK operation of system PINPOINT TEST D FUEL FIRED...

Page 2004: ...es correctly D4 CHECK FUSE F34 CHECK fuse F34 CJB 1 Is the fuse OK Yes GO to D5 No Install a new fuse F34 7 5 A CHECK system operates correctly If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams D5 CHECK THE VOLTAGE AT FUSE F34 Connect fuse F34 CJB 1 Ignition switch in position II 2 Measure the voltage between fuse F34 7 5 A and ground 3 Is battery voltage measured Yes G...

Page 2005: ...o D8 No LOCATE and RECTIFY the break in circuit 15 RD18 GN RD between the fuel fired additional heater and soldered connection S117 with the aid of the Wiring Diagrams CHECK operation of system D8 CHECK GROUND CONNECTION OF FUEL FIRED BOOSTER HEATER Ignition switch in position 0 1 Measure the resistance between the fuel fired additional heater connector C878 pin 2 circuit 31 RD18 BK wiring harness...

Page 2006: ...tion S140 with the aid of the Wiring Diagrams CHECK operation of system PINPOINT TEST E PARKING AID MODULE NOT COMMUNICATING WITH THE DIAGNOSTIC UNIT TEST CONDITIONS DETAILS RESULTS ACTIONS E1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position 0 1 Connect the diagnostic tool 2 Select the safety restraint control module RCM with the diagnostic tester 3 Is it possible ...

Page 2007: ... 1 Disconnect connector C15 from CJB 2 Measure the resistance between the CJB connector C15 pin 3 circuit 15 DA6 GN WH wiring harness side and the parking aid module connector C622 pin 1 circuit 15 GN10 GN YE wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes CHECK the CJB and RENEW as necessary CHECK operation of system No LOCATE and REPAIR the break in the circuit between t...

Page 2008: ...CATE and RECTIFY the break in circuit 8 EE13 WH RD between the parking aid module and soldered connection S10 with the aid of the Wiring Diagrams CHECK operation of system PINPOINT TEST F DOOR LOCKING MODULE NOT COMMUNICATING WITH THE DIAGNOSTIC UNIT TEST CONDITIONS DETAILS RESULTS ACTIONS F1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position 0 1 Connect the diagnost...

Page 2009: ...eration of system F6 CHECK FUSE F48 Ignition switch in position 0 1 CHECK Fuse F48 CJB 2 Is the fuse OK Yes GO to F7 No INSTALL a new fuse F48 7 5 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams F7 CHECK THE VOLTAGE AT FUSE F48 Connect Fuse F48 CJB 1 Ignition switch in position II 2 Measure the voltage between fuse F48 7 5 A and ground 3 Is...

Page 2010: ...DULE Measure the voltage between the door locking module connector C451 pin 2 circuit 29 AA17A OG WH wiring harness side and ground 1 Is battery voltage measured Yes GO to F12 No GO to F11 F11 CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE DOOR LOCKING MODULE Disconnect connector C14 from CJB 1 Measure the resistance between the CJB connector C14 pin 10 circuit 29 AA17A OG WH wiring harness side a...

Page 2011: ...H wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes CHECK the CJB and RENEW as necessary CHECK operation of system No LOCATE and REPAIR the break in the circuit between the door lock module and the CJB using the Wiring Diagrams CHECK operation of system F14 CHECK THE GROUND CONNECTION OF THE DOOR LOCKING MODULE Ignition switch in position 0 1 Measure the resistance between t...

Page 2012: ...the Wiring Diagrams CHECK system operates correctly PINPOINT TEST G INSTRUMENT CLUSTER NOT COMMUNICATING WITH THE DIAGNOSTIC UNIT TEST CONDITIONS DETAILS RESULTS ACTIONS G1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position 0 1 Connect the diagnostic tool 2 Select the powertrain control module PCM with the diagnostic tester 3 Is it possible to establish communication...

Page 2013: ...gnition switch in position 0 1 CHECK Fuse F48 CJB 2 Is the fuse OK Yes GO to G7 No INSTALL a new fuse F48 7 5 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams G7 CHECK THE VOLTAGE AT FUSE F48 Connect Fuse F48 CJB 1 Ignition switch in position II 2 Measure the voltage between fuse F48 7 5 A and ground 3 Is battery voltage measured Yes GO to G...

Page 2014: ...0 G10 CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE INSTRUMENT CLUSTER Ignition switch in position 0 1 Disconnect connector C15 from CJB 2 Measure the resistance between the CJB connector C15 pin 15 circuit 75 GG14 YE BU wiring harness side and instrument cluster connector C809 Pin 10 circuit 75 GG14 YE BU wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes CHECK the CJB and ...

Page 2015: ...ce of less than 2 Ohms registered Yes CHECK the CJB and RENEW as necessary CHECK operation of system No LOCATE and RECTIFY the break in circuit 15 GG14 GN RD between the instrument cluster and CJB with the aid of the Wiring Diagrams CHECK operation of system G13 CHECK THE GROUND CONNECTION OF THE INSTRUMENT CLUSTER Ignition switch in position 0 1 Measure the resistance between the instrument clust...

Page 2016: ... performed using the WDS digital multimeter Failure to observe this instruction can lead to damage Measure the resistance between the instrument cluster connector C809 pin 26 circuit 5 EG8 BU WH wiring harness side and the DLC connector C200 pin 10 circuit 5 EG7 BU RD wiring harness side 1 Is a resistance of less than 2 Ohms registered Yes CHECK and if necessary RENEW the instrument cluster CHECK ...

Page 2017: ...ess side and ground 1 Is battery voltage measured Yes GO to H4 No LOCATE and REPAIR the break in the circuit between the DLC and fuse F10 using the Wiring Diagrams CHECK operation of system H4 CHECK THE GROUND CONNECTION OF THE DLC Measure the resistance between the DLC connector C200 pin 4 circuit 31 RA1 BK wiring harness side and ground 1 Is a resistance of less than 2 Ohms registered Yes GO to ...

Page 2018: ...t control module RCM Yes The component disconnected last is the cause of the concern CHECK component and if necessary RENEW CHECK operation of system No If not all the listed components are disconnected Key in the OFF position DISCONNECT the next component go to test step 3 If all the listed components are disconnected GO to H7 H7 CHECK FOR OPEN CIRCUIT BETWEEN THE SAFETY RESTRAINT CONTROL MODULE ...

Page 2019: ... 4 Is a resistance of less than 2 Ohms registered Yes GO to H8 No LOCATE and REPAIR the break in circuit 8 EE10 WH BK between the DLC and soldered connection S10 using the Wiring Diagrams CHECK operation of system H8 TEST THE ISO 9141 BUS FOR A SHORT TO VOLTAGE Ignition switch in position II 1 Measure the voltage between the DLC connector C200 pin 7 circuit 8 EE10 WH BK wiring harness side and gro...

Page 2020: ...to damage TEST CONDITIONS DETAILS RESULTS ACTIONS I1 CHECK FUSE F10 Ignition switch in position 0 1 CHECK fuse F10 BJB 2 Is the fuse OK Yes GO to I2 No INSTALL A NEW fuse F10 10 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams I2 CHECK THE VOLTAGE AT FUSE F10 Connect fuse F10 BJB 1 Measure the voltage between fuse F10 10 A and ground 2 Is ba...

Page 2021: ...esistance between the DLC connector C200 pin 5 circuit 91 RA1 BK OG wiring harness side and ground 1 Is a resistance of less than 2 Ohms registered Yes GO to I6 No LOCATE and RECTIFY the break in the circuit between the DLC and ground connection G41 with the aid of the Wiring Diagrams CHECK operation of system I6 PERFORM NETWORK TEST Connect the diagnostic tool 1 Disconnect connector C809 from the...

Page 2022: ...n 2 Ohms measured in both cases Yes GO to I10 No Break in the corresponding circuit between DLC and connector C61a vehicles built from 02 2004 C63 LOCATE AND REPAIR THE FAULT with the aid of the Wiring Diagrams CHECK operation of system I8 CHECK FOR OPEN CIRCUIT BETWEEN THE PCM AND THE DLC SCP BUS Ignition switch in position 0 1 Disconnect connector C415 of PCM 2 Measure the resistance between the...

Page 2023: ...BK wiring harness side and the DLC connector C200 pin 10 circuit 5 EG7 BU RD wiring harness side 4 Is a resistance of less than 2 Ohms measured in both cases Yes GO to I10 No Break in the corresponding circuit between DLC and connector C61a vehicles built from 02 2004 C63 LOCATE AND REPAIR THE FAULT with the aid of the Wiring Diagrams CHECK operation of system I10 CHECK SCP BUS FOR A SHORT CIRCUIT...

Page 2024: ...t between the PCM and the DLC using the Wiring Diagrams CHECK operation of system No GO to I12 I12 CHECK CIRCUIT FOR SHORT TO GROUND BETWEEN THE PCM AND THE DLC SCP BUS Ignition switch in position 0 1 Measure the resistance between the DLC connector C200 pin 10 circuit 5 EG7 BU RD wiring harness side and ground 2 Measure the resistance between the DLC connector C200 pin 2 circuit 4 EG7 GY RD and g...

Page 2025: ...No LOCATE and REPAIR the short to ground in the relevant circuit between the PCM and the DLC using the Wiring Diagrams CHECK operation of system http vnx su ...

Page 2026: ...th the displayed fault description CHECK operation of system 5 5 For vehicles with no stored fault s PROCEED in accordance with the symptom chart according to the fault symptom 6 6 Following checking or elimination of the fault and after completion of operations the fault memories of all vehicle modules must be READ OUT and any stored faults must be DELETED READ OUT the fault memory of all modules...

Page 2027: ...module GO to Pinpoint Test H Instrument cluster not communicating with the diagnostic unit Fuse s Circuit s Instrument cluster GO to Pinpoint Test I No communications possible via the ISO 9141 bus Fuse s Circuitry ESP module Fuel fired booster heater Parking aid module Door locking module Restraints control module RCM GO to Pinpoint Test J No communications possible via the HS CAN bus Fuse s Circu...

Page 2028: ...d REPAIR the short using the Wiring Diagrams A5 CHECK THE VOLTAGE AT FUSE F37 Connect fuse F37 CJB 1 Ignition switch in position I 2 Measure the voltage between fuse F37 7 5 A and ground 3 Is battery voltage measured Yes GO to A9 No REPAIR the voltage supply to fuse F37 using the Wiring Diagrams CHECK operation of system A6 CHECK FUSE F3 CHECK Fuse F3 BJB 1 Is the fuse OK Yes GO to A7 No Install a...

Page 2029: ... BK wiring harness side and ground 3 Is battery voltage measured Yes GO to A11 No GO to A10 A10 CHECK THE CIRCUIT BETWEEN THE CJB AND THE AUDIO MODULE FOR OPEN CIRCUIT Disconnect Connector C17 from CJB 1 Measure the resistance between the CJB connector C17 pin 14 circuit 29 MD15 OG BK wiring harness side and the audio module connector C443 pin 15 circuit 29 MD15 OG BK wiring harness side 2 Is a re...

Page 2030: ...tem A13 CHECK THE GROUND CONNECTION OF THE AUDIO MODULE Ignition switch in position 0 1 Measure the resistance between the audio module connector C443 pin 11 circuit 91 MD34 BK YE wiring harness side and ground 2 Is a resistance of less than 2 Ohms registered Yes GO to A14 No LOCATE and RECTIFY the break in the circuit between the audio module and ground connection G63 with the aid of the wiring d...

Page 2031: ... harness side 1 Is a resistance of less than 2 Ohms registered Yes CHECK and if necessary RENEW the audio module CHECK operation of system No LOCATE and RECTIFY the break in the circuit between the audio module and the DLC using the Wiring Diagrams CHECK operation of system PINPOINT TEST B SAFETY RESTRAINT CONTROL MODULE RCM NOT COMMUNICATING WITH THE DIAGNOSTIC UNIT WARNINGS The stored voltage mu...

Page 2032: ...nect Battery ground cable 4 Ignition switch in position II 5 Measure the voltage between RCM connector C424 pin 8 circuit 15 JA10 GN OG wiring harness side and ground 6 Is battery voltage measured Yes GO to B5 No GO to B4 B4 CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE RCM Ignition switch in position 0 1 Disconnect Connector C11 from CJB 2 Measure the resistance between the CJB connector C11 pin...

Page 2033: ...can lead to damage Measure the resistance between the RCM connector C424 pin 7 circuit 8 EE7 WH RD wiring harness side and the DLC connector C200 pin 7 circuit 8 EE10 WH BK wiring harness side 1 Is a resistance of less than 2 Ohms registered Yes GO to Pinpoint Test J No LOCATE and REPAIR the open circuit between the RCM and the DLC using the Wiring Diagrams CHECK operation of system PINPOINT TEST ...

Page 2034: ... voltage between fuse F13 30 A and ground 2 Is battery voltage measured Yes GO to C6 No REPAIR the voltage supply to fuse F13 using the Wiring Diagrams CHECK operation of system C6 CHECK FUSE F61 CHECK Fuse F61 CJB 1 Is the fuse OK Yes GO to C7 No INSTALL NEW fuse F61 7 5 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams C7 CHECK THE VOLTAGE ...

Page 2035: ...or C831 pin 20 circuit 15 CF6B GN YE wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes CHECK the CJB and RENEW as necessary CHECK operation of system No LOCATE and REPAIR the break in the circuit between the ABS module and CJB using the wiring diagrams CHECK operation of system C12 CHECK THE GROUND CONNECTION OF THE ABS MODULE Ignition switch in position 0 1 Measure the resi...

Page 2036: ...agrams CHECK operation of system PINPOINT TEST D ESP MODULE NOT COMMUNICATING WITH THE DIAGNOSTIC TESTER TEST CONDITIONS DETAILS RESULTS ACTIONS D1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position 0 1 Connect the diagnostic tool 2 Select the safety restraint control module RCM with the diagnostic tester 3 Is it possible to establish communication with the safety re...

Page 2037: ...F61 Connect Fuse F61 CJB 1 Ignition switch in position II 2 Measure the voltage between fuse F61 7 5 A and ground 3 Is battery voltage measured Yes GO to D8 No REPAIR the voltage supply to fuse F61 using the Wiring Diagrams CHECK operation of system D8 CHECK THE VOLTAGE AT THE ESP MODULE Ignition switch in position 0 1 Disconnect Connector C830 from electronic stability program module 2 Measure th...

Page 2038: ...witch in position 0 1 Disconnect Connector C11 from CJB 2 Measure the resistance between the CJB connector C11 pin 14 circuit 15 CF6 GN YE wiring harness side and the ESP module connector C830 pin 4 circuit 15 CF6A GN YE wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes CHECK the CJB and RENEW as necessary CHECK operation of system No LOCATE and REPAIR the break in the circu...

Page 2039: ...rement may only be performed using the WDS digital multimeter Failure to observe this instruction can lead to damage Measure the resistance between the ESP module connector C830 pin 2 circuit 8 EE6A WH wiring harness side and the DLC connector C200 pin 7 circuit 8 EE10 WH BK wiring harness side 1 Is a resistance of less than 2 Ohms registered Yes CHECK and if necessary RENEW the electronic stabili...

Page 2040: ... F20 with the aid of the Wiring Diagrams CHECK operation of system E4 CHECK FUSE F18 CHECK Fuse F18 BJB 1 Is the fuse OK Yes GO to E5 No RENEW fuse F18 10 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams E5 CHECK THE VOLTAGE AT FUSE F18 Connect Fuse F18 BJB 1 Ignition switch in position II 2 Measure the voltage between fuse F18 10 A and grou...

Page 2041: ...A at the PCM connector C418 pin C1 to bridge circuit 91S RH9 BK BU wiring harness side and ground 3 Ignition switch in position II 4 Measure the voltage between the PCM connector C419 pin K3 circuit 15 RJ14A GN YE wiring harness side and ground 5 Measure the voltage between the PCM connector C419 pin K2 circuit 15 RJ14B GN YE wiring harness side and ground 6 Measure the voltage between the PCM con...

Page 2042: ... less than 2 Ohms registered Yes GO to E12 No LOCATE and RECTIFY the break in circuit 15 RE17 GN BU between the inertia fuel safety shut off switch and the PCM with the aid of the Wiring Diagrams CHECK operation of system E12 CHECK THE VOLTAGE AT THE INERTIA FUEL SAFETY SHUT OFF SWITCH Ignition switch in position II 1 Measure the voltage between the inertia fuel safety shut off switch connector C8...

Page 2043: ...N YE wiring harness side and ground 4 Is battery voltage measured Yes GO to E19 No GO to E15 E15 CHECK THE VOLTAGE AT THE POWER SUPPLY RELAY Disconnect voltage supply relay from socket C1008 1 Measure the voltage between the power supply relay socket C1008 pin 3 circuit 30 RH10 RD wiring harness side and ground 2 Is battery voltage measured Yes GO to E16 No LOCATE and REPAIR the break in circuit 3...

Page 2044: ...esistance between the power supply relay socket C1008 pin 5 circuit 15 RH10 GN RD wiring harness side and the PCM connector C419 pin K1 circuit 15 RJ14A GN YE wiring harness side 1 Is a resistance of less than 2 Ohms registered Yes RENEW the power supply relay CHECK operation of system No LOCATE and REPAIR the open circuit between the engine management relay and the PCM using the Wiring Diagrams C...

Page 2045: ...HE PCM AND THE DLC FOR OPEN CIRCUIT CAUTION The measurements below may only be performed using the WDS digital multimeter Failure to observe this instruction can lead to damage Measure the resistance between the PCM connector C418 pin A4 circuit 4 EG7 vehicles with ABS 4 EG7A GY RD wiring harness side and the DLC connector C200 pin 6 circuit 4 EG7 GY RD wiring harness side 1 Is a resistance of les...

Page 2046: ...ect the diagnostic tool 2 Select the safety restraint control module RCM with the diagnostic tester 3 Is it possible to establish communication with the safety restraint control module RCM Yes GO to F2 No GO to Pinpoint Test J F2 CHECK FUSE F11 Ignition switch in position 0 1 CHECK Fuse F11 BJB 2 Is the fuse OK Yes GO to F3 No Install a new fuse F11 20 A CHECK system operates correctly If the fuse...

Page 2047: ...al heater connector C878 pin 1 circuit 30 RD18 RD wiring harness side and ground 3 Is battery voltage measured Yes GO to F7 No LOCATE and RECTIFY the break in circuit 30 RD18 RD between the fuel fired additional heater and fuse F11 with the aid of the Wiring Diagrams CHECK operation of system F7 CHECK THE VOLTAGE AT THE FUEL FIRED ADDITIONAL HEATER Ignition switch in position II 1 Measure the volt...

Page 2048: ...ATA LINK CONNECTOR DLC FOR OPEN CIRCUIT CAUTION The following measurement may only be performed using the WDS digital multimeter Failure to observe this instruction can lead to damage Measure the resistance between the fuel fired additional heater connector C878 pin 3 circuit 8 EE11 WH VT wiring harness side and the DLC connector C200 pin 7 circuit 8 EE10 WH BK wiring harness side 1 Is a resistanc...

Page 2049: ... Connect fuse F44 CJB 1 Ignition switch in position II 2 Measure the voltage between fuse F44 7 5 A and ground 3 Is battery voltage measured Yes GO to G4 No REPAIR the voltage supply to fuse F44 with the aid of the Wiring Diagrams CHECK operation of system G4 CHECK THE VOLTAGE AT THE PARKING AID MODULE Ignition switch in position 0 1 Disconnect Connector C622 of the parking aid module 2 Ignition s...

Page 2050: ...red Yes GO to G7 No LOCATE and RECTIFY the break in circuit 91 GN10 BK YE between the parking aid module and soldered connection S12 with the aid of the Wiring Diagrams CHECK operation of system G7 CHECK THE CIRCUIT BETWEEN THE PARKING AID MODULE AND THE DATA LINK CONNECTOR DLC FOR OPEN CIRCUIT CAUTION The following measurement may only be performed using the WDS digital multimeter Failure to obse...

Page 2051: ... new fuse F63 20 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams H3 TEST THE VOLTAGE AT FUSE F63 Connect Fuse F63 CJB 1 Measure the voltage between fuse F63 20 A and ground 2 Is battery voltage measured Yes GO to H4 No REPAIR the voltage supply to fuse F63 with the aid of the Wiring Diagrams CHECK operation of system H4 CHECK FUSE F30 Ignit...

Page 2052: ...itch in position 0 1 Disconnect connector C451 from door locking module 2 Measure the voltage between the door locking module connector C451 pin 5 circuit 29 AA17 OG WH wiring harness side and ground 3 Is battery voltage measured Yes GO to H10 No GO to H9 H9 CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE DOOR LOCKING MODULE Disconnect connector C13 from CJB 1 Measure the resistance between the CJB...

Page 2053: ...CK operation of system No LOCATE and REPAIR the open circuit in 29 AA17A OG WH between the door locking module and the CJB using the Wiring Diagrams CHECK operation of system H12 CHECK THE VOLTAGE AT THE DOOR LOCKING MODULE Disconnect connector C452 from door locking module 1 Ignition switch in position II 2 Measure the voltage between the door locking module connector C452 pin 7 circuit 15 AA17 G...

Page 2054: ...TE and RECTIFY the break in the circuit between the door lock module and ground connection G15 with the aid of the Wiring Diagrams CHECK operation of system H15 CHECK THE CIRCUIT BETWEEN THE DOOR LOCKING MODULE AND THE DATA LINK CONNECTOR DLC FOR OPEN CIRCUIT CAUTION The following measurement may only be performed using the WDS digital multimeter Failure to observe this instruction can lead to dam...

Page 2055: ...ch in position 0 1 CHECK Fuse F48 CJB 2 Is the fuse OK Yes GO to I3 No INSTALL a new fuse F48 7 5 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams I3 CHECK THE VOLTAGE AT FUSE F48 Connect Fuse F48 CJB 1 Measure the voltage between fuse F48 7 5 A and ground 2 Is battery voltage measured Yes GO to I4 No GO to I13 I4 CHECK FUSE F37 CHECK fuse F...

Page 2056: ... CJB 1 Ignition switch in position I 2 Measure the voltage between the CJB connector C11 pin 7 circuit 75 DA1 YE wiring harness side and ground 3 Is battery voltage measured Yes CHECK the CJB and RENEW as necessary CHECK operation of system No GO to I9 I9 CHECK THE CIRCUIT BETWEEN THE CJB AND THE IGNITION SWITCH FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect Connector C456 from the ig...

Page 2057: ... in position 0 1 CHECK fuse F59 CJB 2 Is the fuse OK Yes GO to I12 No RENEW fuse F59 7 5 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams I12 CHECK THE VOLTAGE AT FUSE F59 Connect fuse F59 CJB 1 Ignition switch in position II 2 Measure the voltage between fuse F59 7 5 A and ground 3 Is battery voltage measured Yes GO to I16 No REPAIR the vol...

Page 2058: ...16 CHECK THE VOLTAGE AT THE INSTRUMENT CLUSTER Ignition switch in position 0 1 Disconnect Instrument cluster connector C813 2 Measure the voltage between the instrument cluster connector C813 pin 1 circuit 29 GG14 OG wiring harness side and ground 3 Is battery voltage measured Yes GO to I18 No GO to I17 I17 CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE INSTRUMENT CLUSTER Disconnect Connector C11 ...

Page 2059: ... connector C11 pin 2 circuit 75 GG14 YE BU wiring harness side and instrument cluster connector C809 Pin 14 circuit 75 GG14 YE BU wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes CHECK the CJB and RENEW as necessary CHECK operation of system No LOCATE and RECTIFY the break in circuit 75 GG14 YE BU between the instrument cluster and CJB with the aid of the Wiring Diagrams CH...

Page 2060: ... in position 0 1 Measure the resistance between the instrument cluster connector C813 pin 2 circuit 91 GG14 BK OG wiring harness side and ground 2 Is a resistance of less than 2 Ohms registered Yes GO to I23 No LOCATE and REPAIR the open in circuit between instrument cluster and ground G41 by using the wiring diagrams CHECK operation of system I23 CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER A...

Page 2061: ... THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DATA LINK CONNECTOR DLC FOR OPEN CIRCUIT CAUTION The following measurement may only be performed using the WDS digital multimeter Failure to observe this instruction can lead to damage Measure the resistance between the instrument cluster connector C813 pin 23 circuit 4 EC8 GY VT wiring harness side and the DLC connector C200 pin 6 circuit 4 EC8 ...

Page 2062: ...can lead to damage TEST CONDITIONS DETAILS RESULTS ACTIONS J1 CHECK FUSE F10 Ignition switch in position 0 1 CHECK fuse F10 BJB 2 Is the fuse OK Yes GO to J2 No INSTALL A NEW fuse F10 10 A CHECK operation of system If the fuse blows again LOCATE and REPAIR the short using the Wiring Diagrams J2 CHECK THE VOLTAGE AT FUSE F10 Connect fuse F10 BJB 1 Measure the voltage between fuse F10 10 A and groun...

Page 2063: ...OUND CONNECTION OF THE DLC Measure the resistance between the DLC connector C200 pin 5 circuit 91 RA1 BK OG wiring harness side and ground 1 Is a resistance of less than 2 Ohms registered Yes GO to J6 No LOCATE and REPAIR the break in circuit 91 RA1 BK OG between the DLC and ground connection G41 using the Wiring Diagrams CHECK operation of system J6 PERFORM NETWORK TEST NOTE The number of modules...

Page 2064: ...straint system in order to prevent the risk of accidental deployment of safety restraint system components Failure to observe this instruction can lead to injury Never use terminal probes to test any connectors of the airbag systems or of any other safety restraint systems Failure to observe this instruction can lead to injury NOTE After connecting the battery initialize the power window motors Di...

Page 2065: ...traint control module RCM CHECK system operates correctly No LOCATE and RECTIFY the short to ground in the circuits connected to soldered connection S10 with the aid of the Wiring Diagrams CHECK system operates correctly PINPOINT TEST K FAULTY COMMUNICATIONS BETWEEN THE MODULES MS CAN BUS CAUTION The measurements below may only be performed using the WDS digital multimeter Failure to observe this ...

Page 2066: ...break in circuit 30 RA1 OG between DLC and CJB using the Wiring Diagrams CHECK operation of system K4 CHECK THE GROUND CONNECTION OF THE DLC PIN 4 Ignition switch in position 0 1 Measure the resistance between the DLC connector C200 pin 4 circuit 31 RA1 BK wiring harness side and ground 2 Is a resistance of less than 2 Ohms registered Yes GO to K5 No LOCATE and RECTIFY the break in the circuit bet...

Page 2067: ...hms is measured GO to K10 If a resistance of between 115 and 125 Ohms is not measured GO to K15 K7 PERFORM NETWORK TEST NOTE The number of modules connected to the CAN bus depends on the equipment levels of the vehicle Therefore not every vehicle will have all the modules mentioned below Ignition switch in position 0 1 Disconnect Connector C443 from the audio module 2 Select the vehicle with the d...

Page 2068: ...r C200 pin 3 circuit 4 EC13A GY RD wiring harness side and ground 2 Measure the resistance between the DLC connector C200 pin 11 circuit 5 EC13A BU WH wiring harness side and ground 3 Is a resistance greater than 10 000 Ohms measured in both cases Yes CHECK and if necessary RENEW the instrument cluster CHECK operation of system No LOCATE and REPAIR the short to ground in the relevant circuit using...

Page 2069: ... CHECK operation of system K12 CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR CONTINUITY Measure the resistance between the instrument cluster connector C813 pin 21 circuit 4 EC13A GY RD wiring harness side and the DLC connector C200 pin 3 circuit 4 EC10M GY wiring harness side 1 Is a resistance of less than 2 Ohms registered Yes CHECK and if necessary RENEW the instrument cluste...

Page 2070: ...ration of system K15 PERFORM NETWORK TEST NOTE The number of modules connected to the CAN bus depends on the equipment levels of the vehicle Therefore not every vehicle will have all the modules mentioned below Ignition switch in position 0 1 Disconnect Connector C443 from the audio module 2 Select the vehicle with the diagnostic tester 3 Es it possible to establish a connection to the instrument ...

Page 2071: ...e short to ground in the relevant circuit using the Wiring Diagrams CHECK operation of system K18 CHECK THE MS CAN BUS FOR SHORT CIRCUIT Measure the resistance between the DLC connector C200 between pin 3 circuit 4 EC13 GY RD wiring harness side and pin 11 circuit 5 EC13 BU WH wiring harness side 1 Is a resistance greater than 10 000 Ohms measured in both cases Yes TEST the GEM and RENEW as necess...

Page 2072: ...THE DATA LINK CONNECTOR DLC Measure the voltage between the DLC connector C200 pin 16 circuit 30 RA1 RD wiring harness side and ground 1 Is battery voltage measured Yes GO to L4 No LOCATE and REPAIR the break in circuit 30 RA1 RD between DLC and CJB using the Wiring Diagrams CHECK operation of system L4 CHECK THE GROUND CONNECTION OF THE DLC PIN 4 Ignition switch in position 0 1 Measure the resist...

Page 2073: ...D wiring harness side 2 Is a resistance of between 55 and 65 Ohm measured Yes GO to L7 No If a resistance of between 115 and 125 Ohm is measured GO to L10 If a resistance of between 115 and 125 Ohm is not measured GO to L15 L7 PERFORM NETWORK TEST NOTE The number of modules connected to the CAN bus depends on the equipment levels of the vehicle Therefore not every vehicle will have all the modules...

Page 2074: ...s side and ground 5 Is a voltage registered Yes LOCATE and REPAIR the short to voltage supply in the relevant circuit using the Wiring Diagrams CHECK operation of system No GO to L9 L9 CHECK THE HS CAN BUS FOR A SHORT TO GROUND Ignition switch in position 0 1 Measure the resistance between the DLC connector C200 pin 6 circuit 4 EC7 GY RD wiring harness side and ground 2 Measure the resistance betw...

Page 2075: ...LOCATE and REPAIR the break in circuit 5 EC8 BU WH between the instrument cluster and the DLC with the aid of the Wiring Diagrams CHECK operation of system L12 CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR CONTINUITY Measure the resistance between the instrument cluster connector C813 pin 23 circuit 4 EC8 GY VT wiring harness side and the DLC connector C200 pin 6 circuit 4 EC8 G...

Page 2076: ...m No LOCATE and REPAIR the break in circuit 5 EC7 BU RD between the PCM and the DLC using the Wiring Diagrams CHECK operation of system L15 PERFORM NETWORK TEST NOTE The number of modules connected to the CAN bus depends on the equipment levels of the vehicle Therefore not every vehicle will have all the modules mentioned below Connect the ground cable to the battery 1 Connect the diagnostic tool ...

Page 2077: ...ystem No GO to L17 L17 CHECK THE HS CAN BUS FOR A SHORT TO GROUND Ignition switch in position 0 1 Measure the resistance between the DLC connector C200 pin 6 circuit 4 EC7 GY RD wiring harness side and ground 2 Measure the resistance between the DLC connector C200 pin 14 circuit 5 EC7 BU RD wiring harness side and ground 3 Is a resistance greater than 10 000 Ohms measured in both cases Yes GO to L...

Page 2078: ...of more than 10 000 Ohm measured Yes CHECK the PCM and RENEW if necessary CHECK operation of system No LOCATE and REPAIR the short in the relevant circuit using the Wiring Diagrams CHECK operation of system http vnx su ...

Page 2079: ...tic tester contact the Hotline and quote the vehicle identification number VIN 4 Read off the module code and or vehicle data from the defective module 5 Remove the defective module and install the new module as described in the operation PCM Module Passive Anti Theft System PATS Module ABS Module Airbag Instrument Cluster Central Timer Module CTM 6 Using the diagnostic tester configure the new mo...

Page 2080: ... for normal operation before proceeding to the next step 3 3 Disconnect the electrical connectors and check for the following Moisture in the connector due to misaligned damaged or missing seals Contamination from leaking fluids in the region of the connector Damaged or oxidised connector pins Disengaged connector pins this can be checked by carefully pressing on the individual pins 4 4 If any of ...

Page 2081: ...he wiring harness is subjected to noise vibration and harshness NVH For example transmission or suspension systems 6 6 If any of the conditions listed are present repair or replace the components as required TEST the system for normal operation If the concern persists REFER to the digital multimeter function of the Ford approved diagnostic tool to check the integrity of the wiring harness and elec...

Page 2082: ...amaged NOTE Removal steps in this procedure may contain installation details 1 Remove the left hand front wheel Refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 2 3 4 5 6 7 Lower the vehicle 8 Remove the passenger air bag module Refer to Passenger Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation 9 Remove the gearshif...

Page 2083: ... Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 12 Remove the audio unit Refer to Audio Unit Vehicles Built Up To 08 2006 415 01A Audio Unit Removal and Installation Refer to Audio Unit Vehicles Built From 08 2008 415 01A Audio Unit Removal and Installation 13 Remove the instrument cluster Refer to Instrument Cluster 413 01 Instrument Cluster Removal and Installation 14...

Page 2084: ...20 21 22 23 24 25 26 http vnx su ...

Page 2085: ...27 28 29 30 31 32 33 http vnx su ...

Page 2086: ...34 35 36 37 38 39 40 http vnx su ...

Page 2087: ...41 42 43 44 45 46 47 http vnx su ...

Page 2088: ... both sides 49 On both sides 50 On both sides 51 52 On both sides 53 On both sides 54 Remove the dashboard together with the dashboard crossmember 55 Remove the left and right hand B pillar trim http vnx su ...

Page 2089: ...to Front Headliner Long Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation Refer to Rear Headliner Short Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation Refer to Rear Headliner Long Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 57 Remove the left and right hand rear side trim Refer to Rear Quarter Trim P...

Page 2090: ...64 65 66 http vnx su ...

Page 2091: ...67 On both sides 68 On both sides 69 70 http vnx su ...

Page 2092: ...nnect a new passenger compartment wiring harness to the disconnected connector of the fuel pump module Disconnect the fuel pump module connector from the new wiring harness 2 3 1 Stripped ends of the wires 2 Crimp connector 4 CAUTION When crimping the connector ensure that the cross section of the connector matches that of the cable and that the associated http vnx su ...

Page 2093: ...e connection test it by performing a pull test 5 NOTE Using the hot air blower heat the shrink sleeving of the crimp connector until the sleeving is tight on the connection and sealant emerges from each end 6 7 To install reverse the removal procedure http vnx su ...

Page 2094: ...n Draw cord Electric drill Hot air gun 1 Refer to Supplemental Restraint System SRS Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 3 Refer to Lifting 100 02 Jacking and Lifting Description and Operation 4 5 General Equipment Electric drill General Equipment 4 mm drill...

Page 2095: ...moval and Installation 10 On both sides Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 11 12 13 14 Refer to Gearshift Lever 308 06 Manual Transmission Transaxle External Controls Removal and Installation 15 Torque 9 Nm 16 Torque 8 Nm http vnx su ...

Page 2096: ...17 18 Torque 25 Nm 19 20 21 http vnx su ...

Page 2097: ...r to Audio Unit Vehicles Built From 08 2008 415 01A Audio Unit Removal and Installation Refer to Audio Unit Vehicles Built From 04 2009 Vehicles With Navigation System 415 01A Audio Unit Removal and Installation 26 27 Torque 10 Nm 28 Torque 10 Nm http vnx su ...

Page 2098: ...stallation 33 Remove the rear seats 34 Refer to Front Headliner Short Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation Refer to Front Headliner Long Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation Refer to Rear Headliner Short Wheelbase Kombi 501 05 Interior Trim and http vnx su ...

Page 2099: ... On both sides Refer to Rear Quarter Trim Panel Short Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation Refer to Rear Quarter Trim Panel Long Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 36 On both sides 37 On both sides 38 On both sides 39 40 On both sides 41 On both sides http vnx su ...

Page 2100: ...42 43 General Equipment Draw cord 44 General Equipment Draw cord 45 General Equipment Draw cord http vnx su ...

Page 2101: ...46 On both sides 47 On both sides 48 49 http vnx su ...

Page 2102: ...Installation 50 51 1 To install reverse the removal procedure 2 Cut the fuel pump module connector from the new wiring harness http vnx su ...

Page 2103: ...3 Remove the insulation at the cable ends 4 Insert the stripped ends of the wires into the crimp connector 5 Crimp the connection 6 Heat the shrink sleeving General Equipment Hot air gun http vnx su ...

Page 2104: ... Proceed with care when removing or installing the dashboard and make sure that the surface of the dashboard is not scratched or damaged NOTE Removal steps in this procedure may contain installation details 1 Remove the left hand front wheel Refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 2 3 4 5 6 http vnx su ...

Page 2105: ...lar trim Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 11 Left and right hand side trim Refer to Cowl Side Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 12 Remove the audio unit Refer to Audio Unit Vehicles Built Up To 08 2006 415 01A Audio Unit Removal and Installation Refer to Audio Unit Vehicles Built From 08 2008 415 0...

Page 2106: ...16 17 18 19 20 http vnx su ...

Page 2107: ...21 22 23 24 25 http vnx su ...

Page 2108: ...26 27 28 29 30 http vnx su ...

Page 2109: ...31 32 33 34 35 http vnx su ...

Page 2110: ...36 37 38 39 40 http vnx su ...

Page 2111: ...41 42 43 44 45 http vnx su ...

Page 2112: ...46 47 48 On both sides 49 On both sides 50 On both sides http vnx su ...

Page 2113: ...51 52 On both sides 53 On both sides 54 Remove the dashboard together with the dashboard crossmember 55 56 http vnx su ...

Page 2114: ...57 58 59 http vnx su ...

Page 2115: ...Installation WARNING Screw new nuts and steering shaft bolts into the dashboard crossmember Failure to follow this instruction may result in personal injury 60 1 http vnx su ...

Page 2116: ...2 Follow the disassembly procedure in reverse order http vnx su ...

Page 2117: ...cal system is fully depowered and no other power source is connected NOTE Removal steps in this procedure may contain installation details 4 mm drill bit Blind rivet gun Electric drill Flat bladed screwdriver 1 Refer to Supplemental Restraint System SRS Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Battery Disconnect and Connect 414 01 Battery Mounti...

Page 2118: ...09 501 10 Seating Removal and Installation 10 On both sides Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 11 12 13 14 Refer to Gearshift Lever 308 06 Manual Transmission Transaxle External Controls Removal and Installation 15 Torque 9 Nm http vnx su ...

Page 2119: ...16 Torque 8 Nm 17 18 Torque 25 Nm 19 20 http vnx su ...

Page 2120: ...21 22 23 Torque 25 Nm 24 Refer to Instrument Cluster Vehicles Built From 04 2009 413 01 Instrument Cluster Removal and Installation 25 General Equipment Flat bladed screwdriver http vnx su ...

Page 2121: ...26 27 28 On both sides 29 http vnx su ...

Page 2122: ...ll vehicles 30 Refer to Audio Unit Vehicles Built From 04 2009 415 01A Audio Unit Removal and Installation 31 Refer to Audio Unit Vehicles Built From 04 2009 Vehicles With Navigation System 415 01A Audio Unit Removal and Installation 32 33 34 35 Torque 10 Nm http vnx su ...

Page 2123: ...36 Torque 10 Nm 37 38 Torque 28 Nm 39 Torque 25 Nm 40 http vnx su ...

Page 2124: ...41 42 43 http vnx su ...

Page 2125: ...Installation 44 1 To install reverse the removal procedure http vnx su ...

Page 2126: ...lt Up To 04 2009 417 01 Exterior Lighting Removal and Installation 2 Remove the battery tray Refer to Battery Tray 414 01 Battery Mounting and Cables Removal and Installation 3 Remove air cleaner Refer to Air Cleaner 303 12 Intake Air Distribution and Filtering Removal and Installation 4 Remove the charge air cooler Refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx ...

Page 2127: ...All Vehicles 10 11 12 13 14 15 1 Torque 22 Nm http vnx su ...

Page 2128: ...16 17 18 19 20 Torque 8 Nm http vnx su ...

Page 2129: ...21 22 23 24 Remove the front wheel and tire assemblies Refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 25 26 http vnx su ...

Page 2130: ...umper cover Refer to Front Bumper Cover Vehicles Built Up To 08 2006 501 19 Bumpers Removal and Installation Refer to Front Bumper Cover Vehicles Built From 08 2006 501 19 Bumpers Removal and Installation 30 31 32 33 http vnx su ...

Page 2131: ...34 35 36 37 38 Lower the vehicle 39 40 Torque 5 Nm http vnx su ...

Page 2132: ...41 42 43 44 http vnx su ...

Page 2133: ...Installation 1 NOTE Coat the rubber grommet on the washer pump with soap prior to installation Follow the disassembly procedure in reverse order http vnx su ...

Page 2134: ...Anti Theft Active Specifications Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Item Nm lb ft lb in Anti theft alarm horn retaining bolt 22 16 http vnx su ...

Page 2135: ...tral locking anti theft warning system control unit Alarm horn RHD behind glove compartment Engine hood switch Door contact switch right hand side left hand side analogous tailgate or rear door contact switch Door locking module tailgate rear doors analogous Door locking module right hand sliding door left hand side analogous Door contact switch right hand sliding door left hand side analogous Cen...

Page 2136: ...ar doors analogous Engine hood switch Door contact switches front doors sliding doors tailgate or rear doors Remote control Antenna in wiring harness Radio Alarm horn Turn signal lamps Interior light Data Link Connector DLC Central locking anti theft warning system control unit Locking unlocking functions of the central and double locking system without remote control Item 1 2 3 4 5 6 7 8 9 10 11 ...

Page 2137: ...lock the door On van unlock all the doors On Combi unlock all the doors Lock unlock hood only mechanically Unlock the latch Open the engine hood latch Lock unlock tailgate rear doors Centrally lock all doors Double lock all doors On van unlock the tailgate or rear doors On van unlock all the doors Item A B 1 C E 1 2 3 4 4 5 6 4 D 1 2 F 1 2 3 4 4 5 6 Part Number http vnx su ...

Page 2138: ...On Combi unlock all the doors 4 http vnx su ...

Page 2139: ...rical damage Visual Inspection Chart 3 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 4 If the cause is not visually evident verify the symptom and refer to WDS to diagnose the system Mechanical Electrical Misaligned door s Misaligned hood Door latch es Actuating rod s Door lock cylinder s Cable s Fuse s Wiring ...

Page 2140: ...horn electrical connector Anti theft alarm horn retaining bolt See Installation Detail Anti theft alarm horn 3 To install reverse the removal procedure Installation Details Item 2 Anti theft alarm horn retaining bolt NOTE Make sure that the mating faces of the anti theft alarm horn bracket and cross vehicle beam are clean to insure a good electrical ground contact 1 Open and lower the glove box It...

Page 2141: ...ncoded PATS ignition key More than one PATS key in close proximity of the PATS transceiver Central junction box CJB Powertrain control module PCM Instrument cluster Fuse s Wiring harness Electrical connector s Relay s CJB PCM PATS transceiver Ignition switch Instrument cluster WDS DTC Indicator Flash Code Description Condition Possible Source Action 0000 No DTCs vehicle OK B1681 11 PATS transceive...

Page 2142: ...nk between the PCM and instrument cluster vehicle does not start Circuit PCM or instrument cluster REFER to the WDS Select the PATS test and follow the instructions on the screen B1213 21 Number of programmed PATS encoded keys below minimum Vehicle does not start Incorrect number of keys programmed or PATS encoded ignition key REFER to the WDS Select the PATS test and follow the instructions on th...

Page 2143: ... if equipped 1 Using a thin bladed screwdriver release the locking tang 2 Disconnect the audio control switch electrical connector 2 Remove the steering column lower shroud 3 Disconnect the PATS transceiver electrical connector 4 Remove the PATS transceiver 1 Remove the PATS transceiver retaining screw 2 Remove the PATS transceiver 1 To install reverse the removal procedure http vnx su ...

Page 2144: ...ble Support Electronics PSE Module LHD FWD Vehicles Built Up To 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 2 1 To install reverse the removal procedure http vnx su ...

Page 2145: ...ble Support Electronics PSE Module RHD FWD Vehicles Built Up To 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 2 1 To install reverse the removal procedure http vnx su ...

Page 2146: ...able Support Electronics PSE Module LHD FWD Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 2 1 To install reverse the removal procedure http vnx su ...

Page 2147: ...Cellular Phone Portable Support Electronics PSE Module RHD FWD Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 2 3 4 http vnx su ...

Page 2148: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2149: ...ning screws Handset holder See Removal Detail 3 To install reverse the removal procedure Removal Details Item 1 Handset adapter Item 3 Handset holder 1 Remove the floor console For additional information refer to Floor Console 501 12 Instrument Panel and Console Removal and Installation Item 1 2 3 1 Press in the locking tangs to release the handset adapter 1 Unclip the cellular phone wiring harnes...

Page 2150: ...2 Unclip the cellular phone wiring harness and antenna from the handset holder 3 Release the locking clip and remove the handset holder from the floor console http vnx su ...

Page 2151: ...step CHECK the operation of the system 4 4 If the concern persists after the visual inspection CARRY OUT a fault diagnosis on the instrument cluster ICL with WDS and RECTIFY any displayed faults in accordance with the fault description CHECK the operation of the system 5 5 If no fault code is stored CONTINUE with the Symptom Chart Symptom Chart Symptom Chart Electrical Fuse s Wiring harness Electr...

Page 2152: ...on Removal Left hand drive vehicles Right hand drive vehicles All vehicles Installation 1 Remove the glove compartment 2 Remove the footwell trim panel 3 Disconnect the anti theft alarm and double locking module electrical connectors 4 Remove the anti theft alarm and double locking module 1 To install reverse the removal procedure http vnx su ...

Page 2153: ...Multifunction Electronic Modules Anti Theft Alarm and Double Locking Module Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 2 3 4 http vnx su ...

Page 2154: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2155: ...nect 2002 5 06 2002 Print Lubricants Fluids Sealers and Adhesives Item Specification Butyl sealer fluid C9AZ 19554B ESB M4G162 A Caulking strip D6AZ 19560 A ESB M4G32 A Rubber seal adhesive E8AZ 19552 A ESB M2G14 A Silicone grease C0AZ 19553 AA ESR M13P4 A http vnx su ...

Page 2156: ... the lack of joints and sealant beads in the visible area Furthermore possible water leaks and wind noise are eliminated by this method of bodywork construction The special design of the side panels optimises the interior load space Description Turn indicators Main headlamp Fog lights Mounting points Large headlamps with the latest free form reflector technology and a large transparent plastic len...

Page 2157: ... The rear bumper is made of sheet steel and is provided with a slip resistant coating The optional parking aid is integral with the rear bumper and can be separated when the bumper is detached Both roof variants have weight optimised reinforcements to stiffen the roof construction and mounting points for optional roof rack systems Description Single bump strip Triple bump strip The bump strips on ...

Page 2158: ...ver passenger from loose components coming from the rear during severe braking or in the event of an accident These separators can be very easily changed or expanded as required The following variants are planned Simple protective grille in a ladder form behind the driver s seat Half height steel panel separator across the whole vehicle width Completely closed steel panel also with glass insert in...

Page 2159: ...age the backrest in the end position Install the head restraint Attached parts Doors Reinforcement tubes made of high strength steel in the front doors increase occupant safety by protecting from the effects of forces occurring during a side impact The exterior mirrors are mounted on the doors Fast exit and entry are made possible by the very wide opening doors and the high seat position Item 1 2 ...

Page 2160: ...riant glazed sliding doors can be supplied The stiff construction of the sliding doors double panels helps to reduce noise having a beneficial effect on the NVH performance of the vehicle and improving the closing properties of the doors The guides and mechanical elements of the sliding doors are integrated into the side panel of the vehicle Tailgate and rear doors Because of the special side pane...

Page 2161: ...h hinge is double bolted on both sides There is also a positioning bolt on the bodywork side The hinges can be adjusted on the bodywork side within the tolerance range of the oversize holes Description Area for paint damage free panel beating Mounting points hood side Mounting points bodywork side Positioning bolts Spare wheel The spare wheel is located under the vehicle floor panel behind the fue...

Page 2162: ... steel Stabilisation of the whole body structure is achieved by the use of various reinforcements especially in the floor and rear areas The vehicle is 3 star categorised according to the Euro NCAP The rigid body structure contains a high number of high strength steel components particularly in the passenger compartment area This is surrounded by energy absorbent components in order to allow the m...

Page 2163: ...imised by the installation of very rigid components outside the crash zone The steering column is provided with a designated yield point in order to minimise head and chest injuries All seats are equipped with a 3 point seat belt In addition the driver s seat belt buckle is equipped with a pretensioner The front seats are equipped with wedge shaped seat cushions In the event of a frontal collision...

Page 2164: ...ne component The plastic element has no load bearing function and can be repaired after an accident by following the rules given in Repairing Plastic Parts Floor assembly The floor assembly is made from three individual segments in production In order to create various welded joints four sheet steel plates are present on the floor assembly during production manufacture and these can also be used d...

Page 2165: ...of the floor assembly is very rigidly constructed by the use of several crossmembers between the side members On the bus variants additional stiffening in the rear area is provided by reinforced seat mounting points Description Crossmember in rear area Item 1 2 3 Item 1 Part Number Part Number http vnx su ...

Page 2166: ...Reinforcements of the seat mounting points 2 http vnx su ...

Page 2167: ...s water may also enter the body at any point where dust can enter To determine the exact location of a dust leak it may be necessary to remove the following trim panels from the vehicle Scuff plate REFER to Section 501 05 Interior Trim and Ornamentation C Pillar trim REFER to Section 501 05 Interior Trim and Ornamentation Rear seat backrest and frame and rear seat cushion and frame REFER to Sectio...

Page 2168: ...ater leaks After the road test check for indications of a dust pattern around the door openings cowl side trim panel lower part of the quater panel and in the luggage compartment Sometimes leaks can be located by putting bright lights under the vehicle with the above components removed and checking the interior of the body joints and weld lines A light will show through where leaks exist http vnx ...

Page 2169: ...que Specifications Description Nm lb ft lb in Fender splash shield retaining bolts 4 35 Fender retaining bolts 12 9 Windshield wiper retaining nuts 23 17 Hood hinge to fender retaining bolts 25 18 Hood hinge to hood retaining bolts 12 9 Cowl panel grille retaining bolts 12 9 http vnx su ...

Page 2170: ...ve the cowl panel retaining bolt 2 Remove the trim panel moulding 3 Remove the fender retaining bolt 4 Remove the left hand windshield washer reservoir retaining bolt 5 Remove the wheel and tire For additional information refer to Section 204 04 Wheels and Tires 6 Remove the fender lower splash shield http vnx su ...

Page 2171: ...retaining bolt 9 Detach the left hand windshield washer reservoir from the fender and secure it to one side Allow the fluid to drain into a suitable container 10 Disconnect the turn lamp electrical connector 11 Remove the fender retaining bolt http vnx su ...

Page 2172: ...tension front retaining bolts 13 Remove the fender extension rear retaining bolt 14 Remove the fender extension Remove the clips 15 Detach the bumper cover from the fender 16 Remove the fender lower retaining bolt http vnx su ...

Page 2173: ...Installation 17 Lower the vehicle 18 Remove the fender 1 To install reverse the removal procedure http vnx su ...

Page 2174: ...ation refer to Section 501 14 Handles Locks Latches and Entry Systems 3 Remove the front bumper cover For additional information refer to Section 501 19 Bumpers 4 Lower the vehicle 5 Remove the headlamps For additional information refer to Section 417 01 Exterior Lighting 6 Remove the fender retaining bolts on both sides 7 Remove the fender upper retaining bolts on both sides 8 Remove the radiator...

Page 2175: ...Installation 10 Remove the radiator grille opening panel 1 To install reverse the removal procedure http vnx su ...

Page 2176: ...Assembly Vehicles Built From 04 2009 417 01 Exterior Lighting Removal and Installation 2 3 Refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 1 8L Duratorq TDDi Lynx Diesel 75 PS 90 PS 303 12 Intake Air Distribution and Filtering Removal and Installation Refer to Charge Air Cooler 1 8L Duratorq TDCi Lynx Diesel 75 PS 90 PS 110 PS Vehicles Built From 08 2006 303 12 Intake Air Distribution an...

Page 2177: ...7 1 Torque 7 Nm 2 Torque 25 Nm 8 Torque 25 Nm 9 1 Torque 7 Nm 2 Torque 25 Nm 10 Torque 25 Nm http vnx su ...

Page 2178: ...11 Torque 25 Nm 12 On both sides Torque 7 Nm 13 Torque 11 Nm 14 1 Torque 25 Nm 2 Torque 7 Nm 15 http vnx su ...

Page 2179: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2180: ...ining nuts 10 89 Front door hinge retaining bolts 28 21 Rear door check strap to door pillar retaining screws 12 9 Rear door hinge retaining screws 25 18 Liftgate hinge retaining nuts 10 89 Liftgate guide to body retaining nuts 5 44 Liftgate guide to liftgate retaining screws 10 89 Sliding door check strap to body retaining nuts 10 89 Sliding door arm to sliding door retaining screws 25 18 Sliding...

Page 2181: ...ld the sliding door in the fully open position Adjust the sliding door upper arm to align the sliding door in relation to the front door and the upper edge of the sliding door frame if necessary 1 Loosen the retaining screws two turns 2 Adjust the sliding door upper arm 4 Tighten the sliding door upper arm retaining screws 5 NOTE The striker plate adjustment is carried out by adjusting the retaini...

Page 2182: ...g screws two turns 2 Adjust the sliding door rear arm 8 Tighten the sliding door rear arm retaining screws 9 Close the sliding door 10 NOTE Make sure that the sliding door is in the fully closed position Check the alignment of the sliding door in relation to the front door and the upper edge of the sliding door frame 11 NOTE Make sure that the sliding door is in the fully closed position Check tha...

Page 2183: ...the sliding door guides on the sliding door Adjust the sliding door guides in relation to the sliding door if necessary 1 Loosen the retaining screws two turns 2 Adjust the sliding door guides 14 Tighten the sliding door guide retaining screws http vnx su ...

Page 2184: ...ssary 1 Loosen the retaining screws two turns 2 Using a suitable soft faced hammer adjust the striker plate inwards if necessary 3 Using a suitable lever adjust the striker plate outwards if necessary 16 Tighten the striker plate retaining screws 17 Close the sliding door 18 NOTE Make sure that the sliding door is in the fully closed position Check that the alignment of the sliding door is flush t...

Page 2185: ...amentation Specifications Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Safety belt upper anchor retaining bolt 40 30 Safety belt lower anchor retaining bolt 35 26 http vnx su ...

Page 2186: ...or Trim and Ornamentation A Pillar Trim Panel Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 1 If equipped 1 To install reverse the removal procedure http vnx su ...

Page 2187: ...e Removal Detail B pillar trim panel B pillar trim panel retaining clips See Installation Detail 2 To install reverse the removal procedure Removal Details Item 3 Front door opening weatherstrip Installation Details Item 5 B pillar trim panel retaining clips Item 2 Front door scuff plate trim panel retaining clips Item 1 2 3 4 5 1 Detach the front door weatherstrip 1 Install the B pillar trim pane...

Page 2188: ...illar Trim Panel Short Wheelbase Kombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details 1 1 Torque 40 Nm 2 Torque 35 Nm 2 3 4 http vnx su ...

Page 2189: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2190: ...Pillar Trim Panel Long Wheelbase Kombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details 1 1 Torque 40 Nm 2 Torque 35 Nm 2 3 4 http vnx su ...

Page 2191: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2192: ...ombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 Refer to D Pillar Trim Panel Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 2 3 1 To install reverse the removal procedure http vnx su ...

Page 2193: ...erior Trim and Ornamentation D Pillar Trim Panel Kombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 2 1 To install reverse the removal procedure http vnx su ...

Page 2194: ... illustration s and table s Description Front door latch remote control handle bezel retaining screw Front door latch remote control handle bezel Door pull handle cover Door pull handle retaining screws Door pull handle Power window switch See Removal Detail 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables Item 1 2 3 4 5 6 Part Nu...

Page 2195: ...dow switch Item 7 Exterior mirror control switch Item 9 Door trim panel 7 8 9 1 Detach the power window switch electrical connector 1 Detach the extirior mirror control switch electrical connector 1 To remove the door trim panel 1 Pull the lower section of the door trim panel away from the door 2 Lift the door trim panel upwards and detach from the door glass interior weather seal http vnx su ...

Page 2196: ...nd table s Description Front door latch remote control handle bezel retaining screw Front door latch remote control handle bezel Door pull handle cover Door pull handle retaining screws Door pull handle Window regulator handle retaining clip See Removal Detail Window regulator handle Window regulator handle spacer Exterior mirror control gaiter Exterior mirror control retaining ring Item 1 2 3 4 5...

Page 2197: ...ng clip Item 12 Door trim panel 11 12 1 Fabricate a hook using a suitable piece of wire 1 Remove window regulator handle retaining clip 2 Remove window regulator handle 1 To remove the door trim panel 1 Pull the lower section of the door trim panel away from the door 2 Lift the door trim panel upwards and detach from the door glass interior weather seal http vnx su ...

Page 2198: ...map reading lamp See Removal Detail Left hand sun visor retaining screws Left hand sun visor Left hand sun visor retaining clip screw Left hand sun visor retaining clip 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Remove the A pillar trim panels For additional information refer to A pillar trim panel in this section Item 1 2...

Page 2199: ...ap reading lamp bezel retaining screws Headliner tray retaining screws Headliner tray retaining screws Headliner tray Headliner retaining clips Headliner 4 To install reverse the removal procedure Removal Details Item 1 Interior map reading lamp 6 7 8 9 10 11 12 13 14 15 1 Disconnect the interior map reading lamp electrical connectors http vnx su ...

Page 2200: ...Interior Trim and Ornamentation Front Headliner Short Wheelbase Kombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Vehicles with overhead console 1 2 3 http vnx su ...

Page 2201: ...All vehicles 4 On both sides 5 6 http vnx su ...

Page 2202: ...7 1 On both sides Torque 40 Nm 2 On both sides Torque 35 Nm 8 On both sides Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 9 http vnx su ...

Page 2203: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2204: ...ner Long Wheelbase Kombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 On both sides Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 2 3 On both sides 4 5 http vnx su ...

Page 2205: ...6 1 On both sides Torque 40 Nm 2 On both sides Torque 35 Nm 7 http vnx su ...

Page 2206: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2207: ...1 On both sides Refer to D Pillar Trim Panel Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 2 On both sides Refer to C Pillar Trim Panel Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 3 1 On both sides Torque 40 Nm 2 On both sides Torque 35 Nm 4 Refer to Overhead Console 501 12 Instrument Panel and Console Removal and Installation 5 http vnx su ...

Page 2208: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2209: ...Headliner Long Wheelbase Kombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 1 On both sides Torque 40 Nm 2 On both sides Torque 35 Nm 2 1 To install reverse the removal procedure http vnx su ...

Page 2210: ...l Detail Cowl side trim panel Cowl side trim panel retaining clips See Installation Detail 2 To install reverse the removal procedure Removal Details Item 3 Front door opening weatherstrip Installation Details Item 5 Cowl side trim panel retaining clips Item 2 Front door scuff plate trim panel retaining clips Item 1 2 3 4 5 1 Detach the front door opening weatherstrip 1 Install the cowl side trim ...

Page 2211: ...n the following illustration s and table s Description Rear quarter trim panel See Removal Detail Rear quarter trim panel speaker See Removal Detail Rear safety belt See Removal Detail Rear quarter trim panel retaining clips See Installation Detail 2 To install reverse the removal procedure Removal Details Item 1 Rear quarter trim panel Item 1 2 3 4 Part Number http vnx su ...

Page 2212: ...clips 1 Detach the rear quarter trim panel lower clips and lift upwards to detach the upper clips 1 Disconnect the rear quarter trim panel speaker electrical connector 1 Detach the rear safety belt from the rear quarter trim panel 1 Install the rear quarter trim panel retaining clips to the rear quarter trim panel http vnx su ...

Page 2213: ...ase Kombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 If equipped 2 Refer to D Pillar Trim Panel Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 3 4 1 To install reverse removal procedure http vnx su ...

Page 2214: ...im and Ornamentation Rear Quarter Trim Panel Long Wheelbase Kombi Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 2 3 1 To install reverse removal procedure http vnx su ...

Page 2215: ...terior Trim and Ornamentation Rear Quarter Trim Panel Bus Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 2 1 To install reverse removal procedure http vnx su ...

Page 2216: ...onnectors Mirror motor Switch Symptom Possible Sources Action The mirrors are inoperative Exterior mirror control switch CARRY OUT the Exterior Mirror Control Switch Component Test REFER to the Wiring Diagrams Circuit s GO to Pinpoint Test A A single mirror is inoperative Exterior mirror control switch CARRY OUT the Exterior Mirror Control Switch Component Test REFER to the Wiring Diagrams Circuit...

Page 2217: ... 6 circuit 29 AD12 OG YE harness side and ground 3 Is the voltage greater than 10 volts Yes GO to A3 No REPAIR circuit 29 AD12 OG YE TEST the system for normal operation A3 CHECK THE EXTERIOR MIRROR CONTROL SWITCH GROUND CIRCUIT FOR CONTINUITY NOTE The circuit number changes at soldered joint S197 Ignition switch in position 0 1 Measure the resistance between the exterior mirror control switch C74...

Page 2218: ...xterior mirror C807 pin 1 circuit 32 AD6 WH harness side Passenger exterior mirror C808 pin 1 circuit 32 AD9 WH GN harness side 2 Is the resistance less than 5 ohms Yes INSTALL a new exterior mirror TEST the system for normal operation No REPAIR circuit 32 AD6 WH or circuit 32 AD9 WH GN TEST the system for normal operation PINPOINT TEST C A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC TEST CO...

Page 2219: ...en moved to the DOWN position Yes INSTALL a new exterior mirror TEST the system for normal operation No GO to C3 C3 CHECK CIRCUIT 34 AD7 BU RD FOR CONTINUITY Ignition switch in position 0 1 Disconnect Exterior Mirror Control Switch C741 2 Measure the resistance between the exterior mirror control switch C741 pin 1 circuit 34 AD7 BU RD harness side and the exterior mirror C807 pin 2 circuit 34 AD7 ...

Page 2220: ... exterior mirror control switch is moved to the LEFT position and is the polarity reversed when moved to the RIGHT position Yes INSTALL a new exterior mirror TEST the system for normal operation No GO to C6 C6 CHECK CIRCUIT 33 AD8 YE BU FOR CONTINUITY Ignition switch in position 0 1 Disconnect Exterior Mirror Control Switch C741 2 Measure the resistance between the exterior mirror control switch C...

Page 2221: ... harness side OPERATE the exterior mirror control switch UP and DOWN 3 Is the voltage greater than 10 volts when the exterior mirror control switch is moved to the UP position and is the polarity reversed when moved to the DOWN position Yes INSTALL a new exterior mirror TEST the system for normal operation No GO to C9 C9 CHECK CIRCUIT 34 AD10 BU YE FOR CONTINUITY Ignition switch in position 0 1 Di...

Page 2222: ...h in position II 2 Measure the voltage between the exterior mirror C808 pin 3 circuit 33 AD11 YE VT harness side and C808 pin 1 circuit 32 AD9 WH GN harness side OPERATE the exterior mirror control switch LEFT and RIGHT 3 Is the voltage greater than 10 volts when the exterior mirror control switch is moved to the LEFT position and is the polarity reversed when moved to the RIGHT position Yes INSTA...

Page 2223: ...ON OF THE HEATED REAR WINDOW Ignition ON 1 OPERATE the heated rear window control switch 2 Does the heated rear window function correctly Yes GO to D2 No REPAIR the heated rear window REFER to Section 501 11 Glass Frames and Mechanisms D2 CHECK THE VOLTAGE TO THE INOPERATIVE EXTERIOR MIRROR Ignition switch in position 0 1 Disconnect Inoperative Exterior Mirror C807 or C808 2 Ignition switch in pos...

Page 2224: ...mirror C807 pin 5 circuit 31 HB35 BK harness side and ground Passenger exterior mirror C808 pin 5 circuit 31 HB36 BK harness side and ground 2 Is the resistance less than 5 ohms Yes INSTALL a new heated exterior mirror glass TEST the system for normal operation No REPAIR circuit 31 HB35 BK or circuit 31 HB36 BK TEST the system for normal operation http vnx su ...

Page 2225: ...tall reverse the removal procedure Removal Details Item 1 Exterior mirror electrical connector 1 Remove the front door trim panel For additional information refer to Section 501 05 Interior Trim and Ornamentation Item 1 2 3 1 CAUTION Do not touch the adhesive surface as re bonding will be impaired Detach the watershield from the door panel to gain access to the electrical connector Using a plastic...

Page 2226: ...cond row seat backrest retaining bolts 25 18 Second row seat backrest latch retaining bolts 25 18 Second row center safety belt lower anchor and buckle assembly retaining bolt 25 18 Rear seat safety belt buckle retaining bolt 25 18 Rear seat center safety belt retractor retaining bolt 25 18 Third row seat backrest retaining bolts 45 33 Third row center safety belt lower anchor retaining bolt 45 33...

Page 2227: ...heated seat is inoperative Heated seat control switch Circuit s CARRY OUT the Heated Seat Control Switch Component Test REFER to the Wiring Diagrams GO to Pinpoint Test A PINPOINT TEST A THE HEATED SEAT IS INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS A1 CHECK FOR VOLTAGE TO THE INOPERATIVE HEATED SEAT Disconnect Heated Seat C26 or C27 1 Ignition switch in position II 2 Operate the heated se...

Page 2228: ... 15 HC6 GN YE harness side and ground or right hand heated seat control switch C695 pin 2 circuit 15 HC9 GN BK harness side and ground 4 Is the voltage greater than 10 volts Yes GO to A4 No REPAIR circuit 15 HC6 GN YE or circuit 15 HC9 GN BK TEST the system for normal operation A4 CHECK THE INOPERATIVE HEATED SEAT GROUND CIRCUIT Ignition switch in position 0 1 Connect Inoperative heated seat C26 o...

Page 2229: ...HC11 GN WH TEST the system for normal operation http vnx su ...

Page 2230: ...owered and no other power source is connected NOTE Removal steps in this procedure may contain installation details 1 Refer to Supplemental Restraint System SRS Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 3 WARNING Note the position of the wiring harnesses to aid i...

Page 2231: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2232: ...ses to aid installation An incorrectly routed wiring harness could become damaged when the seat is moved Failure to follow this instruction may result in personal injury 2 Remove the components in the order indicated in the following illustration s and table s Description Front seat track outer lower trim panel See Removal Detail Front seat inner rear retaining nut Front seat inner front retaining...

Page 2233: ...t fully tighten the front seat outer rear retaining bolt until the front seat front retaining bolts have been installed 1 Detach the front seat track outer lower trim panel from the seat track 2 Remove the front seat track outer lower trim panel 1 Detach the retaining clip 2 Disconnect the electrical connectors http vnx su ...

Page 2234: ...in the order indicated in the following illustration s and table s Description Underseat electrical harness See Removal Detail Front seat inner front retaining bolt Front seat outer front retaining bolt Front seat outer rear retaining bolt See Installation Detail Front seat inner rear retaining bolt See Installation Detail Front seat 2 To install reverse the removal procedure Removal Details Item ...

Page 2235: ...n the front seat inner rear retaining bolt until the front seat front retaining bolts have been installed Item 4 Front seat outer rear retaining bolt NOTE Do not fully tighten the front seat outer rear retaining bolt until the front seat front retaining bolts have been installed http vnx su ...

Page 2236: ...Installation Removal Installation 1 Refer to Front Seat Cushion Cover Vehicles Built From 04 2009 501 10 Seating Removal and Installation 2 If equipped Refer to Front Seat Cushion Heater Mat Vehicles Built From 04 2009 501 10 Seating Removal and Installation 1 To install reverse the removal procedure http vnx su ...

Page 2237: ...Installation Removal NOTE Removal steps in this procedure may contain installation details Installation 1 Refer to Front Seat Cushion Cover Vehicles Built From 04 2009 501 10 Seating Removal and Installation 2 CAUTION Touching the adhesive surface will impair rebonding 1 To install reverse the removal procedure http vnx su ...

Page 2238: ...An incorrectly routed wiring harness could become damaged when the seat is moved Failure to follow this instruction may result in personal injury NOTE Removal steps in this procedure may contain installation details hog ring plier 1 Refer to Front Seat Vehicles Built From 04 2009 501 10 Seating Removal and Installation 2 If equipped 3 WARNING Make sure that the wiring harnesses are correctly locat...

Page 2239: ...Installation 5 6 1 General Equipment hog ring plier 2 To install reverse the removal procedure http vnx su ...

Page 2240: ... An incorrectly routed wiring harness could become damaged when the seat is moved Failure to follow this instruction may result in personal injury 2 Remove the components in the order indicated in the following illustration s and table s Description Underseat stowage tray if equipped 1 Remove the front seat For additional information refer to Front Seat in this section Item 1 Part Number http vnx ...

Page 2241: ... cover underseat retainers See Removal Detail Cushion pad See Removal Detail Cushion cover See Removal Detail See Installation Detail 3 To install reverse the removal procedure Removal Details Item 3 Cushion heater wiring harness if equipped Item 10 Backrest cover underseat retainers 2 3 4 5 6 7 8 9 10 11 12 1 Detach the wiring harness from the seat frame Detach the retaining clips 1 Detach the ba...

Page 2242: ...ch the cushion cover retainers from the seat frame 1 Detach the retaining strips 2 Detach the retaining straps 2 Remove the cushion cover and pad Detach the cushion cover retaining strips from the backrest frame 1 Remove the cushion cover http vnx su ...

Page 2243: ...If a replacement cushion cover is to be installed cut the holes for the backrest recliner the height adjuster and the outer side trim panel retaining screws Use the existing cushion cover as a template Use hog ring pliers to close the hog rings Do not use any other tool The hog rings must be closed to overlap as illustrated http vnx su ...

Page 2244: ... 06 2002 Print Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details 1 Remove the front seat Refer to Front Seat Vehicles Built Up To 04 2009 501 10 Seating Removal and Installation 2 3 NOTE Note the position of each component before removal 3 Torque 25 Nm 4 5 http vnx su ...

Page 2245: ...Installation WARNING Make sure that the wiring harnesses are correctly located CAUTION Make sure that the wiring harness does not catch 6 7 http vnx su ...

Page 2246: ...1 To install reverse the removal procedure http vnx su ...

Page 2247: ...quipment Removal NOTE Removal steps in this procedure may contain installation details Flat bladed screwdriver 1 Refer to Front Seat Vehicles Built From 04 2009 501 10 Seating Removal and Installation 2 3 General Equipment Flat bladed screwdriver 4 If equipped 5 NOTE This step requires considerable force If equipped Torque 25 Nm http vnx su ...

Page 2248: ...6 7 8 9 http vnx su ...

Page 2249: ...Installation 10 CAUTION Make sure that the component is not bent 1 To install reverse the removal procedure http vnx su ...

Page 2250: ...ing harness could become damaged when the seat is moved Failure to follow this instruction may result in personal injury 2 Remove the components in the order indicated in the following illustration s and table s Description Underseat stowage tray if equipped Underseat stowage tray retaining panel if equipped 1 Remove the front seat For additional information refer to Front Seat in this section Ite...

Page 2251: ...ation Detail 3 To install reverse the removal procedure Removal Details Item 4 Head restraint guides Item 7 Armrest if equipped Item 8 Armrest housing 3 4 5 6 7 8 9 1 Remove the head restraint guides 1 Using suitable screwdrivers depress the locking tangs 2 Pull the guide upwards 1 Remove the armrest Depress the locking tang 1 Detach the backrest cover from the underside of the seat frame 1 Detach...

Page 2252: ...personal injury 2 Roll the backrest cover up the backrest to gain access to the armrest housing 1 Roll the backrest cover up the backrest 2 Cut the hog rings 3 Remove the armrest housing 1 Roll the backrest pad outwards to gain access to the armrest housing 2 Using a suitable screwdriver depress the locking tang 3 Pull the armrest housing from the backrest frame 1 Cut the hog rings http vnx su ...

Page 2253: ...eployment sleeve 1 NOTE If a replacement backrest cover is to be installed cut the holes for the lumbar support adjuster and the armrest housing Use the existing backrest cover as a template Use hog ring pliers to close the hog rings Do not use any other tool The hog rings must be closed to overlap as illustrated 2 WARNING Do not attempt to install the plastic retaining strips in any other way tha...

Page 2254: ...t 2002 5 06 2002 Print Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details 1 Remove the front seat Refer to Front Seat Vehicles Built Up To 04 2009 501 10 Seating Removal and Installation 2 3 NOTE Note the position of each component before removal 4 5 http vnx su ...

Page 2255: ...6 7 8 2 Torque 25 Nm 9 NOTE This step requires considerable force Remove the armrest from the tapered shaft 10 http vnx su ...

Page 2256: ...rnesses are correctly located CAUTION Make sure that the wiring harness does not catch 11 12 13 CAUTION Make sure that the component is not bent 1 To install reverse the removal procedure 2 CAUTION Make sure that the component is not bent http vnx su ...

Page 2257: ...er indicated in the following illustration s and table s Description Head restraint Backrest rear panel retaining screws Backrest rear panel See Removal Detail Backrest side guide covers Head restraint guides See Removal Detail Backrest pad 1 Remove the front seat For additional information refer to Front Seat in this section Item 1 2 3 4 5 6 Part Number http vnx su ...

Page 2258: ... to damage the backrest cover or panel retaining clips Remove the backrest rear panel 1 Remove the retaining screws 2 Remove the panel 1 Remove the head restraint guides 1 Depress the locking tangs 2 Pull the guides upwards 1 Remove the backrest cover and pad from the backrest frame 1 Detach the retaining strips 2 Cut the hog rings 2 Remove the backrest cover 1 Roll the backrest cover inwards to a...

Page 2259: ...ent backrest cover is to be installed cut holes for the backrest side guides Use the existing backrest cover as a template NOTE Use hog ring pliers to close the hog rings Do not use any other tool The hog rings must be closed to overlap as illustrated http vnx su ...

Page 2260: ...int Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details Installation 1 Refer to Front Seat Backrest Cover Vehicles Built From 04 2009 501 10 Seating Removal and Installation 2 3 Torque 3 Nm 1 To install reverse the removal procedure http vnx su ...

Page 2261: ...in the order indicated in the following illustration s and table s NOTE Double seat shown Description Head restraint Center safety belt webbing trim panel retaining screw Center safety belt webbing trim panel See Removal Detail See Installation Detail Head restraint guides See Removal Detail Item 1 2 3 4 Part Number http vnx su ...

Page 2262: ...ee Installation Detail 2 To install reverse the removal procedure Removal Details Item 3 Center safety belt webbing trim panel WARNING If the safety belt webbing retracts further than the stop on the webbing a new safety belt retractor must be installed CAUTION Make sure the webbing retainer is fitted at least 200 mm from the webbing stop towards the retractor Item 4 Head restraint guides Item 11 ...

Page 2263: ...ke care not to detach the webbing retainer Detach the backrest cover retaining strips from the backrest frame 2 Remove the backrest cover and pad Cut the hog rings 1 Remove the backrest cover 1 Roll the backrest cover inwards to access the pleating hog rings 2 Cut the hog rings http vnx su ...

Page 2264: ...nstruction may result in personal injury Item 3 Center safety belt webbing trim panel WARNING If the safety belt webbing retracts further than the stop on the webbing a new safety belt retractor must be installed CAUTION Make sure the webbing retainer is fitted at least 200 mm from the webbing stop towards the retractor 1 Use hog ring pliers to close the hog rings Do not use any other tool The hog...

Page 2265: ...l Backrest latch retaining nut See Removal Detail Backrest latch tension spring See Removal Detail 3 To install reverse the removal procedure Removal Details Item 1 Backrest latch retaining bolt Item 2 Backrest latch 1 Remove the rear seat backrest cover For additional information refer to Rear Seat Backrest Cover in this section Item 1 2 3 4 1 Remove the backrest latch retaining bolt 1 Use a suit...

Page 2266: ...ove the backrest latch 1 Remove the retaining nut and the backrest latch tension spring from the backrest frame Detach the tension spring outer tang from the backrest frame 1 Remove the backrest latch tension spring Detach the spring inner tang from the retaining nut http vnx su ...

Page 2267: ...ety belt buckle washer Center safety belt lower anchor Center safety belt lower anchor and outer safety belt buckle spacer Center safety belt buckle retaining bolt Center safety belt buckle trim panel Center safety belt buckle See Installation Detail Center safety belt buckle washer Center safety belt buckle spacer Cushion pad See Removal Detail Cushion cover See Removal Detail See Installation De...

Page 2268: ...allation Details Item 13 Cushion cover 1 Remove the cushion cover and pad Detach the retaining strips from the cushion frame 1 Remove the cushion cover 1 Roll the cushion cover inwards to access the pleating hog rings 2 Cut the hog rings 1 Use hog ring pliers to close the hog rings Do not use any other tool The hog rings must be closed to overlap as illustrated http vnx su ...

Page 2269: ...ee to swivel on the mounting spacer Failure to install the buckle correctly may result in personal injury Item 1 Center safety belt lower anchor and outer safety belt buckle retaining bolt WARNING If the safety belt webbing retracts further than the stop on the webbing a new safety belt retractor must be installed CAUTION Make sure the webbing retainer is fitted at least 200 mm from the webbing st...

Page 2270: ...ion Removal NOTE Removal steps in this procedure may contain installation details 1 2 Note the position of the head restraints release clips 3 WARNING If the safety belt webbing retracts further than the safety belt webbing stop a new safety belt retractor must be installed 4 Torque 45 Nm 5 6 http vnx su ...

Page 2271: ...7 8 9 Torque 45 Nm 10 Torque 45 Nm 11 http vnx su ...

Page 2272: ...og ring pliers to close the hog rings Do not use any other tool The hog rings must be closed to overlap as illustrated 3 WARNING If the safety belt webbing retracts further than the safety belt webbing stop a new safety belt retractor must be installed http vnx su ...

Page 2273: ...n Cover Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details 1 Torque 45 Nm 2 Torque 22 Nm 3 4 Torque 45 Nm 5 6 Torque 45 Nm http vnx su ...

Page 2274: ...Installation 7 8 9 1 To install reverse the removal procedure 2 Use hog ring pliers to close the hog rings Do not use any other tool The hog rings must be closed to overlap as illustrated http vnx su ...

Page 2275: ...http vnx su ...

Page 2276: ...nt Disassembly NOTE Removal steps in this procedure may contain installation details Flat bladed screwdriver 1 Refer to Lumbar Assembly Vehicles Built From 04 2009 501 10 Seating Removal and Installation 2 General Equipment Flat bladed screwdriver 3 4 WARNING Make sure that the wiring harnesses are correctly located 5 Torque 5 Nm http vnx su ...

Page 2277: ...Assembly 6 Torque 35 Nm 7 To install reverse the removal procedure http vnx su ...

Page 2278: ...r activator 99 SX M2G342 BA Primer 99 SX M2G343 AA 2K Adhesive 99 SX M2G322 AA 2K Hardener mixer 99 SX M2G322 BA Description Nm lb ft lb in Door window regulator retaining bolts 10 89 Windshield wiper arm retaining nut 23 17 Liftgate wiper arm retaining nut 6 53 Rear door wiper arm retaining nut 6 53 Front quarter window glass division bar retaining screws 10 89 http vnx su ...

Page 2279: ...ector s Switch es Circuit s Initialization process Relay s Symptom Possible Sources Action All power windows are inoperative front power windows Circuit s GO to Pinpoint Test A A single power window is inoperative driver side Driver power window control switch CARRY OUT the Driver Power Window Control Switch Component Test REFER to the Wiring Diagrams One touch down relay Driver power window motor...

Page 2280: ...E The defrost system will not shut off automatically Heated windshield relay CARRY OUT the Heated Windshield Relay Component Test REFER to the Wiring Diagrams Heated rear window relay CARRY OUT the Heated Rear Window Relay Component Test REFER to the Wiring Diagrams Instrument cluster CARRY OUT the Instrument Cluster Self Test REFER to Section 413 01 Instrument Cluster PINPOINT TEST A ALL POWER WI...

Page 2281: ...r normal operation PINPOINT TEST B A SINGLE POWER WINDOW IS INOPERATIVE DRIVER SIDE TEST CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH Ignition switch in position II 1 Does the driver power window control switch LED illuminate Yes GO to B2 No GO to B4 B2 CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW MOTOR UP CIRCUIT Ignition switch in position 0 1...

Page 2282: ...GROUND CIRCUIT Ignition switch in position 0 1 Disconnect Driver Power Window Control Switch C486 2 Measure the resistance between the driver power window control switch C486 pin 3 circuit 31 AJ7 BK harness side and ground 3 Is the resistance less than 5 ohms Yes REPAIR circuit 15 AJ7A GN BU TEST the system for normal operation No REPAIR circuit 31 AJ7 BK TEST the system for normal operation B5 CH...

Page 2283: ... circuit 32 AJ16 WH BK TEST the system for normal operation PINPOINT TEST C A SINGLE POWER WINDOW IS INOPERATIVE PASSENGER SIDE TEST CONDITIONS DETAILS RESULTS ACTIONS C1 CHECK FOR VOLTAGE TO THE PASSENGER POWER WINDOW CONTROL SWITCH Ignition switch in position II 1 Does the passenger power window control switch LED illuminate Yes GO to C2 No GO to C5 C2 CHECK THE PASSENGER POWER WINDOW CONTROL SW...

Page 2284: ...t 33 AJ17 YE VT TEST the system for normal operation C4 CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW CONTROL SWITCH AND THE PASSENGER POWER WINDOW MOTOR Measure the resistance between the passenger power window control switch C489 pin 7 circuit 32 AJ17 WH VT harness side and the passenger power window motor C783 pin 1 circuit 32 AJ17 WH VT harness side 1 Is the resistance less than 5 oh...

Page 2285: ...than 5 ohms Yes VERIFY the customer concern No REPAIR circuit 31 LH31 BK TEST the system for normal operation C7 CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW CONTROL SWITCH AND THE PASSENGER POWER WINDOW CONTROL SWITCH Disconnect Driver Side Passenger Power Window Control Switch C487 1 Measure the resistance between the driver side passenger power window control switch C487 pin 1 circuit 3...

Page 2286: ...CHECK THE ONE TOUCH DOWN RELAY GROUND CIRCUIT Disconnect One touch Down Relay C738 1 Measure the resistance between the one touch down relay C738 pin 1 circuit 31 AJ15 BK harness side and ground 2 Is the resistance less than 5 ohms Yes GO to D2 No REPAIR circuit 31 AJ15 BK TEST the system for normal operation D2 CHECK FOR VOLTAGE TO THE ONE TOUCH DOWN RELAY Ignition switch in position II 1 Measure...

Page 2287: ...tly Yes GO to E4 No GO to E10 E4 CHECK FOR VOLTAGE TO THE HEATED REAR WINDOW Ignition switch in position 0 1 Disconnect Heated Rear Window C949 or C951 2 Ignition switch in position II 3 Measure the voltage between the liftgate heated rear window C949 pin 1 circuit 15S HB41 GN BU harness side and ground left hand rear door heated rear window C949 pin 1 circuit 15S HB40 GN OG harness side and groun...

Page 2288: ...Windshield Element C634 and C635 2 Ignition switch in position III 3 Ignition switch in position II 4 Measure the voltage between the heated windshield left hand grid wire C634 pin 1 circuit 64S HB12 BU harness side and ground heated windshield right hand grid wire C635 pin 1 circuit 64S HB25 BU RD harness side and ground shown 5 Are the voltages greater than 10 volts Yes GO to E8 No GO to E15 E8 ...

Page 2289: ...ION BOX CJB FUSE 49 25A Ignition switch in position 0 1 Disconnect Fuse 49 25A 2 Measure the voltage between fuse 49 25A input side and ground 3 Is the voltage greater than 10 volts Yes GO to E12 No GO to E20 E12 CHECK FOR VOLTAGE TO THE HEATED REAR WINDOW Disconnect Heated Rear Window C949 or C951 1 Ignition switch in position II 2 Measure the voltage between the liftgate heated rear window C949 ...

Page 2290: ...ystem for normal operation E14 CHECK VOLTAGE TO THE HEATED WINDSHIELD RELAY Ignition switch in position 0 1 Disconnect Heated Windshield Relay C1003 2 Ignition switch in position III 3 Ignition switch in position II 4 Measure the voltage between the heated windshield relay C1003 pin 1 circuit 15 HB7 GN BU harness side and ground 5 Is the voltage greater than 10 volts Yes INSTALL a new heated winds...

Page 2291: ...eld relay C1003 pin 3 circuit 30 HB8 RD harness side and ground 4 Is the voltage greater than 10 volts Yes GO to E17 No REPAIR circuit 30 HB8 RD TEST the system for normal operation E17 CHECK THE HEATED WINDSHIELD GRID WIRE GROUND CIRCUITS Ignition switch in position 0 1 Measure the resistance between the heated windshield ground circuits and ground 2 Are the resistances less than 5 ohms Yes GO to...

Page 2292: ...N YE harness side and ground 5 Is the voltage greater than 10 volts Yes INSTALL a new heated rear window relay TEST the system for normal operation No REPAIR the central junction box TEST the system for normal operation E20 CHECK FOR VOLTAGE TO THE HEATED REAR WINDOW RELAY Ignition switch in position 0 1 Disconnect Heated Rear Window Relay C1025 2 Ignition switch in position III 3 Ignition switch ...

Page 2293: ...for normal operation No REPAIR circuit 30 DA1 RD TEST the system for normal operation http vnx su ...

Page 2294: ...Interior Trim and Ornamentation 3 CAUTION Do not touch the adhesive surface as re bonding will be impaired Detach the watershield from the front door panel 4 Remove the front door window glass opening interior weatherstrip 5 Detach the front door window glass exterior weatherstrip from the door 6 Detach the front door window glass top run from the door 7 Detach the front door window glass from the...

Page 2295: ...glass must be removed towards the outside of the window opening Remove the front door window glass 1 NOTE The front door window glass must be installed from the outside of the window opening To install reverse the removal procedure http vnx su ...

Page 2296: ...retaining screws Window regulator retaining nuts Window regulator 4 To install reverse the removal procedure Removal Details Item 4 Watershield 1 Remove the front door trim panel For additional information refer to Section 501 05 Interior Trim and Ornamentation 2 Remove the front door window glass For additional information refer to Front Door Window Glass in this section Item 1 2 3 4 5 6 7 1 CAUT...

Page 2297: ...http vnx su ...

Page 2298: ...l connector Window regulator retaining screws Window regulator retaining nuts Window regulator 4 To install reverse the removal procedure Removal Details Item 4 Watershield 1 Remove the front door trim panel For additional information refer to Section 501 05 Interior Trim and Ornamentation 2 Remove the front door window glass For additional information refer to Front Door Window Glass in this sect...

Page 2299: ...panel http vnx su ...

Page 2300: ...g wire Name Windshield Adhesive Kit Windshield Adhesive Kit 1 1 adhesive 2 Remove the polyurethane PU adhesive cap and heat only the 2K PU adhesive for a minimum of 30 minutes Direct glazing removal replacement equipment 3 Repairs under warranty adhesive 2 NOTE Make sure that the windshield wiper motor is in the park position Remove the windshield wiper arms 3 Remove the cowl panel grille outer re...

Page 2301: ...anel grille 6 Disconnect the heated windshield electrical connectors right hand side shown 7 Disconnect the heated windshield ground cable connectors right hand side shown Remove the screw 8 Remove the interior mirror Release the interior mirrior retaining clip 9 http vnx su ...

Page 2302: ...fety goggles and protective gloves CAUTION If the original window glass is to be installed take care not to damage the electrical connectors and the weatherstrip if equipped NOTE Some resistance may be encountered when cutting through the glass locating spacers Use a suitable brace to prevent trim damages Direct glazing removal replacement equipment http vnx su ...

Page 2303: ...lean and free of foreign material 2 NOTE Touching the adhesive surface will impair rebonding 3 Prepare the windshield glass windshield glass flange and trimmed PU adhesive in accordance with the instructions supplied with the glass adhesive kit 2 NOTE Touching the adhesive surface will impair rebonding Install new windshield glass locating blocks http vnx su ...

Page 2304: ...ons supplied with the glass adhesive kit 4 NOTE Touching the adhesive surface will impair rebonding NOTE Make sure that a new component is installed 5 Apply the activator primer in accordance with the instructions supplied with the glass adhesive kit http vnx su ...

Page 2305: ...equipmentadhesiveadhesive 7 Direct glazing removal replacement equipment CAUTION Make sure that equal pressure is applied to the full length of the component 1 1 Using tape secure the windshield glass in the correct position until the PU adhesive has cured Adhesive tape CAUTION During the curing time of the polyurethane PU adhesive the door windows must be left open 2 8 Install the interior mirror...

Page 2306: ...onnect the heated windshield ground cable connectors right hand side shown Install the screw 11 Install the right hand cowl panel grille 12 Install the left hand cowl panel grille 13 Install the cowl panel grille outer retaining screws right hand side shown 14 Install the windshield wiper arms left hand side shown http vnx su ...

Page 2307: ...http vnx su ...

Page 2308: ...adhesive kit Direct glazing adhesive oven Glazing suction cups 1 Remove the polyurethane PU adhesive cap and heat the PU adhesive for a minimum of 30 minutes 2 Remove the rear window wiper motor if equipped For additional information refer to Section 501 16 Wipers and Washers 3 Remove the rear window wiper motor spindle grommet if equipped 4 Detach the grommet from the liftgate 5 Disconnect the he...

Page 2309: ...OTE Some resistance may be encountered when cutting through the glass locating pegs in the corners of the glass From inside the vehicle using a suitable direct glazing cutter cut the PU adhesive to the given maximum depths 1 30 mm 2 35 mm 3 28 mm 4 25 mm 5 24 mm 7 With the aid of another technician use glazing suction cups to remove the liftgate window glass 8 Remove and discard the liftgate windo...

Page 2310: ...ond line to remove all traces of moisture 5 Prepare the glass liftgate window glass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit 6 Install a new liftgate window glass weatherstrip 7 NOTE Discard the first 100 mm of PU adhesive as this may have a reduced working time NOTE To avoid water leaks any breakage in the continuous bead must be overlap...

Page 2311: ...ntil the PU adhesive has cured 10 If the ambient temperature falls below 10 C use a hot air gun and apply warm air 25 C continuously for 15 minutes inside or outside the vehicle 11 Connect the heated liftgate window glass electrical connectors 12 Attach the grommet to the liftgate 13 Install the rear window wiper motor spindle grommet if equipped 14 Install the rear window wiper motor if equipped ...

Page 2312: ...dhesive kit Direct glazing adhesive oven Glazing suction cups 1 Remove the polyurethane PU adhesive cap and heat the PU adhesive for a minimum of 30 minutes 2 Remove the rear window wiper motor if equipped For additional information refer to Section 501 16 Wipers and Washers 3 Remove the window wiper motor spindle grommet if equipped 4 Detach the grommet from the rear door panel 5 Disconnect the h...

Page 2313: ...the body and trim panels From inside the vehicle using a suitable direct glazing cutter cut the PU adhesive to the given maximum depths 1 23 mm 2 77 mm 3 73 mm 4 103 mm 5 22 mm 6 30 mm 7 25 mm 8 20 mm 7 With the aid of another technician use glazing suction cups to remove the rear door window glass 8 Remove and discard the rear door window glass weatherstrip 1 CAUTION Do not touch the adhesive sur...

Page 2314: ...lass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit 5 Install a new rear door window glass weatherstrip 6 NOTE Discard the first 100 mm of PU adhesive as this may have a reduced working time NOTE To avoid water leaks any breakage in the continuous bead must be overlapped by 20 mm Apply the PU adhesive in a continuous bead of between 8 and 10 mm...

Page 2315: ...until the PU adhesive has cured 9 If the ambient temperature falls below 10 C use a hot air gun and apply warm air 25 C continuously for 15 minutes inside or outside the vehicle 10 Connect the heated rear door glass window electrical connectors 11 Attach the grommet to the rear door panel 12 Install the rear wiper motor spindle grommet if equipped 13 Install the rear window wiper motor if equipped...

Page 2316: ...Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters When using the cutter wear ear protectors Failure to follow these instructions may result in personal injury From inside the vehicle using a suitable direct glazing cutter cut the PU adhesive to the given maximum depth 1 12 mm 3 With the aid of another technician use glazing sucti...

Page 2317: ...To avoid water leaks any breakage in the continuous bead must be overlapped by 20 mm Apply the PU adhesive in a continuous bead of between 8 and 10 mm in height to the rear window glass flange along the bond line 6 NOTE This step is not necessary when installing the original rear window glass Peel back the protective strip 7 With the aid of another technician use glazing suction cups to install th...

Page 2318: ...http vnx su ...

Page 2319: ... protection when working with the glass cutting tool as the cutting operation may produce splinters When using the cutter wear ear protectors Failure to follow these instructions may result in personal injury CAUTION Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels NOTE Some resistance may be encountered when cutting through the g...

Page 2320: ...ing through the glass locating pegs in the corners of the glass From inside the vehicle using a suitable direct glazing cutter cut the PU adhesive to the given maximum depths 1 25 mm 2 56 mm 3 27 mm 4 114 mm 5 25 mm 6 54 mm 7 25 mm 8 58 mm 4 With the aid of another technician use glazing suction cups to remove the sliding door window glass 5 Remove and discard the sliding door window glass weather...

Page 2321: ...aces of moisture 5 Prepare the glass sliding door window glass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit 6 Install a new sliding door window glass weatherstrip 7 NOTE Discard the first 100 mm of PU adhesive as this may have a reduced working time NOTE To avoid water leaks any breakage in the continuous bead must be overlapped by 20 mm Appl...

Page 2322: ...essure when the doors are opened and closed Using suitable tape secure the sliding door window glass in the correct position until the PU adhesive has cured 10 If the ambient temperature falls below 10 C use a hot air gun and apply warm air 25 C continuously for 15 minutes inside or outside the vehicle http vnx su ...

Page 2323: ...with the glass cutting tool as the cutting operation may produce splinters When using the cutter wear ear protectors Failure to follow these instructions may result in personal injury CAUTION Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels NOTE Some resistance may be encountered when cutting through the glass locating pegs in the...

Page 2324: ...sing a suitable direct glazing cutter cut the PU adhesive to the given maximum depths 1 24 mm 2 56 mm 3 25 mm 4 120 mm 5 24 mm 6 54 mm 7 25 mm 8 60 mm 4 With the aid of another technician use glazing suction cups to remove the sliding door window glass 5 Remove and discard the sliding door window glass weatherstrip 1 Carefully remove the remaining part of the locating pegs from the sliding door wi...

Page 2325: ...w glass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit 6 Install a new sliding door window glass weatherstrip 7 NOTE Discard the first 100 mm of PU adhesive as this may have a reduced working time NOTE To avoid water leaks any breakage in the continuous bead must be overlapped by 20 mm Apply the PU adhesive in a continuous bead of between 8 and...

Page 2326: ...essure when the doors are opened and closed Using suitable tape secure the sliding door window glass in the correct position until the PU adhesive has cured 10 If the ambient temperature falls below 10 C use a hot air gun and apply warm air 25 C continuously for 15 minutes inside or outside the vehicle http vnx su ...

Page 2327: ...iew Mirrors 2 Remove the exterior weather strip 3 Remove the door trim panel For additional information refer to Section 501 05 Interior Trim and Ornamentation 4 Remove the interior weather strip 5 CAUTION Do not touch the adhesive surface as re bonding will be impaired Detach the watershield from the front door panel 6 Remove and discard the insulation pads 7 Remove the division bar lower retaini...

Page 2328: ...w Remove the blanking cap 9 Detach the upper weather seal channel from the door 10 Remove the front quarter window glass 1 Tip the glass rearwards 2 Slide the glass upwards 1 NOTE Install new insulation pads To install reverse the removal procedure http vnx su ...

Page 2329: ...as the cutting operation may produce splinters When using the cutter wear ear protectors Failure to follow these instructions may result in personal injury CAUTION Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels NOTE Some resistance may be encountered when cutting through the glass locating pegs in the corners of the glass From i...

Page 2330: ...ange 3 Check the second row window glass flange for damaged sheet metal rust or foreign material which may have caused or may cause glass breakage 4 CAUTION To make sure that the PU adhesive cures it is essential that all bonding surfaces are free of moisture Using a hot air gun apply warm air 25 C to the second row window glass flange and glass bond line to remove all traces of moisture 5 Prepare...

Page 2331: ...echnician use glazing suction cups to install the second row window glass Press firmly and evenly into position 9 CAUTION During the curing period of the PU adhesive the door windows must be left open to avoid a build up of pressure when the doors are opened and closed Using suitable tape secure the second row window glass in the correct position until the PU adhesive has cured 10 If the ambient t...

Page 2332: ...otection when working with the glass cutting tool as the cutting operation may produce splinters When using the cutter wear ear protectors Failure to follow these instructions may result in personal injury CAUTION Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels NOTE Some resistance may be encountered when cutting through the glas...

Page 2333: ...Carefully trim the remaining PU adhesive from the second row window glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the flange 3 Check the second row window glass flange for damaged sheet metal rust or foreign material which may have caused or may cause glass breakage 4 CAUTION To make sure that the PU adhesive cures it is essential that all bonding surfaces are free of ...

Page 2334: ...0 mm in height to the second row widow glass flange along the bond line 8 With the aid of another technician use glazing suction cups to install the second row window glass Press firmly and evenly into position 9 CAUTION During the curing period of the PU adhesive the door windows must be left open to avoid a build up of pressure when the doors are opened and closed Using suitable tape secure the ...

Page 2335: ...Passenger Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation 2 Remove the glove compartment 3 Remove the air bag control module For additional information refer to Air Bag Control Module 501 20B Supplemental Restraint System Removal and Installation 4 Detach the air bag control module ground cable from the floor panel 5 Disconnect the parking...

Page 2336: ...413 01 Instrument Cluster Removal and Installation 9 Remove the audio unit if equipped For additional information refer to Audio Unit Vehicles Built Up To 08 2006 415 01A Audio Unit Removal and Installation 10 Remove the A pillar trim panels Release the clips 11 Remove the ashtray Release the retaining clips 12 Remove the ashtray housing Release the retaining clips 13 Remove the instrument panel c...

Page 2337: ... bezel lower retaining screws 15 Remove the instrument panel center bezel retaining screws 16 Pull the instrument panel center bezel forwards and disconnect the electrical connectors 17 Detach the temperature and air distribution blend door bowden cables from the climate http vnx su ...

Page 2338: ...0 Remove the front scuff plate trim panel on both sides 21 Remove the left hand front wheel and tire For additional information refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 22 Remove the left hand front fender splash shield 23 Remove the engine main wiring harness electrical connectors cover http vnx su ...

Page 2339: ...gine main wiring harness electrical connectors trim panel 26 Detach the engine wiring harness electrical connectors from the fender Release the clips 27 Lower the vehicle 28 Detach the ground cable from the left hand A pillar 29 Disconnect the electrical connectors from the left hand A pillar http vnx su ...

Page 2340: ...ctor 31 Disconnect the heater flap electrical connector 32 Disconnect the blower speed control electrical connector 33 Detach the ground cable from the right hand A pillar 34 Disconnect the electrical connector on the right hand A pillar http vnx su ...

Page 2341: ... the pedal position switches 1 Speed control deactivation switch if equipped 2 Stop lamp switch 3 Clutch position switch 37 Disconnect the heater control electrical connector 38 Remove the cross vehicle beam lower retaining bolts 39 Remove the instrument panel side trim panel on both sides http vnx su ...

Page 2342: ...move the cross vehicle beam side retaining bolts on both sides driver side shown 41 Remove instrument panel side retaining bolt on the driver side 1 Remove the cover 2 Remove the bolt 42 Remove the instrument panel and cross vehicle beam assembly 43 Remove the instrument panel outer retaining screws on both sides http vnx su ...

Page 2343: ...retaining screws on the driver side 45 Remove instrument panel reinforcement bracket retaining screws on the passenger side 46 Remove the instrument panel from the cross vehicle beam 1 CAUTION When installing the instrument panel onto the cross vehicle http vnx su ...

Page 2344: ...beam make sure that the heating ducts are correctly installed onto the vents To install reverse the removal procedure http vnx su ...

Page 2345: ...l system is fully depowered and no other power source is connected NOTE Removal steps in this procedure may contain installation details 4 mm drill bit Blind rivet gun Electric drill Flat bladed screwdriver 1 Refer to Supplemental Restraint System SRS Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Battery Disconnect and Connect 414 01 Battery Mounting...

Page 2346: ...09 501 10 Seating Removal and Installation 10 On both sides Refer to A Pillar Trim Panel 501 05 Interior Trim and Ornamentation Removal and Installation 11 12 13 14 Refer to Gearshift Lever 308 06 Manual Transmission Transaxle External Controls Removal and Installation 15 Torque 9 Nm http vnx su ...

Page 2347: ...16 Torque 8 Nm 17 18 Torque 25 Nm 19 20 http vnx su ...

Page 2348: ...21 22 23 Torque 25 Nm 24 Refer to Instrument Cluster Vehicles Built From 04 2009 413 01 Instrument Cluster Removal and Installation 25 General Equipment Flat bladed screwdriver http vnx su ...

Page 2349: ...stem 26 27 On both sides 28 29 Refer to Audio Unit Vehicles Built From 04 2009 415 01A Audio Unit Removal and Installation 30 Refer to Audio Unit Vehicles Built From 04 2009 Vehicles With Navigation System 415 01A Audio Unit Removal and Installation 31 http vnx su ...

Page 2350: ...All vehicles 32 33 34 Torque 10 Nm 35 Torque 10 Nm http vnx su ...

Page 2351: ...36 37 Torque 28 Nm 38 Torque 25 Nm 39 1 Torque 8 Nm 2 Torque 8 Nm http vnx su ...

Page 2352: ...Installation 40 41 Torque 25 Nm 1 To install reverse the removal procedure http vnx su ...

Page 2353: ...g screws Floor console front retaining screws Parking brake control boot Floor console See Removal Detail Instrument panel center trim panel retaining clips Instrument panel center trim panel 2 To install reverse the removal procedure Removal Details Item 2 Gearshift trim panel Item 7 Floor console Item 1 2 3 4 5 6 7 8 9 1 Disconnect the heated seat s electrical connector s if equipped 2 Disconnec...

Page 2354: ...2 Remove the power socket if equipped http vnx su ...

Page 2355: ...Instrument Panel and Console Floor Console Vehicles Built From 04 2009 Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 2 3 http vnx su ...

Page 2356: ...Installation 4 1 To install reverse the removal procedure http vnx su ...

Page 2357: ...Instrument Panel and Console Overhead Console Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 2 3 http vnx su ...

Page 2358: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2359: ...pply has been disconnected Wait for a minimum of 3 minutes before disconnecting or removing any SRS components Make sure that the vehicle electrical system is fully depowered and no other power source is connected NOTE Removal steps in this procedure may contain installation details 1 Refer to Instrument Panel Wiring Harness Vehicles Built From 04 2009 418 02 Wiring Harnesses Removal and Installat...

Page 2360: ...Installation 5 Torque 17 Nm 1 To install reverse the removal procedure http vnx su ...

Page 2361: ... nut 5 44 Sliding door latch retaining bolts 12 9 Exterior sliding door handle retaining screw 2 18 Exterior sliding door handle retaining nut 5 44 Sliding door latch striker plate retaining bolts 25 18 Rear door latch retaining bolts 12 9 Rear door upper latch retaining bolts 12 9 Rear door latch striker plate retaining bolts 25 18 Exterior rear door handle retaining screw 2 18 Exterior rear door...

Page 2362: ...ration Vehicles with RKE remote keyless entry Description Liftgate latch Tailgate lock cylinder Rear door latch Rear door lock cylinder PATS passive anti theft system transceiver module Front door latch Sliding door latch Tank flap lock cylinder Front door lock cylinder Ignition lock cylinder barrel GEM generic electronic module Hood lock cylinder Item 1 2 3 4 5 6 7 8 9 10 11 12 http vnx su ...

Page 2363: ...the sliding door s and the tailgate rear door are closed and the locking button on the radio remote control is pressed twice within 3 seconds or the key in a front door lock cylinder is turned first to the unlocked position and then to the locked position within 3 seconds Vehicle unlocking When the vehicle is unlocked the indicator lights flash once The anti theft alarm system is deactivated when ...

Page 2364: ...r is unlocked One step unlocking Vehicle unlocking is changed in the following respects when one step unlocking is activated Press the unlock button on the radio remote control once all doors are unlocked Turn the key in one of the front doors once to the unlocked position all doors are unlocked To activate one step unlocking with the ignition switched off simultaneously press the locking and unlo...

Page 2365: ...int Description and Operation Control Diagram Vehicles with RKE remote keyless entry Description Key with radio frequency remote control DLC data link connector GEM generic electronic module Front door latch Sliding door latch Tailgate or rear door latch depending on equipment level Rear turn signal lamp Turn signal side repeater lamp Front turn signal lamp Item 1 2 3 4 5 6 7 8 9 http vnx su ...

Page 2366: ...witches signal that a sliding door is open while the other doors are closed all the other doors are locked while the corresponding sliding door remains unlocked The sliding door will only be locked once it has been closed and the door contact switch has sent the appropriate signal to the GEM Double locking The GEM only sends the signal for double locking once all the door contact switches have sen...

Page 2367: ...rect the cause if possible before proceeding to the next step 4 4 If the cause is not visually evident verify the symptom and refer to WDS to diagnose the system Mechanical Electrical Misaligned door s hood liftgate tailgate luggage compartment or hood Door latch es Actuating rod s Exterior door handle s Door latch remote control s Door lock cylinder Cable s Fuse s Vehicle battery Electrical conne...

Page 2368: ...heck that the vehicle battery is fully charged and that the anti theft alarm system is not armed or triggered 2 Close the vehicle doors 3 NOTE After cycling the ignition the ignition key must be in position II Turn the ignition key from position 0 to position II eight times within ten seconds The door locks will cycle to confirm that the anti theft alarm and double locking module has entered the p...

Page 2369: ...cal connector Exterior liftgate handle actuating rod retaining clip See Removal Detail Liftgate latch retaining bolts Liftgate latch 3 To install reverse the removal procedure Removal Details Item 2 Exterior liftgate handle actuating rod retaining clip 1 Remove the liftgate lock cylinder For additional information refer to Liftgate Lock Cylinder in this section Item 1 2 3 4 1 Detach the exterior l...

Page 2370: ... trim panel For additional information refer to Front Door Trim Panel Vehicles With Power Windows 501 05 Interior Trim and Ornamentation Removal and Installation Front Door Trim Panel Vehicles With Manual Windows 501 05 Interior Trim and Ornamentation Removal and Installation 3 NOTE Do not touch the adhesive surface as re bonding will be impaired Detach the watershield from the front door panel 4 ...

Page 2371: ... and rotate 90 degrees counterclockwise 2 Using a suitable tool press in the front door lock cylinder locking pin and release the key 7 Remove the front door lock cylinder NOTE Left hand door lock cylinder shown right hand door lock cylinder must be rotated clockwise 1 Rotate the front door lock cylinder counterclockwise 2 Pull out the front door lock cylinder 1 To install reverse the removal proc...

Page 2372: ...ral Procedures 2 Remove the rear door trim panel 3 Remove the rear door lock cylinder retaining clip 4 Release the rear door lock cylinder locking pin 1 Insert the key into the rear door lock cylinder and rotate 90 clockwise 2 Using a suitable tool press in the rear door lock cylinder locking pin and release the key 5 Remove the rear door lock cylinder 1 Rotate the rear door lock cylinder counterc...

Page 2373: ...move the liftgate latch trim panel 3 Remove the liftgate lock cylinder retaining clip 4 Release the liftgate lock cylinder locking pin 1 Insert the key into the liftgate lock cylinder and rotate 90 clockwise 2 Using a suitable tool press in the liftgate lock cylinder locking pin and release the key 5 Remove the liftgate lock cylinder 1 Rotate the liftgate lock cylinder anticlockwise 2 Remove the l...

Page 2374: ...ood lock key Charge air cooler air duct retaining screws Charge air cooler air duct retaining clips Charge air cooler air duct Radiator grill retaining clips Radiator grill retaining screw Radiator grill Hood lock latch and housing bracket retaining bolts Hood lock latch and housing retaining bracket Hood lock latch and housing retaining bolts Hood lock and latch housing Item 1 2 3 4 5 6 7 8 9 10 ...

Page 2375: ...Hood lock and latch retaining bolt Hood latch Hood lock 2 To install reverse the removal procedure 12 13 14 http vnx su ...

Page 2376: ...See Installation Detail Door latch remote control cable to door latch remote control See Removal Detail Front door latch retaining bolts Front door latch Front door latch remote control cable See Removal Detail 3 To install reverse the removal procedure Removal Details Item 2 Exterior door handle actuating rod retaining clip 1 Remove the front door lock cylinder For additional information refer to...

Page 2377: ...e door latch remote control Place the door latch remote control into the locked position Detach the door latch remote control cable 1 Remove the door latch remote control cable 1 Detach the door latch remote control cable 2 Deatch the door latch remote control inner cable from the front door latch lever 1 The exterior door handle must be in its rest position before the exterior door handle actuati...

Page 2378: ... and Installation 3 Remove the components in the order indicated in the following illustration s and table s Description 1 Remove the rear door lock cylinder For additional information refer to Rear Door Lock Cylinder in this section 2 Remove the rear door top latch retaining bolts ItemPart Number http vnx su ...

Page 2379: ... door latch retaining bolts Item 5 Rear door top latch to rear door latch remote cable Installation Details Item 4 Rear door latch retaining bolts Item 2 Exterior rear door handle actuating rod retaining clip NOTE The exterior rear door handle must be in its rest position before the exterior rear door handle actuating rod retaining clip is secured 1 2 3 4 5 6 1 Detach the exterior rear door handle...

Page 2380: ...terior front door handle trim See Removal Detail Exterior front door handle See Removal Detail See Installation Detail Exterior front door handle seals Exterior front door handle bracket retaining nut See Removal Detail Exterior front door handle bracket 3 To install reverse the removal procedure Removal Details Item 2 Exterior front door handle trim 1 Remove the front door latch For additional in...

Page 2381: ...e exterior front door handle 1 Slide the exterior front door handle towards the rear of the vehicle to disengage it from the exterior front door handle bracket 2 Remove the exterior front door handle 1 Loosen the exterior front door handle bracket retaining nut 1 Install the exterior front door handle 1 Push the exterior front door handle return lever forward 2 Slide the exterior front door handle...

Page 2382: ...on Exterior rear door handle trim retaining screw Exterior rear door handle trim See Removal Detail Exterior rear door handle See Removal Detail See Installation Detail Exterior rear door handle seal Exterior rear door handle bracket retaining nut See Removal Detail Exterior rear door handle bracket 1 Remove the rear door latch For additional information refer to Rear Door Latch in this section It...

Page 2383: ...terior rear door handle return lever 1 Remove the exterior rear door handle 1 Slide the exterior rear door handle towards the center of the vehicle to disengage it from the the exterior rear door handle bracket 2 Remove the exterior rear door handle 1 Loosen the exterior rear door handle bracket retaining nut 1 Install the exterior rear door handle 1 Push the exterior rear door handle return lever...

Page 2384: ...roud retaining clips See Removal Detail Steering column upper shroud See Removal Detail Steering wheel audio control switch See Removal Detail Steering wheel audio control switch electrical connector Steering column height adjustment lever See Removal Detail Steering column lower shroud retaining screws 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Batter...

Page 2385: ...lock mechanism from position I when the ignition lock cylinder has been removed If the ignition lock mechanism is moved the security features are activated and will not be recovered 7 8 9 10 11 1 Using a thin bladed screwdriver release the steering column upper shroud retaining clips 1 Detach the steering column upper shroud 1 Using a suitable thin bladed screwdriver release the audio control swit...

Page 2386: ...ess retaining clip Sliding door latch retaining bolts Sliding door exterior door handle cable to sliding door latch See Removal Detail See Installation Detail Sliding door latch remote control cable to sliding door latch See Removal Detail 3 To install reverse the removal procedure Removal Details Item 5 Sliding door exterior door handle cable to sliding door latch 1 Remove the sliding door lock c...

Page 2387: ...ing door exterior handle cable retaining tangs and detach the sliding door exterior handle cable 1 Detach the sliding door latch remote control cable 1 Pull the sliding door latch lever forward and detach the sliding door latch remote control inner cable 2 Release the sliding door remote control cable retaining tangs and detach the sliding door remote control cable 1 The sliding door exterior door...

Page 2388: ...or handle trim retaining screw Exterior sliding door handle trim See Removal Detail Exterior sliding door handle See Removal Detail See Installation Detail Exterior sliding door handle seals Exterior sliding door handle bracket retaining nut Exterior sliding door handle bracket 3 To install reverse the removal procedure Removal Details Item 1 Sliding door exterior door handle cable to sliding door...

Page 2389: ...iding door exterior handle cable retaining tangs and detach the sliding door exterior handle cable 1 Remove the exterior sliding door handle 1 Slide the exterior sliding door handle towards the front of the vehicle to disengage it from the exterior sliding door handle bracket 2 Remove the exterior sliding door handle 1 Install the exterior sliding door handle 1 Push the exterior sliding door handl...

Page 2390: ...e the sliding door trim panel 3 Remove the sliding door lock cylinder retaining clip 4 Release the sliding door lock cylinder locking pin 1 Insert the key into the sliding door lock cylinder and rotate 90 clockwise 2 Using a suitable thin blade screwdriver press in the sliding door lock cylinder locking pin and release the key 5 Remove the sliding door lock cylinder 1 Rotate the sliding door lock ...

Page 2391: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2392: ...latch See Removal Detail Sliding door latch remote control retaining bolt covers Sliding door latch remote control retaining bolts Sliding door latch remote control 3 To install reverse the removal procedure Removal Details Item 5 Sliding door latch remote control cable to sliding door latch 1 Remove the sliding door lock cylinder For additional information refer to Sliding Door Lock Cylinder in t...

Page 2393: ...cable retaining tangs and detach the sliding door remote control cable http vnx su ...

Page 2394: ...ts in the order indicated in the following illustration s and table s Description Liftgate release handle actuating rod retaining clip See Removal Detail Licence plate illumination panel retaining nuts Licence plate illumination electrical connectors 1 Remove the liftgate trim panel 2 Remove the liftgate latch trim panel Item 1 2 3 Part Number http vnx su ...

Page 2395: ...lumination panel Liftgate release handle retaining bolts Liftgate release handle 4 To install reverse the removal procedure Removal Details Item 1 Liftgate release handle actuating rod retaining clip 4 5 6 http vnx su ...

Page 2396: ...t Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details Installation 1 Torque 3 Nm 2 3 1 Torque 10 Nm 2 Torque 10 Nm 4 1 To install reverse the removal procedure http vnx su ...

Page 2397: ...el retaining clip See Disassembly Detail Door lock cylinder barrel Door lock cylinder barrel locking pin Door lock cylinder barrel tumblers See Disassembly Detail See Assembly Detail Door lock cylinder barrel spring washer Door lock cylinder barrel spacers 2 To assemble reverse the disassembly procedure Disassembly Details Item 1 Door lock cylinder return spring and guide Item 2 Door lock cylinder...

Page 2398: ...inder barrel tumber identification numbers and the order in which the tumblers and washers are removed 1 The first tumbler to be installed into the door lock cylinder barrel corresponds to the ignition key cut F 2 Make sure that the door lock cylinder barrel tumbler indents align with the barrel locking pin hole 1 Make sure that the door lock cylinder return spring locates either side of the door ...

Page 2399: ...and guide See Disassembly Detail See Assembly Detail Hood lock cylinder barrel retaining clip Hood lock cylinder washer Hood lock cylinder barrel Hood lock cylinder barrel locking pin Hood lock cylinder barrel tumblers See Assembly Detail Hood lock cylinder barrel spring washer Hood lock cylinder barrel spacers 2 To assemble reverse the disassembly procedure Disassembly Details Item 1 Hood lock la...

Page 2400: ...er return spring and guide locking tangs and remove 1 The first tumbler to be installed into the door lock cylinder barrel corresponds to the ignition key cut F 2 Make sure that the hood lock cylinder barrel tumbler indents align with the barrel locking pin hole 1 Make sure that the hood lock cylinder return spring locates either side of the hood lock cylinder spring retainer http vnx su ...

Page 2401: ...clip See Disassembly Detail Ignition lock cylinder barrel retaining circlip See Disassembly Detail Ignition lock cylinder barrel Ignition lock cylinder barrel locking pin Ignition lock cylinder barrel key hole shield See Disassembly Detail See Assembly Detail Ignition lock cylinder barrel tumbler retainer See Assembly Detail Ignition lock cylinder barrel tumblers See Assembly Detail Ignition lock ...

Page 2402: ...TE Make note of the position of the ignition lock cylinder barrel key hole shield Assembly Details Item 7 Ignition lock cylinder barrel tumblers Item 6 Ignition lock cylinder barrel tumbler retainer 9 1 The first tumbler to be installed into the door lock cylinder barrel corresponds to the ignition key cut F 2 Make sure that the ignition lock cylinder barrel tumbler and spacer indents align with t...

Page 2403: ...Item 5 Ignition lock cylinder barrel key hole shield NOTE Install the ignition lock cylinder barrel key hole shield in the same position as removed 4 grease http vnx su ...

Page 2404: ...ock Cylinder Transit Tourneo Connect 2002 5 06 2002 Print Disassembly and Assembly 1 NOTE The liftgate lock cylinder is similar in construction to the door lock cylinder For additional information refer to Door Lock Cylinder in this section http vnx su ...

Page 2405: ... values Tightening torques Degrees Angle of wiper arms to windscreen LHD RHD 4 1 Description Nm lb ft lb in Rear wiper motor bolts 8 53 Rear wiper arm nut 15 11 Windshield wiper arm nut 22 16 Windshield wiper motor bolts 8 71 Windshield wiper motor unit bolts 8 71 Front wiper drive arm nut 22 16 http vnx su ...

Page 2406: ...n It is controlled by the multi function switch on the steering column via the windshield wiper relay and the CTM After switching on the ignition position II the following five wiper functions are available Off Once Slow Fast Intermittent Wiper lever in the OFF position If the wiper lever is moved from any other position to the OFF position then the windshield wiper motor continues to run at slow ...

Page 2407: ...lected wiper delay interval depending on trim level The current flows via the wiper relay normally open contact and the multi function switch to the wiper motor Windshield Washer WARNING Washer fluid contains the poisonous substance methanol Refer to the Safety Regulations CAUTION Operate the washer with the headlamps switched on for a maximum of 10 seconds and not with an empty washer reservoir T...

Page 2408: ... via the washer pump to the washer switch The washer switch makes the ground connection in its active state Headlamp washer CAUTION Operate the headlamp washer for a maximum of 10 seconds and not with an empty reservoir The headlamp washer comprises the following parts Headlamp wash pump on the outside of the washer reservoir Headlamp wash relay underneath the instrument panel on the left hand sid...

Page 2409: ... If the opening in the ventilation tube of the reservoir is too large then washer system water can leak out if the vehicle accelerates or decelerates strongly when the reservoir is full If there is a concern then this can be prevented by pressing an additional cap onto the rear vent tube of the reservoir For additional information refer to Pump and Windshield Washer System Reservoir in this sectio...

Page 2410: ...nt washer jets Windshield wiper arms Combined rain sensor light sensor Front wiper linkage Front windshield wiper motor Rear windshield wiper arms Rear wiper motors Switch wash wipe system CJB central junction box GEM generic electronic module Window washer pump Washer reservoir Reversing lamp switch Cap washer reservoir Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 http vnx su ...

Page 2411: ...tor Front wiper linkage Rear windshield wiper When reverse gear is engaged the rear wiper is automatically switched on if the rear wiper is switched off and the front wiper is switched on or if automatic wipe mode is selected and the front windshield wipers have been switched on by the rain sensor The rear wiper delay interval is regulated according to the speed of the front wipers Vehicles with r...

Page 2412: ...behind the rear view mirror on the windshield The rain sensor is an optical measuring instrument Contamination such as oil grease or dust will prevent correct operation Before switching on the automatic windshield wipers the windshield must be clean in the area of the rain sensor Windshield washer control Description Item 1 2 Item http vnx su ...

Page 2413: ...her pump Comments Vehicles with rear windshield washer system Description Rear windshield washer nozzles Comments Vehicles with rear door Rear window washer nozzle Comments Vehicles with liftgate Water is pumped to both the front window washer and the rear window washer from a washer reservoir via a washer pump 1 2 3 4 5 Item 1 2 http vnx su ...

Page 2414: ...iption and Operation Control Diagram Description Combined rain sensor light sensor DLC data link connector Window washer pump Rear wiper motor Front windshield wiper motor Heated window washer nozzles front Comments depending on level of equipment CJB central junction box GEM generic electronic module Switch wash wipe system Item 1 2 3 4 5 6 7 8 9 http vnx su ...

Page 2415: ...val at level 1 1 second Rotary switch at lower end point Time interval at level 2 3 5 seconds Time interval at level 3 6 seconds Time interval at level 4 9 5 seconds Time interval at level 5 15 5 seconds Time interval at level 6 22 seconds Rotary switch at upper end point Auto The signal from the combined rain sensor light sensor is transmitted to the GEM where it is processed together with the si...

Page 2416: ...ash wipe switch is in the rear wiper position The GEM actuates the rear window wiper motor The windshield wiper runs in intermittent mode the rear windshield washer system is operated The GEM switches on the rear window washer system The washer pump is supplied with power Reversing the polarity of the pump enables the washing fluid to flow to the rear washer jets instead of the front washer jets T...

Page 2417: ...ight By comparing the received signal with the known transmitted signal the rain sensor can determine the moisture on the outside of the windshield and request that the windshield wipers are switched on Description Raindrop LED Comments transmitter diode Lens Photodiode Comments receiver diode Light loss due to deflection The LED emits a beam of light with a known intensity The emitted beam emerge...

Page 2418: ...peed The integrated home switch is connected directly to the GEM The home switch contacts are open in all wiper motor positions except the home position When the home switch contacts are open the wiper motor remains switched on even if a signal from the steering wheel module requests that the wipers stop In home position the home switch contacts create a ground connection The GEM recognizes this g...

Page 2419: ...cal and electrical damage NOTE Ensure correct locking of wiring harness connector Visual Inspection Chart 3 3 Resolve any obvious causes or concerns found during the visual inspection before carrying out any further tests 4 4 If the concern persists after the visual inspection PERFORM a fault diagnosis on the central timer module CTM using WDS and RESOLVE the fault s displayed according to the fau...

Page 2420: ...CTM WDS trouble code table central timer module CTM to test Odometer display Checked instrument Description Action Intermittent front wiper 2L Intermittent front wiper switch input A display of 2L indicates that the intermittent front wiper switch has not been operated GO to Pinpoint Test B Intermittent front wiper 2H Intermittent front wiper switch input A display of 2H indicates that the intermi...

Page 2421: ...iper motor left right hand side with double doors Instrument cluster Central junction box CJB GO to Pinpoint Test A Brief wipe is inoperative slow wipe OK Wash wipe switch RENEW the wash wipe switch CHECK operation of system Wipers are permanently switched on Circuit s Windshield wiper relay Rear window wiper relay Wash wipe switch Windshield wiper motor Rear wiper motor with tailgate Rear wiper m...

Page 2422: ...pe switch Instrument cluster GO to Pinpoint Test J PINPOINT TEST A WINDSHIELD WIPER INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS A1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position II 1 SWITCH ON windshield wipers 2 SWITCH ON rear wiper 3 Are both wipers inoperative Yes GO to A2 No Windshield wipers inoperative GO to A5 Rear wiper with tailgate or both rear ...

Page 2423: ...f necessary RENEW CHECK operation of system A4 CHECK THE VOLTAGE SUPPLY TO THE WASH WIPE SYSTEM SWITCH FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect Wash wipe switch from connector C441 2 Ignition switch in position II 3 Measure voltage between wash wipe switch connector C441 pin 6 circuit 15 KA19 GN OG wiring harness side and ground 4 Is battery voltage measured Yes RENEW the wash w...

Page 2424: ... built from 08 2006 F45 20 A CJB 2 CHECK Fuse Vehicles built before 08 2006 F43 20 A CJB Vehicles built from 08 2006 F45 20 A CJB 3 Is the fuse OK Yes GO to A7 No RENEW fuse F43 45 20 A CJB and CHECK the operation of the system If the fuse blows again LOCATE and RECTIFY short using the Wiring Diagrams CHECK operation of system A7 CHECK THE VOLTAGE SUPPLY TO FUSE F43 45 20A CJB FOR OPEN CIRCUIT Con...

Page 2425: ... Yes GO to A9 No CHECK CJB and if necessary RENEW CHECK the operation of the system A9 CHECK THE VOLTAGE SUPPLY TO THE REAR WIPER RELAY PIN 5 FOR OPEN CIRCUIT Measure the voltage between the rear wiper relay Vehicles built before 08 2006 Socket C1018 pin 5 CJB side and ground Vehicles built from 08 2006 Socket C1020 pin 5 CJB side and ground 1 Is battery voltage measured Yes GO to A10 No CHECK CJB...

Page 2426: ...CHECK CIRCUIT 32 KA28 A WH RD BETWEEN THE REAR WIPER RELAY AND THE REAR WIPER MOTOR FOR BREAKS NOTE The fused jumper lead used in the previous step is still connected to the rear wiper relay socket Ignition switch in position 0 1 Disconnect Rear wiper motor from connector C971 2 Ignition switch in position II 3 Measure the voltage between the rear wiper motor connector C971 pin 1 circuit 32 KA28 H...

Page 2427: ...ocket C1020 2 Disconnect Wash wipe switch from connector C441 3 Connect a fused jumper wire 20 A to the wash wipe switch connector C441 between pin 6 circuit 15 KA19 GN OG and pin 5 circuit 32 KA35 WH RD wiring harness side 4 Ignition switch in position II 5 Is are the rear wiper motor s working Yes RENEW the wash wipe switch CHECK operation of system No GO to A14 A14 CHECK CIRCUIT 32 KA35 WH RD B...

Page 2428: ...etween the wash wipe system switch and the instrument cluster using the Wiring Diagrams CHECK operation of system A15 CHECK CIRCUIT 31S KA29 BK YE BETWEEN THE WINDSCREEN WIPER RELAY AND THE INSTRUMENT CLUSTER FOR A SHORT CIRCUIT TO BATTERY VOLTAGE Connect Instrument cluster Vehicles built before 08 2006 to connector C813 Vehicles built from 08 2006 to connector C809 1 Disconnect Rear window wiper ...

Page 2429: ...and ground 7 Is battery voltage measured Yes GO to A17 No Install a new instrument cluster CHECK operation of system A17 CHECK CIRCUIT 31S KA29 BK YE BETWEEN THE CJB AND THE INSTRUMENT CLUSTER FOR A SHORT CIRCUIT TO BATTERY VOLTAGE Ignition switch in position 0 1 Disconnect CJB Vehicles built before 08 2006 from connector C13 Vehicles built from 08 2006 from connector C11 2 Ignition switch in posi...

Page 2430: ... 08 2006 from socket C1018 Vehicles built from 08 2006 from socket C1020 3 Vehicles built before 08 2006 4 Measure the resistance between the rear wiper relay socket C1018 pin 2 CJB side and the instrument cluster connector C809 pin 24 circuit 31S KA29 BK YE wiring harness side 5 Vehicles built from 08 2006 6 Measure the resistance between the rear wiper relay socket C1020 pin 2 CJB side and the i...

Page 2431: ...r C809 pin 11 circuit 31S KA29 BK YE wiring harness side and ground 6 CHECK the rear wiper motor s 7 Is are the rear wiper motor s working Yes RENEW the rear wiper relay CHECK operation of system No Install a new instrument cluster CHECK operation of system A20 CHECK THE VOLTAGE SUPPLY TO THE INOPERATIVE REAR WIPER MOTOR FOR OPEN CIRCUIT NOTE The minimum measurement duration is 20 seconds Ignition...

Page 2432: ...PEN CIRCUIT Measure resistance between rear wiper motor connector C971 or C970 pin 3 circuit 31 KA28 BK wiring harness side and ground 1 Is a resistance of less than 2 Ohms registered Yes RENEW the rear wiper motor CHECK operation of system No Left rear wiper motor LOCATE and RECTIFY the break in the circuit between the rear wiper motor and soldered connection S196 using the Wiring Diagrams CHECK ...

Page 2433: ...ONS B1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position II 1 Is the windshield wiper motor on continually Yes The windshield wiper motor is running continually at the slow wipe speed GO to B2 The windshield wiper motor is running continually at the fast wipe speed GO to B7 The windshield wiper motor is running continually in intermittent wipe mode GO to B9 No The r...

Page 2434: ... pin 7 circuit 32 KA19 WH BK wiring harness side and ground 4 Is battery voltage measured Yes GO to B4 No RENEW the wash wipe switch CHECK system operates correctly B4 CHECK INSTRUMENT CLUSTER Ignition switch in position 0 1 Disconnect Instrument cluster from connector C809 2 Ignition switch in position II 3 Measure voltage between wash wipe switch connector C441 pin 7 circuit 32 KA19 WH BK wiring...

Page 2435: ...of system B6 CHECK THE CJB Disconnect Central junction box CJB from connector C11 1 Measure the resistance between the CJB connector C11 pin 10 circuit 31S KA12 BK WH wiring harness side and ground 2 Is a resistance of more than 10 000 ohms measured Yes RENEW THE CJB CHECK operation of system No LOCATE and RECTIFY the short to ground in circuit 31S KA12 BK WH between the CJB and the instrument clu...

Page 2436: ...es LOCATE and RECTIFY the short to battery voltage in the circuit between the wash wipe system switch and the front wiper motor using the Wiring Diagrams No RENEW the wash wipe switch CHECK operation of system B9 CHECK INSTRUMENT CLUSTER Ignition switch in position 0 1 Disconnect Instrument cluster Vehicles built before 08 2006 from connector C813 Vehicles built from 08 2006 from connector C809 2 ...

Page 2437: ...witch in position 0 1 Disconnect Wash wipe switch from connector C441 2 Ignition switch in position II 3 Vehicles built before 08 2006 4 Measure voltage between instrument cluster connector C813 pin 6 circuit 8 KA19 WH BK wiring harness side and ground 5 Vehicles built from 08 2006 6 Measure the voltage between instrument cluster connector C809 pin 25 circuit 8 KA19 WH BK wiring harness side and g...

Page 2438: ...ocket C1020 2 Measure the resistance between the rear wiper relay Vehicles built before 08 2006 Socket C1018 pin 2 CJB side and ground Vehicles built from 08 2006 Socket C1020 pin 2 CJB side and ground 3 Is a resistance of more than 10 000 ohms measured Yes RENEW the rear wiper relay CHECK operation of system No LOCATE AND REPAIR the short to ground in the circuit between the rear wiper relay and ...

Page 2439: ...TAILS RESULTS ACTIONS C1 DETERMINE THE CAUSE OF THE FAULT Ignition switch in position II 1 SWITCH ON slow wipe speed 2 SWITCH ON fast wipe speed 3 CHECK wipers 4 Do the wipers operate at slow speed Yes Fast wipe speed inoperative GO to C2 No GO to C4 C2 CHECK THE VOLTAGE SUPPLY TO THE WINDSCREEN WIPER MOTOR PIN 4 FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect Windshield wiper motor fr...

Page 2440: ...shield wipers 6 Do the wipers operate at fast speed Yes RENEW the wash wipe switch CHECK operation of system No LOCATE and RECTIFY the break in circuit 32 KA11 WH BK between the wash wipe system switch and the front wiper motor using the Wiring Diagrams CHECK operation of system C4 CHECK THE VOLTAGE SUPPLY TO THE WINDSCREEN WIPER MOTOR PIN 5 FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconn...

Page 2441: ... slow speed Yes RENEW the wash wipe switch CHECK operation of system No LOCATE and RECTIFY the break in circuit 32 KA10 WH GN between the wash wipe system switch and the front wiper motor using the Wiring Diagrams CHECK operation of system PINPOINT TEST D INTERMITTENT WIPE MODE NOT WORKING PROPERLY FAST SLOW WIPE OK TEST CONDITIONS DETAILS RESULTS ACTIONS D1 DETERMINE THE CONDITIONS UNDER WHICH TH...

Page 2442: ...ss side 3 Ignition switch in position II 4 CHECK windshield wipers 5 Do the wipers operate in intermittent mode Yes RENEW the wash wipe switch CHECK operation of system No Vehicles built before 08 2006 GO to D4 Vehicles built from 08 2006 GO to D11 D4 CHECK THE VOLTAGE SUPPLY TO THE FRONT WIPER RELAY FOR OPEN CIRCUIT Ignition switch in position 0 1 Connect Wash wipe system switch to connector C441...

Page 2443: ...K WH wiring harness side and ground 4 Is battery voltage measured Yes GO to D6 No GO to D7 D6 CHECK CIRCUIT 31S KA12 BK WH BETWEEN THE INSTRUMENT CLUSTER AND THE CJB FOR A SHORT CIRCUIT TO BATTERY VOLTAGE Ignition switch in position 0 1 Disconnect CJB from connector C10 2 Ignition switch in position II 3 Measure the voltage between the instrument cluster connector C809 pin 25 circuit 31S KA12 BK W...

Page 2444: ... switch in position 0 1 Disconnect Instrument cluster from connector C809 2 Measure resistance between windscreen wiper relay socket C1020 pin 2 CJB side and instrument cluster connector C809 pin 25 circuit 31S KA12 BK WH wiring harness side 3 Is a resistance of less than 2 Ohms registered Yes GO to D9 No LOCATE and RECTIFY the break in the circuit between the windshield wiper relay and the instru...

Page 2445: ...ntermittent wipe 4 Vehicles built before 08 2006 5 Measure voltage between instrument cluster connector C813 pin 6 circuit 8 KA19 WH BK wiring harness side and ground 6 Vehicles built from 08 2006 7 Measure the voltage between instrument cluster connector C809 pin 25 circuit 8 KA19 WH BK wiring harness side and ground 8 Is battery voltage measured Yes Install a new instrument cluster CHECK operati...

Page 2446: ... position 0 1 Disconnect fuse F46 20 A CJB 2 Measure the voltage between the instrument cluster connector C809 pin 10 circuit 31S KA12 BK WH wiring harness side and ground 3 Is battery voltage measured Yes GO to D13 No GO to D14 D13 CHECK CIRCUIT 31S KA12 BK WH BETWEEN THE INSTRUMENT CLUSTER AND THE CJB FOR A SHORT CIRCUIT TO BATTERY VOLTAGE Ignition switch in position 0 1 Disconnect CJB from conn...

Page 2447: ...IRCUIT Ignition switch in position 0 1 Measure the resistance between the instrument cluster connector C809 pin 10 circuit 31S KA12 BK WH wiring harness side and the CJB connector C11 pin 10 circuit 31S KA12 BK WH wiring harness side 2 Is a resistance of less than 2 Ohms registered Yes RENEW THE CJB CHECK operation of system No LOCATE and RECTIFY the break in the circuit between the instrument clu...

Page 2448: ...em PINPOINT TEST E WASH WIPE FUNCTION INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS E1 DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS Ignition switch in position II 1 SWITCH ON the front and rear screen washer systems 2 CHECK the wash wipe function 3 Is the wipe function inoperative but the wash function OK Yes GO to E3 No Wash and wipe function inoperative GO to E2 E2 CHECK THE GROUN...

Page 2449: ...6 WH BK and pin 17 circuit 33 KA6 YE BK wiring harness side 6 Vehicles built from 08 2006 7 Measure voltage at instrument cluster connector C809 between pin 22 circuit 32 KA6 WH BK and pin 20 circuit 33 KA6 YE BK wiring harness side 8 Is battery voltage measured Yes Install a new instrument cluster CHECK operation of system No Windshield wipers inoperative LOCATE and RECTIFY the break in circuit 3...

Page 2450: ...wipers vehicles with double doors built from 02 2004 to 08 2006 LOCATE and RECTIFY the break in circuit 15 KA28 GN BU between CJB connector C17 pin 10 and soldered connection S174 using the Wiring Diagrams If necessary RENEW the CJB CHECK operation of system Incorrect park position of both rear wipers vehicles with double doors built from 08 2006 LOCATE and RECTIFY the break in circuit 15 KA28 GN ...

Page 2451: ...17 pin 5 and the front wiper motor using the Wiring Diagrams CHECK operation of system F4 CHECK CIRCUIT 32 KA9 WH BU BETWEEN WINDSHIELD WIPER MOTOR AND WINDSHIELD WIPER RELAY FOR BREAKS Ignition switch in position 0 1 Connect a fused jumper wire 20A to the wiper relay socket C1020 between pin 4 and pin 5 CJB side 2 Ignition switch in position II 3 Measure voltage between windshield wiper motor con...

Page 2452: ...EN WINDSHIELD WIPER RELAY AND WASH WIPE SWITCH FOR BREAKS Ignition switch in position 0 1 Disconnect Wash wipe switch from connector C441 2 Connect a fused jumper wire 20A to the windshield wiper relay socket C1020 between pin 3 and pin 5 CJB side 3 Ignition switch in position II 4 Measure voltage between wash wipe switch connector C441 pin 7 circuit 32 KA19 WH BK wiring harness side and ground 5 ...

Page 2453: ...HECK CIRCUIT 32 KA19 WH BK BETWEEN THE CJB AND THE WASH WIPE SWITCH FOR OPEN CIRCUIT Disconnect Wash wipe switch from connector C441 1 Measure the resistance between the wash wipe system switch connector C441 pin 7 circuit 32 KA19 WH BK wiring harness side and the CJB connector C14 pin 7 circuit 32 KA19 WH BK wiring harness side 2 Is a resistance of less than 2 Ohms registered Yes GO to F9 No LOCA...

Page 2454: ...r C970 or C971 pin 2 circuit 15 KA28 H GN BU wiring harness side and ground 4 Is battery voltage measured Yes RENEW the rear wiper motor CHECK operation of system No Vehicles with double doors built before 02 2004 LOCATE and RECTIFY the break in the circuit between intermediate connector C61 pin 17 and the rear wiper motor using the Wiring Diagrams CHECK operation of system Vehicles with double do...

Page 2455: ...round 4 Is battery voltage measured Yes GO to G2 No LOCATE and RECTIFY the break in the circuit between the wash wipe system switch and the front rear washer pump using the Wiring Diagrams CHECK operation of system G2 CHECK THE VOLTAGE SUPPLY TO THE FRONT REAR WASHER PUMP PIN 2 FOR OPEN CIRCUIT Measure voltage between front rear washer pump connector C828 pin 2 circuit 32 KA34 WH BK wiring harness...

Page 2456: ...n 1 circuit 15 HB13 GN BU wiring harness side and ground 4 Is battery voltage measured Yes LOCATE and RECTIFY the break in circuit 91 HB1 BK BU between soldered connection S122 and soldered connection S118 using the Wiring Diagrams CHECK operation of system No LOCATE and RECTIFY the break in circuit 15 HB1 GN BU between soldered connection S114 and soldered connection S123 with the aid of the Wiri...

Page 2457: ...d soldered connection S122 using the Wiring Diagrams CHECK operation of system H5 CHECK VOLTAGE SUPPLY TO RIGHT WINDSHIELD WASHER NOZZLE HEATER FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect Right hand windshield washer nozzle heater from connector C720 2 Ignition switch in position II 3 Measure voltage between right hand windshield washer nozzle heater connector C720 pin 1 circuit 15...

Page 2458: ...CHECK the wash wipe system switch according to the component check at the end of this section Check the wash wipe system switch at pins 2 and 3 3 Is the wash wipe switch OK Yes Install a new instrument cluster CHECK operation of system No RENEW the wash wipe switch CHECK operation of system PINPOINT TEST J SHORT CIRCUIT AT THE INPUT OF THE REAR WINDOW WASHER SYSTEM SHORT TO GROUND TEST CONDITIONS ...

Page 2459: ...ff Closed circuit Intermittent Closed circuit Normal Open circuit High Open circuit Normal windshield wiper 6 and 9 Flick wipe Open circuit Off Open circuit Intermittent Open circuit Normal Closed circuit High Open circuit Fast windshield wiper 6 and 8 Flick wipe Open circuit Off Open circuit Intermittent Open circuit Normal Open circuit High Closed circuit Windscreen washer off 2 and 6 Off Closed...

Page 2460: ...dscreen wiper motor is in the parked position 2 2 CHECK the front wiper motor in the park position Measure the resistance at the windscreen wiper motor between pin 2 and the wiper motor housing Is the resistance less than 2 ohms 1 If yes then the windshield wiper motor is OK 2 If not RENEW the windshield wiper motor Rear washer off 4 and 6 Off Closed circuit Rear wipers on Closed circuit Rear wash...

Page 2461: ... three support points of the special tool must be in contact with the glass NOTE The angle of the wiper on the scale must point from the zero center line to the center of the windshield rear window Ignore the sign on the alignment tool Using the special tool read off the angle between the wiper arm and the windshield 1 Center of windshield 4 NOTE Lift the special tool away from the glass when corr...

Page 2462: ...nment tool Using the angle measuring instrument read off the angle between the wiper arm and the windshield 5 CAUTIONS Make sure that no mechanical force is applied to the wiper blade holder while adjusting the angle The wiper arm must not be adjusted by more than three degrees If a bigger adjustment is necessary check the wiper arm for damage replace if necessary NOTE Lift the angle measuring ins...

Page 2463: ...rmation refer to Section 100 02 Jacking and Lifting 3 Remove the left hand wheel house cover shown with wheel removed for clarity 4 Detach the washer fluid reservoir from the fender 5 Remove the windshield washer fluid reservoir together with the windshield washer system pump 1 Detach the connector 2 Disconnect the hoses 1 NOTE Apply Vaseline to the washer reservoir filler neck before installation...

Page 2464: ...icated in the following illustration s and table s Description Caps wiper arm nuts Wiper arm nuts Windshield wiper arms See Installation Detail Water drain panel rubber seal Cowl panel screws Cowl panels Pollen filter cover screws Pollen filter cover WARNING Ensure that the ignition switch is in the OFF position Failure to observe this instruction can lead to injury Item 1 2 3 4 5 6 7 8 Part Numbe...

Page 2465: ...rm windshield wiper arms See Installation Detail Description Windshield wiper motor retaining bolts See Installation Detail Windshield wiper motor Windshield wiper motor connector 2 To install reverse the removal procedure Installation Details Item 9 10 11 Item 12 13 14 Part Number Part Number http vnx su ...

Page 2466: ... the linkage Attach the windshield wiper crank arm to the windshield wiper motor 1 Installation position of windshield wiper crank arm on RHD vehicles 2 Installation position of windshield wiper crank arm on LHD vehicles 1 NOTE Before attaching the wiper arms mark the installation position on the windshield using adhesive tape Move the wiper arms to the installation position and adjust LHD shown P...

Page 2467: ...http vnx su ...

Page 2468: ...ll except vehicles with diesel engine 1 Remove the EGR valve from the bulkhead and secure to one side 2 Remove the manifold absolute pressure MAP sensor from the bulkhead and secure to one side 3 Remove the EVAP canister solenoid valve from the bulkhead and secure to one side 4 Remove the EVAP canister solenoid valve from the bulkhead and secure to one side 5 Detach the EGR valve wiring harness fr...

Page 2469: ...tach the fuel pipe from the bulkhead 7 Detach the EGR position sensor wiring harness from the bulkhead 8 CAUTION If brake fluid comes into contact with the paintwork rinse off the affected areas with cold water without delay Remove the brake fluid reservoir from the bulkhead and secure to one side http vnx su ...

Page 2470: ...r arm nuts Windshield wiper arms See Installation Detail Water drain panel rubber seal Cowl panel screws Cowl panels Pollen filter cover screws Pollen filter cover Description Item 1 2 3 4 5 6 7 8 Item Part Number Part Number http vnx su ...

Page 2471: ...indshield wiper motor with linkage Windshield wiper motor with linkage Windshield wiper motor connector Description Crank arm retaining nut for windshield wiper arms Crank arm washer for windshield wiper arms Crank arm for windshield wiper arms 9 10 Item 11 12 13 Item 14 15 16 Part Number Part Number http vnx su ...

Page 2472: ...dure Removal Details Item 9 Bulkhead extension screws Installation Details Item 10 Bulkhead extension Item 17 18 1 Unscrew the bulkhead extension bolts 2 Detach the left hand and right hand heated windshield connectors from the bulkhead extension 1 Insert the bulkhead extension side fixings Part Number http vnx su ...

Page 2473: ...sive tape Move the windshield wiper arms to the installation position and adjust LHD shown Position the passenger side windshield wiper arm 20 30mm above the marks small circles in the lower left hand area of the windshield for RHD vehicles and in the lower right hand area for LHD vehicles Position the driver side windshield wiper arm 20 30mm above the marks small triangles in the center of the wi...

Page 2474: ...nd Installation 2 Remove the components in the order indicated in the following illustration s and table s Description Cap rear wiper arm Nut rear wiper arm Washer rear wiper arm Rear wiper arm See Installation Detail 1 Remove the cover for the rear wiper motor Item 1 2 3 4 Part Number http vnx su ...

Page 2475: ...tor Bolts rear wiper motor Rear wiper motor 3 To install reverse the removal procedure Installation Details Item 4 Rear wiper arm CAUTION Move the rear wiper motor to the parked position before installing the wiper arm Item 5 6 7 8 Part Number http vnx su ...

Page 2476: ...sor Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal Installation 1 2 3 1 CAUTION Make sure that the surface is clean and free of foreign material To install reverse the removal procedure http vnx su ...

Page 2477: ...s Transit Tourneo Connect 2002 5 06 2002 Print Torque Specifications Description Nm lb ft lb in Front bumper retaining bolts 25 18 Front bumper cover retaining bolts 12 9 Rear bumper cover retaining bolts 36 27 http vnx su ...

Page 2478: ...n both sides 1 Remove the retaining clip 2 Release the retaining clip 3 Release the retaining clips 3 NOTE With the aid of another technician support the bumper cover center section Remove the bumper cover center section retaining bolts 4 NOTE With the aid of another technician support the bumper cover center section Detach the parking aid sensors from the bumper cover center section if equipped 5...

Page 2479: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2480: ...and table s Description Front bumper cover See Removal Detail Fog lamps See Removal Detail Air deflector See Removal Detail 3 To install reverse the removal procedure Removal Details 1 Raise and support the vehicle For additional information refer to Jacking 100 02 Jacking and Lifting Description and Operation Lifting 100 02 Jacking and Lifting Description and Operation Item 1 2 3 Part Number http...

Page 2481: ...the front bumper cover from the inside of the fender on both sides Remove the retaining screw 4 Disconnect the fog lamp electrical connector on both sides 5 Remove the front license plate 6 Detach the front bumper cover from the front bumper 1 Remove the retaining screw covers 2 Remove the retaining screws 7 Remove the front bumper cover Detach the radiator opening panel reinforcement retaining cl...

Page 2482: ...Item 2 Fog lamps Item 3 Air deflector 1 Remove the fog lamp on both sides Remove the retaining screws 1 Remove the air deflector http vnx su ...

Page 2483: ... Transit Tourneo Connect 2002 5 06 2002 Print Removal and Installation Removal 1 Raise and support the vehicle Refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 On both sides 3 On both sides 4 On both sides 5 On both sides http vnx su ...

Page 2484: ...6 On both sides 7 1 Torque 12 Nm 8 On both sides http vnx su ...

Page 2485: ...Installation 9 1 To install reverse the removal procedure http vnx su ...

Page 2486: ...rint Removal and Installation Removal NOTE Removal steps in this procedure may contain installation details Vehicles with diesel engine All vehicles 1 Refer to Lifting 100 02 Jacking and Lifting Description and Operation 2 3 1 Torque 12 Nm 4 If equipped on both sides 5 On both sides 6 http vnx su ...

Page 2487: ...7 8 On both sides 9 http vnx su ...

Page 2488: ...Installation 10 11 12 1 1 To install reverse the removal procedure 2 Refer to Front Fog Lamp Adjustment 417 01 Exterior Lighting General Procedures http vnx su ...

Page 2489: ...Safety belt retractor retaining bolts 40 30 Safety belt retractor and pretensioner retaining bolt 40 30 Front safety belt buckle retaining bolt 30 22 Rear safety belt buckle retaining bolt 25 18 Rear center safety belt retractor retaining bolt 25 18 Rear center safety belt lower anchor and buckle assembly retaining bolt 25 18 Third row center safety belt retractor retaining bolt 25 18 Third row ce...

Page 2490: ...th a torsion bar load limiting device The device consists of a retractor reel which is mounted onto a spindle torsion bar which once the sensor has locked the retractor reel and a predetermined load is applied twists and pays out additional webbing into the system The deceleration force required to initiate this sequence is approximately the same as that required to initiate air bag deployment The...

Page 2491: ... by the tests below Vehicle Motion Sensor Test Either of the following two procedures may be used to check correct operation of the vehicle motion sensor Both methods require two technicians but note that technicians of larger than normal build should not be asked to conduct these tests This is to avoid the possibility of a fully unrolled safety belt webbing being mistaken for a correctly locked s...

Page 2492: ...rrectly adjusted with no slack The passenger should occupy a rear seat with the safety belt correctly adjusted with no slack Start the engine and with the steering on full right hand lock drive the vehicle in a continuous circle at 16 km h 10 mph Do not exceed 16 km h 10 mph for this test When the speed is stable the passenger should attempt to slowly extract the safety belt webbing from each safe...

Page 2493: ...ation Removal and Installation 2 NOTE Hold the safety belt webbing when detaching the safety belt lower anchor from the floor panel Detach the safety belt lower anchor from the floor panel 3 CAUTION The bolt securing the safety belt anchor is held captive by a paper washer The bolt spacer and paper washer must remain on the safety belt anchor at all times when the safety belt is detached or remove...

Page 2494: ...ng tang is correctly located NOTE Make sure the safety belt shoulder height adjuster locking control is correctly located on the safety belt shoulder height adjuster To install reverse the removal procedure http vnx su ...

Page 2495: ...he safety belt anchor at all times when the safety belt is detached or removed Detach the safety belt upper anchor from the safety belt shoulder height adjuster 1 Remove the bolt cover 2 Remove the retaining bolt 3 Remove the safety belt shoulder height adjuster trim panel 4 Remove the safety belt shoulder height adjuster 1 NOTE When installing the safety belt shoulder height adjuster install the ...

Page 2496: ...estraint system Failure to follow this instruction may result in personal injury Never probe the electrical connectors of air bag modules or any other supplemental restraint system component Failure to follow this instruction may result in personal injury Van All vehicles 1 Disconnect the battery ground cable For additional information refer to Section 414 01 Battery Mounting and Cables 2 Remove t...

Page 2497: ...his instruction may result in personal injury 5 Disconnect the safety belt retractor pretensioner electrical connector 6 Remove the front safety belt retractor and pretensioner 1 Remove the retaining bolt 2 Lift the retractor to detach the locating tang 1 CAUTION Make sure the safety belt retractor locating tang is correctly located NOTE Make sure the safety belt shoulder height adjuster locking c...

Page 2498: ...Feed the safety belt webbing and safety belt buckle through the guide loop 1 WARNING If the safety belt webbing retracts further than the stop on the webbing a new safety belt retractor must be installed Failure to follow this instruction may result in personal injury CAUTIONS To prevent the safety belt webbing retracting further than the stop make sure a safety belt webbing retainer is fitted at ...

Page 2499: ...im and Ornamentation 5 CAUTION The bolt securing the safety belt anchor is held captive by a paper washer The bolt spacer and paper washer must remain on the safety belt anchor at all times when the safety belt is detached or removed Detach the safety belt upper anchor from the strengthening bar 6 Remove the rear safety belt retractor 1 Remove the retaining bolt 2 Lift the retractor to detach the ...

Page 2500: ...safety belt retractor 1 Remove the retaining bolt 2 Lift the retractor to detach the locating tang 1 CAUTION Make sure the safety belt retractor locating tang is correctly located To install reverse the removal procedure http vnx su ...

Page 2501: ...elf 2 Fold the rear seat backrest forwards 3 Remove the rear quater trim panel Refer to Rear Quarter Trim Panel Long Wheelbase Kombi 501 05 Interior Trim and Ornamentation Removal and Installation 4 Torque 40 Nm 5 NOTE Note the position of each component before removal NOTE Make sure that these components are installed to the noted removal position 2 Torque 40 Nm 3 Torque 40 Nm 1 To install revers...

Page 2502: ...nd Installation Removal NOTE Removal steps in this procedure may contain installation details 1 2 NOTE Note the position of each component before removal 3 NOTE If the safety belt webbing retracts further than the safety belt webbing stop a new safety belt retractor must be installed 4 Torque 45 Nm 5 http vnx su ...

Page 2503: ...ation 6 7 NOTE Note the position of the component before removal NOTE Make sure that this component is installed to the noted removal position Torque 25 Nm 1 To install revers the removal procedure http vnx su ...

Page 2504: ...ir bag module 501 074 40 017 418 057 40 007 02 Side air bag module 501 075 40 018 418 142 40 007 09 Driver safety belt retractor and pretensioner 418 037 40 001 418 056 40 007 01 Description Nm lb ft lb in Air bag control module retaining nuts 8 71 Passenger air bag module retaining nuts 6 53 Side air bag module retaining nuts 5 44 Side impact sensor retaining nuts 6 53 Front safety belt lower anc...

Page 2505: ...enger air bag module Side impact sensor Passenger safety belt retractor Air bag control module Driver safety belt retractor and pretensioner Side air bag module Driver air bag module Two stage air bag module shown Clockspring System Structure The following components form part of the supplemental restraint system SRS Air bag control module Side impact sensors Item 1 2 3 4 5 6 7 8 Part Number http ...

Page 2506: ...lue then the air bag control module triggers the air bags and safety belt pretensioner as required If the vehicle battery is destroyed in the collision a voltage hold circuit in the air bag control module will still enable the air bags to be triggered up to 150 ms after the start of the impact If a system fault is detected by the air bag control module the air bag warning indicator illuminates The...

Page 2507: ...e system deploys The passenger air bag is deployed simultaneously with the driver air bag A new passenger air bag module must be installed following deployment Side Air Bag Modules NOTE Side air bag modules are not available on vehicles equipped with a front passenger fold flat seat The side air bag modules are incorporated in the front seat backrests a sewn on label on the respective backrest ind...

Page 2508: ... designed to carry signals between the air bag control module and the driver air bag module The clockspring is installed on the steering column and consists of fixed and moving parts connected by a coiled Mylar tape with internal conducting tracks The Mylar tape is able to wind up and unwind as the steering wheel is rotated maintaining electrical contact at all times between the air bag control mo...

Page 2509: ...ction may result in personal injury NOTE Following the pinpoint tests when a diagnostic trouble code lamp fault code DTC LFC is not present will result in needless replacement of air bag system components and repeat repairs Speak with the customer to determine if a particular set of conditions must be met in order for a fault to occur If a LFC is reported by the customer but is not present when th...

Page 2510: ...e to follow this instruction may result in personal injury 1 1 Disconnect the battery ground cable REFER to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 2 Wait at least one minute for the backup power supply in the air bag control module to deplete its stored energy WARNING Place the air bag module s on a ground wired bench with the trim cover facing up to...

Page 2511: ...in a collision Failure to follow this instruction may result in personal injury 1 1 Disconnect the battery ground cable REFER to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 2 Wait at least one minute for the backup power supply in the air bag control module to deplete its stored energy 3 3 Remove the driver air bag module simulators from the driver air ba...

Page 2512: ...bag simulators are used to simulate air bag module connections to the system Deactivate the System Deactivate the system means to carry out the deactivation procedure REFER to Deactivation in this procedure Prove Out the System The air bag warning indicator will illuminate for approximately three seconds at key ON If the system self tests OK the indicator extinguishes if a fault is detected the in...

Page 2513: ...ule REFER to Air Bag Control Module 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs DTC B1869 Air bag warning indicator open circuit or short to ground Lamp flash code continuous Air bag control module Instrument cluster Circuit s GO to Pinpoint Test C DTC B1870 Air bag warning indicator short to battery Lamp flash code No lamp Instrument cluster ...

Page 2514: ...Clockspring Circuit s GO to Pinpoint Test O DTC B1933 Passenger air bag open circuit Lamp flash code 21 Passenger air bag module Circuit s GO to Pinpoint Test P DTC B1934 Driver air bag first stage low resistance Lamp flash code 1 Driver air bag module Clockspring Circuit s GO to Pinpoint Test Q DTC B1935 Passenger air bag low resistance Lamp flash code 2 Passenger air bag module Circuit s GO to P...

Page 2515: ...oint Test AE DTC B2234 Driver air bag second stage low resistance on squib Lamp flash code 1 Driver air bag module Clockspring Circuit s GO to Pinpoint Test AF DTC B2444 Driver side impact sensor communications fault Lamp flash code 5 Circuit s GO to Pinpoint Test AG DTC B2444 Driver side impact sensor internal fault Lamp flash code 5 Driver side impact sensor INSTALL a new driver side impact sens...

Page 2516: ...ult is present the air bag warning will begin to flash after five seconds 2 Is the air bag warning indicator operating Yes GO to A3 No CHECK the instrument cluster REFER to Instrument Cluster 413 01 Instrument Cluster Diagnosis and Testing A3 CHECK THE DLC CIRCUIT Ignition switch in position 0 1 Deactivate the supplemental restraint system 2 Disconnect Air Bag Control Module C424 3 Measure the res...

Page 2517: ...he air bag control module C424 pin 8 circuit 15 JA10 GN OG harness side 3 Is the resistance less than 5 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No CHECK the connector terminals for corrosion or dirt ingress REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST C DTC B1869 AIR BAG WARNING INDICATOR OPEN CIRCUIT OR SHORT TO GROUND TEST CONDITIONS DETAILS ...

Page 2518: ... REFER to Instrument Cluster 413 01 Instrument Cluster Removal and Installation REPEAT the self test CLEAR the DTC REACTIVATE the system No GO to C6 C4 CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS WARNING Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector Failure to follow this instruction may result ...

Page 2519: ...wire between the air bag control module C424 pin 4 circuit 91S JA14 BK GN and ground 1 Disconnect the fused jumper wire from the ground 2 Is the air bag warning indicator illuminated Yes INSTALL a new air bag control module REFER to Air Bag Control Module 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPEAT the self test...

Page 2520: ...traint system electrical connector Failure to follow this instrument may result in personal injury Deactivate the supplemental restraint system 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out correctly Yes GO to E2 No CHECK the air bag module simulator is installed correctly REPEAT the self test CLEAR the DTCs REACTIVATE the syst...

Page 2521: ... 4 Carry out the self test 5 Does the system prove out correctly Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new driver safety belt retractor and pretensioner REFER to Safety Belt Retractor and Pretensioner 501 20A Safety Belt System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system F3 CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR OPE...

Page 2522: ...NER Ignition switch in position 0 1 Disconnect Driver Safety Belt Pretensioner Simulator 2 Connect Driver Safety Belt Pretensioner C28 3 Ignition switch in position II 4 Carry out the self test 5 Does the system prove out correctly Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new driver safety belt retractor and pretensioner REFER to Safety Belt Retractor and Pretensi...

Page 2523: ...straint system 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out correctly Yes GO to H2 No GO to H3 H2 PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER Ignition switch in position 0 1 Disconnect Driver Safety Belt Pretensioner Simulator 2 Connect Driver Safety Belt Pretensioner C28 3 Ignition switch in position II 4 Carry out the self...

Page 2524: ...Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector Failure to follow this instruction may result in personal injury Deactivate the supplemental restraint system 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out correctly Yes GO to I2 No G...

Page 2525: ... cable before disconnecting any supplemental restraint system electrical connector Failure to follow this instruction may result in personal injury TEST CONDITIONS DETAILS RESULTS ACTIONS J1 CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT Deactivate the supplemental restraint system 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out co...

Page 2526: ...NESS FOR A SHORT TO GROUND Ignition switch in position 0 1 Disconnect Air Bag Control Module C424 2 Disconnect Driver Air Bag Module Simulator 3 Measure the resistance between the air bag control module C424 pin 2 circuit 15S JA8 GN RD harness side and ground air bag control module C424 pin 3 circuit 91S JA8 BK OG harness side and ground 4 Turn the steering wheel from lock to lock and note the res...

Page 2527: ...ery ground cable before disconnecting any supplemental restraint system electrical connector Failure to follow this instruction may result in personal injury Deactivate the supplemental restraint system 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out correctly Yes GO to K2 No GO to K3 K2 CHECK THE PASSENGER AIR BAG MODULE WARNING...

Page 2528: ...ms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA11 GN WH or 91S JA11 BK WH REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST L DTC B1916 DRIVER AIR BAG FIRST STAGE SHORT TO BATTERY TEST CONDITIONS DETAILS RESULTS ACTIONS L1 CHECK THE AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO BATTERY WARNING Wait at least one minute after discon...

Page 2529: ...age present Yes GO to L3 No INSTALL a new driver air bag module wiring harness REFER to Driver Air Bag Module Wiring Harness 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system L3 CHECK THE AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO BATTERY Ignition switch in position 0 1 Disconnect Clockspring C896 2 Ignition switch in po...

Page 2530: ...air bag control module 3 Is the air bag control module correctly mounted and all bolts tightened to the correct torque Yes GO to M2 No SECURE the air bag control module REFER to Passenger Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system M2 CHECK THE AIR BAG CONTROL MODULE CASE GROUND...

Page 2531: ...on may result in personal injury Deactivate the supplemental restraint system 1 Disconnect Air Bag Control Module C424 2 Disconnect Passenger Air Bag Module Simulator 3 Ignition switch in position II 4 Measure the voltage between the air bag control module C424 pin 5 circuit 15S JA11 GN WH harness side and ground air bag control module C424 pin 6 circuit 91S JA11 BK WH harness side and ground 5 Is...

Page 2532: ...g module first stage 2 Select DMM specific on WDS 3 Connect the Test and Deployment Lead to WDS 4 Measure the resistance of the air bag module squib first stage 5 Is the resistance between 2 and 3 ohms Yes INSTALL a new driver air bag module wiring harness REFER to Driver Air Bag Module Wiring Harness 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTC...

Page 2533: ... side 2 Are the resistances less than 5 ohms Yes Install a new clockspring REFER to Clockspring Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA8 GN RD or 91S JA8 BK OG REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST P DTC B1933 PASSENGER AIR BAG OPE...

Page 2534: ...raint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST Q DTC B1934 DRIVER AIR BAG FIRST STAGE CIRCUIT LOW RESISTANCE TEST CONDITIONS DETAILS RESULTS ACTIONS Q1 CHECK THE DRIVER AIR BAG FIRST STAGE MODULE CIRCUIT RESISTANCE WARNING Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restra...

Page 2535: ...n REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new driver air bag module REFER to Driver Air Bag Module 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system Q3 CHECK THE AIR BAG WIRING SUB HARNESS FOR LOW RESISTANCE Ignition switch in position 0 1 Disconnect Air Bag Module Sub harness C920 2 Disconnect Ai...

Page 2536: ...ULTS ACTIONS R1 CHECK THE PASSENGER AIR BAG MODULE CIRCUIT RESISTANCE WARNING Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector Failure to follow this instruction may result in personal injury Deactivate the supplemental restraint system 1 Ignition switch in position II 2 Carry out the self test with th...

Page 2537: ...side and pin 6 circuit 91S JA11 BK WH harness side 4 Is the resistance greater than 10 000 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA11 GN WH or 91S JA11 BK WH REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST S DTC B1992 DRIVER SIDE AIR BAG SHORT TO BATTERY TEST CONDITIONS DETAILS RESULTS ACTIONS S1 CHECK THE DRIVER AIR BAG CI...

Page 2538: ...er Side Air Bag Module Simulator C30 3 Ignition switch in position II 4 Measure the voltage between the air bag control module C423 pin 15 circuit 15S JA37 GN BK harness side and ground air bag control module C423 pin 16 circuit 91S JA37 BK GN harness side and ground 5 Is any voltage present Yes REPAIR circuit 15S JA37 GN BK or 91S JA37 BK GN REPEAT the self test CLEAR the DTCs REACTIVATE the syst...

Page 2539: ...on 0 1 Disconnect Air Bag Control Module C423 2 Disconnect Driver Side Air Bag Module Simulator C30 3 Measure the resistance between the air bag control module C423 pin 15 circuit 15S JA37 GN BK harness side and ground air bag control module C423 pin 16 circuit 91S JA37 BK GN harness side and ground 4 Are the resistances greater than 10 000 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE t...

Page 2540: ...ide Air Bag Module Simulator C30 3 Measure the resistance between the air bag control module C423 pin 15 circuit 15S JA37 GN BK harness side and the driver underseat connector C30 pin 1 circuit 15S JA37 GN BK harness side air bag control module C423 pin 16 circuit 91S JA37 BK GN harness side and the driver underseat connector C30 pin 2 circuit 91S JA37 BK GN harness side 4 Are the resistances less...

Page 2541: ... CIRCUIT FOR LOW RESISTANCE Ignition switch in position 0 1 Disconnect Air Bag Control Module C423 2 Disconnect Driver Side Air Bag Module Simulator C30 3 Measure the resistance between the air bag control module C423 pin 15 circuit 15S JA37 GN BK harness side and pin 16 circuit 91S JA37 BK GN harness side 4 Is the resistance greater than 10 000 ohms Yes REPEAT the self test CLEAR the DTCs REACTIV...

Page 2542: ...Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system W3 CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY Ignition switch in position 0 1 Disconnect Air Bag Control Module C423 2 Disconnect Passenger Side Air Bag Module Simulator C31 3 Ignition switch in position II 4 Measure the voltage between the air bag control module C423 pin 23 circuit 15S JA15 GN ...

Page 2543: ...VATE the system No INSTALL a new passenger side air bag module REFER to Side Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system X3 CHECK THE PASSENGER SIDE AIR BAG FOR A SHORT TO GROUND Ignition switch in position 0 1 Disconnect Air Bag Control Module C423 2 Disconnect Passenger Side A...

Page 2544: ...DTCs REACTIVATE the system No INSTALL a new passenger side air bag module REFER to Side Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system Y3 CHECK THE PASSENGER SIDE AIR BAG FOR OPEN CIRCUIT OR HIGH RESISTANCE Ignition switch in position 0 1 Disconnect Air Bag Control Module C423 2 Di...

Page 2545: ...r Side Air Bag Module C31 3 Ignition switch in position II 4 Carry out the self test 5 Does the system prove out correctly Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new passenger side air bag module REFER to Passenger Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTI...

Page 2546: ...on switch in position II 4 Carry out the self test 5 Does the system prove out correctly Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new driver side air bag module REFER to Driver Air Bag Module 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST AB DTC B2118 PASSENGER SIDE AIR BAG MOD...

Page 2547: ...TIONS DETAILS RESULTS ACTIONS AC1 CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT Deactivate the supplemental restraint system 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out correctly Yes GO to AC2 No GO to AC3 AC2 CHECK THE DRIVER AIR BAG MODULE WARNING Do not proceed with the test unless using WDS Failure to follow this instruct...

Page 2548: ... 20 circuit 15S JA48 GN BK harness side and ground air bag control module C423 pin 21 circuit 91S JA48 BK GN harness side and ground 4 Turn the steering wheel from lock to lock and note the resistance readings 5 Are the resistances greater than 10 000 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No GO to AC4 AC4 CHECK THE CLOCKSPRING FOR A SHORT TO GROUND Disconnect Clockspri...

Page 2549: ...ontrol Module C423 3 Ignition switch in position II 4 Measure the voltage between the air bag control module C423 pin 20 circuit 15S JA48 GN BK harness side and ground air bag control module C423 pin 21 circuit 91S JA48 BK GN harness side and ground 5 Is any voltage present Yes GO to AD2 No CONNECT the driver air bag module second stage simulator and the air bag control module REPEAT the self test...

Page 2550: ...INSTALL a new clockspring REFER to Clockspring Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST AE DTC B2232 DRIVER AIR BAG SECOND STAGE OPEN CIRCUIT WARNING Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system el...

Page 2551: ... Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system AE3 CHECK THE AIR BAG SECOND STAGE WIRING SUB HARNESS FOR OPEN CIRCUIT Ignition switch in position 0 1 Disconnect Air Bag Control Module C423 2 Disconnect Air Bag Module Sub harness C920 3 Measure the resistance between the air bag control module C423 pin 20 circuit 15S JA48 GN RD harness side and ...

Page 2552: ...st one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector Failure to follow this instruction may result in personal injury TEST CONDITIONS DETAILS RESULTS ACTIONS AF1 CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE Deactivate the supplemental restraint system 1 Ignition switch in position II 2 Carry out the self ...

Page 2553: ...CE Ignition switch in position 0 1 Disconnect Air Bag Module Sub harness C920 2 Disconnect Air Bag Control Module C424 3 Measure the resistance between the air bag control module C423 pin 20 circuit 15S JA48 GN BK harness side and pin 21 circuit 91S JA48 BK GN harness side 4 Turn the steering wheel from lock to lock and note the resistance readings 5 Is the resistance greater than 10 000 ohms Yes ...

Page 2554: ... may result in personal injury Deactivate the supplemental restraint system 1 Disconnect Side Impact Sensor C427 or C428 2 Disconnect Air Bag Control Module C423 3 Measure the resistance between the air bag control module C423 pin 18 circuit 15S JA39 GN YE harness side and the driver side impact sensor C427 pin 2 circuit 15S JA39 GN YE harness side air bag control module C423 pin 19 circuit 91 JA3...

Page 2555: ...stem No REPAIR circuit 15 JA10 GN OG or 15S JA39 GN YE or 91 JA10 BK RD or 91 JA39 BK YE REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST AH DTC B2445 PASSENGER SIDE IMPACT SENSOR COMMUNICATIONS FAULT TEST CONDITIONS DETAILS RESULTS ACTIONS AH1 CHECK THE PASSENGER SIDE IMPACT SENSOR CIRCUIT WARNING Wait at least one minute after disconnecting the battery ground cable before ...

Page 2556: ... C423 pin 25 circuit 91S JA40 BK WH harness side and ground 2 Are the resistances greater than 10 000 ohms Yes INSTALL a new passenger side impact sensor REFER to Side Impact Sensor 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15 JA10 GN OG or 15S JA40 GN YE or 91 JA40 BK WH REPEAT the self test CLEAR the...

Page 2557: ...24 pin 8 circuit 15 JA10 GN OG harness side and ground 3 Is the voltage between 9 and 16 volts Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15 JA10 GN OG REPEAT the self test CLEAR the DTCs REACTIVATE the system http vnx su ...

Page 2558: ...system SRS or any component s adjacent to the SRS sensors Failure to follow these instructions may result in personal injury NOTE Following the pinpoint tests when a diagnostic trouble code lamp fault code DTC LFC is not present or the air bag warning indicator is not permanently illuminated will result in needless replacement of air bag system components and repeat repairs Speak with the customer...

Page 2559: ...Wait at least one minute after disconnecting the battery ground cable s before commencing any repair or adjustment to the SRS or any component s adjacent to the SRS sensors Failure to follow these instructions may result in personal injury 1 1 Disconnect the battery ground cable REFER to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 2 Wait at least one minu...

Page 2560: ...simulators must be removed and the air bag modules reconnected when reactivated to avoid non deployment in a collision Failure to follow this instruction may result in personal injury 1 1 Disconnect the battery ground cable REFER to Battery Disconnect and Connect 414 01 Battery Mounting and Cables General Procedures 2 2 Wait at least one minute for the backup power supply in the air bag control mo...

Page 2561: ...connect and Connect 414 01 Battery Mounting and Cables General Procedures 16 16 Prove out the system Glossary Air Bag Simulator Air bag simulators are used to simulate air bag module connections to the system Deactivate the System Deactivate the system means to carry out the deactivation procedure REFER to Deactivation in this procedure Prove Out the System The air bag warning indicator will illum...

Page 2562: ...Circuit s GO to Pinpoint Test B DTC B1342 Air bag control module is defective Lamp flash code continuous Air bag control module INSTALL a new air bag control module REFER to Air Bag Control Module 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs DTC B1869 Air bag warning indicator open circuit or short to ground Lamp flash code continuous Air bag c...

Page 2563: ...ntinuous Air bag control module Circuit s GO to Pinpoint Test M DTC B1925 Passenger air bag circuit short to battery Lamp flash code 3 Circuit s GO to Pinpoint Test N DTC B1932 Driver air bag open circuit Lamp flash code 1 Driver air bag module Clockspring Circuit s GO to Pinpoint Test O DTC B1933 Passenger air bag open circuit Lamp flash code 1 Passenger air bag module Circuit s GO to Pinpoint Te...

Page 2564: ...5 Driver side impact sensor INSTALL a new driver side impact sensor REFER to Side Impact Sensor 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs DTC B2445 Passenger side impact sensor communications fault Lamp flash code 6 Circuit s GO to Pinpoint Test AD DTC B2445 Passenger side impact sensor internal fault Lamp flash code 6 Passenger side impact ...

Page 2565: ...strument Cluster Diagnosis and Testing A3 CHECK THE DLC CIRCUIT Ignition switch in position 0 1 Deactivate the SRS 2 Disconnect Air Bag Control Module C424 3 Measure the resistance between the DLC C200 pin 7 circuit 8 EE10 WH BK and the air bag control module C424 pin 7 circuit 8 EE7 WH RD harness side 4 Is the resistance less than 5 ohms Yes INSTALL a new air bag control module REFER to Air Bag C...

Page 2566: ...rness side 3 Is the resistance less than 5 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No CHECK the connector terminals for corrosion or dirt ingress REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST C DTC B1869 AIR BAG WARNING INDICATOR OPEN CIRCUIT OR SHORT TO GROUND TEST CONDITIONS DETAILS RESULTS ACTIONS C1 CHECK THE AIR BAG WARNING INDICATOR NOTE U...

Page 2567: ...rning indicator illuminated Yes INSTALL a new instrument cluster REFER to Instrument Cluster 413 01 Instrument Cluster Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No GO to C6 C4 CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS WARNING Wait at least one minute after disconnecting the battery ground cable before disconnecting any SRS electrical connector Failure...

Page 2568: ... circuit 91S JA14 BK GN and ground 1 Disconnect the fused jumper wire from the ground 2 Is the air bag warning indicator illuminated Yes INSTALL a new air bag control module REFER to Air Bag Control Module 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TES...

Page 2569: ...dule back up power supply must be depleted Wait at least one minute after disconnecting the battery ground cable s before commencing any repair or adjustment to the SRS or any component s adjacent to the SRS sensors Failure to follow these instructions may result in personal injury NOTE Use a digital multimeter for all electrical measurements Deactivate the SRS 1 Ignition switch in position II 2 C...

Page 2570: ...ut the self test with the simulators installed 3 Does the system prove out correctly Yes GO to F2 No GO to F3 F2 PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER Ignition switch in position 0 1 Disconnect Driver Side Safety Belt Pretensioner Simulator 2 Connect Driver Side Safety Belt Pretensioner C28 3 Ignition switch in position II 4 Carry out the self test 5 Does the system prove out correctl...

Page 2571: ...connecting the battery ground cable s before commencing any repair or adjustment to the SRS or any component s adjacent to the SRS sensors Failure to follow these instructions may result in personal injury NOTE Use a digital multimeter for all electrical measurements Deactivate the SRS 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove ...

Page 2572: ...ER SIDE SAFETY BELT PRETENSIONER SHORT TO GROUND TEST CONDITIONS DETAILS RESULTS ACTIONS H1 CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT WARNING To avoid accidental deployment the air bag control module back up power supply must be depleted Wait at least one minute after disconnecting the battery ground cable s before commencing any repair or adjustment to the SRS or any component s adja...

Page 2573: ...he resistances greater than 10 000 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA33 GN BU or 91S JA33 BK BU REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST I DTC B1885 DRIVER SIDE SAFETY BELT PRETENSIONER LOW RESISTANCE TEST CONDITIONS DETAILS RESULTS ACTIONS I1 CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT WARNING To av...

Page 2574: ...afety Belt Pretensioner Simulator 3 Measure the resistance between the air bag control module C423 pin 11 circuit 15S JA33 GN BU harness side and pin 12 circuit 91S JA33 BK BU harness side 4 Is the resistance greater than 10 000 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA33 GN BU and 91S JA33 BK BU REPEAT the self test CLEAR the DTCs REACTIVATE the s...

Page 2575: ...re the resistances greater than 10 000 ohms Yes INSTALL a new driver air bag module wiring harness REFER to Driver Air Bag Module Wiring Harness 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new driver air bag module REFER to Driver Air Bag Module 501 20B Supplemental Restraint System Removal and Installation R...

Page 2576: ...d Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA8 GN RD or 91S JA8 BK OG REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST K DTC B1888 PASSENGER AIR BAG CIRCUIT SHORT TO GROUND TEST CONDITIONS DETAILS RESULTS ACTIONS K1 CHECK THE PASSENGER AIR BAG CIRCUIT WARNING To avoid accidental deployment the air bag control module back up...

Page 2577: ...ssenger air bag module REFER to Passenger Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system K3 CHECK THE PASSENGER AIR BAG CIRCUIT FOR A SHORT TO GROUND Ignition switch in position 0 1 Disconnect Air Bag Control Module C424 2 Disconnect Passenger Air Bag Module Simulator 3 Measure the...

Page 2578: ...witch in position II 4 Measure the voltage between the Air bag control module C424 pin 2 circuit 15S JA8 GN RD harness side and ground Air bag control module C424 pin 3 circuit 91S JA8 BK OG harness side and ground 5 Is any voltage present Yes GO to L2 No CONNECT the driver air bag module simulator and air bag control module REPEAT the self test CLEAR the DTCS REACTIVATE the system L2 CHECK THE CL...

Page 2579: ... the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST M DTC B1921 AIR BAG WARNING INDICATOR GROUND MONITORING CIRCUIT OPEN TEST CONDITIONS DETAILS RESULTS ACTIONS M1 CHECK THE AIR BAG CONTROL MODULE MOUNTING WARNING To avoid accidental deployment the air bag control module back up power supply must be depleted Wait at least one minute after disconnecting the battery ground cable s befo...

Page 2580: ...ance less than 5 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new air bag control module REFER to Air Bag Control Module 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST N DTC B1925 PASSENGER AIR BAG CIRCUIT SHORT TO BATTERY TEST CONDITIONS DETAILS RESULTS ACTIONS N1 CHECK THE P...

Page 2581: ...he air bag control module back up power supply must be depleted Wait at least one minute after disconnecting the battery ground cable s before commencing any repair or adjustment to the SRS or any component s adjacent to the SRS sensors Failure to follow these instructions may result in personal injury NOTE Use a digital multimeter for all electrical measurements Deactivate the SRS 1 Ignition swit...

Page 2582: ...t 15S JA8 GN RD harness side and the clockspring C920 pin 6 circuit 15S JA8 GN RD component side Air bag control module C424 pin 3 circuit 91S JA8 BK OG harness side and the clockspring C920 pin 5 circuit 91S KA8 BK OG component side 3 Turn the steering wheel from lock to lock and note the resistance readings 4 Are the resistances less than 5 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE...

Page 2583: ...ctions may result in personal injury NOTE Use a digital multimeter for all electrical measurements Deactivate the SRS 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out correctly Yes GO to P2 No REPAIR circuit 15S JA11 GN WH or 91S JA11 BK WH REPEAT the self test CLEAR the DTCs REACTIVATE the system P2 CHECK THE PASSENGER AIR BAG MO...

Page 2584: ...ed 3 Does the system prove out correctly Yes GO to Q2 No GO to Q3 Q2 CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE WARNING Do not proceed with this test unless using WDS Failure to follow this instruction may result in personal injury Disconnect the driver air bag module from the driver air bag module wiring harness 1 Connect the Test and Deployment Lead to the driver air bag module 2 Select DM...

Page 2585: ...RD harness side and pin 3 circuit 91S JA8 BK OG harness side 2 Is the resistance greater than 10 000 ohms Yes INSTALL a new clockspring REFER to Clockspring Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA8 GN RD or 91S JA8 BK OG REPEAT the self test CLEAR the DTCs REACTIVA...

Page 2586: ... the air bag module squib 4 Is the resistance between 2 and 3 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new passenger air bag module REFER to Passenger Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system R3 CHECK THE PASSENGER AIR BAG CIRCUIT FOR LO...

Page 2587: ... S3 S2 PROVE OUT THE DRIVER SIDE AIR BAG CIRCUIT Ignition switch in position 0 1 Disconnect Driver Side Air Bag Module Simulator 2 Connect Driver Side Air Bag Module C30 3 Ignition switch in position II 4 Carry out the self test 5 Does the system prove out correctly Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new driver side air bag module REFER to Side Air Bag Modul...

Page 2588: ...ow these instructions may result in personal injury NOTE Use a digital multimeter for all electrical measurements Deactivate the SRS 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out correctly Yes GO to T2 No GO to T3 T2 PROVE OUT THE DRIVER SIDE AIR BAG CIRCUIT Ignition switch in position 0 1 Disconnect Driver Side Air Bag Module ...

Page 2589: ...ment the air bag control module back up power supply must be depleted Wait at least one minute after disconnecting the battery ground cable s before commencing any repair or adjustment to the SRS or any component s adjacent to the SRS sensors Failure to follow these instructions may result in personal injury NOTE Use a digital multimeter for all electrical measurements Deactivate the SRS 1 Ignitio...

Page 2590: ...at connector C30 pin 2 circuit 91S JA37A BK GN harness side 4 Are the resistances less than 5 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA37 GN BK or 91S JA37 BK GN REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST V DTC B1995 DRIVER SIDE AIR BAG CIRCUIT LOW RESISTANCE TEST CONDITIONS DETAILS RESULTS ACTIONS V1 CHECK THE DRIVER S...

Page 2591: ...es Air bag control module C423 pin 15 circuit 15S JA37A GN BK harness side and pin 16 circuit 91S JA37A BK GN harness side 4 Is the resistance greater than 10 000 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15S JA37 GN BK and circuit 91S JA37 BK GN or circuit 15S JA37A GN BK and circuit 91S JA37A BK GN REPEAT the self test CLEAR the DTCs REACTIVATE the syst...

Page 2592: ...rol Module C423 2 Disconnect Passenger Side Air Bag Module Simulator 3 Ignition switch in position II 4 Measure the voltage between the Left hand drive vehicles Air bag control module C423 pin 23 circuit 15S JA15 GN RD harness side and ground Air bag control module C423 pin 24 circuit 91S JA15 BK OG harness side and ground Right hand drive vehicles Air bag control module C423 pin 23 circuit 15S JA...

Page 2593: ... the system prove out correctly Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No INSTALL a new passenger side air bag module REFER to Side Air Bag Module Vehicles Built Up To 04 2009 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system X3 CHECK THE PASSENGER SIDE AIR BAG FOR A SHORT TO GROUND Ignition switch in pos...

Page 2594: ...ith the simulators installed 3 Does the system prove out correctly Yes GO to Y2 No GO to Y3 Y2 PROVE OUT THE PASSENGER SIDE AIR BAG CIRCUIT Ignition switch in position 0 1 Disconnect Passenger Side Air Bag Module Simulator 2 Connect Passenger Side Air Bag Module C31 3 Ignition switch in position II 4 Carry out the self test 5 Does the system prove out correctly Yes REPEAT the self test CLEAR the D...

Page 2595: ... ACTIONS Z1 CHECK THE PASSENGER SIDE AIR BAG CIRCUIT WARNING To avoid accidental deployment the air bag control module back up power supply must be depleted Wait at least one minute after disconnecting the battery ground cable s before commencing any repair or adjustment to the SRS or any component s adjacent to the SRS sensors Failure to follow these instructions may result in personal injury NOT...

Page 2596: ...circuit 91S JA15A BK OG REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST AA DTC B2117 DRIVER SIDE AIR BAG MODULE CIRCUIT CAPACITANCE OUT OF RANGE TEST CONDITIONS DETAILS RESULTS ACTIONS AA1 CHECK THE DRIVER SIDE AIR BAG MODULE CIRCUIT CAPACITANCE WARNING To avoid accidental deployment the air bag control module back up power supply must be depleted Wait at least one minute a...

Page 2597: ... SRS 1 Ignition switch in position II 2 Carry out the self test with the simulators installed 3 Does the system prove out correctly Yes GO to AB2 No CHECK the air bag simulator is installed correctly REPEAT the self test CLEAR the DTCs REACTIVATE the system AB2 PROVE OUT THE PASSENGER SIDE AIR BAG CIRCUIT Ignition switch in position 0 1 Disconnect Passenger Side Air Bag Module Simulator 2 Connect ...

Page 2598: ...he driver side impact sensor C427 pin 1 circuit 91 JA39A BK YE harness side 4 Are the resistances less than 5 ohms Yes GO to AC2 No REPAIR circuit 15S JA39 GN YE circuit 15S JA39A GN YE or circuit 91 JA39 BK YE or circuit 91 JA39A BK YE REPEAT the self test CLEAR the DTCs REACTIVATE the system AC2 CHECK THE DRIVER SIDE IMPACT SENSOR CIRCUIT FOR A SHORT CIRCUIT Disconnect Air Bag Control Module C42...

Page 2599: ...INSTALL a new driver side impact sensor REFER to Side Impact Sensor 501 20B Supplemental Restraint System Removal and Installation REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15 JA10 GN OG or circuit 15 JA10A GN OG or circuit 15S JA39 GN YE or circuit 15S JA39A GN YE or circuit 91 JA10 BK RD or circuit 91 JA10A BK RD or circuit 91 JA39 BK YE or circuit 91 JA39A BK Y...

Page 2600: ...T FOR A SHORT CIRCUIT Disconnect Air Bag Control Module C424 1 Measure the resistance between the Left hand drive vehicles Air bag control module C423 pin 25 circuit 91S JA40 BK WH harness side and the air bag control module C424 pin 8 circuit 15 JA10 GN OG harness side Air bag control module C423 pin 25 circuit 91S JA40 BK WH harness side and the air bag control module C424 pin 9 circuit 91 JA10 ...

Page 2601: ...40A GN YE or circuit 91 JA40 BK WH or circuit 91 JA40A BK WH REPEAT the self test CLEAR the DTCs REACTIVATE the system PINPOINT TEST AE AIR BAG CONTROL MODULE DISCONNECTED OR INOPERATIVE TEST CONDITIONS DETAILS RESULTS ACTIONS AE1 CHECK THE AIR BAG CONTROL MODULE ELECTRICAL CONNECTORS WARNING To avoid accidental deployment the air bag control module back up power supply must be depleted Wait at le...

Page 2602: ...24 pin 8 circuit 15 JA10 GN OG harness side and ground 3 Is the voltage between 9 and 16 volts Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system No REPAIR circuit 15 JA10 GN OG REPEAT the self test CLEAR the DTCs REACTIVATE the system http vnx su ...

Page 2603: ...rritating to the skin Use protective gloves when handling any deployed air bag module Failure to follow this instruction may result in personal injury 1 Remove the deployed air bag module s For additional information refer to the relevant procedure in this section 2 Seal the deployed air bag module s in the packaging from the new air bag module s or a suitable polythene bag and then dispose of in ...

Page 2604: ...formation refer to the relevant procedure in this section 2 WARNING Under no circumstances is an unserviceable air bag module s to be returned through the local mailing system Failure to follow this instruction may result in personal injury Seal the unserviceable air bag module s in the packaging from the new air bag module s and address to the appropriate manufacturer The package should then be f...

Page 2605: ... module or the safety belt pretensioner should not be handled immediately following deployment as the air bag module or safety belt pretensioner will be hot Failure to follow this instruction may result in personal injury After deployment the inflator s become inert direct contact with the skin or eyes of any free pyrotechnic residues should be avoided Failure to follow this instruction may result...

Page 2606: ...ag Pyrotechnic Safety Belt 3 Deployment lead Part of Test and Deployment lead Air Bag Pyrotechnic Safety Belt 3 Connect the test lead to the air bag module and the adapter For additional information refer to Specifications in this section 4 CAUTION To protect the test lead http vnx su ...

Page 2607: ...C button 6 To deploy the side air bag module depress the adapter box AC button 7 Move as far away as possible from the air bag module and depress both switches to deploy the air bag module 8 WARNING DO not connect both test leads to the adapter at this stage Each inflator must be deployed separately Failure to follow this instruction may result in personal injury Connect the test leads to the air ...

Page 2608: ...e with the air bag module cover upper most driver air bag shown 10 To deploy the driver or passenger air bag module first inflator release the adapter box AC button 11 Move as far away as possible from the air bag module and depress both switches to deploy the air bag module 12 To deploy the driver or passenger air bag module second inflator connect the second test lead to the adapter http vnx su ...

Page 2609: ...Detach the safety belt buckle pretensioner electrical connector from the front seat 16 Install the front seat if necessary For additional information refer to Section 501 10 Seating 17 CAUTION Make sure the front seat mounting bolts are installed Connect the test lead to the safety belt buckle pretensioner electrical connector For additional information refer to Specifications in this section 18 T...

Page 2610: ...ton 22 Move as far away as possible from the vehicle and depress both switches to deploy the safety belt retractor pretensioner 23 Deployed air bag module s and safety belt pretensioners should be sealed in suitable bags and then disposed of in accordance with local contaminated waste regulations 24 WARNINGS Under no circumstances is an unserviceable air bag module or safety belt buckle pretension...

Page 2611: ...n placed on the Mandatory Return List All discolored or damaged air bag modules should be treated the same as any unserviceable live air bag module being returned If an air bag module or safety belt buckle pretensioner fails to deploy seal the unserviceable air bag module or safety belt buckle pretensioner in suitable packaging and return to the Exchange Plan Center as appointed through the local ...

Page 2612: ...f the clockspring must be repeated CAUTION The clockspring and steering wheel rotation sensor assembly must not be rotated in a clockwise direction more than 3 revolutions NOTE Make sure that the road wheels are in the straight ahead position 1 1 Turn the clockspring in a counterclockwise direction until a resistance is felt 2 Turn the clockspring in a clockwise direction 3 revolutions until the a...

Page 2613: ...allation Removal NOTE Removal steps in this procedure may contain installation details Installation 1 Refer to Front Seat Backrest Cover Vehicles Built From 04 2009 501 10 Seating Removal and Installation 2 WARNING Make sure that the wiring harnesses are correctly located 3 Torque 5 Nm 1 To install reverse the removal procedure http vnx su ...

Page 2614: ... possibility of premature deployment live air bag modules must only be placed on work benches which have been ground bonded and with the trim cover facing up Failure to follow these instructions may result in personal injury Never probe the electrical connectors of air bag modules or any other supplemental restraint system component Failure to follow this instruction may result in personal injury ...

Page 2615: ...e retaining straps 2 Detach the retaining strips 6 Remove the armrest if equipped Depress the locking tang 7 Roll the backrest cover up the backrest to gain access to the armrest housing 1 Roll the backrest cover up the backrest 2 Cut the hog rings http vnx su ...

Page 2616: ...ng tang 3 Remove the armrest housing 9 Detach the side air bag cover from the backrest frame 1 Pull the air bag cover retaining strip from the backrest frame 2 Detach the retaining strip 10 Roll the backrest cover up the backrest to gain access to the side air bag module Cut the hog rings 11 Remove the air bag Discard the retaining nuts http vnx su ...

Page 2617: ...onal injury To minimize the possibility of premature deployment live air bag modules must only be placed on work benches which have been ground bonded and with the trim cover facing up Failure to follow these instructions may result in personal injury Never probe the electrical connectors of air bag modules or any other supplemental restraint system component Failure to follow this instruction may...

Page 2618: ...o not use radio key code savers when working on the supplemental restraint system Failure to follow this instruction may result in personal injury Never probe the electrical connectors of air bag modules or any other supplemental restraint system component Failure to follow this instruction may result in personal injury 1 Detach the instrument panel lower panel from the instrument panel 1 Remove t...

Page 2619: ...he steering column locking lever 2 Remove the retaining screws 8 Detach the multifunction switches from the clockspring and position them to one side Depress the locking tang in turn and slide each switch upwards 9 Disconnect the clockspring electrical connector Using a thin bladed screwdriver release the locking tang 10 CAUTION Note the position of the spacing collar within the center of the cloc...

Page 2620: ...omponent Failure to follow this instruction may result in personal injury steering column 1 Install the clockspring Make sure the retaining tangs lock into position on the steering column 2 NOTE An audible click will be heard when the locking tangs are fully engaged Connect the clockspring electrical connector http vnx su ...

Page 2621: ... 2 Lock the steering column locking lever 5 NOTE An audible click will be heard when the locking tangs are fully engaged Install the audio control switch if equipped 1 Connect the audio control switch electrical connector 2 Engage the locking tang into the lower shroud 6 Install the steering column upper shroud 7 CAUTIONS Make sure the road wheels are in the straight ahead position http vnx su ...

Page 2622: ...ury CAUTION Make sure the road wheels are in the straight ahead position Centralize the clockspring 1 Turn the clockspring in a counterclockwise direction until a resistance is felt 2 Turn the clockspring in a clockwise direction until the arrow marked on the rotor of the clockspring aligns with the raised V section at the 12 o clock position on the outer cover of the clockspring approximately two...

Page 2623: ...12 Install the instrument panel lower panel to the instrument panel 1 Secure the clips 2 Install the screws http vnx su ...

Page 2624: ... 5 06 2002 Print Removal and Installation General Equipment Removal Flat bladed screwdriver 1 Refer to Steering Wheel 211 04 Steering Column Removal and Installation 2 If equipped General Equipment Flat bladed screwdriver 3 If equipped 4 5 6 CAUTIONS Make sure that the clockspring rotor http vnx su ...

Page 2625: ...th stability assist Installation does not rotate Make sure that the clockspring pins are not bent or damaged 1 Using a suitable piece of tape secure the clockspring rotor to the clockspring body 7 8 9 http vnx su ...

Page 2626: ...1 To install reverse the removal procedure 2 Refer to Clockspring Adjustment Vehicles Built From 04 2009 501 20B Supplemental Restraint System General Procedures http vnx su ...

Page 2627: ...ag modules must only be placed on work benches which have been ground bonded and with the trim cover facing up Failure to follow these instructions may result in personal injury Never probe the electrical connectors of air bag modules or any other supplemental restraint system component Failure to follow this instruction may result in personal injury Painting over the driver air bag module trim co...

Page 2628: ...imize the possibility of premature deployment do not use radio key code savers when working on the supplemental restraint system Failure to follow this instruction may result in personal injury To minimize the possibility of premature deployment live air bag modules must only 4 Detach the driver air bag module from the steering wheel 1 Pull the top of the air bag module away from the steering whee...

Page 2629: ...ry Painting over the driver air bag module trim cover or instrument panel could lead to deterioration of the trim cover and air bag modules Do not for any reason attempt to paint discolored or damaged air bag module trim covers or instrument panel Install a new component Failure to follow this instruction may result in personal injury CAUTION Make sure that the driver air bag module retaining clip...

Page 2630: ...n the supplement restraint system Failure to follow this instruction may result in personal injury Never probe the electrical connectors of air bag modules or any other supplemental restraint system component Failure to follow this instruction may result in personal injury 4 Remove the components in the order indicated in the following illustration s and table s Description Lower anchor retaining ...

Page 2631: ... install reverse the removal procedure Removal Details Item 1 Lower anchor retaining bolt 3 4 1 NOTE Hold the safety belt webbing when detaching the safety belt lower anchor from the floor panel Detach the safety belt lower anchor from the floor panel http vnx su ...

Page 2632: ...o minimize the possibility of premature deployment do not use radio key code savers when working on the supplemental restraint system Failure to follow this instruction may result in personal injury Never probe the electrical connectors of air bag modules or any other supplemental restraint system component Failure to follow this instruction may result in personal injury 3 Remove the components in...

Page 2633: ...ng bracket See Removal Detail Air bag control module retaining screws Air bag control module See Installation Detail 4 To install reverse the removal procedure Removal Details Item 4 Gearshift housing Item 6 Gearshift mounting bracket Item 1 2 3 4 5 6 7 8 1 Detach the gearshift housing from the gear shift mounting bracket 1 Detach the gearshift mounting bracket from the floor panel Part Number htt...

Page 2634: ...g control module 1 NOTE New air bag control modules supplied in service require configuring following installation Configure the air bag control module For additional information refer to Section 418 01 Module Configuration http vnx su ...

Page 2635: ...ts Make sure that the vehicle electrical system is fully depowered and no other power source is connected NOTE Removal steps in this procedure may contain installation details Vehicles with navigation system 1 Refer to Supplemental Restraint System SRS Health and Safety Precautions 100 00 General Information Description and Operation 2 Refer to Battery Disconnect and Connect 414 01 Battery Mountin...

Page 2636: ...Vehicles without navigation system All vehicles 7 8 1 Torque 8 Nm 2 Torque 8 Nm 9 http vnx su ...

Page 2637: ...Installation 1 To install reverse the removal procedure http vnx su ...

Page 2638: ...th the bag and trim cover pointed away from the body Failure to follow this instruction may result in personal injury To minimize the possibility of premature deployment live air bag modules must only be placed on work benches which have been ground bonded and with the trim cover facing up Failure to follow these instructions may result in personal injury Never probe the electrical connectors of a...

Page 2639: ...tallation Details Item 4 Passenger air bag Item 1 2 3 4 1 Detach the passenger air bag electrical connector from the air bag mounting bracket 1 NOTE If necessary use a trim tool to aid the release of the passenger air bag cover retaining clips from the instrument panel Push the air bag module upwards to detach the air bag cover from the instrument panel 2 NOTE It may be necessary to use a pair of ...

Page 2640: ...CAUTION Make sure that all the passenger air bag trim cover retaining clips are correctly engaged and the trim cover is flush with the instrument panel http vnx su ...

Page 2641: ...ors of air bag modules or any other supplemental restraint system SRS component Failure to follow this instruction may result in personal injury To minimize the possibility of injury in the event of premature deployment do not work on the air bag module with the trim cover facing downwards Support the air bag module vertically and work to the side of the air bag module Failure to follow these inst...

Page 2642: ...river air bag module 4 Remove the driver air bag module wiring harness Release the driver air bag module wiring harness locking tangs 5 Detach the driver air bag module wiring harness from the driver air bag module 6 Remove the driver air bag module wiring harness Release the driver air bag module wiring harness locking tangs http vnx su ...

Page 2643: ...work benches which have been ground bonded and with the trim cover facing up Failure to follow these instructions may result in personal injury Never probe the electrical connectors of air bag modules or any other SRS component Failure to follow this instruction may result in personal injury 1 CAUTIONS Make sure that the driver air bag module electrical connectors are free from any wiring harness ...

Page 2644: ...al repair techniques provide valuable support when undertaking body repairs Introduction Body development is becoming more and more complex and as a result the topics covered in the body repair manual are changing In future only the most important repair methods and techniques will be described in the general section Extensive knowledge of fundamental body repair techniques is assumed For example ...

Page 2645: ...fety passenger cell is protected by front and rear crumple zones with well defined deformation characteristics The crumple zones serve the following purposes Dynamic absorption of deforming forces Protection of the passenger cell Always follow the repair instructions published in the workshop literature particularly on repairs in the crumple zone Failure to observe this instruction can result in s...

Page 2646: ...me This design has the following advantages High pay load and large trailer capacity Excellent strength properties for off road use Extremely high ground clearance If any repairs are to be carried out on an off road vehicle then the following notes should be observed It is quite common for the two longitudinal members of the frame to be displaced parallel to one another If necessary the bolted on ...

Page 2647: ...om the surface e g weld spot mill have a reduced life expectancy because of the higher degree of hardness Do not apply heat during straightening work as losses of mechanical strength can occur already at temperatures of approx 400 C Bake hardening steel achieves its final hardness during production when it is placed into the paint drying oven Item 1 2 3 Type of steel Special properties Low alloy t...

Page 2648: ...nergy If any unprofessional repair techniques or methods are used in these areas then this can pose a fundamental threat to vehicle safety Hidden damage As well as looking at external indicators like flaked off paint it is vital to check for hidden body damage or deformation that is not visible from the outside Large attached parts hardening steel surface hardness is achieved in combination with h...

Page 2649: ...Pre determined deformation points by special shaping of the body panels Pre determined deformation points by the use of different material thicknesses Description Material thickness 2 0 mm Material thickness 3 0 mm Material thickness 1 75 mm Node welds Node welds are key points in the body shell of a vehicle Indications of damage such as flaking paint in the area of node welds are often a clear si...

Page 2650: ...s e g transmission mountings should be thoroughly checked Electronic components should be checked to ensure that they still operate correctly Furthermore it is possible to deduce the overall extent of damage from the direction and magnitude of the impact forces This does however require extensive body specific knowledge If for instance an impact occurs at the front left hand side member then the r...

Page 2651: ...ons at the site of the impact However the impact forces are transferred to the entire vehicle floor which often results in so called banana damage where the vehicle is bent into a banana shape across the length of its longitudinal axis Impact energy is transferred via the side member to the A pillar Description Deformation area roof rail Deformation area roof Deformation area door sill Measuring t...

Page 2652: ... required for accurate measurements of the floor pan of the body The measuring systems are categorised by their means of operation Mechanical measuring system Optical measuring system Quick and accurate measuring results can be obtained using computerised measuring systems A minimum of three intact measuring points on the floor pan are required for measurements of length width and height dimension...

Page 2653: ... attached parts that need to be renewed including small parts like rivets clips etc After receiving all of the spare parts check them on the vehicle to make sure they are correct and complete Straightening repairs Straightening repairs are often required to restore the body to its original shape after an accident This can be done with Alignment jigs Universal straightening and measuring jigs Weldi...

Page 2654: ...uring straightening Never apply heat during straightening Follow the instructions in the chapter Protective Equipment Safety at Work Cutting out body parts Depending on how the parts are joined connected different tools are suitable for cutting separating body parts NOTE All other parts like interior equipment window glass etc must be protected against flying sparks NOTE Ensure that the milling de...

Page 2655: ...e of the blade can be substantially increased by cooling it with oil Any swarf caused by sawing must always be removed from cavities using suction to prevent the risk of corrosion If there are any brazed connections on the part that is to be cut out then use a welding torch to heat them evenly until the brazing solder melts Then peel off the old part Reciprocating saw Carrying out the repairs Comp...

Page 2656: ...rs and pillars or on short severance cuts Butt joint Edge setting NOTE Although the width of the set edge is 12 mm only 10 mm should be given as material allowance on the new part This automatically produces the required welding gap between the set edge of the old panel and the edge of the new panel For corrosion protection reasons the set edge created is shortened to 6 mm before inserting the new...

Page 2657: ...air sections can vary in size Special repair sections are available for sectional repairs and they are listed separately in the Spare Parts microfiche Metal backing strip Description Resistance spot weld MIG welded intermittent seam Example Repair panel sections Ford Ka Sectional replacement side member Ford Puma Prepare parts remaining on the vehicle new parts Reshape the adjoining surface of any...

Page 2658: ... dimensions can be found in the model specific repair manuals NOTE Any attached body parts that require accurate alignment and fitting must be incorporated in this step for instance bumpers seals headlamps rear lamps and lock assembly components If this is not done carefully it may result in water leaks wind noises and substantial follow on work Ensure that edges line up with adjacent parts and ch...

Page 2659: ...t Removal 501 25G Body Repairs Noise Vibration and Harshness Body Repairs Corrosion Protection Cavity wax after painting Panel beating Types of steel used in body manufacture Vehicle bodies are manufactured using thin steel with a thickness ranging from 0 5 to 2 75 mm There are two main types Pressed steel quality body panels High strength low alloy steel Pressed steel quality body panels These bo...

Page 2660: ...l by more than they were originally stretched Different heat treatment techniques NOTE Different heat treatment techniques are used depending on the amount of excess material Flattening using a flame A welding torch is used if the material excess extends over a larger area torch size 0 5 1 0 mm Use a soft flame The surface of the metal is briefly spot heated and then immediately cooled with a wet ...

Page 2661: ...cle ABS airbag etc Do not allow electronic units or lines to come into contact with the ground connection or the welding electrode Remove the battery before carrying out welding work in its vicinity Utmost care must be taken when welding near the fuel tank or other components that contain fuel If the tank filler neck or a fuel line must be detached to allow access for welding work then the fuel ta...

Page 2662: ...g performance MIG MAG welding Setting up the equipment and co ordinating the welding parameters Any joins that are MIG MAG welded in production must also be MIG MAG welded during repairs Also during repairs some resistance spot welds need to be replaced by puddle welds If access is difficult or if a suitably powerful spot welder see above for total panel thicknesses of 3 mm or more is not availabl...

Page 2663: ...s Application and safety instructions Always follow the handling instructions supplied by the manufacturer when using adhesives or sealants NOTE Observe the manufacturer s safety instructions Adhesives are chemicals and as such are subject to specific safety regulations Bonded clinched flanges The bonded clinched flanges of the hood tailgate and doors are bonded in production and during repair on ...

Page 2664: ...ls and decorative strips as well as all electrical connections Mask any painted areas that are adjacent to the window Cut off any surplus adhesive as this makes it easier to cut out the window Secure vertical windows against dropping out Cutting out the window Cut into the adhesive bead at easily accessible points using the cutting tool Carefully guide the cutting tool around the window cutting th...

Page 2665: ...its torsional rigidity This is achieved by making constructional changes to existing saloon body parts and by installing additional strengthening parts Reinforcements to the door sill area NOTE If a damaged vehicle is placed on the straightening jig with all its aggregates still in place then the body needs to be supported to take some of the load The following design features should be noted duri...

Page 2666: ...r instance PVC is burned then gases containing hydrochloric acid are produced For this reason a suitable extraction unit should always be used when performing grinding welding or soldering work Always ensure good ventilation when working with materials that contain solvents wear breathing equipment and use an extraction unit Ear defenders should always be worn when cutting grinding or straightenin...

Page 2667: ... and is a requirement for any later warranty claim Ford original spare part If repair work is necessary on vehicle bodywork the repair instructions given in the model specific chapters of this manual and the instructions in the paint and corrosion protection manual must be followed If hairline cracks at bodywork connection areas appear after reshaping work e g at door hinges it must be ensured tha...

Page 2668: ... Thoroughly clean with silicone remover and rub dry Apply corrosion protection to bare areas Depending on the vehicle the clinched flanges on the hood doors tailgate and trunk lid must be sealed with clinched flange sealer The model specific body repair manuals contain detailed information After repair the paint finish must be recreated according to the paint and corrosion protection manual Welded...

Page 2669: ...ally rather than completely renewed concerns the preparation of butt or lap joints When bodywork components are cut through attention must be paid to the adequate removal of the paint and zinc coatings on inner areas This specially applies to areas which are difficult to access internally It is important for the weld quality that the inner area is bare metal Zinc and paint residues in the weld are...

Page 2670: ...lose with a plug and seal with underseal Classification of the different corrosion protection measures for dent removal Classification of different corrosion protection measures for installation of new components Item 1 2 3 4 Corrosion protection method Exterior surfaces Accessible inner surfaces Inaccessible inner surfaces Painting X X Cavity protection X Corrosion protection method Weld flanges ...

Page 2671: ... state Duroplastics duromers Duroplastics are much harder and more brittle than thermoplastics Their strength remains largely unchanged when they are heated Duroplastics are destroyed when the critical temperature point is exceeded Cooling down will not restore the original state Plastics used by Ford Plastic identification If a plastic has no identifying marks the type can be established using tw...

Page 2672: ...ations which occur in the elastic area These normally take the form of dents indentations and bends Many of these deformations e g to bumper bars correct themselves of their own accord immediately or after a certain period of time This self correction depends on the extent of the damage and the temperature Most flat deformations in the elastic area revert to their original form when heated with a ...

Page 2673: ...ot air blower approx 1500 W Welding nozzles Various welding rods Face cutter Ø 5 5 mm for processing the welding groove Scraper heart shaped Plastic welding gun Description Plastic welding gun Rapid welding nozzle Wedge nozzle fixed nozzle Face cutter Preparing the repair location crack Prepare cracking for the welding process in V formation V groove weld seam Description Part to be repaired Weld ...

Page 2674: ... thickness 5 7 mm x 3 7 mm Only weld PBT PC plastic using a PP welding rod Glass fiber reinforced plastics cannot be welded Blue dyed plastic parts on the Ford Ka cannot be painted and are therefore not suited to plastic repairs Rear side of the plastic welding gun Description Air intake opening Temperature control unit Rocker switch Air volume switch The temperatures given are air temperatures fo...

Page 2675: ...ding rod through the heated pre heating chamber of the rapid welding nozzle until the tip of the welding rod emerges from the underside Aligning the rapid welding nozzle The underside of the rapid welding nozzle must run parallel to the repair surface in a lengthways direction Parallel alignment in a lengthways direction is achieved with the welding equipment at the appropriate inclination Positio...

Page 2676: ...ld speed too fast Welding together differing materials Weld seam sinks Crack groove too wide Weld temperature too high Re working the weld seam After cooling down the raised part of the weld seam can be sanded down using an angle sander and abrasive paper of P80 grit Surface grinding is then carried out using the orbital sander and abrasive paper of P120 P220 grit Clean the ground repair surface u...

Page 2677: ... advantages over welding technology Within the group of thermoelastics all semi rigid ancillary components such as bumper bars front grilles etc can be repaired without identification A two component adhesive with a polyurethane basis must be used for all thermoplastic parts Reinforcement strips can be attached to crack grooves cracks up to max 100mm and fractures to ensure the original tensile pr...

Page 2678: ...surface using plastic cleaner Grinding out the scratch Description Preparation of the scratch Preparation of the crack Grind out the scratches thoroughly flat using an orbital sander Abrasive paper P80 P120 grit Fine sanding with orbital sander Abrasive paper P120 grit NOTE Wear protective gloves for cleaning Thoroughly clean the repair location using plastic cleaner and paper towels Spray plastic...

Page 2679: ... of cracking and fracture damage over a large area To this end suitable reinforcement materials metal strips reinforcement fibers are affixed to the rear side Cover the crack on the front side with a PE sheet and with adhesive tape From the rear side fill the ground out crack groove with plastic adhesive A wide strip of reinforcing fiber is fixed over the crack groove in the bead of adhesive The e...

Page 2680: ...lowing points The room temperature should be at least 15 C and the air should be as dry as possible NOTE Fingerprints leave behind a film that prevents a proper joint The repair location must be thoroughly dry and clean Before the repair the GRP part being repaired must be dried using an infrared heater or in a drying oven In cases of large cracks and fractures the strength of the outer skin can b...

Page 2681: ...necessary NOTE Completely soak the glass fiber mat in polyester resin No air may be trapped in the repair area Apply polyester resin using a brush Allow the polyester resin to dry at room temperature Back larger cracks and fractures with reinforcement material to restore the strength of the outer skin Apply stopper The depression on the front side is filled with polyester fiber stopper to achieve ...

Page 2682: ...action systems are available only use tools with extraction systems Protective equipment such as gloves protective goggles aprons and breathing masks are essential For additional information refer to Section 501 25A Body Repairs General Information 501 25B Body Repairs Corrosion Protection 501 25C Body Repairs Plastic Repairs 501 25D Body Repairs Water Leaks 501 25E Body Repairs Wind Noise 501 25F...

Page 2683: ...ror test Chalk powder test Flow tube smoke test Practical execution of tests and checks Water test NOTE Never aim a jet of water directly at a rubber seal Carry out the water test with a second person present passenger compartment Use variable washer nozzles concentrated water jet to fine spray mist Start in the lower section and spray the whole area working upwards in stages The following are sui...

Page 2684: ...Benefits A switchable light is built into the mirror area The angle of inclination of the mirror can be set manually using the handle The connector between the handle and the mirror is flexible Chalk test powder test In this test the clamping load and the bearing surface of the seal are checked Performing the test Dust the door seal with powder or coat with chalk Coat the bearing surface of the se...

Page 2685: ...ticker Clinched flange sealer Window sealing compound Water shield PVC Foam watershield Double sided adhesive tape for water shield Butyl tape for foam watershield Methylated spirit available from trade outlets PU adhesive Silicone remover Tar remover Water leaks according to mileage or running time Increasing mileage has an effect on the problem of leaks in a vehicle Possible influencing factors ...

Page 2686: ...es must be checked The associated seals must not be damaged and must be installed correctly Check that welded seams are correctly sealed The correct seating of rubber grommets must be checked The seals of windows fitted using rubber seals must be installed precisely and make contact all the way round Directly glazed windows must have correct and complete bonding Water drainage system If a vehicle ...

Page 2687: ...rame Wipe off excess sealing compound immediately If a new leak is found after the necessary leak check then the rubber seal must be renewed Windscreen seal Description Window frame seal Window seal Windscreens directly glazed version Diagnosis Ingress of water into A pillar area or instrument cluster area Cause Breaks in adhesive beads Corrective action NOTE The repair must be carried out in line...

Page 2688: ...In addition to this the drainage holes can become clogged with leaves dirt or excess cavity protection agents Water gathers in the door and ingresses into the passenger compartment NOTE If a water shield or foam watershield becomes damaged in any way then it must always be renewed Check water shield or foam watershield for damage or correct fitting NOTE When detaching a foam watershield the butyl ...

Page 2689: ...s be taken into consideration The clamping load is normally adjusted using the striker When doing so the edge alignment from the door to the side panel or from the front door to the rear door must be taken into account Another setting method is to realign the panel flange for the seal mounting The clamping load is increased by moving the flange towards the door NOTE Do not realign the flange too f...

Page 2690: ...rubber hammer The installed seal must not be kinked at any point NOTE The prescribed length of a seal must not be shortened Correct installation of the door seal Other cause The door seal is attached to the welded flange all the way round If this welded flange is uneven or damaged at any point usually in areas with narrow radii then this point could be subject to leaks A stretched seal carrier can...

Page 2691: ...C pillar The drain holes or drain hoses can become clogged with leaves dirt underbody protection and so on Corrective action NOTE In the case of a sliding or tilting roof the external rubber seal and the lock actuator or latch mechanism must be checked first of all Check the water trap for leaks Check the drain hoses for leaks and for correct connection to the water trap Check the drainage system ...

Page 2692: ...gh area is sealed with a foam watershield that is fixed to the housing The housing has drain holes to allow the water to drain off If the foam watershield is defective or the drain hole is clogged water can ingress into the front footwell area Heater and ventilation housing seal Corrective action Seal the broken seal welds If a leak is found in the heater or ventilation housing the drain holes mus...

Page 2693: ...able routing holes must also be checked Door light switch seal Rear drip rail seal Diagnosis Ingress of water into side headlining area Cause The roof outer panel is sealed with a seal weld at the connection point to the side panel This seal weld can be concealed with a bezel or trim strip In the case of estate and hatchback vehicles there is an additional seal to the rear roof crossmember Water c...

Page 2694: ... adjustment of the lid is made using the lock striker or the lock Rubber bump stops are attached to both sides of the luggage compartment opening These are normally adjustable and the clamping load can be modified The narrow radii of the luggage compartment lid seal are also problem areas Check the seal for correct installation position Other cause The seal is not attached evenly around the lid be...

Page 2695: ...ct seating fully unhooked The mounting points of the tailgate hinges may leak Corrective action Check the rubber grommets and renew if necessary Check the hinge mounting points and re seal with sealing compound if necessary Check the routing holes for rubber grommets cables and hoses Forced air extraction Diagnosis Ingress of water into side luggage compartment area Cause The forced air extraction...

Page 2696: ...ght has a leak this usually means that the seal was fitted incorrectly Corrective action Remove the rear light Check the housing and glass for damage Check the plastic seal for leaks NOTE The sealing compound must always be removed during repair work Check the seal for the rear lights Panel connections with seal welds Diagnosis Ingress of water into the luggage compartment area Cause Several panel...

Page 2697: ...Locate the leak in the seal weld Re seal using sealing compound Possible water leaks at the panel connections in the luggage compartment http vnx su ...

Page 2698: ... layers form in which air pressure variations occur Part of this pressure variation spreads in the form of sound waves and is transferred to the vehicle interior by the side windows and seals Here the noise is particularly loud because of the closeness of the side window to the driver or passenger The noise experienced is mostly a low roaring which becomes louder as speed increases Noises caused p...

Page 2699: ...tions caused by pressure variations on the outside of the vehicle which then means transfer of noise into the vehicle interior The vibrating part of the seal operates here in the same way as loudspeaker membrane Origin of vibrations diagram Description Vibrating seal Radiation into the vehicle interior Escaping noises Small leaks in the vehicle interior sealing system allow small currents of air t...

Page 2700: ... speeds above about 60km h close the sliding roof slightly until the drumming noise is no longer heard Wind noises from the door seals Because of the air currents passing by the sides of the bodywork and over the roof the pressure outside is slightly lower Because of the heating and ventilation system the pressure inside the vehicle is slightly higher This pressure difference causes for example th...

Page 2701: ...practice Seal on driver and passenger door Diagnosis Wind noise from the door seal at the top Cause The alignment of the door frame to the roof is incorrect Corrective action Re align the door with the side window open Check the door seal to sealing surface contact area The width of the sealing area must be at least 5mm The correct gap between the door and A pillar or door and roof 5 6 7 8 Type of...

Page 2702: ...ailgate too high Sliding roof adjustment Diagnosis Wind noise from the sliding roof Cause Sliding roof incorrectly adjusted Corrective action Adjust the sliding roof according to the following requirements There must be an equal gap all round the sliding roof The sliding roof must be adjusted to suit the roof contour The front edge of the sliding roof should close flush with the top face of the ro...

Page 2703: ...adjust it so that it lies below the air turbulence which exists at the wind guide plate when it is in its rest position Adjustment of the wiper arm Description Too high Correct Sequence for performing a wind noise diagnosis diagram 1 1 Customer concern What is the customer concern and what details can he supply about the wind noise 2 2 Under which conditions does the wind noise appear Item 1 2 Par...

Page 2704: ... the fit of the doors When the doors are adjusted to fit exactly development of wind noise can often be eliminated at high speeds lifting of doors off the seals Stethoscope testing The stethoscope is a simple and appropriate tool for finding bodywork air leaks If the blower is turned on at the highest speed and all the doors windows and other openings are closed the air pressure inside the vehicle...

Page 2705: ...be tested Prepare the vehicle as necessary use adhesive tape to blank off areas Pay special attention to door openings and door seals during the road test http vnx su ...

Page 2706: ...k components or closed bodywork profiles The same applies to edge areas beads and folds in bodywork components which are very rigid Satisfactory results are only possible for minor dents that are shallow and with a small deformation radius This method is therefore particularly suitable for damage arising from hail parking and transport Economic considerations Whether it is economically worthwhile ...

Page 2707: ... help recognition 3 3 Prepare the repair area It must be certain that the inside of the dent is accessible Repair openings must not be made Clean the bodywork in the damaged area Good visual checking is vital to success Polish the repair surface if it is matt The repair procedure can only be checked exactly if there is enough reflection of light 4 4 Place the adjustable lamp in position The adjust...

Page 2708: ... of the dent restores on its own through tension produced by the pressure Diagram Description Sequence of pressure Starting position NOTE Never begin in the centre of the dent If a dent is worked from the centre first the edge will be lifted up and will remain visible as a high area material stretching This lifted edge can only then be restored by lengthy reworking High edge Description High edges...

Page 2709: ...more stable surface than weak pressure areas Only short pressure movements are required here because the steel of the bodywork is less sprung Particular care must be taken with the pressure procedure if tools with a small contact face are used Optical check It is only possible completely to remove all remaining unevenness by making continual visual checks of the surface using the adjustable lamp I...

Page 2710: ...air work if the dent is near the sliding roof Repairs near inner braces are worked using the special tools found in the tool kit Separate the adhesive bead of the brace using a metal spatula so that the pressure tool can be put in position Special lever for dents near inner braces Description Contact point Direction of movement Door area Dents in the upper half of the door can usually be worked on...

Page 2711: ...rotection All repair inner areas must be reworked where accessible the paintwork must be refinished Clean the inner area with silicone remover Prime and paint the inner repair area Finally spray in cavity protection where the repair is not accessible Quality control In order to achieve a repair quality that meets production standards the following points must be observed Check the repair area for ...

Page 2712: ...wling and whistling is painful to the ears Where the different notes come from in a vehicle Low notes are mostly produced by the engine Low notes are also caused by the road surface especially if the surface is rough This is a form of droning which can be felt by the vehicle occupants as vibration or roughness High notes however which are experienced as howling or whistling noises are often air cu...

Page 2713: ...ectly through the air transmitted as vibrations from the engine to the bodywork and radiated into the passenger compartment as air borne sound for instance by the bulkhead Vibration technology Frequencies below 20 Hz low frequencies and those above 20 000 Hz 20 kHz high frequencies are not heard by the human ear The engine is made to oscillate vertically in its flexible mountings by unevenness in ...

Page 2714: ...n object or system The mass being moved is damped by a correctly operating shock absorber so that shaking of the bodywork stops immediately The shock absorber in a vehicle is an oscillation damper which allows the bodywork to oscillate in a damped manner Oscillation Description Undamped oscillation Damped oscillation Isolation In oscillation technology the term isolation means decoupling separatio...

Page 2715: ...escription Reflection of sound waves Absorption of sound waves Example All sound deadening components such as door trim carpets headlining parcel shelves and the seats are removed from a vehicle The result of this is that the sound is directly reflected the sound level rises and a concert hall effect is produced Noise and oscillation behaviour in a vehicle The occupants of a vehicle experience dif...

Page 2716: ...a wave calm Rear passenger sits in a wave swell Noise and oscillation behaviour of intake and exhaust systems The vehicle intake system as an air borne sound and solid body sound source The vehicle exhaust system as an air borne sound and solid body sound source Item 1 2 Part Number http vnx su ...

Page 2717: ... volume and length of intake systems are matched exactly No changes may be carried out during service or repair work When attaching components hoses and tubes pay attention that all connections are air tight The surfaces of all components affected by the strong pressure variations in the intake system are especially subject to strong oscillations The effects of temperature such as warming of the a...

Page 2718: ...t supports one at a time and road test the vehicle after fitting each one By proceeding in steps in this way the mounting that is causing the noise in the passenger compartment can be found Bodywork Function Different types of demand are made on the bodywork of a vehicle particularly when it is being driven Predominant here are vibrations caused mainly by other vehicle components such as the engin...

Page 2719: ...Further points Openings into the engine compartment Door and window sealing Heater and ventilation openings Sliding roof drainage hoses The side and crossmembers in the body structure are often linking channels allowing sound transmission Possible corrective measures are Installation of dividing walls at critical points such as the joint between the sidemember and the A pillar in order to ensure g...

Page 2720: ...s the vehicle is extremely rigid in the area of the passenger compartment cell and in the floor area The front wheel housings are located comparatively far back This almost entirely prevents any deformation of the wheel housing in the event of a frontal collision at low speeds Front crossmember with crash elements Behind the plastic bumper bar a steel crossmember with integrated crash elements on ...

Page 2721: ...nd the crash elements is detected the body part does not require replacement Flaking paint should be checked for in particular during the visual inspection Side view Description Crossmember Crash element Side member Front side member Thanks to the use of high strength low alloy steel in appropriate material thicknesses the front side members have a high rigidity In the event of impacts at speeds a...

Page 2722: ...uter pre determined folding points Crossmember between the A pillars A crossmember is bolted between the A pillars to reinforce the body structure particularly in the event of side impacts This crossmember also prevents excessive penetration of the steering column into the passenger compartment The crash padding steering column and other components such as heating ventilation etc are attached to t...

Page 2723: ...connection pieces There is also a bolted connection at the front crossmember NOTE Minor straightening repairs can be performed to this sheet steel element more extensive repairs are not economically worthwhile Hood lock panel sheet steel element Description Connections to fender apron panel Connections to side member connection piece Connection to crossmember A plastic element is fitted onto the s...

Page 2724: ...t tubes are built into the doors to protect against side impacts The reinforcement tubes are attached to the door inner panel via welded joints NOTE Repairs to these reinforcement tubes are not economically worthwhile Reinforcement tube Door hinges The front door hinges are attached at the body and door sides via bolted connections A locating pin is fitted to the body side half of the hinge NOTE I...

Page 2725: ...e hinge connections should only be released at the body when removing the hood Hood hinge Description Hood side connection Body side connection Locating pin High strength low alloy and bake hardening steel parts High strength low alloy and bake hardening steel parts are used in all Connect model variants NOTE The working methods given in Part I of the Body Repair Manual 501 25A must be observed in...

Page 2726: ...Description High strength low alloy steel parts Bake hardening steel parts Overview of parts bulkhead underbody and roof Item 1 2 Part Number http vnx su ...

Page 2727: ...Description High strength low alloy steel parts Bake hardening steel parts Overview of parts load space floor Item 1 2 Part Number http vnx su ...

Page 2728: ...gh strength low alloy steel parts Bake hardening steel parts Bus models only for seat locking devices Overview of parts side view delivery van with short wheel base and normal roof Item 1 2 3 Part Number http vnx su ...

Page 2729: ...Description High strength low alloy steel parts Overview of parts side view bus with long wheel base and high roof Item 1 Part Number http vnx su ...

Page 2730: ...01 25A must be observed in all repair work Sheet metal parts for sectional replacement Various replacement body parts are available to the Service department for sectional replacement repairs depending on the model variant NOTE The sectional replacement repairs described in the Repairs chapter must be exactly followed Overview of parts side panels vehicles with short wheel base SWB Item 1 Part Num...

Page 2731: ...Overview of parts side panels vehicles with long wheel base LWB http vnx su ...

Page 2732: ...Overview of parts load space floor and rear side member Description ItemPart Number http vnx su ...

Page 2733: ...Load space floor all models Rear side member all models 1 2 http vnx su ...

Page 2734: ...and starting from the centre of each hole A tolerance of 3 mm applies to all measurements given All detailed illustrations correspond to the right hand side of the vehicle 2 Body frame dimensions short wheel base All dimensions are measured with the assemblies removed using an electronic measuring system and starting from the centre of each hole A tolerance of 3 mm applies to all measurements give...

Page 2735: ...termined starting from the centre of each hole using a symmetrically adjusted measuring gauge and with assemblies installed A tolerance of 3 mm applies to all measurements given All detailed illustrations correspond to the left hand side of the vehicle http vnx su ...

Page 2736: ...termined starting from the centre of each hole using a symmetrically adjusted measuring gauge and with assemblies installed A tolerance of 3 mm applies to all measurements given All detailed illustrations correspond to the left hand side of the vehicle http vnx su ...

Page 2737: ...http vnx su ...

Page 2738: ...the centre of each hole or panel edge using a symmetrically adjusted measuring gauge 1 2 458 mm 1 3 1 502 mm 3 4 1 491 mm 5 7 1 544 mm 6 8 1 544 mm 2 Body dimensions side view delivery van and glazed bus with long wheel base and high roof All dimensions with tolerance 3mm All dimensions were determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gau...

Page 2739: ... and glazed bus with short wheel base and normal roof All dimensions with tolerance 3mm All dimensions were determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge 21 22 1 240 mm 23 24 606 mm 25 26 1 132 mm Measuring points 21 22 25 and 26 are measured in the curve and represent the greatest distance to the measuring point opposite http vnx su ...

Page 2740: ...ce 3mm All dimensions were determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge 27 28 1 298 mm 29 30 1 739 mm 31 32 1 337 mm Measurement point 29 is measured in the curve and corresponds to the greatest distance to the opposite measurement point http vnx su ...

Page 2741: ...ance 3mm All dimensions were determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge 33 34 1 295 mm 35 36 1 630 mm 37 38 1 150 mm Measurement point 35 is measured in the curve and corresponds to the greatest distance to the opposite measurement point http vnx su ...

Page 2742: ... with long wheel base and high roof All dimensions with tolerance 3mm All dimensions were determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge 39 40 1 445 mm 41 42 1 443 mm 43 44 1 521 mm http vnx su ...

Page 2743: ...of All dimensions with tolerance 3mm All dimensions were determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge 45 46 1 445 mm 47 48 1 443 mm 50 50 1 513 mm 49 51 1 510 mm Detail 49 only 4 door door side Detail 51 only 3 door http vnx su ...

Page 2744: ...http vnx su ...

Page 2745: ...ourneo Connect 2002 5 06 2002 Print General Procedures 1 Body gap dimensions front all models The gap dimensions given must be the same along the whole length of the gap 2 Body gap dimensions rear all models The gap dimensions given must be the same along the whole length of the gap http vnx su ...

Page 2746: ...http vnx su ...

Page 2747: ...neral Notes Required disassembly operations Hood fender door lock carrier and cowl panel 2 Fender apron panel reinforcement Preliminary cut location 3 Fender apron panel reinforcement 1 Mill out the spot welds 2 Mill out the spot welds two panel thicknesses 1 Fender apron panel reinforcement Drill holes for puddle welding diameter 10 mm 2 Fender apron panel reinforcement 1 Resistance spot weld 2 P...

Page 2748: ...member Inner side member 1 General Notes The crossmember is already removed before repair work starts Required disassembly operations Hood fender and lock carrier 2 NOTE Cut through the complete cross section of the side member using a large jigsaw Side member Preliminary cut location 3 Side member 1 Cut location 2 Mill out the spot welds 1 Side member Continuous MIG weld 2 Side member 1 Continuou...

Page 2749: ...3 Side member Resistance spot weld 4 Side member Resistance spot weld http vnx su ...

Page 2750: ...ith deformation elements are already removed before the repair starts Required disassembly operations Hood hood hinge fender lock carrier front door windshield and crash padding Fold back the carpets and move the wiring out of the working area 2 Side member with fender apron panel 1 Mill out the spot welds 2 Mill out the spot welds two panel thicknesses 3 Side member with fender apron panel 1 Mill...

Page 2751: ... 1 Side member with fender apron panel Drill holes for puddle welding diameter 10 mm 2 Side member with fender apron panel Drill holes for puddle welding diameter 10 mm 3 Side member with fender apron panel Puddle weld 4 Side member with fender apron panel 1 Puddle weld http vnx su ...

Page 2752: ...5 Side member with fender apron panel 1 Resistance spot weld 2 Puddle weld http vnx su ...

Page 2753: ...ired removal operations Bumper and front module 2 NOTE Before commencing repairs remove the front crossmember retaining bolts Front Crossmember Grind out the spot welds 1 Front Crossmember Drill holes for puddle welding 10 mm 2 NOTE Before performing puddle welding install the front crossmember and check the fit Front Crossmember 1 Puddle welding http vnx su ...

Page 2754: ...Sheet Metal Repairs Specifications Transit Tourneo Connect 2002 5 06 2002 Print Yağlama maddesi sızdırmaz madde ve yapıştırıcılar Parça numarası Nitelik Cam yapışkanı PU 150 ml 1 102 109 WSK M11 P57 A1 http vnx su ...

Page 2755: ...ved before repair work starts Required disassembly operations Hood fender front door windshield crash padding A pillar trim panel rocker panel trim and driver s seat If a cut is necessary at the upper cut location in the roof area owing to the damage the headliner must also be removed Move the carpet and wiring out of the working area 2 A pillar with reinforcement 1 Cut location 2 Mill out the spo...

Page 2756: ...Installation 1 A pillar with reinforcement 1 Drill holes for puddle welding diameter 10 mm 2 A pillar with reinforcement 1 Continuous MIG weld 2 Puddle weld 3 Resistance spot weld http vnx su ...

Page 2757: ...3 A pillar with reinforcement Drill holes for puddle welding diameter 8 mm 4 A pillar with reinforcement 1 Continuous MIG weld seam 2 Puddle weld 3 Resistance spot weld http vnx su ...

Page 2758: ...http vnx su ...

Page 2759: ...önce kapılar kapı menteşeleri ve çamurluk sökülüdür Gerekli sökme çalışmaları Ön ve arka koltuklar A B ve C direği aynı zamanda marşpiye kaplamaları Halı tabanını ve kablo demetini çalışma bölgesinden kaldırın 2 Kapı eşiği 1 Ayırma kesiti 2 Kaynak noktasını frezeleyiniz 3 Kapı eşiği 1 Kaynak noktasını zımparalayın 2 Bölgeyi ısıtın yaklaşık 170 ve NVH elemanını sökün 4 Kapı eşiği 1 Ön ayırma kesiti...

Page 2760: ...10 mm 2 Kapı eşiği 1 2 Koruyucu gaz kesintisiz kaynağı 3 Delikli nokta kaynağı 3 NOTE Kaynak çalışmaları öncesinde kılavuz rayların pozisyonu sürgülü kapının adaptasyonu sayesinde kontrol edilmelidir Sürgülü kapı kılavuz rayı Kılavuz rayı sürgülü kapıya derinlemesine ve boylamasına tam düzenleyin 4 Sürgülü kapı kılavuz rayı Kesintili koruyucu gaz kaynağı 5 Kapı eşiği Delik nokta kaynağı için delik...

Page 2761: ...6 Kapı eşiği 1 NVH elemanlarını PU cam yapışkanı ile yapıştırın 2 Koruyucu gaz kesintisiz kaynağı 7 Kapı eşiği 1 Direnç nokta kaynağı 2 Delikli nokta kaynağı http vnx su ...

Page 2762: ... outer panel B Pillar reinforcement 1 General Notes Required disassembly operations Front door rear door B pillar trim rocker panel trim front and rear seats Fold back the carpets and move the wiring harness out of the working area 2 B pillar 1 Preliminary cut location 2 Mill out the spot welds 3 Mill out the spot welds two panel thicknesses 4 Grind out the spot welds 3 B Pillar reinforcement Mill...

Page 2763: ...Installation 1 B Pillar reinforcement 1 Drill holes for puddle welding diameter 10 mm 2 B Pillar reinforcement 1 Puddle weld 2 Resistance spot weld http vnx su ...

Page 2764: ...3 B pillar 1 Drill holes for puddle welding diameter 8 mm 4 B pillar 1 Continuous MIG weld 2 Resistance spot weld 3 Puddle weld http vnx su ...

Page 2765: ...http vnx su ...

Page 2766: ... The back panels can be replaced individually depending on the damage When replacing the right hand center section of the corner panel the corner panel must always also be replaced Overview of multipart back panel 1 Right and left hand side sections of back panel 2 Lower center section of back panel 3 Upper center section of back panel 4 Threaded bush for screw in towing eye 3 Back panel 1 Mill ou...

Page 2767: ...2 Back panel 1 Puddle weld 2 Resistance spot weld 3 Back panel 1 Resistance spot weld 2 Puddle weld http vnx su ...

Page 2768: ...s 1 Separating variant separating cuts 1a 1b 2 Separating variant separating cuts 1a 2 3 Separating variant separating cuts 1b 2 4 Separating variant separating cuts 3 5 Separating variant separating cuts 4 3 Side door guide rails 1 Remove the bolts 2 Mill out the spot welds 4 Side panel 1 Separating cut 2 Mill out the spot welds 5 Side panel 1 Mill out the spot welds 2 Preliminary separating cut ...

Page 2769: ... seam 3 Resistance spot welding 4 Puddle weld 3 NOTE Before beginning the welding work the alignment of the guide rails must be checked by fitting the side door Side door guide rails 1 Insert the bolts 2 Puddle weld 4 NOTE Before beginning the welding work the bore holes on the roof connection must be transferred the side wall http vnx su ...

Page 2770: ...Side panel 1 Resistance spot welding 2 Puddle weld http vnx su ...

Page 2771: ...uired disassembly operations Left and right hand D pillar trim rear seats Fold back the carpets out of the working area Depending on the damage the sections rear floor panel can be replaced individually 2 Rear floor panel 1 Complete sectional replacement 2 Sectional cut out 3 Rear floor panel 1 Cut location 2 Mill out the spot welds 4 NOTE To enable resistance spot welding during installation the ...

Page 2772: ...Resistance spot weld 2 Rear floor panel 1 Continuous MIG weld butt weld 2 Resistance spot weld http vnx su ...

Page 2773: ...r alignment angle system Name Rear side member section 1 General Notes Back panel rear floor panel section and rear crossmember are already removed before the start of repairs Required disassembly operations Luggage compartment covering rear seat quarter panel trim 2 Rear side member 1 Cut location 2 Mill out the spot welds 1 Rear side member 1 Continuous MIG weld 2 Resistance spot weld http vnx s...

Page 2774: ...inforcements consisting of two parts Water drainage plate Side panel sectional repair NVH elements two parts 1 General notes The rear panel is already removed before starting the repair Necessary removal work rear doors or tailgate rear lamp side panel trim D pillar trim wheel arch cover and floor covering 2 Side panel 1 Separating cut 2 Mill out the spot welds 3 Side panel 1 Mill out the spot wel...

Page 2775: ...rind out the spot welds 3 Mill out the spot welds 4 Remove the bolts 5 Reinforcement 1 Separating cut 2 Mill out the spot welds 3 Mill out the spot welds two panel thicknesses 4 Warm the area approx 170 C and release the NVH element http vnx su ...

Page 2776: ...elds 3 Grind out the weld seam 7 Reinforcement Grind out the spot welds two panel thicknesses 8 Reinforcement 1 Preliminary separating cut 2 Mill out the spot welds two panel thicknesses 9 Crossmember 1 Mill out the spot welds 2 Grind out the spot welds http vnx su ...

Page 2777: ...m diameter 2 Resistance spot welding 2 Crossmember 1 Resistance spot welding 2 Puddle weld 3 Reinforcement 1 Resistance spot welding 2 Puddle weld 4 NOTE Before beginning the welding work the bore holes on the reinforcement must be transferred to the crossmember Reinforcement Puddle weld 5 Reinforcement Drill holes for puddle welding 10 mm diameter http vnx su ...

Page 2778: ...ddle weld 7 Reinforcement 1 Resistance spot welding 8 Reinforcement 1 Apply PU glass adhesive to the NVH element 2 Continuous MIG weld seam 3 Resistance spot welding 4 Puddle weld 9 Water drainage plate side panel 1 Drill holes for puddle welding 8 mm in diameter http vnx su ...

Page 2779: ... Continuous MIG weld seam 3 Resistance spot welding 4 Puddle weld 11 Side panel 1 Apply PU glass adhesive to the NVH element 2 Continuous MIG weld seam 3 Resistance spot welding 12 Side panel 1 Resistance spot welding 2 Puddle weld http vnx su ...

Page 2780: ...http vnx su ...

Page 2781: ... support insulator to transaxle center retaining bolt 50 37 Exhaust flexible pipe to front muffler pipe retaining nuts All except vehicles with diesel engine 47 35 Exhaust flexible pipe to catalytic converter retaining clamp bolt Vehicles with diesel engine 55 41 Crossmember retaining bolts M12 125 85 Crossmember retaining bolts M14 200 148 Stabilizer bar connecting link to stabilizer bar retainin...

Page 2782: ...Pins Subframe 205 316 15 097A Separator Ball Joint 211 020 13 006 Transmission jack Two leg puller Securing strap Name Anti seize grease 1 NOTE Make sure the road wheels are in the straight ahead position Centralize the steering wheel 2 Disconnect the steering column shaft from the steering gear pinion extension Discard the bolt 3 Detach the power steering fluid reservoir from the wheel housing ht...

Page 2783: ...llation 6 CAUTION Protect the ball joint seal using a soft cloth to prevent damage NOTE Use a T50 Torx driver to prevent the ball joint from rotating Remove the lower arm ball joint retaining nut on both sides Discard the nuts 7 Using a suitable two leg puller detach the lower arm from the wheel knuckle on both sides 8 NOTE Use a 5 mm Allen key to prevent the ball joint from rotating Detach the st...

Page 2784: ...move the tie rod end retaining nut Discard the nut 11 CAUTION Over bending of the exhaust flexible pipe may cause damage resulting in failure Support the exhaust flexible pipe with a suitable support wrap or a suitable splint 12 Detach the exhaust flexible pipe from the front muffler pipe Discard the nuts and gasket 13 Remove the engine support insulator to transaxle center retaining bolt 14 Using...

Page 2785: ...ve the steering gear heat shield two bolts 19 Detach the power steering lines from the steering gear valve body crossmember shown removed for clarity 1 Remove the bolt 2 Rotate the clamp counterclockwise Allow the fluid to drain into a suitable container 20 Remove the power steering line retaining bracket crossmember shown removed for clarity 21 Remove the crossmember http vnx su ...

Page 2786: ... mm from the body 3 Install new power steering line O ring seals 4 Attach the power steering lines to the steering gear valve body crossmember shown removed for clarity 1 Rotate the clamp clockwise 2 Install the bolt 5 Install the power steering line retaining bracket crossmember shown removed for clarity 6 Install the steering gear heat shield two bolts 7 CAUTION Make sure the crossmember ball be...

Page 2787: ...ning bolts Install the crossmember retaining bolts transmission jack shown removed for clarity 9 Remove the securing strap and the transmission jack 10 Install the engine support insulator to transaxle center retaining bolt 11 NOTE Install new exhaust flexible pipe retaining nuts and gasket NOTE Coat the exhaust flexible pipe studs with anti seize grease Attach the exhaust flexible pipe to the fro...

Page 2788: ...tating Attach the lower arm to the wheel knuckle on both sides 16 Install the front wheels and tires For additional information refer to Wheel and Tire 204 04 Wheels and Tires Removal and Installation 17 WARNING Install a new steering column shaft retaining bolt to the steering gear pinion extension Failure to follow this instruction may result in personal injury NOTE Make sure the road wheels are...

Page 2789: ...General Procedures Power Steering System Bleeding 211 00 Steering System General Information General Procedures 21 Check the toe setting and adjust as necessary For additional information refer to Front Toe Adjustment 204 00 Suspension System General Information General Procedures Specifications 204 00 Suspension System General Information Specifications http vnx su ...

Page 2790: ...illars being measured Since all measurements should be made from the bare metal remove all interior trim or chassis components from the points being checked For additional information refer to Section 501 05 Interior Trim and Ornamentation 2 Align each section proportionately until the proper dimensions are obtained If body alignment is questionable refer to Underbody Dimensions illustration 3 Due...

Page 2791: ...restored in repairing major body damage to provide correct front and rear wheel alignment geometry Refer to Underbody Dimensions diagram in this section for the correct underbody dimensions All the dimensions are detailed to the centerline of existing holes in the underbody assembly Once the unibody and suspension points are aligned other underbody operations can be carried out as outlined 1 NOTE ...

Page 2792: ...2 Valid for three and five door vehicles http vnx su ...

Page 2793: ...3 Valid for three and five door vehicles http vnx su ...

Page 2794: ...4 Valid for four door vehicles http vnx su ...

Page 2795: ...5 Valid for four door vehicles http vnx su ...

Page 2796: ...6 Valid for estate vehicle http vnx su ...

Page 2797: ...7 Valid for estate vehicle http vnx su ...

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