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Ford Transit 2007.50 Workshop Manual – Complete Service & Repair Guide

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The complete Ford Transit 2007.50 Workshop Manual covering all systems, engines, transmissions, brakes, steering, electrical and body repairs. 2347 pages of detailed procedures, specifications and diagnostics.

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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
Introductionp. 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
Jackingp. 64
Liftingp. 66
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
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
Specificationsp. 106
DESCRIPTION AND OPERATIONp. 107
Front Suspensionp. 107
DIAGNOSIS AND TESTINGp. 109
Front Suspensionp. 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
Specificationsp. 135
DESCRIPTION AND OPERATIONp. 136
Rear Suspensionp. 136
DIAGNOSIS AND TESTINGp. 138
Rear Suspensionp. 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
Specificationsp. 147
DIAGNOSIS AND TESTINGp. 148
Wheels and Tiresp. 148
Inspection and Verificationp. 148
Symptom Chartp. 149
REMOVAL AND INSTALLATIONp. 153
Wheel and Tirep. 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
Specificationsp. 169
DIAGNOSIS AND TESTINGp. 170
Driveshaftp. 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
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
Axle Assemblyp. 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
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
Specificationsp. 220
DESCRIPTION AND OPERATIONp. 223
Brake Systemp. 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
Checkp. 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
Specificationsp. 255
DESCRIPTION AND OPERATIONp. 256
Front Disc Brakep. 256
DIAGNOSIS AND TESTINGp. 257
Front Disc Brakep. 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
Specificationsp. 265
DESCRIPTION AND OPERATIONp. 266
Rear Disc Brakep. 266
DIAGNOSIS AND TESTINGp. 268
Rear Disc Brakep. 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
Specificationsp. 276
DESCRIPTION AND OPERATIONp. 277
Parking Brakep. 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
Specificationsp. 291
DESCRIPTION AND OPERATIONp. 292
Parking Brakep. 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
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
Specificationsp. 343
DESCRIPTION AND OPERATIONp. 344
Brake Boosterp. 344
DIAGNOSIS AND TESTINGp. 345
Power Brake Systemp. 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
Specificationsp. 350
DESCRIPTION AND OPERATIONp. 351
Anti-Lock Controlp. 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
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
Specificationsp. 383
DESCRIPTION AND OPERATIONp. 384
Power Steeringp. 384
DIAGNOSIS AND TESTINGp. 387
Power Steeringp. 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
Specificationsp. 406
DESCRIPTION AND OPERATIONp. 407
Steering Linkagep. 407
DIAGNOSIS AND TESTINGp. 408
Steering Linkagep. 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
Specificationsp. 415
DESCRIPTION AND OPERATIONp. 416
Steering Columnp. 416
DIAGNOSIS AND TESTINGp. 418
Steering Columnp. 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
Specificationsp. 481
DESCRIPTION AND OPERATIONp. 485
Enginep. 485
DIAGNOSIS AND TESTINGp. 489
Enginep. 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
Enginep. 521
DISASSEMBLYp. 526
Enginep. 526
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESp. 533
Cylinder Head (21 165 6)p. 533
ASSEMBLYp. 535
Enginep. 535
INSTALLATIONp. 543
Enginep. 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
Specificationsp. 549
DESCRIPTION AND OPERATIONp. 551
Enginep. 551
DIAGNOSIS AND TESTINGp. 553
Enginep. 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
Enginep. 588
DISASSEMBLYp. 593
Enginep. 593
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESp. 601
Cylinder Headp. 601
ASSEMBLYp. 603
Enginep. 603
INSTALLATIONp. 616
Enginep. 616
SECTION 303-03 Engine Coolingp. 621
SECTION 303-03-Engine Coolingp. 621
SPECIFICATIONSp. 622
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
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
Glow Plug Systemp. 804
DIAGNOSIS AND TESTINGp. 806
Glow Plug Systemp. 806
Inspection and Verificationp. 806
REMOVAL AND INSTALLATIONp. 807
Glow Plugsp. 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
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
Specificationsp. 884
DIAGNOSIS AND TESTINGp. 885
Clutchp. 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
Specificationsp. 891
DESCRIPTION AND OPERATIONp. 892
Clutch Controlsp. 892
DIAGNOSIS AND TESTINGp. 893
Clutch Controlsp. 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
Specificationsp. 897
DESCRIPTION AND OPERATIONp. 899
Manual Transmissionp. 899
Power Flowp. 906
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
Transmissionp. 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
Transmissionp. 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
External Controlsp. 961
External Controlsp. 961
DIAGNOSIS AND TESTINGp. 962
External Controlsp. 962
Inspection and Verificationp. 962
Symptom Chartp. 962
Pinpoint Testsp. 962
REMOVAL AND INSTALLATIONp. 964
Gearshift Cablesp. 964
SECTION 309-00 Exhaust Systemp. 966
SECTION 309-00-Exhaust Systemp. 966
SPECIFICATIONSp. 967
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
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
Specificationsp. 1121
DESCRIPTION AND OPERATIONp. 1122
Air Conditioningp. 1122
Refrigerant circuitp. 1122
Overview – air conditioning systemp. 1123
DIAGNOSIS AND TESTINGp. 1125
Air Conditioningp. 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
Specificationsp. 1218
DIAGNOSIS AND TESTINGp. 1219
Batteryp. 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
Generatorp. 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
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
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
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
Fenderp. 1721
SECTION 501-03 Body Closuresp. 1722
SECTION 501-03-Body Closuresp. 1722
SPECIFICATIONSp. 1723
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
Specificationsp. 1746
DESCRIPTION AND OPERATIONp. 1747
Rear View Mirrorsp. 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
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
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
Specificationsp. 1879
REMOVAL AND INSTALLATIONp. 1880
Instrument Panelp. 1880
DISASSEMBLY AND ASSEMBLYp. 1885
Instrument Panelp. 1885
SECTION 501-14 Handles, Locks, Latches and Entryp. 1892
SECTION 501-14-Handles, Locks, Latches and Entry Systemsp. 1892
SPECIFICATIONSp. 1893
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
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
Escape Hatchp. 1998
SECTION 501-19 Bumpersp. 2001
SECTION 501-19-Bumpersp. 2001
SPECIFICATIONSp. 2002
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
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
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
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
Specificationsp. 2178
DESCRIPTION AND OPERATIONp. 2179
Body and Framep. 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
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
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
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
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.

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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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