Description
Ford Transit 2007.50 Workshop Manual
This is the complete Ford Transit 2007.50 Workshop Manual, the comprehensive service and repair guide used by professional technicians for the 2007.50 Transit model range. Spanning 2347 pages, this manual delivers the full scope of repair, diagnostic and maintenance procedures for Ford Transit vehicles built to 2007.50 specifications. Whether you are servicing a 2.4L Duratorq-TDCi diesel or a 2.3L Duratec-HE petrol engine, this Ford Transit 2007.50 Workshop Manual provides the exact specifications, torque values, and step-by-step instructions needed to complete the job correctly.
File Details
- Manual Type: Workshop Manual (Service & Repair)
- Brand: Ford
- Model: Transit 2007.50
- Language: English
- Page Count: 2347 pages
- File Format: PDF
- Publication Date: 11/2006
- Market: Vietnam Market
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Ford Transit 2007.50 Workshop Manual – Complete Service & Repair Guide” are as follows:
INDEXp. 1
+SECTION 100-00 General Informationp. 9
+SECTION 100-00-General Informationp. 9
+DESCRIPTION AND OPERATIONp. 11
+About This Manualp. 11
Introductionp. 11
Special Toolsp. 11
Important Safety Instructionsp. 11
Warnings, Cautions and Notes in This Manualp. 11
Overview Proceduresp. 11
Trustmark Authoring Standards (TAS) Removal and Installation Proceduresp. 12
How to Use This Manualp. 21
+Health and Safety Precautionsp. 23
Introductionp. 23
Acids and Alkalisp. 23
Air Bagsp. 23
Air Conditioning Refrigerantp. 23
Adhesives and Sealersp. 24
Antifreezep. 25
Asbestosp. 25
Battery Acidsp. 25
Brake and Clutch Linings and Padsp. 25
Brake Fluids (Polyalkylene Glycols)p. 25
Brazingp. 25
Chemical Materialsp. 25
Chlorofluorocarbons (CFC)p. 26
Clutch Fluidsp. 26
Clutch Linings and Padsp. 26
Corrosion Protection Materialsp. 26
Cuttingp. 26
Dewaxingp. 27
Dustsp. 27
Electric Shockp. 27
Engine Oilsp. 27
Exhaust Fumesp. 27
Fibre Insulationp. 27
Firep. 27
First Aidp. 28
Fluoroelastomerp. 28
Foams – Polyurethanep. 28
Freonp. 28
Fuelsp. 28
Gas Cylindersp. 29
Gasesp. 29
Gaskets (Fluoroelastomer)p. 29
General Workshop Tools and Equipmentp. 29
High Pressure Air, Lubrication and Oil Test Equipmentp. 30
Halonp. 30
Legal Aspectsp. 30
Lubricants and Greasesp. 30
Transmission Fluidsp. 30
Noisep. 31
Noise Insulation Materialsp. 31
O-Rings (Fluoroelastomer)p. 31
Paintsp. 31
Pressurized Equipmentp. 32
Solderp. 32
Solventsp. 32
Sound Insulationp. 32
Suspended Loadsp. 32
Transmission Brake Bandsp. 33
Undersealp. 33
Vitonp. 33
Weldingp. 33
Warning Symbols on Vehiclesp. 34
White Spiritp. 35
+Standard Workshop Practicesp. 36
Vehicle in Workshopp. 36
Alternative Fuelp. 36
Alternative Fuel — Do'sp. 36
Alternative Fuel — Do Notsp. 36
Towing the Vehiclep. 37
Connecting a Slave Battery Using Jumper Cablesp. 37
Component Cleaningp. 38
Calibration of Essential Measuring Equipmentp. 38
+Solvents, Sealants and Adhesivesp. 39
+Road/Roller Testingp. 40
Pre-Test Checksp. 40
Starting the Enginep. 40
Road or Roller Testingp. 40
Brake Testingp. 41
Battery and Battery Charging Health and Safety Precautionsp. 42
Engine Cooling System Health and Safety Precautionsp. 43
Petrol Fuel System Health and Safety Precautionsp. 44
Diesel Fuel System Health and Safety Precautionsp. 45
Air Conditioning (A/C) System Health and Safety Precautionsp. 46
Supplemental Restraint System (SRS) Health and Safety Precautionsp. 47
Brake System Health and Safety Precautionsp. 48
+SECTION 100-01 Identification Codesp. 49
+SECTION 100-01-Identification Codesp. 49
+DESCRIPTION AND OPERATIONp. 50
+Identification Codesp. 50
Vehicle Identification Numberp. 51
Vehicle Certification Label (Typical) or VIN Platep. 54
+SECTION 100-02 Jacking and Liftingp. 63
+SECTION 100-02-Jacking and Liftingp. 63
+DESCRIPTION AND OPERATIONp. 64
+SECTION 100-04 Noise, Vibration and Harshnessp. 68
+SECTION 100-04-Noise, Vibration and Harshnessp. 68
+DIAGNOSIS AND TESTINGp. 69
+Noise, Vibration and Harshness (NVH)p. 69
Inspection and Verificationp. 69
Noise Diagnostic Procedurep. 69
Road Testp. 70
Road Test Quick Checksp. 70
Road Conditionsp. 71
Vehicle Preparationp. 71
Power Steering Conditionsp. 71
Power Steering Operation Noise Checkp. 71
Symptom Chartp. 74
Pinpoint Testsp. 81
+GENERAL PROCEDURESp. 88
Exhaust System Neutralizing (25 001 0)p. 88
+SECTION 204-00 Suspension System – Generalp. 89
+SECTION 204-00-Suspension System – General Informationp. 89
+SPECIFICATIONSp. 90
+DIAGNOSIS AND TESTINGp. 91
+Suspension Systemp. 91
Inspection and Verificationp. 91
Pinpoint Testsp. 95
Component Testsp. 101
+GENERAL PROCEDURESp. 103
Front Toe Adjustment (14 117 0)p. 103
Wheel Bearing Inspectionp. 104
+SECTION 204-01 Front Suspensionp. 105
+SECTION 204-01-Front Suspensionp. 105
+SPECIFICATIONSp. 106
+DESCRIPTION AND OPERATIONp. 107
+DIAGNOSIS AND TESTINGp. 109
+REMOVAL AND INSTALLATIONp. 110
Wheel Hub — RWD (14 371 0)p. 110
Front Wheel Bearing (14 411 0)p. 114
Front Stabilizer Bar (14 752 0)p. 115
Lower Arm (14 706 0)p. 116
Lower Arm Bushing (14 724 0)p. 118
Wheel Knuckle (14 343 0)p. 120
Lower Arm Ball Joint — RWD (14 735 0)p. 123
Driver Side Strut and Spring Assembly (14 781 0)p. 128
Passenger Side Strut and Spring Assembly (14 781 0)p. 130
+DISASSEMBLY AND ASSEMBLYp. 132
Front Strut and Spring Assembly (14 783 4)p. 132
+SECTION 204-02 Rear Suspensionp. 134
+SECTION 204-02-Rear Suspensionp. 134
+SPECIFICATIONSp. 135
+DESCRIPTION AND OPERATIONp. 136
+DIAGNOSIS AND TESTINGp. 138
+REMOVAL AND INSTALLATIONp. 139
Rear Stabilizer Bar (15 752 0)p. 139
Wheel Spindle (15 366 0)p. 140
Spring (15 621 0)p. 144
+SECTION 204-04 Wheels and Tiresp. 146
+SECTION 204-04-Wheels and Tiresp. 146
+SPECIFICATIONSp. 147
+DIAGNOSIS AND TESTINGp. 148
+Wheels and Tiresp. 148
Inspection and Verificationp. 148
Symptom Chartp. 149
+REMOVAL AND INSTALLATIONp. 153
+SECTION 205-00 Driveline System – Generalp. 154
+SECTION 205-00-Driveline System – General Informationp. 154
+DIAGNOSIS AND TESTINGp. 155
+Driveline Systemp. 155
Inspection and Verificationp. 155
Noise Acceptabilityp. 155
Universal Joint Inspectionp. 155
Inspection for Bent Rear Axlep. 155
Analysis of Leakagep. 157
Axle Ventp. 157
Drive Pinion Oil Sealp. 157
Axle Shaft Oil Sealsp. 158
Analysis of Vibrationp. 158
Tiresp. 158
Driveline Anglep. 158
Universal Joint Wearp. 159
Pilot Runoutp. 159
Wheel hub or Axle Flange Face Runoutp. 160
Drive Pinion and Drive Pinion Flangep. 160
Axle Noisep. 160
Gear Howl and Whinep. 160
Bearing Whinep. 160
Chucklep. 161
Knockp. 161
Clunkp. 162
Total Backlash Checkp. 162
Axle Shaft Bearing Noisep. 162
Bearing Rumblep. 163
Analysis of Inoperative Conditionsp. 163
Broken Weldsp. 163
Wheel Bearing Wear or Damagep. 163
Symptom Chartp. 163
Component Testsp. 163
Driveshaft Vibratesp. 165
Drive Pinion Flange Runout Checkp. 165
Tooth Contact Pattern Check – Gearsetp. 166
Contact Pattern Locationp. 166
+SECTION 205-01 Driveshaftp. 168
+SECTION 205-01-Driveshaftp. 168
+SPECIFICATIONSp. 169
+DIAGNOSIS AND TESTINGp. 170
+REMOVAL AND INSTALLATIONp. 171
Driveshaft (15 514 0)p. 171
+DISASSEMBLY AND ASSEMBLYp. 175
Driveshaft Center Bearing (15 564 4)p. 175
+SECTION 205-02A Rear Drive Axle-Differentialp. 177
+SECTION 205-02A-Rear Drive Axle/Differentialp. 177
+SPECIFICATIONSp. 178
+DESCRIPTION AND OPERATIONp. 180
Rear Drive Axle and Differentialp. 180
+DIAGNOSIS AND TESTINGp. 183
Rear Drive Axle and Differentialp. 183
+IN-VEHICLE REPAIRp. 184
Drive Pinion Flange and Drive Pinion Sealp. 184
Drive Pinion Bearing Cupsp. 187
Drive Pinionp. 189
Differential Casep. 193
+REMOVAL AND INSTALLATIONp. 204
+DISASSEMBLY AND ASSEMBLYp. 209
Differential Case and Ring Gearp. 209
+SECTION 205-02B Wheel Hubs and Bearings – Fullp. 212
+SECTION 205-02B-Wheel Hubs and Bearings – Full Floating Axlep. 212
+SPECIFICATIONSp. 213
+DIAGNOSIS AND TESTINGp. 214
Wheel Hubs and Bearingsp. 214
+REMOVAL AND INSTALLATIONp. 215
Axle Shaft — Vehicles With: Single Rear Wheelsp. 215
Wheel Hubp. 216
Wheel Bearings, Wheel Hub Seal and Wheel Bearing Cupsp. 217
+SECTION 206-00 Brake System – General Informationp. 219
+SECTION 206-00-Brake System – General Informationp. 219
+SPECIFICATIONSp. 220
+DESCRIPTION AND OPERATIONp. 223
+DIAGNOSIS AND TESTINGp. 224
+Brake Systemp. 224
Inspection and Verificationp. 224
Symptom Chartp. 224
Pinpoint Testsp. 228
Component Testsp. 245
+GENERAL PROCEDURESp. 248
Brake System Leak Checkp. 248
Brake Load Sensor Proportioning Valve Adjustment (12 136 0)p. 249
+Brake Disc Runout Check (12 221 0)p. 250
Brake System Bleeding (12 141 0)p. 252
Brake System Pressure Bleeding (12 141 0)p. 253
+SECTION 206-03 Front Disc Brakep. 254
+SECTION 206-03-Front Disc Brakep. 254
+SPECIFICATIONSp. 255
+DESCRIPTION AND OPERATIONp. 256
+DIAGNOSIS AND TESTINGp. 257
+REMOVAL AND INSTALLATIONp. 258
Brake Pads (12 234 0)p. 258
Brake Caliper (12 243 0)p. 259
Brake Caliper Anchor Platep. 260
Brake Disc — RWD (12 223 0)p. 261
+SECTION 206-04 Rear Disc Brakep. 264
+SECTION 206-04-Rear Disc Brakep. 264
+SPECIFICATIONSp. 265
+DESCRIPTION AND OPERATIONp. 266
+DIAGNOSIS AND TESTINGp. 268
+REMOVAL AND INSTALLATIONp. 269
Brake Pads (12 238 0)p. 269
Brake Caliperp. 271
Brake Disc — RWDp. 273
+SECTION 206-05A Parking Brake and Actuationp. 275
+SECTION 206-05A-Parking Brake and Actuationp. 275
+SPECIFICATIONSp. 276
+DESCRIPTION AND OPERATIONp. 277
+DIAGNOSIS AND TESTINGp. 278
+Parking Brakep. 278
Inspection and Verificationp. 278
Symptom Chartp. 278
Pinpoint Testsp. 278
+GENERAL PROCEDURESp. 282
Parking Brake Cable Adjustment — Vehicles With: Rear Disc Brakes (12 662 0)p. 282
+REMOVAL AND INSTALLATIONp. 283
Parking Brake Control (12 664 0)p. 283
Parking Brake Front Cablep. 285
Parking Brake Intermediate Cablep. 287
Parking Brake Rear Cablesp. 288
+SECTION 206-05B Parking Brake and Actuation —p. 290
+SECTION 206-05B-Parking Brake and Actuation-Vehicles With: Parking Brake Assistp. 290
+SPECIFICATIONSp. 291
+DESCRIPTION AND OPERATIONp. 292
+DIAGNOSIS AND TESTINGp. 294
+Parking Brakep. 294
Inspection and Verificationp. 294
Symptom Chartp. 296
Pinpoint Testsp. 297
+GENERAL PROCEDURESp. 317
Parking Brake Cable Adjustment (12 662 0)p. 317
+REMOVAL AND INSTALLATIONp. 320
Parking Brake Control (12 664 0)p. 320
Parking Brake Front Cablep. 323
Parking Brake Intermediate Cablep. 326
Parking Brake Rear Cablesp. 327
Parking Brake Modulep. 329
Parking Brake Wheel Speed Sensorp. 330
Parking Brake Actuatorp. 331
+SECTION 206-06 Hydraulic Brake Actuationp. 333
+SECTION 206-06-Hydraulic Brake Actuationp. 333
+SPECIFICATIONSp. 334
+DESCRIPTION AND OPERATIONp. 335
Hydraulic Brake Actuationp. 335
+DIAGNOSIS AND TESTINGp. 336
Hydraulic Brake Actuationp. 336
+REMOVAL AND INSTALLATIONp. 337
Brake Master Cylinderp. 337
Brake Fluid Reservoirp. 338
Brake Pedal and Bracketp. 340
+SECTION 206-07 Power Brake Actuationp. 342
+SECTION 206-07-Power Brake Actuationp. 342
+SPECIFICATIONSp. 343
+DESCRIPTION AND OPERATIONp. 344
+DIAGNOSIS AND TESTINGp. 345
+REMOVAL AND INSTALLATIONp. 346
Brake Vacuum Pump — 2.4L Duratorq-TDCi (Puma) Dieselp. 346
Brake Boosterp. 347
+SECTION 206-09 Anti-Lock Controlp. 349
+SECTION 206-09-Anti-Lock Controlp. 349
+SPECIFICATIONSp. 350
+DESCRIPTION AND OPERATIONp. 351
+DIAGNOSIS AND TESTINGp. 353
+Anti-Lock Controlp. 353
Inspection and Verificationp. 353
+REMOVAL AND INSTALLATIONp. 354
Hydraulic Control Unit (HCU)p. 354
Front Wheel Speed Sensorp. 356
Rear Wheel Speed Sensorp. 357
Anti-Lock Brake System (ABS) Modulep. 358
+SECTION 211-00 Steering System – Generalp. 360
+SECTION 211-00-Steering System – General Informationp. 360
+SPECIFICATIONSp. 361
+DIAGNOSIS AND TESTINGp. 362
+Steering Systemp. 362
Inspection and Verificationp. 362
Symptom Chartp. 362
Components Testsp. 368
Steering Gear Checks After a Collisionp. 372
+GENERAL PROCEDURESp. 374
Power Steering System Flushing — 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (13 001 0)p. 374
Power Steering System Flushing — 2.3L Duratec-HE (MI4) (13 001 0)p. 377
Power Steering System Bleeding (13 416 1)p. 379
Power Steering System Filling (13 002 0)p. 381
+SECTION 211-02 Power Steeringp. 382
+SECTION 211-02-Power Steeringp. 382
+SPECIFICATIONSp. 383
+DESCRIPTION AND OPERATIONp. 384
+DIAGNOSIS AND TESTINGp. 387
+REMOVAL AND INSTALLATIONp. 388
Power Steering Pump — 2.4L Duratorq-TDCi (Puma) Diesel (13 434 0)p. 388
Power Steering Pump — 2.3L Duratec-HE (MI4)p. 391
Power Steering Pump to Steering Gear Pressure Line — 2.4L Duratorq-TDCi (Puma) Diesel (13 440 0)p. 392
Power Steering Pump to Steering Gear Pressure Line — 2.4L Duratorq-TDCi (Puma) Dieselp. 395
Power Steering Pump to Steering Gear Pressure Line — 2.3L Duratec-HE (MI4)p. 397
Power Steering Fluid Cooler (13 444 0)p. 399
Steering Gearp. 400
Steering Gear to Fluid Cooler Return Hosep. 403
+SECTION 211-03 Steering Linkagep. 405
+SECTION 211-03-Steering Linkagep. 405
+SPECIFICATIONSp. 406
+DESCRIPTION AND OPERATIONp. 407
+DIAGNOSIS AND TESTINGp. 408
+REMOVAL AND INSTALLATIONp. 409
Tie Rod (13 263 0)p. 409
Tie Rod End (13 273 0)p. 412
Steering Gear Boot (13 134 0)p. 413
+SECTION 211-04 Steering Columnp. 414
+SECTION 211-04-Steering Columnp. 414
+SPECIFICATIONSp. 415
+DESCRIPTION AND OPERATIONp. 416
+DIAGNOSIS AND TESTINGp. 418
+REMOVAL AND INSTALLATIONp. 419
Steering Wheelp. 419
Steering Columnp. 420
Steering Column Flexible Couplingp. 422
+SECTION 211-05 Steering Column Switchesp. 423
+SECTION 211-05-Steering Column Switchesp. 423
+DIAGNOSIS AND TESTINGp. 424
+Steering Column Switchesp. 424
Inspection and Verificationp. 424
Pinpoint Testp. 425
+REMOVAL AND INSTALLATIONp. 428
Ignition Switch (36 424 0)p. 428
Steering Column Multifunction Switchp. 430
+SECTION 303-00 Engine System – General Informationp. 431
+SECTION 303-00-Engine System – General Informationp. 431
+DIAGNOSIS AND TESTINGp. 432
+Enginep. 432
Inspection and Verificationp. 432
Engine Oil Leaksp. 443
Ultraviolet (UV) Testingp. 443
Measure the compression pressure (21 111 0)p. 443
Measure the compression (Engine – 2.4L Diesel with EGR)p. 444
Measure the compression (Engine – 2.4L Diesel without EGR)p. 445
Measure the compression (Engine – 2.0L Diesel)p. 447
Measure the compression (Engine – 2.3L)p. 448
Oil Pressure – Measure (21 113 0)p. 450
Measure the oil pressure (Engine – 2.4L Diesel)p. 450
Measure the oil pressure (Engine – 2.0L Diesel)p. 452
Measure the oil pressure (Engine – 2.3L)p. 453
Valve train analysis – static (engine off)p. 454
+GENERAL PROCEDURESp. 455
Camshaft Bearing Journal Diameterp. 455
Camshaft Bearing Journal Clearancep. 456
Camshaft End Playp. 457
Camshaft Surface Inspectionp. 458
Camshaft Lobe Liftp. 459
Crankshaft Main Bearing Journal Diameterp. 460
Crankshaft End Playp. 461
Cylinder Bore Taperp. 462
Piston Inspectionp. 463
Piston Pin to Bore Diameterp. 464
Piston Diameterp. 465
Piston Ring End Gapp. 466
Piston Ring-to-Groove Clearancep. 467
Piston Pin Diameterp. 468
Connecting Rod Large End Borep. 469
Valve Stem Diameterp. 470
Valve Seat Inspectionp. 471
Flywheel Inspectionp. 472
Flywheel Inspection — Vehicles With: Dual Mass Flywheelp. 473
Flywheel Clutch Surface Inspectionp. 474
Cylinder Head Distortionp. 475
Cylinder Block Distortionp. 476
Exhaust Manifold Cleaning and Inspectionp. 477
Bearing Inspectionp. 478
+SECTION 303-01A Engine — 2.4L Duratorq-TDCi(puma) Dieselp. 479
+SECTION 303-01A-Engine-2.4L Duratorq-TDCi (Puma) Dieselp. 479
+SPECIFICATIONSp. 481
+DESCRIPTION AND OPERATIONp. 485
+DIAGNOSIS AND TESTINGp. 489
+IN-VEHICLE REPAIRp. 490
Intake Manifold (21 183 0)p. 490
Valve Cover (21 141 0)p. 491
Crankshaft Front Seal (21 467 0)p. 492
Engine Front Cover (21 148 0)p. 494
Valve Springsp. 499
Valve Seals (21 238 0)p. 501
Valves (21 215 4)p. 502
Camshafts (21 284 0)p. 504
Exhaust Manifold (21 187 0)p. 509
Cylinder Head (21 163 0)p. 511
Oil Pan (21 154 0)p. 515
Oil Pump (21 714 0)p. 517
Crankshaft Rear Seal (21 468 4)p. 519
+REMOVALp. 521
+DISASSEMBLYp. 526
+DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESp. 533
Cylinder Head (21 165 6)p. 533
+ASSEMBLYp. 535
+INSTALLATIONp. 543
+SECTION 303-01B Engine — 2.3L Duratec-HE (MI4)p. 548
+SECTION 303-01B-Engine-2.3L Duratec-HE (MI4)p. 548
+SPECIFICATIONSp. 549
+DESCRIPTION AND OPERATIONp. 551
+DIAGNOSIS AND TESTINGp. 553
+REMOVAL AND INSTALLATIONp. 554
Intake Manifoldp. 554
Crankshaft Pulleyp. 556
Engine Front Coverp. 562
Camshaftsp. 564
Exhaust Manifoldp. 571
Cylinder Headp. 573
Oil Panp. 578
Crankshaft Front Sealp. 581
Valve Stem Sealsp. 582
Timing Chainp. 584
Oil Pumpp. 586
Crankshaft Rear Sealp. 587
+REMOVALp. 588
+DISASSEMBLYp. 593
+DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESp. 601
+ASSEMBLYp. 603
+INSTALLATIONp. 616
+SECTION 303-03 Engine Coolingp. 621
+SECTION 303-03-Engine Coolingp. 621
+SPECIFICATIONSp. 622
+DESCRIPTION AND OPERATIONp. 623
+Engine Coolingp. 623
Vehicles with 2.3L Duratec-HE (MI4) enginep. 623
Vehicles with 2.2L Duratorq-TDCi (Puma) diesel enginep. 624
Vehicles with 2.4L Duratorq-TDCi (Puma) diesel enginep. 625
+DIAGNOSIS AND TESTINGp. 627
+Engine Cooling — 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Dieselp. 627
Inspection and Verificationp. 627
Symptom Chartp. 627
Component Testsp. 632
+Engine Cooling — 2.3L Duratec-HE (MI4)p. 636
Inspection and Verificationp. 636
Symptom Chartp. 636
Component Testsp. 641
+GENERAL PROCEDURESp. 645
Cooling System Draining, Filling and Bleeding — 2.3L Duratec-HE (MI4), Vehicles Without: Fuel Fired Booster Heaterp. 645
Cooling System Draining, Filling and Bleeding — 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel, Vehicles Without: Fuel Fired Booster Heaterp. 646
+REMOVAL AND INSTALLATIONp. 647
Thermostat — 2.4L Duratorq-TDCi (Puma) Dieselp. 647
Thermostat Housing — 2.4L Duratorq-TDCi (Puma) Dieselp. 648
Coolant Pump — 2.4L Duratorq-TDCi (Puma) Diesel(24 404 0)p. 650
Cooling Fan — 2.4L Duratorq-TDCi (Puma) Dieselp. 652
Coolant Pump — 2.3L Duratec-HE (MI4)p. 653
Thermostat — 2.3L Duratec-HE (MI4)p. 654
Coolant Outlet Connector — 2.3L Duratec-HE (MI4)p. 655
Radiatorp. 657
Cooling Fan Motor and Shroudp. 660
+SECTION 303-04A Fuel Charging and Controls — 2.3Lp. 661
+SECTION 303-04A-Fuel Charging and Controls-2.3L Duratec-HE (MI4)p. 661
+SPECIFICATIONSp. 662
+DESCRIPTION AND OPERATIONp. 663
Fuel Charging and Controlsp. 663
+DIAGNOSIS AND TESTINGp. 665
+Fuel Charging and Controlsp. 665
Inspection and Verificationp. 665
Symptom Chartp. 665
+REMOVAL AND INSTALLATIONp. 678
Fuel Railp. 678
Throttle Bodyp. 679
+SECTION 303-04B Fuel Charging and Controls -Turbop. 680
+SECTION 303-04B-Fuel Charging and Controls – Turbochargerp. 680
+DESCRIPTION AND OPERATIONp. 681
+Turbochargerp. 681
2.2L Duratorq-TDCi (Puma) diesel enginep. 681
2.4L Duratorq-TDCi (Puma) diesel enginep. 683
+DIAGNOSIS AND TESTINGp. 685
+Turbochargerp. 685
Principles of Operation – Vehicles with fixed vane turbocharger (2.2L Duratorq-TDCi (Puma) Diesel (85 PS/110 PS)/2.4L Duratorq-TDCi (Puma) Diesel (100 PS/115 PS)p. 685
Principles of Operation – Vehicles with variable vane turbocharger (2.2L Duratorq-TDCi (Puma) Diesel (130 PS)/2.4L Duratorq-TDCi (Puma) Diesel (140 PS)p. 685
Inspection and Verificationp. 685
Symptom Chartp. 686
Pinpoint Testsp. 687
+REMOVAL AND INSTALLATIONp. 697
Turbocharger — 2.4L Duratorq-TDCi (Puma) Diesel (100 PS/115 PS)p. 697
Turbocharger — 2.4L Duratorq-TDCi (Puma) Diesel (140 PS)p. 699
+SECTION 303-04C Fuel Charging and Controls — 2.4Lp. 700
+SECTION 303-04C-Fuel Charging and Controls-2.4L Duratorq-TDCi (Puma) Dieselp. 700
+DESCRIPTION AND OPERATIONp. 701
+Fuel Charging and Controlsp. 701
Overviewp. 701
Generalp. 702
Fuel pumpp. 702
Fuel railp. 703
Fuel injectorsp. 704
+DIAGNOSIS AND TESTINGp. 705
+Fuel Charging and Controlsp. 705
Principles of Operationp. 706
Symptom Chartp. 719
+GENERAL PROCEDURESp. 753
Fuel Injection Component Cleaningp. 753
+REMOVAL AND INSTALLATIONp. 754
Fuel Pumpp. 754
Fuel Railp. 759
Fuel Pressure Relief Valvep. 763
Fuel Injectorsp. 765
+SECTION 303-05 Accessory Drivep. 768
+SECTION 303-05-Accessory Drivep. 768
+DESCRIPTION AND OPERATIONp. 769
+Accessory Drivep. 769
Vehicles with 2.3L Duratec-HE (MI4) enginep. 769
Vehicles with 2.2L Duratorq-TDCi (Puma) diesel enginep. 771
Vehicles with 2.4L Duratorq-TDCi (Puma) diesel enginep. 773
+DIAGNOSIS AND TESTINGp. 775
+Accessory Drivep. 775
Inspection and Verificationp. 775
Accessory Drive Belt Concernsp. 775
Symptom Chartp. 780
Component Testsp. 785
+REMOVAL AND INSTALLATIONp. 787
Accessory Drive Belt — Vehicles Without: Accessory Drive Belt Tensioner (21 567 0)p. 787
Accessory Drive Belt — 2.4L Duratorq-TDCi (Puma) Diesel (21 567 0)p. 789
Accessory Drive Belt Tensioner — 2.4L Duratorq-TDCi (Puma) Dieselp. 791
Accessory Drive Belt — 2.3L Duratec-HE (MI4) (21 567 0)p. 792
+SECTION 303-06 Starting Systemp. 793
+SECTION 303-06-Starting Systemp. 793
+DIAGNOSIS AND TESTINGp. 794
+Starting Systemp. 794
Inspection and Verificationp. 794
Symptom Chartp. 794
Pinpoint Testsp. 795
+REMOVAL AND INSTALLATIONp. 801
Starter Motor — 2.4L Duratorq-TDCi (Puma) Dieselp. 801
Starter Motor — 2.3L Duratec-HE (MI4)p. 802
+SECTION 303-07A Glow Plug System — 2.4Lp. 803
+SECTION 303-07A-Glow Plug System-2.4L Duratorq-TDCi (Puma) Dieselp. 803
+DESCRIPTION AND OPERATIONp. 804
+DIAGNOSIS AND TESTINGp. 806
+Glow Plug Systemp. 806
Inspection and Verificationp. 806
+REMOVAL AND INSTALLATIONp. 807
+SECTION 303-07B Engine Ignition — 2.3L Duratec-HEp. 808
+SECTION 303-07B-Engine Ignition-2.3L Duratec-HE (MI4)p. 808
+DIAGNOSIS AND TESTINGp. 809
+Engine Ignitionp. 809
Inspection and Verificationp. 809
Symptom Chartp. 809
+SECTION 303-08 Engine Emission Controlp. 810
+SECTION 303-08-Engine Emission Controlp. 810
+DESCRIPTION AND OPERATIONp. 811
+Engine Emission Controlp. 811
Vehicles with 2.3L Duratec-HE (MI4) enginep. 811
Vehicles with 2.2L Duratorq-TDCi (Puma) diesel enginep. 812
Vehicles with 2.4L Duratorq-TDCi (Puma) diesel enginep. 813
+DIAGNOSIS AND TESTINGp. 814
+Engine Emission Controlp. 814
Inspection and Verificationp. 814
+Engine Emission Control — 2.3L Duratec-HE (MI4)p. 815
Inspection and Verificationp. 815
Symptom Chartp. 815
+REMOVAL AND INSTALLATIONp. 816
Crankcase Vent Oil Separator — 2.3L Duratec-HE (MI4)p. 816
Exhaust Gas Recirculation (EGR) Valve — 2.4L Duratorq-TDCi (Puma) Dieselp. 817
Exhaust Gas Recirculation (EGR) Cooler — 2.4L Duratorq-TDCi (Puma) Dieselp. 818
Exhaust Gas Recirculation (EGR) Valve Outlet Tube — 2.4L Duratorq-TDCi (Puma) Dieselp. 820
+SECTION 303-12 Intake Air Distribution and Filteringp. 822
+SECTION 303-12-Intake Air Distribution and Filteringp. 822
+DESCRIPTION AND OPERATIONp. 823
Intake Air Distribution and Filteringp. 823
+DIAGNOSIS AND TESTINGp. 826
+Intake Air Distribution and Filteringp. 826
Inspection and Verificationp. 826
Component Testp. 826
+REMOVAL AND INSTALLATIONp. 827
Air Cleaner — 2.3L Duratec-HE (MI4)/2.4L Duratorq-TDCi (Puma) Dieselp. 827
Charge Air Coolerp. 828
+SECTION 303-13 Evaporative Emissionsp. 830
+SECTION 303-13-Evaporative Emissionsp. 830
+DESCRIPTION AND OPERATIONp. 831
Evaporative Emissionsp. 831
+DIAGNOSIS AND TESTINGp. 833
+Evaporative Emissionsp. 833
Inspection and Verificationp. 833
+REMOVAL AND INSTALLATIONp. 834
Evaporative Emission Canisterp. 834
+SECTION 303-14 Electronic Engine Controlsp. 835
+SECTION 303-14-Electronic Engine Controlsp. 835
+DESCRIPTION AND OPERATIONp. 836
+Electronic Engine Controlsp. 836
Vehicles with 2.3L Duratec-HE (MI4)p. 836
Vehicles with 2.2L Duratorq-TDCi (Puma) diesel enginep. 839
Vehicles with 2.4L Duratorq-TDCi (Puma) diesel enginep. 841
+DIAGNOSIS AND TESTINGp. 843
+Electronic Engine Controlsp. 843
Principles of Operationp. 843
MIL Code Listp. 846
Inspection and Verificationp. 850
+REMOVAL AND INSTALLATIONp. 851
Powertrain Control Module (PCM) — Vehicles Without: PCM Security Shieldp. 851
Cylinder Head Temperature (CHT) Sensor — 2.4L Duratorq-TDCi (Puma) Dieselp. 852
Camshaft Position (CMP) Sensor — 2.4L Duratorq-TDCi (Puma) Dieselp. 853
Knock Sensor (KS) — 2.3L Duratec-HE (MI4)p. 854
Camshaft Position (CMP) Sensorp. 855
Heated Oxygen Sensor (HO2S)p. 856
Engine Coolant Temperature (ECT) Sensor — 2.3L Duratec-HE (MI4)p. 857
Catalyst Monitor Sensorp. 858
Manifold Absolute Pressure (MAP) Sensorp. 859
Crankshaft Position (CKP) Sensor — 2.3L Duratec-HE (MI4)p. 860
Crankshaft Position (CKP) Sensor — 2.4L Duratorq-TDCi (Puma) Dieselp. 862
+SECTION 308-00 Manual Transmission and Clutch (general)p. 864
+SECTION 308-00-Manual Transmission/Transaxle and Clutch – General Informationp. 864
+SPECIFICATIONSp. 865
+DIAGNOSIS AND TESTINGp. 866
+Manual Transmission and Clutch — Vehicles With: MT-75p. 866
Inspection and Verificationp. 866
Gear shifting concernsp. 866
Transmission noise concernsp. 866
Oil leakage concernsp. 868
+GENERAL PROCEDURESp. 880
Clutch System Bleeding — Vehicles With: MT-75 (16 843 0)p. 880
Gearshift Cable Adjustment — Vehicles With: MT-75/MT82 (16 513 0)p. 881
+SECTION 308-01 Clutch — Vehicles With MT-75p. 883
+SECTION 308-01-Clutch-Vehicles With: MT-75p. 883
+SPECIFICATIONSp. 884
+DIAGNOSIS AND TESTINGp. 885
+REMOVAL AND INSTALLATIONp. 886
Clutch Disc and Pressure Plate (16 724 4)p. 886
Pilot Bearingp. 887
+SECTION 308-02 Clutch Controls — Vehicles With MT-75p. 890
+SECTION 308-02-Clutch Controls-Vehicles With: MT-75p. 890
+SPECIFICATIONSp. 891
+DESCRIPTION AND OPERATIONp. 892
+DIAGNOSIS AND TESTINGp. 893
+REMOVAL AND INSTALLATIONp. 894
Clutch Master Cylinder (16 856 0)p. 894
Clutch Slave Cylinder (16 862 4)p. 895
+SECTION 308-03 Manual Transmission Vehicles with MT-75p. 896
+SECTION 308-03-Manual Transmission/Transaxle-Vehicles With: MT-75p. 896
+SPECIFICATIONSp. 897
+DESCRIPTION AND OPERATIONp. 899
+Manual Transmissionp. 899
+DIAGNOSIS AND TESTINGp. 912
Manual Transmissionp. 912
+GENERAL PROCEDURESp. 913
Transmission Draining and Fillingp. 913
+REMOVALp. 914
Transmission — 2.4L Duratorq-Di (Puma) Dieselp. 914
Transmission — 2.3L Duratec-HE (MI4)p. 919
+DISASSEMBLYp. 924
+DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESp. 932
Input Shaftp. 932
Output Shaftp. 933
Countershaftp. 937
Reverse Idler Gearp. 938
Synchronizersp. 939
Gearshift Control Shaftp. 940
+ASSEMBLYp. 941
+INSTALLATIONp. 951
Transmission — 2.4L Duratorq-Di (Puma) Dieselp. 951
Transmission — 2.3L Duratec-HE (MI4)p. 956
+SECTION 308-06 Manual Transmission External controlsp. 960
+SECTION 308-06-Manual Transmission/Transaxle External Controls-Vehicles With: MT-75p. 960
+DESCRIPTION AND OPERATIONp. 961
+DIAGNOSIS AND TESTINGp. 962
+External Controlsp. 962
Inspection and Verificationp. 962
Symptom Chartp. 962
Pinpoint Testsp. 962
+REMOVAL AND INSTALLATIONp. 964
+SECTION 309-00 Exhaust Systemp. 966
+SECTION 309-00-Exhaust Systemp. 966
+SPECIFICATIONSp. 967
+REMOVAL AND INSTALLATIONp. 968
Catalytic Converter — 2.4L Duratorq-TDCi (Puma) Dieselp. 968
Catalytic Converter — 2.3L Duratec-HE (MI4)p. 970
+SECTION 310-00 Fuel System – General Informationp. 975
+SECTION 310-00-Fuel System – General Informationp. 975
+DIAGNOSIS AND TESTINGp. 976
+Fuel Systemp. 976
Inspection and Verificationp. 976
Symptom Chartp. 976
Pinpoint Testsp. 982
Component Testsp. 984
+GENERAL PROCEDURESp. 987
Fuel System Pressure Release — 2.3L Duratec-HE (MI4) (23 420 0)p. 987
Fuel Tank Draining (23 551 0)p. 988
Quick Release Couplingp. 989
Fuel System Pressure Check — 2.3L Duratec-HE (MI4)p. 991
+SECTION 310-01 Fuel Tank and Linesp. 994
+SECTION 310-01-Fuel Tank and Linesp. 994
+DESCRIPTION AND OPERATIONp. 995
+Fuel Tank and Linesp. 995
Vehicles with 2.2L/2.4L Duratorq-TDCi (Puma) diesel enginep. 995
Vehicles with 2.3L Duratec-HE (MI4) enginep. 998
All vehiclesp. 1001
+DIAGNOSIS AND TESTINGp. 1002
Fuel Tank and Linesp. 1002
+REMOVAL AND INSTALLATIONp. 1003
Fuel Tank (23 554 0)p. 1003
Fuel Filter — 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Dieselp. 1006
Fuel Filter — 2.3L Duratec-HE (MI4)p. 1008
Fuel Filter Element — 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Dieselp. 1009
Water-in-Fuel Sensorp. 1013
+SECTION 310-02A Acceleration Controlp. 1014
+SECTION 310-02A-Acceleration Control-2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Dieselp. 1014
+DIAGNOSIS AND TESTINGp. 1015
+Acceleration Controlp. 1015
Inspection and Verificationp. 1015
+SECTION 310-02B Acceleration Control 2.3Lp. 1016
+SECTION 310-02B-Acceleration Control-2.3L Duratec-HE (MI4)p. 1016
+DIAGNOSIS AND TESTINGp. 1017
+Acceleration Controlp. 1017
Inspection and Verificationp. 1017
Symptom Chartp. 1017
+SECTION 310-03 Speed Controlp. 1018
+SECTION 310-03-Speed Controlp. 1018
+DIAGNOSIS AND TESTINGp. 1019
+Speed Controlp. 1019
Principles of Operationp. 1019
Inspection and Verificationp. 1019
Symptom Chartp. 1019
Pinpoint Testp. 1020
Component Tests – Speed Control Switchp. 1024
+SECTION 412-00 Climate Control System – Generalp. 1026
+SECTION 412-00-Climate Control System – General Informationp. 1026
+SPECIFICATIONSp. 1027
+DIAGNOSIS AND TESTINGp. 1028
+Climate Control Systemp. 1028
Inspection and Testingp. 1028
Refrigerant Circuit – Quick Checkp. 1028
Symptom chartp. 1029
System Checksp. 1031
+GENERAL PROCEDURESp. 1079
Spring Lock Couplingp. 1079
Air Conditioning (A/C) Clutch Air Gap Adjustmentp. 1081
Fluorescent Dye Leak Detectionp. 1082
Electronic Leak Detectionp. 1083
Refrigerant Oil Addingp. 1084
Contaminated Refrigerant Handlingp. 1085
Air Conditioning (A/C) System Recovery, Evacuation and Chargingp. 1086
Vacuum Leak Detectionp. 1088
+SECTION 412-01 Air Distribution and Filteringp. 1089
+SECTION 412-01-Air Distribution and Filteringp. 1089
+DESCRIPTION AND OPERATIONp. 1090
+Air Distribution and Filteringp. 1090
Air distributionp. 1090
Pollen filterp. 1090
+DIAGNOSIS AND TESTINGp. 1091
Air Distribution and Filteringp. 1091
+SECTION 412-02 Heating and Ventilationp. 1092
+SECTION 412-02-Heating and Ventilationp. 1092
+DESCRIPTION AND OPERATIONp. 1093
+Heating and Ventilationp. 1093
Overview of the heater housingp. 1093
Overview of the heater/evaporator housingp. 1093
+DIAGNOSIS AND TESTINGp. 1095
Heating and Ventilationp. 1095
+REMOVAL AND INSTALLATIONp. 1096
Heater Core and Evaporator Core Housingp. 1096
Blower Motorp. 1105
Heater Core — Vehicles Without: Air Conditioningp. 1114
Heater Core — Vehicles With: Air Conditioningp. 1115
+DISASSEMBLY AND ASSEMBLYp. 1116
Heater Core Housing — Vehicles With: Air Conditioningp. 1116
Heater Core Housing — Vehicles Without: Air Conditioningp. 1118
+SECTION 412-03A Air Conditioningp. 1120
+SECTION 412-03A-Air Conditioningp. 1120
+SPECIFICATIONSp. 1121
+DESCRIPTION AND OPERATIONp. 1122
+Air Conditioningp. 1122
Refrigerant circuitp. 1122
Overview – air conditioning systemp. 1123
+DIAGNOSIS AND TESTINGp. 1125
+REMOVAL AND INSTALLATIONp. 1126
Clutch and Clutch Field Coil (34 628 0)p. 1126
Air Conditioning (A/C) Compressor — 2.4L Duratorq-TDCi (Puma) Dieselp. 1127
Air Conditioning (A/C) Compressor — 2.3L Duratec-HE (MI4)p. 1128
Evaporator Corep. 1129
Evaporator Core Orificep. 1131
Suction Accumulatorp. 1133
Low-Pressure Cutoff Switchp. 1134
High-Pressure Cutoff Switchp. 1135
Condenser Corep. 1136
Compressor to Condenser Discharge Line — 2.4L Duratorq-TDCi (Puma) Dieselp. 1138
Condenser to Evaporator Linep. 1139
Evaporator Outlet Linep. 1142
Suction Accumulator to Compressor Line — 2.4L Duratorq-TDCi (Puma) Dieselp. 1145
Suction Accumulator to Condenser Line — 2.3L Duratec-HE (MI4)p. 1146
+SECTION 412-03B Auxiliary Climate Controlp. 1147
+SECTION 412-03B-Auxiliary Climate Controlp. 1147
+DESCRIPTION AND OPERATIONp. 1148
+Auxiliary Climate Controlp. 1148
Refrigerant circuitp. 1148
Overview – air conditioning systemp. 1149
+DIAGNOSIS AND TESTINGp. 1150
Auxiliary Climate Controlp. 1150
+REMOVAL AND INSTALLATIONp. 1151
Auxiliary Climate Control Housingp. 1151
Auxiliary Blower Motorp. 1152
Evaporator Corep. 1153
Thermostatic Expansion Valvep. 1154
Auxiliary Evaporator Inlet Linep. 1155
Auxiliary Evaporator Outlet Linep. 1156
Auxiliary Evaporator Front Outlet and Inlet Linep. 1157
Auxiliary Evaporator Rear Outlet and Inlet Linep. 1158
+DISASSEMBLY AND ASSEMBLYp. 1159
Auxiliary Climate Control Housingp. 1159
+SECTION 412-04 Control Componentsp. 1160
+SECTION 412-04-Control Componentsp. 1160
+DESCRIPTION AND OPERATIONp. 1161
+Control Componentsp. 1161
Climate control Assemblyp. 1161
Overview of the heater/evaporator housingp. 1162
+DIAGNOSIS AND TESTINGp. 1164
Control Componentsp. 1164
+REMOVAL AND INSTALLATIONp. 1165
Climate Control Assembly — Vehicles With: Air Conditioningp. 1165
Climate Control Assembly — Vehicles Without: Air Conditioningp. 1167
Blower Motor Resistorp. 1169
Air Inlet Blend Door Actuator — Vehicles With: Air Conditioningp. 1171
Air Inlet Blend Door Actuator — Vehicles Without: Air Conditioningp. 1179
Temperature Blend Door Actuatorp. 1180
+SECTION 413-00 Instrument Cluster and Panelp. 1182
+SECTION 413-00-Instrument Cluster and Panel Illuminationp. 1182
+DIAGNOSIS AND TESTINGp. 1183
+Instrument Cluster and Panel Illuminationp. 1183
Inspection and Verificationp. 1183
Symptom Chartp. 1183
Pinpoint Testsp. 1184
+SECTION 413-01 Instrument Clusterp. 1192
+SECTION 413-01-Instrument Clusterp. 1192
+DIAGNOSIS AND TESTINGp. 1193
+Instrument Clusterp. 1193
Inspection and Verificationp. 1193
Symptom Chartp. 1193
Pinpoint Testsp. 1193
Configuration of the Instrument Clusterp. 1195
+REMOVAL AND INSTALLATIONp. 1196
Instrument Clusterp. 1196
+SECTION 413-06 Hornp. 1198
+SECTION 413-06-Hornp. 1198
+DIAGNOSIS AND TESTINGp. 1199
+Hornp. 1199
Inspection and Verificationp. 1199
Symptom Chartp. 1199
Pinpoint Testsp. 1199
+SECTION 413-09 Warning Devicesp. 1205
+SECTION 413-09-Warning Devicesp. 1205
+GENERAL PROCEDURESp. 1206
Oil Change Reminder Indicator Resetp. 1206
+SECTION 414-00 Charging System – Generalp. 1207
+SECTION 414-00-Charging System – General Informationp. 1207
+DIAGNOSIS AND TESTINGp. 1208
+Charging Systemp. 1208
Inspection and Verificationp. 1208
Symptom Chartp. 1209
Component Testsp. 1210
+GENERAL PROCEDURESp. 1215
Battery Charging (31 003 0)p. 1215
+SECTION 414-01 Battery, Mounting and Cablesp. 1217
+SECTION 414-01-Battery, Mounting and Cablesp. 1217
+SPECIFICATIONSp. 1218
+DIAGNOSIS AND TESTINGp. 1219
+GENERAL PROCEDURESp. 1220
Battery Disconnectp. 1220
+REMOVAL AND INSTALLATIONp. 1222
Battery (31 214 0)p. 1222
+SECTION 414-02 Generator and Regulatorp. 1223
+SECTION 414-02-Generator and Regulatorp. 1223
+DIAGNOSIS AND TESTINGp. 1224
+REMOVAL AND INSTALLATIONp. 1225
Generator — 2.3L Duratec-HE (MI4)p. 1225
Generator — 2.4L Duratorq-TDCi (Puma) Dieselp. 1226
+SECTION 415-00 Information and Entertainment Generalp. 1227
+SECTION 415-00-Information and Entertainment System – General Informationp. 1227
+DIAGNOSIS AND TESTINGp. 1228
+Audio Systemp. 1228
Inspection and Verificationp. 1228
Self-Diagnostic Modep. 1228
Diagnostic Trouble Code (DTC) Index Chartp. 1229
Symptom Chartp. 1230
Pinpoint Testsp. 1231
+SECTION 415-01 Information and Entertainment systemp. 1239
+SECTION 415-01-Information and Entertainment Systemp. 1239
+DIAGNOSIS AND TESTINGp. 1240
Information and Entertainment Systemp. 1240
+REMOVAL AND INSTALLATIONp. 1241
Audio Unitp. 1241
Handset Holderp. 1242
Portable Support Electronics (PSE) Modulep. 1243
+SECTION 417-01 Exterior Lightingp. 1244
+SECTION 417-01-Exterior Lightingp. 1244
+SPECIFICATIONSp. 1246
+DESCRIPTION AND OPERATIONp. 1247
+Exterior Lightingp. 1247
Headlampp. 1247
Headlamp leveling systemp. 1247
Automatic headlampsp. 1248
Headlamp switch-off delayp. 1248
Combined rain sensor/light sensorp. 1248
Rear lightingp. 1249
+DIAGNOSIS AND TESTINGp. 1250
+Headlampsp. 1250
Inspection and Testingp. 1250
Symptom chartp. 1250
System Checksp. 1251
Component Testsp. 1296
+Stoplampsp. 1299
Inspection and Testingp. 1299
Symptom chartp. 1299
Pinpoint testp. 1300
+Turn Signal and Hazard Lampsp. 1312
Inspection and Testingp. 1312
Symptom chartp. 1312
Pinpoint testp. 1313
+Parking, Rear and License Plate Lampsp. 1355
Inspection and Testingp. 1355
Symptom Chartp. 1355
System Checksp. 1356
+Fog Lampsp. 1397
Inspection and Testingp. 1397
Symptom Chartp. 1397
System Checksp. 1398
+Reversing Lampsp. 1433
Inspection and Testingp. 1433
Symptom chartp. 1433
Pinpoint testp. 1433
+Trailer Lampsp. 1443
Inspection and Testingp. 1443
Symptom chartp. 1443
Pinpoint Testp. 1443
+Headlamp Levelingp. 1462
Inspection and Testingp. 1462
Symptom chartp. 1462
Pinpoint Testp. 1462
+GENERAL PROCEDURESp. 1470
Headlamp Adjustment (32 113 0)p. 1470
Front Fog Lamp Adjustmentp. 1471
Headlamp Maskingp. 1472
+REMOVAL AND INSTALLATIONp. 1479
Headlamp Assemblyp. 1479
Headlamp Leveling Motorp. 1480
Headlamp Switchp. 1481
Stoplamp Switchp. 1482
Front Fog Lampp. 1483
+SECTION 417-02 Interior Lightingp. 1484
+SECTION 417-02-Interior Lightingp. 1484
+DIAGNOSIS AND TESTINGp. 1485
+Interior Lightingp. 1485
Inspection and Verificationp. 1485
Symptom Chartp. 1485
Pinpoint Testsp. 1486
+SECTION 418-00 Module Communications Networkp. 1512
+SECTION 418-00-Module Communications Networkp. 1512
+DESCRIPTION AND OPERATIONp. 1513
+Communications Networkp. 1513
Generalp. 1513
Network Componentsp. 1514
+DIAGNOSIS AND TESTINGp. 1518
+Communications Networkp. 1518
Inspection and Testingp. 1518
Symptom chartp. 1518
Pinpoint Testsp. 1520
Component checksp. 1639
+SECTION 418-01 Module Configurationp. 1640
+SECTION 418-01-Module Configurationp. 1640
+GENERAL PROCEDURESp. 1641
Module Configurationp. 1641
Programmable Module Installationp. 1642
+SECTION 418-02 Wiring Harnessesp. 1643
+SECTION 418-02-Wiring Harnessesp. 1643
+REMOVAL AND INSTALLATIONp. 1644
Engine Compartment Wiring Harnessp. 1644
Passenger Compartment Wiring Harnessp. 1647
Instrument Panel Wiring Harnessp. 1664
+SECTION 419-01 Anti-Theft – Passivep. 1674
+SECTION 419-01-Anti-Theft – Passivep. 1674
+DESCRIPTION AND OPERATIONp. 1675
+Anti-Theft – Passivep. 1675
Component locationp. 1675
Operationp. 1675
+DIAGNOSIS AND TESTINGp. 1677
+Anti-Theft – Passivep. 1677
Principles of Operationp. 1677
Inspection and Verificationp. 1678
Symptom Chartp. 1678
+GENERAL PROCEDURESp. 1680
Anti-Theft Security Accessp. 1680
Key and Remote Transmitter Programming Using Diagnostic Equipmentp. 1681
Erasing One or More Key Codes Using Diagnostic Equipmentp. 1682
+REMOVAL AND INSTALLATIONp. 1683
Passive Anti-Theft System (PATS) Transceiverp. 1683
+SECTION 419-10 Multifunction Electronic Modulesp. 1684
+SECTION 419-10-Multifunction Electronic Modulesp. 1684
+DESCRIPTION AND OPERATIONp. 1685
+Module Controlled Functionsp. 1685
GEM.p. 1685
Automatic headlampsp. 1685
Headlamp switch-off delayp. 1685
Combined rain sensor/light sensorp. 1686
Interior lightingp. 1686
Battery protection functionp. 1687
Heated windscreenp. 1687
Heated rear window and heated external mirrorsp. 1688
Windshield wash/wipe systemp. 1688
Mode of operation of the rain sensorp. 1689
Rear window wash/wipe systemp. 1690
Speed control systemp. 1691
central door lockingp. 1691
Key-free vehicle systemp. 1693
PATSp. 1694
Recharging function for the remote controlp. 1694
Smart Charge systemp. 1694
Ambient air temperaturep. 1695
Ignition overload protectionp. 1695
Electric window regulatorsp. 1695
Brake fluid levelp. 1695
Energy managementp. 1695
Hazard warning lights for an accidentp. 1696
Emergency functionp. 1696
Service modep. 1696
Module Configurationp. 1697
+DIAGNOSIS AND TESTINGp. 1699
+Generic Electronic Module (GEM)p. 1699
Description of operationp. 1699
Inspection and Testingp. 1700
Diagnostic Trouble Code (DTC) Tablep. 1701
Symptom chartp. 1706
Pinpoint testp. 1706
+REMOVAL AND INSTALLATIONp. 1709
Generic Electronic Module (GEM)p. 1709
+SECTION 501-00 Body System – General Informationp. 1711
+SECTION 501-00-Body System – General Informationp. 1711
+SPECIFICATIONSp. 1712
+DESCRIPTION AND OPERATIONp. 1713
Bodyp. 1713
Insulationp. 1714
Body Sealer Types and Applicationsp. 1715
+SECTION 501-02 Front End Body Panelsp. 1716
+SECTION 501-02-Front End Body Panelsp. 1716
+SPECIFICATIONSp. 1717
+DESCRIPTION AND OPERATIONp. 1718
Front End Body Panelsp. 1718
+GENERAL PROCEDURESp. 1719
Hood Alignment (41 213 0)p. 1719
+REMOVAL AND INSTALLATIONp. 1721
+SECTION 501-03 Body Closuresp. 1722
+SECTION 501-03-Body Closuresp. 1722
+SPECIFICATIONSp. 1723
+GENERAL PROCEDURESp. 1724
Sliding Door Alignmentp. 1724
+SECTION 501-05 Interior Trim and Ornamentationp. 1727
+SECTION 501-05-Interior Trim and Ornamentationp. 1727
+REMOVAL AND INSTALLATIONp. 1728
A-Pillar Trim Panel (43 616 0)p. 1728
B-Pillar Trim Panel (43 617 0)p. 1729
Front Door Trim Panel (43 705 0)p. 1731
Sliding Door Trim Panelp. 1733
Rear Door Trim Panel — Van/Kombi/Bus (43 706 0)p. 1734
Rear Door Trim Panel — Chassis Cab (43 706 0)p. 1735
Liftgate Trim Panel (43 744 0)p. 1736
Loadspace Trim Panel LH (43 746 0)p. 1737
Loadspace Trim Panel RH (43 746 0)p. 1738
Front Headliner (43 609 0)p. 1739
Rear Headliner — Van/Kombi/Bus (43 611 0)p. 1741
Rear Headliner — Chassis Double Cab (43 611 0)p. 1742
+SECTION 501-08 Exterior Trim and Ornamentationp. 1743
+SECTION 501-08-Exterior Trim and Ornamentationp. 1743
+REMOVAL AND INSTALLATIONp. 1744
Rear Quarter Panel Mouldingp. 1744
+SECTION 501-09 Rear View Mirrorsp. 1745
+SECTION 501-09-Rear View Mirrorsp. 1745
+SPECIFICATIONSp. 1746
+DESCRIPTION AND OPERATIONp. 1747
+DIAGNOSIS AND TESTINGp. 1748
+Rear View Mirrorsp. 1748
Inspection and Verificationp. 1748
Pinpoint Testsp. 1749
+REMOVAL AND INSTALLATIONp. 1759
Exterior Mirror (43 364 0)p. 1759
+SECTION 501-10 Seatingp. 1760
+SECTION 501-10-Seatingp. 1760
+SPECIFICATIONSp. 1761
+DESCRIPTION AND OPERATIONp. 1762
Seats — Vehicles With: Central Junction Box (CJB)p. 1762
+DIAGNOSIS AND TESTINGp. 1763
+Seatsp. 1763
Inspection and Verificationp. 1763
Symptom Chartp. 1763
Pinpoint Testsp. 1763
+REMOVAL AND INSTALLATIONp. 1771
Front Seat Backrestp. 1771
Double Passenger Seatp. 1772
Seat Trackp. 1774
Front Seat (40 100 0)p. 1775
+DISASSEMBLY AND ASSEMBLYp. 1777
Front Seat Cushion (40 104 0)p. 1777
Double Passenger Seat Cushionp. 1779
Rear Seat Cushion — Chassis Double Cabp. 1781
Treble Second Row Seat Cushionp. 1783
Treble Third Row Seat Cushionp. 1785
Front Seat Backrest (40 106 0)p. 1787
Double Passenger Seat Backrestp. 1789
Rear Seat Backrest — Chassis Double Cab (40 127 0)p. 1792
Treble Second Row Seat Backrestp. 1794
Treble Third Row Seat Backrestp. 1797
+SECTION 501-11 Glass, Frames and Mechanismsp. 1800
+SECTION 501-11-Glass, Frames and Mechanismsp. 1800
+SPECIFICATIONSp. 1801
+DESCRIPTION AND OPERATIONp. 1802
+Glass, Frames and Mechanismsp. 1802
Opening Windowsp. 1802
Fixed/Direct Glazed Windowsp. 1802
+DIAGNOSIS AND TESTINGp. 1803
+Glass, Frames and Mechanismsp. 1803
Inspection and Verificationp. 1803
Pinpoint Testsp. 1805
Component Testsp. 1835
+REMOVAL AND INSTALLATIONp. 1837
Front Door Window Glass (42 314 0)p. 1837
Front Quarter Window Glassp. 1841
Second Row Side Window Glassp. 1842
Sliding Door Window Glassp. 1844
Third Row Side Window Glassp. 1847
Rear Door Window Glass (42 315 0)p. 1850
Rear Door Window Glass — Chassis Double Cab (42 315 0)p. 1855
Rear Window Glass — Chassis Double Cabp. 1858
Liftgate Window Glassp. 1861
Front Door Window Regulator (42 338 0)p. 1864
Front Door Window Regulator and Motor (42 338 0)p. 1866
Windshield Glass (42 115 0)p. 1868
Front Door Glass Top Run (42 333 0)p. 1876
+SECTION 501-12 Instrument Panel and Consolep. 1878
+SECTION 501-12-Instrument Panel and Consolep. 1878
+SPECIFICATIONSp. 1879
+REMOVAL AND INSTALLATIONp. 1880
+DISASSEMBLY AND ASSEMBLYp. 1885
+SECTION 501-14 Handles, Locks, Latches and Entryp. 1892
+SECTION 501-14-Handles, Locks, Latches and Entry Systemsp. 1892
+SPECIFICATIONSp. 1893
+DESCRIPTION AND OPERATIONp. 1894
Handles, Locks, Latches and Entry Systemsp. 1894
+DIAGNOSIS AND TESTINGp. 1896
+Locks, Latches and Entry Systemsp. 1896
Inspection and Verificationp. 1896
+GENERAL PROCEDURESp. 1897
Remote Keyless Entry Transmitter Programmingp. 1897
+REMOVAL AND INSTALLATIONp. 1898
Front Door Latch (41 351 0)p. 1898
Sliding Door Latchp. 1900
Liftgate Latch (41 666 0)p. 1902
Rear Door Latch — Van/Kombi/Bus (41 352 0)p. 1903
Rear Door Latch — Chassis Double Cab (41 352 0)p. 1905
Rear Door Lower Latchp. 1907
Rear Door Upper Latchp. 1908
Exterior Front Door Handlep. 1909
Exterior Sliding Door Handlep. 1910
Exterior Rear Door Handle LH — Van/Kombi/Busp. 1911
Exterior Rear Door Handle RH — Van/Kombi/Busp. 1912
Exterior Rear Door Handle — Chassis Double Cabp. 1913
Liftgate Release Handlep. 1914
Front Door Lock Cylinderp. 1916
Sliding Door Lock Cylinderp. 1918
Rear Door Lock Cylinder — Van/Kombi/Busp. 1920
Rear Door Lock Cylinder — Chassis Double Cabp. 1922
Liftgate Lock Cylinder (41 664 0)p. 1924
Front Door Latch Remote Controlp. 1926
Rear Door Latch Remote Control — Chassis Double Cabp. 1927
Sliding Door Latch Remote Controlp. 1928
Hood Latchp. 1930
Hood Lock Cylinderp. 1931
Ignition Lock Cylinderp. 1932
+SECTION 501-16 Wipers and Washersp. 1933
+SECTION 501-16-Wipers and Washersp. 1933
+SPECIFICATIONSp. 1934
+DESCRIPTION AND OPERATIONp. 1935
+Wipers and Washersp. 1935
Windshield wash/wipe systemp. 1936
Rear window wash/wipe systemp. 1937
+DIAGNOSIS AND TESTINGp. 1938
+Wipers and Washersp. 1938
Inspection and Testingp. 1938
Symptom chartp. 1938
Pinpoint Testp. 1940
Component Testsp. 1986
+GENERAL PROCEDURESp. 1989
Windshield Wiper Blade and Pivot Arm Adjustmentp. 1989
+REMOVAL AND INSTALLATIONp. 1991
Windshield Wiper Motorp. 1991
Windshield Washer Pump — Van/Kombi/Busp. 1992
Windshield Washer Pump — Chassis Cab/Chassis Double Cabp. 1993
Windshield Washer Pump and Reservoir — Van/Kombi/Busp. 1994
Windshield Washer Pump and Reservoir — Chassis Cab/Chassis Double Cabp. 1995
Wiper Linkage Assemblyp. 1996
+SECTION 501-17 Roof Opening Panelp. 1997
+SECTION 501-17-Roof Opening Panelp. 1997
+REMOVAL AND INSTALLATIONp. 1998
+SECTION 501-19 Bumpersp. 2001
+SECTION 501-19-Bumpersp. 2001
+SPECIFICATIONSp. 2002
+REMOVAL AND INSTALLATIONp. 2003
Front Bumperp. 2003
Rear Bumper (43 443 0)p. 2004
Front Bumper Coverp. 2005
Rear Bumper Coverp. 2007
+SECTION 501-20A Safety Belt Systemp. 2008
+SECTION 501-20A-Safety Belt Systemp. 2008
+SPECIFICATIONSp. 2009
+DESCRIPTION AND OPERATIONp. 2010
Safety Belt Systemp. 2010
+DIAGNOSIS AND TESTINGp. 2011
+Safety Belt System — Vehicles With: Central Junction Box (CJB)p. 2011
Principles of Operationsp. 2011
Inspection and Verificationp. 2012
Symptom Chartp. 2012
Component Testp. 2012
Static Testp. 2013
+REMOVAL AND INSTALLATIONp. 2014
Front Safety Belt Retractor (40 222 0)p. 2014
Front Safety Belt Retractor — Vehicles With: Double Passenger Seat (40 222 0)p. 2015
Rear Safety Belt Retractor (40 248 0)p. 2016
Rear Safety Belt Retractor — Chassis Double Cab (40 248 0)p. 2018
Safety Belt Shoulder Height Adjuster (40 225 0)p. 2020
Safety Belt Retractor and Pretensionerp. 2022
+SECTION 501-20B Supplemental Restraint Systemp. 2024
+SECTION 501-20B-Supplemental Restraint Systemp. 2024
+SPECIFICATIONSp. 2025
+DESCRIPTION AND OPERATIONp. 2026
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)p. 2026
+DIAGNOSIS AND TESTINGp. 2030
+Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)p. 2030
Diagnosing Customer Concerns Without Hard DTCsp. 2030
Diagnosing Customer Concerns with Hard DTCsp. 2030
Deactivationp. 2031
Reactivationp. 2031
Glossaryp. 2032
Principles of Operationp. 2032
Inspection and Verificationp. 2033
Symptom Chartp. 2033
Pinpoint Testsp. 2037
+GENERAL PROCEDURESp. 2087
Deployed Air Bag Disposalp. 2087
Unserviceable Air Bag Disposalp. 2088
Scrapped Vehicle Undeployed Air Bag Disposalp. 2089
+Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal – In-Vehicle Disposalp. 2092
All air bag modulesp. 2095
+REMOVAL AND INSTALLATIONp. 2096
Driver Air Bag Modulep. 2096
Restraints Control Module (RCM)p. 2097
Clockspringp. 2098
+SECTION 501-25 Body Repairs – General Informationp. 2101
+SECTION 501-25-Body Repairs – General Informationp. 2101
+SPECIFICATIONSp. 2103
+DESCRIPTION AND OPERATIONp. 2104
Description and Usage of Body Repair Literaturep. 2104
Symbolsp. 2105
+Health and Safety Precautionsp. 2107
Generalp. 2107
Personal protectionp. 2107
Protection of the vehiclep. 2107
Protective equipmentp. 2108
Electronic componentsp. 2108
Environmental Regulationsp. 2109
+Body Constructionp. 2110
Generalp. 2110
Integral body-framep. 2110
Frame structuresp. 2112
+Diagnosis and Damage Evaluationp. 2113
Visual recording of the damagep. 2113
Hidden damagep. 2113
Light commercial vehicles and off-road vehiclesp. 2113
Convertible-specific crash characteristicsp. 2114
+Body Sheet Metalp. 2115
Types of steelp. 2115
Aluminump. 2117
+Tools and Equipment for Body Repairsp. 2120
Alignment systemsp. 2120
Measuring systemsp. 2121
Panel beating toolsp. 2123
Welding gearp. 2125
Separating toolsp. 2126
+Establish Repair Methodp. 2128
Generalp. 2128
Planningp. 2128
Chronological sequence of repairp. 2128
Alignment Checkp. 2129
+Straighteningp. 2131
Generalp. 2131
Off-road vehiclesp. 2131
+Complete Panel Replacement/Partial Replacementp. 2133
Complete replacementp. 2133
Sectional replacementp. 2133
+Corrosion Preventionp. 2135
Corrosion protection measures during repair workp. 2135
Corrosion Damage/Corrosion Repairp. 2138
Sealer, Underbody Protection Material and Adhesivesp. 2139
+Cutting Techniquep. 2140
Spot weld milling toolp. 2140
Rod sanderp. 2140
Short stroke sawp. 2140
Orbital sawp. 2141
+Panel Beating Technique and Smart Repairsp. 2142
Generalp. 2142
Hollow leveling (removing dent without a dolly)p. 2142
Dent removal using hammer and dollyp. 2142
Dent removal from the outside using the slide hammerp. 2143
Dynamic puller with counter bearingp. 2143
Dent removal using special panel beating leversp. 2144
Heat working of panelsp. 2144
Heat-induced material shrinkingp. 2144
Lead loadingp. 2145
Paintless Dent Removalp. 2147
+Joining Techniquesp. 2149
Weldingp. 2149
MIG brazesp. 2153
Rivetsp. 2154
Brazed connectionsp. 2154
Lead loadingp. 2155
Bondingp. 2155
Bonding and weldingp. 2156
Bonding and rivetingp. 2156
+Plastic Repairsp. 2158
Generalp. 2158
Plastic weldingp. 2160
Adhesive bonding of plasticsp. 2160
GRP repairsp. 2161
+Special Repair Techniquesp. 2163
Cabriolet vehiclesp. 2163
Liquefied gas vehiclesp. 2164
Refrigerated conversion vehiclesp. 2164
Impact of Insufficient Repair Qualityp. 2166
+Water Leaksp. 2168
Diagnosisp. 2168
Executionp. 2168
Sequencep. 2169
Test equipmentp. 2169
+Wind Noisep. 2170
Diagnosisp. 2170
Test equipmentp. 2172
Noise, Vibration and Harshnessp. 2173
+SECTION 501-26 Body Repairs – Vehicle Specificp. 2177
+SECTION 501-26-Body Repairs – Vehicle Specific Information and Tolerance Checksp. 2177
+SPECIFICATIONSp. 2178
+DESCRIPTION AND OPERATIONp. 2179
+GENERAL PROCEDURESp. 2192
Underbody Tolerance Checkp. 2192
Body Tolerance Checkp. 2214
+SECTION 501-27 Front End Sheet Metal Repairsp. 2221
+SECTION 501-27-Front End Sheet Metal Repairsp. 2221
+REMOVAL AND INSTALLATIONp. 2222
Fender Apron Panelp. 2222
Fender Apron Panel Reinforcement (44 277 4)p. 2223
Fender Apron Panel Inner Reinforcementp. 2224
Front Side Member Sectionp. 2225
Front Side Member and Fender Apron Panel LHp. 2227
+SECTION 501-29 Side Panel Sheet Metal Repairsp. 2230
+SECTION 501-29-Side Panel Sheet Metal Repairsp. 2230
+SPECIFICATIONSp. 2231
+REMOVAL AND INSTALLATIONp. 2232
A-Pillar Outer Panel Section and Reinforcementp. 2232
Sliding Door Step Outer Panelp. 2234
Front Door Stepp. 2235
Side Panel Lower Sectionp. 2239
Side Panelp. 2241
+SECTION 501-30 Rear End Sheet Metal Repairsp. 2244
+SECTION 501-30-Rear End Sheet Metal Repairsp. 2244
+SPECIFICATIONSp. 2245
+REMOVAL AND INSTALLATIONp. 2246
Quarter/Side Panel Rear Section LHp. 2246
Lower Quarter Panel Sectionp. 2249
Lower Side Panel Rear Sectionp. 2251
Rear Inner Wheelhouse Halfp. 2253
Rear Outer Wheelhouse Halfp. 2254
Box Cornerp. 2256
Box Corner Sectionp. 2263
Back Panel and Crossmemberp. 2268
Rear Side Member Sectionp. 2271
+SECTION 501-36 Paint – General Informationp. 2273
+SECTION 501-36-Paint – General Informationp. 2273
+SPECIFICATIONSp. 2275
+DESCRIPTION AND OPERATIONp. 2276
Description and Usage of Paint Literaturep. 2276
+Symbolsp. 2277
Generalp. 2277
Hazardous materials designationsp. 2277
Instructions on measures to be taken for personal protection.p. 2279
Iconsp. 2279
+Health and Safety Precautionsp. 2282
General instructions for the paint shop and handling paint materialsp. 2282
Personal protectionp. 2282
+Environmental Regulationsp. 2284
Waste disposal in the repair paint shopp. 2284
The new VOC (Volatile Organic Compounds) solvent regulationp. 2284
+Factory Paint Applicationp. 2285
General fundamentals of paint technologyp. 2285
Painting process and corrosion protection.p. 2285
The structure of an original paint finishp. 2286
Colored fillers applied in productionp. 2286
+Paintwork Defects and Damagep. 2287
Diagnosis and Damage Assessmentp. 2287
Paint damage guidep. 2287
Paint damage caused by environmental factorsp. 2287
Mechanical damagep. 2291
Damage due to corrosionp. 2291
Damage caused by faults in treatmentp. 2291
+Tools and Equipment for Paint Repairsp. 2301
General work equipmentp. 2301
Filler and spray gunsp. 2301
Hand and machine sanding toolsp. 2303
Polishing and finishing toolsp. 2306
Infrared drying technologyp. 2306
Air dryersp. 2306
Paint mixing systemp. 2307
Painting cabinp. 2307
+Refinishing Materialsp. 2308
Stopper materialsp. 2308
Primersp. 2309
HS primer filler and HS tinted fillerp. 2310
Paintp. 2310
+Additional Materialsp. 2312
Adhesive sealantsp. 2312
Underbody protectionp. 2312
Paint additivesp. 2313
Additive materialsp. 2315
+Paint Repairsp. 2316
General informationp. 2316
Pre-treatment of the surfacep. 2316
Top coat applicationp. 2318
Repair stages for repair paintingp. 2319
Polishp. 2320
Aidsp. 2321
+Painting Plastic Partsp. 2322
Generalp. 2322
Plastic groupsp. 2322
Painting new componentsp. 2323
Unknown primerp. 2323
Paint faults on plastic substratesp. 2324
+Spot Repairsp. 2325
Generalp. 2325
Repair processp. 2326
Dirt inclusionsp. 2327
+Corrosion Preventionp. 2329
Generalp. 2329
Operations after paintingp. 2329
Definition of the degree of rustp. 2329
+Color Identification and Chromaticsp. 2331
Basic color theoryp. 2331
Metallic and pearl pigmentsp. 2332
Color codes and their determination on Ford vehiclesp. 2333
Matching tinted filler to the color codep. 2336
+Tips and Tricksp. 2337
Comparing paint structuresp. 2337
Etching substratep. 2337
Masking the vehiclep. 2337
Color shade problemsp. 2339
Isopropanol and waterp. 2339
Temperature reduction sprayp. 2339
Paint planep. 2339
Shadingp. 2339
Sanding marksp. 2340
Improving touch-up workp. 2340
+SECTION 502-00 Uni-Body, Subframe and Mountingp. 2341
+SECTION 502-00-Uni-Body, Subframe and Mounting Systemp. 2341
+SPECIFICATIONSp. 2342
+REMOVAL AND INSTALLATIONp. 2343
Engine Crossmember — Vehicles With: 5-Speed Manual Transmission (MT-75)p. 2343
Front Axle Crossmemberp. 2345
Chapters Covered
- General Information — Service Information, Identification Codes, Jacking and Lifting, Noise Vibration and Harshness
- Suspension — General Information, Front Suspension, Rear Suspension, Wheels and Tires
- Driveline — General Information, Driveshaft, Rear Drive Axle/Differential, Wheel Hubs and Bearings
- Brake System — General Information, Front Disc Brake, Rear Disc Brake, Parking Brake, Hydraulic Brake Actuation, Power Brake Actuation, Anti-Lock Control
- Steering System — General Information, Power Steering, Steering Linkage, Steering Column, Steering Column Switches
- Engine — 2.4L Duratorq-TDCi (Puma) Diesel, 2.3L Duratec-HE (MI4), Engine Cooling, Fuel Charging and Controls, Accessory Drive, Starting System, Glow Plug System, Engine Ignition, Engine Emission Control, Intake Air Distribution, Evaporative Emissions, Electronic Engine Controls
- Manual Transmission/Transaxle, Clutch and Transfer Case — General Information, Clutch, Clutch Controls, Manual Transmission, External Controls
- Exhaust System
- Fuel System — General Information, Fuel Tank and Lines, Acceleration Control, Speed Control
- Climate Control System — General Information, Air Distribution and Filtering, Heating and Ventilation, Air Conditioning, Auxiliary Climate Control, Control Components
- Instrumentation and Warning Systems — Instrument Cluster and Panel Illumination, Instrument Cluster, Horn, Warning Devices
- Battery and Charging System — Charging System, Battery Mounting and Cables, Generator and Regulator
- Information and Entertainment Systems
- Lighting — Exterior Lighting, Interior Lighting
- Electrical Distribution — Module Communications Network, Module Configuration, Wiring Harnesses
- Electronic Feature Group — Anti-Theft Passive, Multifunction Electronic Modules
- Body System — General Information, Front End Body Panels, Body Closures, Interior Trim and Ornamentation, Exterior Trim and Ornamentation, Rear View Mirrors, Seating, Glass Frames and Mechanisms, Instrument Panel and Console, Handles Locks Latches and Entry Systems, Wipers and Washers, Roof Opening Panel, Bumpers, Safety Belt System, Supplemental Restraint System
- Body Repairs — General Information, Vehicle Specific Information and Tolerance Checks, Front End Sheet Metal Repairs, Side Panel Sheet Metal Repairs
This Ford Transit 2007.50 Workshop Manual is organised into five main groups — General Information, Chassis, Powertrain, Electrical, and Body and Paint — with each section containing Specifications, Description and Operation, Diagnosis and Testing, In-Vehicle Repairs, Disassembly and Assembly, and Removal and Installation procedures. The manual covers the 2.4L Duratorq-TDCi (Puma) diesel engine in 100 PS, 115 PS and 140 PS variants, the 2.3L Duratec-HE (MI4) petrol engine, and the associated transmission options including the MT-75 and VXT-75 manual transmissions. Every torque specification, clearance, capacity and diagnostic procedure is presented with the precision required for professional repair work.
Why This Manual Matters
When you are repairing a Ford Transit 2007.50, having the correct procedures and specifications is not optional — it is essential. This workshop manual gives you the exact sequence for removing and installing components, the torque figures to tighten them correctly, the diagnostic routines to trace faults efficiently, and the specifications to verify that every system operates within tolerance. From engine overhauls and transmission repairs to brake servicing, steering diagnostics, electrical troubleshooting and body panel replacement, this manual covers the full range of work that a Transit may require.
The manual includes detailed removal and installation procedures for major components such as the engine, transmission, driveshaft, rear axle, suspension assemblies, brake calipers and discs, steering gear, instrument panel, seats, doors, and body panels. Diagnosis and testing sections provide pinpoint tests, symptom charts and component tests for electrical and mechanical systems, allowing you to identify the root cause of a fault before committing to repairs. Wiring diagram references, connector information and diagnostic trouble code tables are included for the electrical systems.
What You Get
This Ford Transit 2007.50 Workshop Manual is delivered as an instant PDF download. There is no shipping, no waiting, and no physical book to store. The PDF works on any device — laptop, desktop, tablet or smartphone — and every page is printable, so you can take the relevant sections into the workshop with you. The manual is fully illustrated with diagrams, exploded views, and step-by-step graphics that make complex procedures easier to follow.
Whether you are a professional technician maintaining a fleet of Transit vans, a workshop owner expanding your service capabilities, or a knowledgeable owner performing your own repairs and maintenance, this Ford Transit 2007.50 Workshop Manual provides the complete technical information you need. From routine servicing to major repairs, every procedure is documented to the standard required for correct and safe work.
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