Transit 2002 PDF

General Information - About This Manual Transit/Tourneo Connect 2002.
5 (06/2002-)
Print
Description and Operation
Introduction
This manual has been written in a format that is designed to meet the needs of technicians
worldwide. The objective is to use common formats and include similar content in each
manual.
This manual provides general descriptions for accomplishing diagnosis and testing, service
and repair work with tested, effective techniques. Following them will help assure reliability.
Special Tools
The special tool(s) table provided at the beginning of each procedure shows all special tools
required to carry out a repair. Where possible, illustrations are provided to assist in
identifying the special tool required.
Important Safety Instructions
Appropriate service methods and correct repair procedures are essential for the safe,
reliable operation of all motor vehicles as well as the personal safety of the individual
carrying out the work.
This manual cannot possibly anticipate all such variations and provide advice or cautions as
to each. Anyone who departs from the instructions provided in this manual must first
establish that he compromises neither his personal safety nor the vehicle integrity by his
choice of methods, tools or components.
Warnings, Cautions and Notes in This Manual
WARNING: Warnings are used to indicate that failure to follow a procedure correctly
may result in personal injury.
CAUTION: Cautions are used to indicate that failure to follow a procedure correctly
may result in damage to the vehicle or equipment being used.
NOTE: Notes are used to provide additional essential information required to carry out a
complete and satisfactory repair.
As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES.
A warning, caution or note is placed at the beginning of a series of steps if it applies to
multiple steps. If the warning, caution or note only applies to one step, it is placed at the
beginning of the specific step (after the step number).
How to Use This Manual
This manual covers diagnosis and testing, service and repair procedures.
This manual is structured into groups and sections, with specific system sections collected
together under their relevant group.
A group covers a specific portion of the vehicle. The manual is divided into five groups,
General Information, Chassis, Powertrain, Electrical and Body and Paint. The number of the
group is the first number of a section number.
Pages at the start of the manual list all sections available. Each section has a contents list
detailing Specifications, Description and Operation, Diagnosis and Testing, In Vehicle
Repairs, Disassembly and Assembly, Removal and Installation.
If components need to be removed or disassembled in sequence, the sequence will be
identified numerically in a graphic and the corresponding text will be numbered accordingly.
All left and right-hand references to the vehicle are taken from a position sitting in the
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driver seat looking forward.
All left and right-hand references to the engine are taken from a position at the flywheel
looking towards the front camshaft pulley.
Where appropriate, instructions will be given for the use of the diagnostic tool.
Overview Procedures
Overview procedures contain an exploded view illustration(s). The numbered sequence
within the illustration(s) indicate the order to be followed when removing/disassembling or
when installing/assembling a component. Additional information, symbol(s) or a torque
figure, may also be shown alongside the component.
There are ten symbols used to give additional information when removing/disassembling or
when installing/assembling a component.
Item Designation Description

1 Special tool A special tool is required for this component. There will also be a
removal or installation symbol alongside the special tool symbol.
2 Install new Discard the old component and install a new component.
component
3 Inspect Check the component for damage.
4 Apply sealant Apply sealant to the component as specified in the mate-rials table.
5 Apply petroleum Apply petroleum jelly to the component as specified in the materials
jelly table.
6 Apply oil Apply oil to the component as specified in the materials table.
7 Apply fluid Apply fluid to the component as specified in the materials table.
8 Apply grease Apply grease to the component as specified in the mate-rials table.
9 Removal or Go to the removal or disassembly detail for additional information to
Disassembly detail remove or disassemble a component
10 Installation or Go to the installation or assembly detail for additional information to
Assembly detail install or assemble a component
Inspection and Verification
Visual Inspection Charts, Symptom Charts and other information charts (such as diagnostic
routines) or supplement test procedures with technical specifications will navigate the user
to a specific test procedure.
Symptom Chart
The symptom chart indicates symptoms, sources and actions to address a condition.
Pinpoint Tests
For electrical systems, pinpoint test steps are used to identify the source of a concern in a
logical, step-by-step manner. pinpoint tests have two columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is used exclusively for graphics and icons (with or without
captions) and the DETAILS/RESULTS/ACTIONS column provides direction to another test
step or specific corrective actions.
The boxed numbers indicate the order in which the described action is to be performed.

Component Tests
A component test is used when a component is tested in multiple pinpoint tests, or if a
procedure is too complicated to be formatted within a single page of the pinpoint test.
Graphics
Test graphics show the measurement or test to be performed in a test step.
A representative tester graphic is used for voltmeters and ohmmeters.
If multiple measurements are made in a single graphic, the test leads are drawn with a
solid line until the test lead splits to indicate the multiple measurements, at which point
dashed lines are used.
Breakout box-type testers are represented by a double circle test pin. Test pins are labeled
with the pin number.
Special Tools and Torque Figures
Any requirement for special tools will picture the tool, showing it in use and with its tool
number shown. Torque settings will be given at the relevant point in the procedure.

General Information - Health and Safety
Transit/Tourneo Connect 2002.5 (06/2002-)
Precautions
Print
Introduction
Many of the procedures associated with vehicle maintenance and repair involve physical
hazards or other risks to health. This subsection lists, alphabetically, some of these
hazardous operations and the materials and equipment associated with them. Precautions
necessary to avoid these hazards are identified.
The list is not exhaustive and all operations and procedures, and the handling of materials,
should be carried out with health and safety in mind.
Before using any product the Materials Safety Data Sheet supplied by the manufacturer or
supplier should be consulted.
Acids and Alkalis
See also Battery Acids.
For example caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary
protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron,
gloves and goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and soap are readily available for splashing
accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials.
Highly flammable, explosive – observe No Smoking policy.
Used as a safety restraint system mounted in the steering wheel and passenger side of the
instrument panel.
The inflator contains a high-energetic propellant which, when ignited, produces a VERY HOT
GAS (2500°C).
The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in
the module and is completely consumed during deployment. No attempt should be made to
open an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas
generator is ruptured, full protective clothing should be worn when dealing with the
spillage.
After normal deployment, gloves and safety goggles must be worn during the handling
process.
Deployed air bags should be disposed of in a plastic bag in accordance with local
regulations at an approved chemical waste site.
Following any direct contact with gas generant.
wash affected areas thoroughly with water.

seek medical assistance if necessary.

Air Bags - Do's
Do store modules in an upright position.

Do keep modules dry.
Do carry modules with the cover side pointing away from the body.
Do place modules with their cover side upwards.
Do carefully inspect modules for damage.
Do stand to one side when connecting modules.
Do make sure all test equipment is properly calibrated and maintained.
Do wash hands after handling deployed air bags.
Air Bags - Do Nots
Do not store highly flammable material together with modules or gas generators.
Do not store gas generators at temperatures exceeding 80°C.
Do not store modules upside down.
Do not attempt to open a gas generator housing.
Do not expose gas generators to open flame or sources of heat.
Do not place anything on top of a module cover.
Do not use damaged modules.
Do not touch a fired module or gas generator for at least 10 minutes.
Do not use any electrical probes on the wiring circuit.
Air Conditioning Refrigerant

See also Chlorofluorocarbon, Chemical Materials
Highly flammable, combustible – observe No Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable
protective gloves and goggles.
If refrigerant comes into contact with the skin or eyes, immediately rinse the affected areas
with water. Eyes should also be rinsed with an appropriate irrigation solution and should
not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.
Air Conditioning Refrigerant - Do Nots
Do not expose refrigerant bottles to sunlight or heat.

Do not stand refrigerant bottles upright; when filling, hold them with the valve
downwards.
Do not expose refrigerant bottles to frost.
Do not drop refrigerant bottles.
Do not vent refrigerant to atmosphere under any circumstance.
Do not mix refrigerants, for example R12 (Freon) and R134a.
Adhesives and Sealers

See also Fire, Chemical Materials.
Highly flammable, flammable, combustible – observe No Smoking policy.
Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be
observed, for example disposable paper covering benches; should be dispensed from
applicators where possible; containers, including secondary containers, should be labeled
appropriately.
Solvent-based Adhesives/Sealers - See Solvents
Follow manufacturers instructions.

Water-based Adhesives/Sealers

Those based on polymer emulsions and rubber latexes may contain small amounts of
volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate
ventilation provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state they may cause burns and health
hazards may arise from the inhalation of toxic fumes.
Use appropriate protective clothing and a thermostatically controlled heater with a thermal
cut-out and adequate extraction.
Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based
Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals
may be released.
Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and
absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact.
Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye
irritants.
Skin and eye contact should be avoided and the manufacturers instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye
tissue is bonded, cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION.
Do not attempt to pull tissue apart. Use in well ventilated areas as vapors can cause
irritation to the nose and eyes.
For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.
Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin-based Adhesives.

Individuals suffering from asthma or respiratory allergies should not work with or near
these materials as sensitivity reactions can occur.
Over exposure is irritating to the eyes and respiratory system. Excessive concentrations
may produce effects on the nervous system including drowsiness. In extreme cases, loss of
consciousness may result. Long term exposure to vapor concentrations may result in
adverse health effects.
Prolonged contact with the skin may have a defatting effect which may lead to skin
irritation and in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage.
Any spraying should preferably be carried out in exhaust ventilated booths, removing
vapors and spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory protection.
Antifreeze
See also Fire, Solvents.
For example isopropanol, ethylene glycol, methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapors may be given off from coolant antifreeze (glycol) when heated. Avoid breathing

these vapors.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if
swallowed, can be fatal and MEDICAL ATTENTION SHOULD BE SOUGHT IMMEDIATELY.
These products must not be used in any cooling or industrial water system that is
connected or linked to general, food preparation or drinking water supplies.
Asbestos
See also Warning Symbols on Vehicles at the end of this subsection.
Breathing asbestos dust may cause lung damage or, in some cases, cancer.
Used in brake and clutch linings, transmission brake bands and gaskets.
The use of drum cleaning units, vacuum cleaning or damp wiping is preferred.
Asbestos dust waste should be dampened, placed in a sealed container and marked for safe
disposal. If any cutting or drilling is attempted on materials containing asbestos the item
should be dampened and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis.
Gases released during charging are explosive. Never use naked flames or allow sparks near
charging or recently charged batteries.
Make sure there is adequate ventilation.
Brake and Clutch Linings and Pads
See Asbestos.
Brake Fluids (Polyalkylene Glycols)
See also Fire.
Splashes to the skin and eyes are slightly irritating. Avoid skin and eye contact as far as
possible. Inhalation vapor hazards do not arise at ambient temperatures because of the
very low vapor pressure.
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease should always be used with caution and
stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly
flammable and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly
experienced or permanent; cumulative; superficial; life threatening; or may reduce life
expectancy.
Chemical Materials - Do's
Do carefully read and observe hazard and precaution warnings given on material
containers (labels) and in any accompanying leaflets, posters or other instructions.
Material health and safety data sheets can be obtained from manufacturers.
Do remove chemical materials from the skin and clothing as soon as practicable after
soiling. Change heavily soiled clothing and have it cleaned.
Do organize work practices and protective clothing to avoid soiling of the skin and eyes;

breathing vapors, aerosols, dusts or fumes; inadequate container labeling; fire and
explosion hazards.
Do wash before job breaks, before eating, smoking, drinking or using toilet facilities
when handling chemical materials.
Do keep work areas clean, uncluttered and free of spills.
Do store chemical materials according to national and local regulations.
Do keep chemical materials out of the reach of children.
Chemical Materials - Do Nots
Do not mix chemical materials except under the manufacturers instructions; some
chemicals can form other toxic or harmful chemicals, give off toxic or harmful fumes or
become explosive when mixed together.
Do not spray chemical materials, particularly those based on solvents, in confined
spaces, for example when people are inside a vehicle.
Do not apply heat or flame to chemical materials except under the manufacturers
instructions. Some are highly flammable and some may release toxic or harmful fumes.
Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than air and will accumulate in confined areas
such as pits.
Do not transfer chemical materials to unlabelled containers.
Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels,
will dry the skin and may cause irritation leading to dermatitis or be absorbed through
the skin in toxic or harmful quantities.
Do not use emptied containers for other materials except when they have been cleaned
under supervised conditions.
Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes
can be toxic or harmful.
Chlorofluorocarbons (CFC)
There is concern in the scientific community that CFCs and Halons are depleting the upper
ozone layer which filters out harmful ultraviolet radiation. Decreased filtration of ultraviolet
radiation may result in increases in skin cancer, cataracts and immune system suppression
in humans, as well as decreased productivity of crops and aquatic systems.
CFCs are used primarily as refrigerants in vehicle air conditioning systems and as aerosol
propellants. Halons are used as fire extinguishants.
Clutch Fluids
See Brake fluids.
Clutch Linings and Pads
See Asbestos.
Corrosion Protection Materials
See also Solvents, Fire.
Highly flammable, flammable – observe No Smoking policy.
These materials are varied and the manufacturers instructions must be followed. They may
contain solvents, resins or petroleum products. Skin and eye contact should be avoided.
They should only be sprayed in conditions of adequate ventilation and not in confined
spaces.
Cutting
See Welding.
Dewaxing
See Solvents and Fuels (Kerosene).

Dusts
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations. Wear respiratory
protection if ventilation is inadequate.
Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits
and sources of ignition.
Electric Shock
Electric shock can result from the use of faulty electrical equipment or from the misuse of
equipment in good condition.
Make sure that electrical equipment is maintained in good condition and frequently tested.
Faulty equipment should be labeled and preferably removed from the workstation.
Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or
otherwise damaged.
Make sure that electrical equipment and flexes do not come into contact with water.
Make sure that electrical equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment that is in any way faulty. The
results could be fatal.
Make sure that the cables of mobile electrical equipment cannot get trapped and damaged,
such as in a vehicle hoist.
Make sure that the designated electrical workers are trained in basic First Aid.
In cases of electrocution:
switch off the power supply before approaching the victim.

if this is not possible push or drag the victim from the source of electricity using dry non-
conductive material.
commence resuscitation if trained to do so.
SUMMON MEDICAL ASSISTANCE.
Engine Oils
See Lubricants and Grease.
Exhaust Fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon
oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run
only under conditions of adequate exhaust extraction or general ventilation and not in
confined spaces.
Gasoline (petrol) engine
There may not be adequate warning of odor or of irritation before toxic or harmful effects
arise. These may be immediate or delayed.
Diesel engine
Soot, discomfort and irritation usually give adequate warning of hazardous fume
concentrations.
Fibre Insulation
See also Dusts.
Used in noise and sound insulation.

The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a
physical and not a chemical effect.
Precautions should be taken to avoid excessive skin contact through careful organization of
work practices and the use of gloves.
Fire
See also Welding, Foams, Legal Aspects.
Many of the materials found on or associated with the repair of vehicles are highly
flammable. Some give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling flammable materials or solvents,
particularly near electrical equipment or welding processes.
Make sure, before using electrical or welding equipment, that there is no fire hazard
present.
Have a suitable fire extinguisher available when using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is desirable for someone in the workshop to
be trained in First Aid procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place affected area in cool to cold water.
Individuals affected by inhalation of gases and fumes should be removed to fresh air
immediately. If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving him the information on the
container or label. Do not induce vomiting unless this action is indicated on the label.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturers instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves
and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or
histories of allergic diseases should not work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and
may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with
adequate ventilation and respiratory protection. Do not remove the respirator immediately
after spraying; wait until the vapors/mists have cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful
fumes. Smoking, naked flames or the use of electrical equipment during foaming operations
and until vapors/mists have cleared should not be allowed. Any heat cutting of cured foams
or partially cured foams should be conducted with extraction ventilation. See also the
vehicle Body Repair Manual.

Freon
See Air Conditioning Refrigerant.
Fuels
See also, Fire, Legal Aspects, Chemicals and Solvents.
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin
with soap and water.
Gasoline (Petrol)
Highly flammable - observe No Smoking policy.

Swallowing can result in mouth and throat irritation and absorption from the stomach can
result in drowsiness and unconsciousness. Small amounts can be fatal to children.
Aspiration of liquid into the lungs, through vomiting, is a very serious hazard.
Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated
contact. Liquid in the eye causes severe smarting.
Motor gasoline may contain appreciable quantities of benzene, which is toxic upon
inhalation, and the concentration of gasoline vapors must be kept very low. High
concentrations will cause eye, nose and throat irritation, nausea, headache, depression and
symptoms of drunkenness. Very high concentrations will result in rapid loss of
consciousness.
Make sure there is adequate ventilation when handling and using gasoline. Great care must
be taken to avoid the serious consequences of inhalation in the event of vapor build up
arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage
tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth. See
First Aid.
Gas-oil (Diesel Fuel)
Combustible.
Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin
disorders including skin cancer.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.

Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from swallowing. The main hazard from
swallowing arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may
be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to
mists and vapors from kerosene at elevated temperature should be avoided (mists may
arise in dewaxing). Avoid skin and eye contact and make sure there is adequate ventilation.
Alternative Fuel
Highly flammable. Observe ``NO SMOKING" signs.

Make sure there is adequate ventilation when working on alternative fuelled vehicles. Great
care must be taken to avoid the serious consequences of inhalation in the event of vapor
build up in confined spaces.

Inhalation in high concentrations may cause dizziness, headache, nausea and loss of co-
ordination. Very high concentrations may result in loss of consciousness.
Contact with liquefied petroleum gas (LPG) or compressed natural gas (CNG) to the skin
may cause cold burns and frost bite.
Long sleeved cotton overalls, steel toe capped safety boots and rubber neoprene gloves
should be worn during removal and installation of LPG/CNG fuel system components.
LPG/CNG fuel leaks could cause a fire and be a hazard to health that can lead to personal
injury, illness or even death.
If a leak is detected, under no circumstances attempt to seal the leak by tightening the
union/connection until the fuel in the system or component is depressurized. Once
tightened the system should be checked for integrity following the specified procedures.
If the fuel tank is to be removed for service or repair the fuel must be evacuated using
dedicated equipment and following the specified procedures.
Gas Cylinders
See also Fire.
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at
pressures of up to 138 bar (2000 psi) and great care should be taken in handling these
cylinders to avoid mechanical damage to them or to the valve gear attached. The contents
of each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well-ventilated enclosures, and protected from ice and snow,
or direct sunlight. Fuel gases, for example acetylene and propane, should not be stored in
close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid
sources of ignition.
Only trained personnel should undertake work involving gas cylinders.
Gases
See Gas Cylinders.
Gaskets (Fluoroelastomer)
See Viton.
General Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition and that the
correct safety equipment is used where required.
Never use tools or equipment for any purpose other than that for which they were
designed. Never overload equipment such as hoists, jacks, axle and chassis stands or lifting
slings. Damage caused by overloading is not always immediately apparent and may result
in a fatal failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high-speed equipment
such as grinding wheels. A damaged grinding wheel can disintegrate without warning and
cause serious injury.
Wear suitable eye protection when using grinding, chiseling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with
asbestos-based materials or using spraying equipment.
Make sure there is adequate ventilation to control dusts, mists and fumes.
High Pressure Air, Lubrication and Oil Test Equipment

See also Lubricants and Greases.
Always keep high-pressure equipment in good condition, and regularly maintained,
particularly at joints and unions.
Never direct a high-pressure nozzle, for example diesel injector, at the skin as the fluid may
penetrate to the underlying tissue, and cause serious injury.
Halon
See CFCs.
Legal Aspects
There are many laws and regulations relating to health and safety in the use and disposal
of materials and equipment in a workshop.
For a safe working environment and to avoid environmental pollution, workshops should be
familiar, in detail, with the many health and safety laws and regulations within their
country, published by both national and local authorities.
Lubricants and Greases
Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may
be irritating to the eyes and skin.
Transmission Fluids
Safety instructions
Certain Transmission and Power Steering fluids supplied to Ford may contain additives
which have the potential to cause skin disease (dermatitis) to exposed persons. The
dermatitis may be irritant or allergic in nature. Risks are higher where prolonged or
repeated skin contact with a fluid may occur. These fluids are used for vehicle initial fill and
service purposes. This sub-section is to:
Inform Service personnel who may come into contact with these vehicle fluids (hazard
communication).
Summarise appropriate workplace control measures and personal protective equipment
requirements.
Draw attention to the existence of Material Safety Datasheets (MSDS's) for the fluids
(available from Ford Customer Service Division). These MSDS's contain detailed
information on hazards and appropriate controls.
Control measures
Workplace risk assessments made under national chemical control regulations should
identify operations involving the fluids as potentially hazardous and specify workplace
control and worker awareness measures. In such circumstances, the relevant Material
Safety Datasheet (see the details specified below) which specifies hazards and control
measures in detail should be made available for guidance.
Avoid unprotected skin contact with the fluids, and in particular, avoid prolonged or
repeated skin contact. Work practices should be organised so as to minimise the potential
for skin contact. This may include the use of drip trays, absorbents, correct fluid handling
equipment (funnels etc), and workplace housekeeping measures such as the cleaning of
contaminated surfaces.
Personnel engaged in operations where skin contact could occur (such as fluid draining or
filling) should wear impervious gloves made from nitrile rubber, certified to a chemical
protection standard, e.g. Europe Standard EN374. This glove type is widely available from
reputable suppliers of gloves for chemical protection [including the manufacturers Ansell-
Admont (Solvex Range), North Safety products (North Nitrile Latex Gloves range), and
Marigold Industrial (Blue Nitrile range)]. If gloves become torn or contaminated on the
inside they should be replaced. Eye protection with safety glasses is appropriate. Use of an

impervious apron and arm protectors may be necessary if more extensive exposure is
possible. Use of skin barrier creams suitable for work with mineral oil products may offer
some supplementary protection, but such barrier creams should not be used in place of
protective clothing.
If accidental skin contact occurs with the fluids, wash the area thoroughly with soap or skin
cleanser and water.
Accidental eye contact should be dealt with as per normal first aid practices, by flushing the
eyes with an eye wash or clean cool water for 10 minutes, after which medical attention
should be obtained.
Remove and launder clothing which becomes contaminated with the fluids. Do not place
rags contaminated with fluid in clothing pockets.
Wash thoroughly after completing operations where skin exposure may have occurred.
It is important that personnel do not smoke, eat or drink whilst handling the fluids or
affected transmissions. These measures are designed to limit the risk from accidental
ingestion.
Label any decanted fluid properly/use an equivalent label to that on original product
containers.
Clean up any spills promptly using an inert absorbent and wash down contaminated
surfaces with detergent and water.
Dispose of any waste fluids safely as hazardous waste.
Safety Data Sheets
Safety Data Sheets, which detail specific material handling instructions and precautions are
available from the respective national sales company, and via internet www.msds.ford.com.
Used Engine Oil
Prolonged and repeated contact with mineral oil will result in the removal of natural fats
from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil
contains potentially harmful contaminants, which may cause skin cancer. Adequate means
of skin protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin
contact is likely to occur.
Environmental Precautions
Burning used engine oil in small space heaters or boilers can be recommended only for
units of approved design. If in doubt check with the appropriate local authority and
manufacturer of approved appliances.
Dispose of used oil and used oil filters through authorized waste disposal contractors or
licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the
relevant local authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or drains, or into watercourses.
Noise
Some operations may produce high noise levels, which could, in time, damage hearing. In
these cases, suitable ear protection must be worn.
Noise Insulation Materials
See Foams, Fibre Insulation.
O-Rings (Fluoroelastomer)
See Viton.

Paints
See also Solvents, Chemical Materials.
Highly flammable, flammable - observe No Smoking policy
One Pack
Can contain harmful or toxic pigments, driers and other components as well as solvents.
Spraying should be carried out only with adequate ventilation.
Two Pack
Can also contain harmful and toxic unreacted resins and resin hardening agents. The
manufacturers instructions should be followed. See also Resin-based Adhesives and
Isocyanate Adhesives and Sealers under Adhesives and Sealers.
Spraying should preferably be carried out in exhausted ventilated booths removing vapor
and spray mists from the breathing zone. Individuals working in booths should wear
appropriate respiratory protection. Those doing small-scale repair work in the open
workshop should wear air-fed respirators.
Pressurized Equipment
See High Pressure Air, Lubrication and Oil Test Equipment.
Solder
Solders are mixtures of metals such that the melting point of the mixture is below that of
the constituent metals (normally lead and tin). Solder application does not normally give
rise to toxic lead fumes, provided a gas/air flame is used. Oxy-acetylene flames should not
be used, as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with
grease, and inhalation of these should be avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust
is not produced, which can give toxic effects if inhaled. Respiratory protection may be
necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air
contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or
inhalation of solder dust from clothing.
Solvents
See also Chemical Materials, Fuels (Kerosene), Fire.
For example acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following
repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful
quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation,
drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists,
for which there might not be adequate warning indications, can cause more serious toxic or
harmful effects.

Aspiration into the lungs, for example through vomiting, is the most serious consequence of
swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing
if necessary.
Make sure there is good ventilation when in use, avoid breathing fumes, vapors and spray
mists and keep containers tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, for example paints, adhesive, coatings, use
extraction ventilation or personal respiratory protection in the absence of adequate general
ventilation.
Do not apply heat or flame except under specific and detailed manufacturers instructions.
Sound Insulation
See Fibre Insulation, Foams.
Suspended Loads
CAUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an
unsupported, suspended or raised load, for example a suspended engine.
Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are
adequate and suitable for the job, in good condition and regularly maintained.
Transmission Brake Bands
See Asbestos.
Underseal
See Corrosion Protection.
Viton
In common with many other manufacturers vehicles, some components have O-rings, seals
or gaskets, which contain a material known as `Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber type material, which contains Fluorine.
It is commonly used for O-rings, gaskets and seals of all types. Although Viton is the most
well known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they
are exposed to temperatures in excess of 400°C, the material will not burn, but will
decompose, and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the
general body system.
O-rings, seals or gaskets which have been exposed to very high temperatures will appear
charred or as a black sticky substance.
DO NOT; under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has
been used in the affected O-ring, seal or gasket. If they are of natural rubber or nitrile
there is no hazard. If in doubt, be cautious, as the material may be Viton or any
fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be
decontaminated before the commencement of work.
Disposable heavy duty plastic gloves should be worn at all times, and the affected area
washed down using wire wool and a limewater (calcium hydroxide) solution to neutralize

the acid before disposing of the decomposed Viton residue and final cleaning of the area.
After use, the plastic gloves should be discarded carefully and safely.
Welding
See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas
Welding.
Resistance Welding
This process may cause particles of molten metal to be emitted at a high velocity, and the
eyes and skin must be protected.
Arc Welding
This process emits a high level of ultra-violet radiation, which may cause arc-eye, and skin
burns to the operator and to other persons nearby. Gas-shielded welding processes are
particularly hazardous in this respect. Personal protection must be worn, and screens used
to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN
ARC WELDING as the arc spectrum is believed to emit microwaves which dry out the fluid
between the lens and the eye. This may result in blindness when the lens is removed from
the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded,
the rods and from any applied coatings or contamination on the surfaces being worked on.
These gases and fumes may be toxic and inhalation of these should be avoided. The use of
extraction ventilation to remove the fumes from the working area may be necessary
particularly in cases where the general ventilation is poor, or where considerable welding
work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot
be provided, air-fed respirators may be necessary.
Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken
to prevent leakage of these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright, and eye protection should be used, but the ultra-violet emission is
much less than that from arc welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced
from coatings on the work, particularly during cutting away of damaged body parts, and
inhalation of the fumes should be avoided.
In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe
hazard may arise if brazing rods containing cadmium are used. In this event particular care
must be taken to avoid inhalation of fumes and expert advice may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE
ON VESSELS, WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, FOR EXAMPLE
BOILING OR STEAMING OUT OF FUEL TANKS.
Warning Symbols on Vehicles
Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators
and persons carrying out service or repair operations on the vehicle.
The most commonly found decals are reproduced below together with an explanation of the

warnings.
1. 1. Components or assemblies displaying the caution triangle and open book symbol
advise consultation of the relevant section of the owner literature before touching or
attempting adjustments of any kind.
2. 2. Components or assemblies displaying the warning triangle with the `electrified'

arrow and open book symbol give warning of inherent high voltages. Never touch
these with the engine running or the ignition switched on. See Electric Shock in this
subsection.
3. 3. Vehicles and replacement components which contain asbestos are identified by this
symbol. See Asbestos in this subsection.

4. 4. Components or assemblies displaying this symbol give warning that the component
contains a corrosive substance. See Acids and Alkalis in this subsection.
5. 5. Displaying the caution circle with a deleted lighted match symbol, caution against
the use of naked lights or flames within the immediate vicinity due to the presence
of highly flammable or explosive liquids or vapors. See Fire in this subsection.
6. 6. Displaying this symbol (normally in conjunction with 5 above) warn of the

presence of potentially explosive matter within the immediate vicinity.
7. 7. Displaying this symbol warn that children should not be allowed in the immediate
vicinity unsupervised.
White Spirit
See Solvents.

General Information - Standard Workshop
Practices
Print
Vehicle in Workshop
When working on a vehicle in the workshop always make sure that:
the parking brake is applied or the wheels are securely chocked to prevent the vehicle
moving forwards or backwards.
the key is removed from key operated hood locks before any work is carried out around
the front of the vehicle.
if the engine is to be run, there is adequate ventilation, or an extraction hose to remove
exhaust fumes.
there is adequate room to raise the vehicle and remove the wheels, if necessary.
fender covers are always fitted if any work is to be carried out in the engine
compartment.
the battery is disconnected if working on the engine, underneath the vehicle, or if the
vehicle is raised.
CAUTION: When electric arc welding on a vehicle, always disconnect the generator
wiring to prevent the possibility of a surge of current causing damage to the internal
components of the generator.
if using welding equipment on the vehicle, a suitable fire extinguisher is readily available.
Towing the Vehicle
WARNING: When the vehicle is being towed, the ignition switch must be in position II
(steering lock released and warning lamps illuminated). Only then will the steering, turn
signal lamps, horn and stop lamps be operational. Failure to follow these instructions may
result in personal injury.
NOTE: The removable towing eye (if equipped), has a left-hand thread and must be fully
tightened before towing can commence.
When towing is necessary, the vehicle towing eyes should be used. The rope must be
securely fastened to the towing eyes and must also be attached to the other vehicle such
that the rope will not foul the bodywork.
When a vehicle with automatic transmission is towed, the gear selector must be in position
N (Neutral). Never tow a vehicle with automatic transmission at a speed greater than 30
mph (50 km/h) or for a distance greater than 30 miles (50 km). If it is necessary to tow the
vehicle a greater distance, the drive wheels must be lifted clear off the ground.
Alternatively the vehicle can be transported on a low loader or a trailer.
Connecting a Slave Battery Using Jumper Cables
WARNING: If the slave battery has recently been charged and is gassing, cover the
vent plugs or covers with a damp cloth to reduce the risk of explosion should arcing occur
when connecting the jumper cables. Failure to follow these instructions may result in
personal injury.
CAUTIONS:
A discharged battery condition may have been caused by an electrical short circuit. If
this condition exists there will be an apparently live circuit on the vehicle even when all
normal circuits are switched off. This can cause arcing when the jumper cables are

connected.
While it is not recommended that the vehicle is jump started, it is recognized that
this may occasionally be the only practical way to mobilize a vehicle. In such an instance,
the discharged battery must be recharged immediately after jump starting to avoid
permanent damage.
Always make sure that the jumper cables are adequate for the task. Heavy duty cables
must be used.
Always make sure that the slave battery is of the same voltage as the vehicle battery.
The batteries must be connected in parallel.
Always make sure that switched electric circuits are switched off before connecting
jumper cables. This reduces the risk of arcing occurring when the final connection is
made.
WARNING: Make sure that the ends of the jumper cables do not touch each other or
ground against the vehicle body at any time while the cables are attached to the battery.
A fully charged battery, if shorted through jumper cables, can discharge at a rate well
above 1000 amps causing violent arcing and very rapid heating of the jumper cables and
terminals, and can even cause the battery to explode. Failure to follow these instructions
Always connect the jumper cables in the following sequence:
Slave battery positive first and then vehicle battery positive.

Slave battery negative next and then vehicle ground at least 12 inches (300 mm) from
the battery terminal, for example engine lifting eye.
Always reduce the engine speed to idle before disconnecting the jumper cables.
Before removing the jumper cables from the vehicle that had the discharged battery, switch
on the heater blower (high) or the heated rear window, to reduce the voltage peak when
the cables are removed.
Always disconnect the jumper cables in the reverse order to the connecting sequence and
do not short the ends of the cables.
Do not rely on the generator to restore a discharged battery. For a generator to recharge a
battery, it would take in excess of eight hours continuous driving with no additional loads
placed on the battery.
Component Cleaning
To prevent the ingress of dirt, accumulations of loose dirt and greasy deposits should be
removed before disconnecting or dismantling components or assemblies.
Components should be thoroughly cleaned before inspection prior to reassembly.
Cleaning Methods:

Dry cleaning.
Removal of loose dirt with soft or cable brushes.
Scraping dirt off with a piece of metal or wood.
Wiping off with a rag.
WARNING: Wear eye protection when cleaning vehicle components with compressed
air, a steam cleaner or a power washer. Failure to follow this instruction may result in
personal injury.
CAUTIONS:
Compressed air is sometimes 'wet' so use with caution, especially on hydraulic

systems.
To prevent damage to the electrical connectors in the engine compartment, do not

use a steam cleaner or a power washer to clean the engine compartment.
Blowing dirt off with compressed air.

Removal of dry dust using vacuum equipment. This method must always be used to
remove friction lining material dust (asbestos particles).
Steam cleaning.
WARNING: Most solvents require careful handling and some are harmful. Refer to
Health and Safety Precautions and to the manufacturers literature for the relevant safety
precautions. Failure to follow these instructions may result in personal injury.
Various solvents are available which are suitable for component cleaning. Some
components, such as brake hydraulic parts and electrical assemblies should be cleaned only
with recommended solvents — refer to Solvents, Sealers and Adhesives or to the section of
the manual relevant to the component.
Calibration of Essential Measuring Equipment
WARNING: Equipment, which requires regular calibration, must be calibrated in

accordance with the manufacturers instructions. Failure to follow this instruction may
result in personal injury or damage to components.
It is of fundamental importance that certain essential equipment, for example torque
wrenches, multimeters, exhaust gas analyzers or rolling roads, are regularly calibrated in
accordance with the manufacturers instructions.

General Information - Solvents, Sealants
and Adhesives
Print
Introduction
WARNING: Always handle all solvents, sealers and adhesives with extreme care.
Some contain chemicals or give off fumes which can be dangerous to health. Always
follow the manufacturers instructions. If in doubt about any substance, particularly a
solvent, DO NOT use it.
CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a
particular application, contact the manufacturer of the product for information regarding
storage, handling and application.
The Health and Safety Precautions subsection refers to some commonly used chemicals and
materials, hazards associated with their use, and safety measures to be taken.

General Information - Road/Roller
Testing
Print
Road or roller testing may be carried out for various reasons and a procedure detailing pre-
test checks, engine starting and stopping, pre-driving checks, on-test checks and final
checks to be completed on completion of the test is given below.
Unless complete vehicle performance is being checked, the full road test procedure need
not be carried out. Instead, those items particularly relevant to the system(s) being
checked can be extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt to road test the vehicle until the reason for
the low fluid level, excessive pedal travel or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional tests of those systems and circuits which
affect the safe and legal operations of the vehicle, such as brakes, lights and steering,
should always be carried out before the road or roller test.
With the ignition switched off, check:
the engine oil level.

the engine coolant level.
the tires, for correct pressure, compatible types and tread patterns, and wear within
limits.
that there is sufficient fuel in the tank to complete the test.
all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and
fuel leaks. Make a note of any apparent leaks and wipe off the surrounding areas to
make it easier to identify the extent of the leak on completion of the test.
Starting the Engine

NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress
the accelerator pedal beyond half travel until the vehicle has attained a minimum speed
of 25 km/h (15 miles/h). Never operate at high engine speed or with the accelerator
pedal at full travel whilst the engine is cold.
With the ignition switched off, check:
that the parking brake is applied.

that the gear lever is in the neutral position.
that all instrument gauges (except fuel gauge) read zero.
With the ignition switched on, check:
that the ignition controlled warning lamps are illuminated.

that the engine temperature gauge registers a reading compatible with the engine
temperature.
that the fuel gauge registers a reading appropriate to the fuel level in the tank.
the operation of the parking brake warning lamp and fluid level warning indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake operation while still traveling at low speed
before continuing with the test. If the brakes pull to one side, or appear to be otherwise
faulty, do not continue with the road test until the fault has been found and rectified.

During the road or roller test, check:
that the clutch pedal operation is not stiff or heavy.

that the initial gear engagement is smooth and there is no evidence of clutch drag.
that the parking brake control operates smoothly and releases quickly and completely.
that the clutch takes up the drive smoothly, without slip or judder.
that gear changing is smooth with no abnormal noises or vibrations from the
transmission.
the engine power output is satisfactory, full power is achieved, acceleration is smooth
and pedal operation is not stiff or heavy, and engine speed returns to idle correctly.
there is no excessive or abnormally colored smoke from the engine under normal driving,
heavy load or overrun conditions.
that steering operation, including power steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play or vibration.
that the steering does not pull to one side and self centers smoothly after cornering.
that the speedometer, coolant temperature gauge and tachometer (if equipped) register
the correct readings and operate correctly.
that the switches and controls operate smoothly and positively, warning and indicator
lamps operate correctly and the direction indicator control self cancels when the steering
is returned to the straight ahead position.
that the heating and ventilation systems operate correctly and effectively.
the brake operation and efficiency.
Brake Testing
WARNING: When brake testing, avoid breathing the fumes from hot brakes, this may
contain asbestos dust which is hazardous to health. Failure to follow this instruction may
For additional information, refer to: Health and Safety Precautions (100-00 General
Information, Description and Operation).
CAUTIONS:
Avoid brake testing on busy roads where it may cause inconvenience or danger to
other road users.
Brake testing which includes heavy brake applications should not be carried out with
new brake pads/discs or linings/drums until the components have bedded-in. New brake
friction components will not reach full efficiency until the bedding-in process is complete.
Test the brakes at several speeds within the normal operating range using both light and
heavy pedal pressure. Note any tendency to snatch, pull or drag, and any undue delay in
application or release.
Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the
brakes are binding.
After stopping the vehicle (not immediately after a period of heavy braking), carefully check
the brake temperature. A brake disc or brake drum that feels hot or is appreciably hotter
than the others, indicates that the brake is binding.
After completion of the test, check for:
oil, coolant, hydraulic, air and fuel leaks.

abnormal temperature of any moving components or assemblies, for example wheel
hubs, transmission and axle, which might indicate over tightness or lack of lubrication.

General Information - Diesel Fuel System
Health and Safety Precautions
Print
WARNINGS:
Fuel may not give adequate warning before toxic or harmful effects arise.
Exposure to fuel can be harmful and can cause severe health damage or death.
Provide adequate ventilation when working on fuel systems.
Extreme care must be exercised when handling hot fluids. Always wash off spilled
fluids from affected areas of skin immediately.
Fuel must not be used as a cleaning agent.
Keep fuel containers tightly closed, out of direct sunlight and in a cool area. Keep
away from heat sources, ignition sources and oxidizing agents.
SKIN CONTACT: Fuel is mildly irritating to the skin and may cause dermatitis due to
defatting effect. Remove contaminated clothing. Wash affected areas of skin with soap
and water. Seek medical attention for any persistent skin irritation or abnormality. Wash
contaminated clothing before reuse.
SKIN CONTACT: Excessive or prolonged skin contact with diesel fuel may cause
serious skin disorders including skin cancer.
EYE CONTACT: Fuel is mildly irritating to the eyes. Flush with plenty of running
water, blinking as often as possible. Do not force the eyelid open. Seek medical attention
for any persistent eye irritation or abnormality.
SWALLOWED: Fuel is moderately toxic and tends to foam on vomiting. If drawn into
the lungs, inflammation may develop. Do not induce vomiting. If spontaneous vomiting
occurs place the victim in a forward position to reduce the risk of fuel being drawn into
the lungs. Give nothing by mouth. If breathing but unconscious, place in the recovery
position. If breathing has stopped, apply artificial respiration. Seek immediate medical
attention.
INHALED: Fuel is toxic to the respiratory and other body systems. Exposure may
result in various symptoms including drowsiness, unconsciousness or severe health
damage. Move a victim to fresh air. Keep a victim warm and at rest. If unconscious, place
in the recovery position. If not breathing, apply artificial respiration. Give cardiac
massage if necessary. Seek immediate medical attention.
CAUTIONS:
Fuel injection equipment is manufactured to very precise tolerances and fine

clearances. It is essential that absolute cleanliness is observed when working with these
components.
Make sure that the workshop area in which the vehicle is being worked on is as clean
and as dust free as possible.
Make sure that non-plated tools are used.
Tools must be cleaned using a new brush and fresh suitable evaporative cleaning
agent.

Make sure to use a steel topped workbench covered with clean, lint-free, non-flocking
material.
Make sure that all parts removed from the vehicle are placed on the lint-free, non-
flocking material.
Make sure that any protective clothing worn is clean and made from lint-free, non-
flocking material.
Make sure to wear non-powdered latex type gloves.
Make sure to protect all electrical components and connectors with lint-free non-
flocking material before using the suitable evaporative cleaning agent.
NOTE: Soot, discomfort and irritation usually give adequate warning of hazardous fume
concentrations.

General Information - Battery and Battery
Charging Health and Safety Precautions
Print
WARNINGS:
Batteries contain sulphuric acid, avoid contact with skin, eyes or clothing. Wear
safety goggles when working near the battery to protect against possible splashing of the
acid solution.
EYE CONTACT: If acid comes into contact with the eyes, flush immediately with
plenty of running water for a minimum of 15 minutes. Seek immediate medical attention.
SKIN CONTACT: If acid comes into contact with the skin, flush immediately with
plenty of running water for a minimum of 15 minutes. Seek immediate medical attention.
SWALLOWED: If acid is swallowed, rinse the mouth with plenty of water and then
drink plenty of water or milk. Do not induce vomiting. Seek immediate medical attention.
Batteries normally produce explosive gases. Do not allow naked flames, sparks or
lighted substances to come near the battery.
When charging the battery shield your face and wear safety goggles. Provide
adequate ventilation.
CAUTION: Boost charging with excessive current or voltage above 16 volts will
damage the battery.

General Information - Supplemental
Restraint System (SRS) Health and Safety Transit/Tourneo Connect 2002.5 (06/2002-)
Precautions
Print
WARNINGS:
Only qualified technicians are allowed to work on pyrotechnic components.
INHALED: Exposure to pyrotechnic residue may cause low blood pressure, severe
headache, irritation of mucous membranes, fainting, shortness of breath or rapid pulse.
Move a victim to fresh air. Seek immediate medical attention.
EYE CONTACT: Exposure to unburned pyrotechnic residue may cause irritation,

burning and etching of the eyes. Flush immediately with plenty of cold running water for
at least 15 minutes. Seek immediate medical attention.
EYE CONTACT: Exposure to burned pyrotechnic residue may cause irritation, burning
and etching of the eyes. Flush immediately with diluted boric acid solution. Seek
immediate medical attention.
SKIN CONTACT: Unburned pyrotechnic residue may be rapidly absorbed through the
skin in toxic quantities. Wash immediately with plenty of soap and water. Seek medical
attention.
SKIN CONTACT: Burned pyrotechnic residue may be rapidly absorbed through the
skin in toxic quantities. Wash with plenty of water. Do not use soap. Seek medical
attention.
SWALLOWED: Unburned pyrotechnic residue is extremely toxic. If conscious drink

plenty of water then induce vomiting. Seek immediate medical attention. If unconscious,
or in convulsions do not attempt to induce vomiting or give anything by mouth. Seek
immediate medical attention.
SWALLOWED: Burned pyrotechnic residue is extremely toxic. Drink plenty of water

and seek immediate medical attention.
The deployment key must only be accessible to authorized personnel.
Make sure that the deployment key remains removed from the deployment
equipment except during deployment.
If permenantly disabling or enabling the passenger air bag a new seat belt for
vehicles without or with a passenger air bag must be installed.
Undeployed pyrotechnic components must not be deployed in the vehicle.
Pyrotechnic components must be deployed following local regulations.
Check thoroughly that no loose objects can be spread during the deployment of
pyrotechnic components.
Pyrotechnic components must be transported following local regulations.
Never carry out any electrical measurement on disconnected, undeployed pyrotechnic

components.

Pyrotechnic components must not be disassembled.
Pyrotechnic components are not interchangeable between vehicles.
Always carry a live air bag module away from the body with the air bag or trim cover
pointing upwards.
Live air bag modules must be placed in a suitable cage when removed from the
vehicle. The air bag or trim cover must be facing upwards.
Do not install a rearward facing child safety seat to the passenger seat with an
activated passenger air bag.
CAUTIONS:
Pyrotechnic components must not be subjected to temperatures higher than 110°C.
Never install aftermarket accessories to the vehicle on or adjacent to the

supplemental restraint system module.

Identification Codes - Identification Codes Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Identification Codes
NOTE: The beginning and end of the Vehicle Identification Number are each shown by an
asterisk (*).
The Vehicle Identification Number (VIN) number for identifying the vehicle is stamped into
the body on the right-hand sill.
The VIN is also located on the instrument panel (visible through the windshield).
The vehicle identification plate (VIN plate) is located on the B-pillar on the passenger side
(item 1).
ItemPart Number Description

1 - VIN plate
2 - Visible VIN (behind the windshield)
VIN (an example of VIN shown)

1 - VIN Position 1, 2 and 3 - World manufacturer identifier
2 - VIN Position 5 and 6 - Constant X
3 - VIN Position 7 and 8 - Product source company and assembly plant
4 - VIN Position 9 - Model
5 - VIN Position 11 - Year of manufacture
6 - VIN Position 12 - Month of manufacture
7 - VIN Positions 13 to 17 - Vehicle serial number
8 - VIN Position 4 and 10 - Body type
VIN Position 1, 2 and 3 - World Manufacturer Identifier
Code World Manufacturer

WF0 Ford-Werke AG Germany (European vehicles)
NMO Ford Otomotiv Sanayi A. S., Turkey (for the Turkish market).
VIN Position 4 and 10 - Body Type
Code Body Type

G 5 seat van (N1)
H Combi, short wheelbase (M1)
J Combi, long wheelbase (M1)
K 5 seat van, long wheelbase (N1)
M Double cab van (N1)
N Double cab van, long wheelbase (N1)
T Box van, short wheelbase
U Box van, long wheelbase
VIN Position 5 and 6 - Constant X
VIN Position 7 and 8 - Product Source Company and Assembly Plant
Code Product Source Company and Assembly Plant

TT Ford Turkey/Izmit
VIN Position 9 - Model

Code Model
P Transit/Tourneo Connect
VIN Position 11 - Year of Manufacture
Code Year of Manufacture

2 2002
3 2003
4 2004
5 2005
6 2006
7 2007
8 2008
9 2009
VIN Position 12 - Month of Manufacture
Build month 2002 2003 2004 2005 2006 2007 2008 2009
January L C B J L C B J
February Y K R U Y K R U
March S D A M S D A M
April T E G P T E G P
May J L C B J L C B
June U Y K R U Y K R
July M S D A M S D A
August P T E G P T E G
September B J L C B J L C
October R U Y K R U Y K
November A M S D A M S D
December G P T E G P T E
VIN Positions 13 to 17 - Vehicle Serial Number Five Digit Number
Vehicle Certification Label (Typical) or VIN Plate

1 - National or whole vehicle type approval
2 - VIN
-

-
3 Gross vehicle mass (GVM)
4 - Gross train mass (GTM)
5 - Maximum permissible front axle mass
6 - Maximum permissible rear axle mass
7 - Model type codes
8 - Wheelbase codes
9 - Final drive ratio codes
10 - Special vehicles only
11 - Transaxle codes
12 - Door combination codes
13 - Suspension codes
14 - Hand of drive codes
15 - Body color codes
16 - Brake codes
17 - Interior trim codes
18 - Smoke emission (diesel only)
19 - Engine codes
20 - Version codes
Items 1 to 6: Vehicle Certification Label
Position Description
Item 1: National or whole vehicle A unique code required by legislation in certain territories.
type approval
Item 2: VIN Vehicle Identification Number.
Item 3: GVM Indicates the maximum legal laden mass, in territories
where this is required.
Item 4: GTM Indicates the maximum combined mass of vehicle and
trailer or caravan.
Item 5: Maximum permissible front Maximum permissible loading on the front wheels of the
axle mass vehicle.
Item 6: Maximum permissible rear Maximum permissible loading on the rear wheels of the
axle mass vehicle.
Item 7: Model type codes
Code Model type

PH2 Combi, short wheelbase
PJ2 Combi, long wheelbase
PT2 Double cab van, 5 seat van, short wheelbase
PU2 Double cab van, 5 seat van, long wheelbase
Item 8: Wheelbase
Code Wheelbase
2912 Long wheelbase (in mm)
2665 Short wheelbase (in mm)
Item 9: Final drive ratio codes
Code Description (overall ratio)

A 3.41
B 3.56
C 3.80

D 4.06
3 4.06
4 3.80
Item 10: Special vehicles only
Code Description
Only used for special vehicles
Field 11: Transaxle codes
Code Transaxle
P1 MTX-75 (diesel)
Q MTX-75 (petrol)
Item 12: Door combination codes
Code Door combination

A 4-door
B 5-door, sliding door on RHS
C 5-door, sliding door on LHS
D 6-door
E 3-door
F 4-door (with tailgate)
G 4-door (with tailgate), sliding door on LHS
H 5-door (with tailgate)
J 4-door, with high roof
K 5-door, with high roof, sliding door on RHS
L 5-door, with high roof, sliding door on LHS
M 6-door, with high roof
Item 13: Suspension codes
Code Suspension
AA Standard
IL strengthened construction
Item 14: Hand of drive codes
Code Drive
J Left-hand drive
K Right-hand drive
L Left-hand drive
M Right-hand drive
Item 15: Body Color Codes
Code Body Color

BD Saffron Yellow or Sand Yellow
EC Pepper Red or Sky Blue
JA Panther Black
KL Dark True Blue
MC Metropolis Blue
MT Steel Grey or Moondust Silver
ND Colorado Red
PC Jewel Green
TJ Bermuda Blue
UM Magnum Grey
ZA Diamond White
ZJ Polar Silver or Moondust Silver

3B Tonic
3D Sublime or Blue Ambition
3G Caramella, Frozen White, Plum Blush, Marmalade or Willow
Item 16: Brakes codes
Code Brake
B With anti-lock brakes (ABS) with Traction Control or Electronic Stability Program
C With ABS without Traction Control or Electronic Stability Program
D With ABS with Traction Control or Electronic Stability Program
Item 17: Interior trim codes
Code Interior Trim

4BA Flint, medium dark (material)
4BB Flint, medium dark (leather)
4BB Vinly, dark pewter (leather)
4BB Vinly, dark pewter (leather
4BB Lozenge, dark pewter (material)
4BB Lozenge, dark pewter (material)
4BB Papercut, Blue (Material)
4BB Papercut, Orange (material)
Item 18: Smoke emission (diesel only)
Code Description
1.72 only diesel (per metre)
Item 19: Engine codes
Code Engine
EYPA 1.8L Duratec-DOHC (Zetec) (Europe)
EYPB 1.8L Duratec-DOHC (Zetec) (Turkey)
EYPC 1.8L Duratec-DOHC (Zetec) (LPG) (Europe)
EYPD 1.8L Duratec-DOHC (Zetec) (CNG) (Europe)
BHPA 1.8L Duratorq-TDDi (Lynx) (55 kW / 75 PS) (Europe)
BHPB 1.8L Duratorq-TDDi (Lynx) (55 kW / 75 PS) (Turkey)
HCPA 1.8L Duratorq-TDCi (Lynx) (66 kW / 90 PS) (Europe)
HCPB 1.8L Duratorq-TDCi (Lynx) (66 kW / 90 PS) (Europe)
HCPC 1.8L Duratorq-TDCi (Lynx) (66 kW / 90 PS) (Turkey)
P7PA 1.8L Duratorq-TDCi (Lynx) VNT (56 kW / 76 PS) (Europe)
R2PA 1.8L Duratorq-TDCi (Lynx) FNT (56 kW / 76 PS) (Europe)
P9PA 1.8L Duratorq-TDCi (Lynx) VNT (67 kW / 91 PS) (Europe)
RWPA 1.8L Duratorq-TDCi (Lynx) VNT (81 kW / 110 PS) (Europe)
RWPB 1.8L Duratorq-TDCi (Lynx) VNT (67 kW / 110 PS) (Turkey)
HCPD 1.8L Duratorq-TDCi (Lynx) FNT (67 kW / 91 PS) (Turkey)
BHPC 1.8L Duratorq-TDCi (Lynx) FNT (56 kW / 76 PS) (Turkey)
P9PB 1.8L Duratorq-TDCi (Lynx) VNT (67 kW / 91 PS) (Europe)
RWPC 1.8L Duratorq-TDCi (Lynx) VNT (81 kW / 110 PS) (Europe)
Version codes
Code Total vehicle weight (kg) Vehicle and trailer total weight (kg)
T200 1970 2770

T200 2025 2825
T200 2025 2825
T220 2230 3030
T200 2035 2835
T200 2035 2835
T220 2240 3040
T210 2080 2880
T220 2260 3060
T230 2260 3060
T230 2340 3140
T230 2340 3140
K200 2045 2845
K210 2110 2910
K220 2175 2975
K230 2340 3140

Jacking and Lifting - Jacking Transit/Tourneo Connect 2002.5 (06/2002-)
Print
WARNING: Only the specified jacking points may be used for jacking up and
supporting the vehicle.
CAUTION: Park the vehicle on a flat, level and stable surface. If the vehicle must be
lifted on a soft surface, the supporting forces must be spread by using a suitable base
under the jack. Place a wheel chock against the wheel opposite the jack. Injury may
occur if these instructions are not followed !

Jacking and Lifting - Lifting Transit/Tourneo Connect 2002.5 (06/2002-)
Print
WARNING: Only raise the vehicle at the specified lifting points.
CAUTION: Place blocks underneath the hoist points if a two-column ramp is used.

Noise, Vibration and Harshness - Noise,
Vibration and Harshness (NVH)
Print
Noise, vibration and harshness (NVH) is becoming more important as vehicles become
more sophisticated and passenger comfort levels increase. This section is designed to aid in
the diagnosis and testing and repair of NVH concerns.
Noise is defined as sounds not associated with the operation of passenger compartment
equipment that interface with customer satisfaction.
Vibration is defined as impulses felt by the customer that are not caused by road surface
changes.
Harshness is a ride quality issue where the customer feels that the vehicle response to
the road surface is sharply transmitted to the customer.
Diagnostic Theory
Diagnosis is more than just following a series of interrelated steps in order to find the
solution to the specific condition. It is a way of looking at systems that are not functioning
the way they should and finding out why. Also it is knowing how the system should work
and whether it is working correctly.
There are basic rules for diagnosis. If these rules are followed, the cause of the condition is
usually found the first time through the system.
Know the System
Know how the parts go together.

Know how the system operates as well as its limits and what happens when the system
goes wrong.
Sometimes this means checking the system against one that is known to be working
correctly.
Know the History of the System

A clue in any one of these areas may save time:
How old or new is the system?

What kind of treatment has it had?
Has it been serviced in the past in such a manner that might relate to the present
condition?
What is the service history?
Know the History of the Condition
Did it start suddenly or appear gradually?

Was it related to some other occurrence such as a collision or previous part replacement?
Know how the condition made itself known; it may be an important clue to the cause.
Know the Probability of Certain Conditions Developing
Look for the simple rather than the complex.

For example:
- Electrical conditions usually occur at connections rather than components.
- An engine no-start is more likely to be caused by a loose wire or small adjustment
rather than a sheared-off camshaft.
Know the difference between impossible and improbable. Certain failures in a system can
be improbable but still happen.
New parts are just that, new. It does not mean they are always good functioning parts.

Do Not Cure the Symptom and Leave the Cause
Lowering the pressure in a front tire may correct the condition of a vehicle leaning to one
side, but it does not correct the original condition.
Be Positive the Cause is Found
Double check findings.

What caused a worn component?
A loose transmission or engine mount could indicate that other mounts are also loose.
Diagnostic Charts
Charts are a simple way of expressing the relationship between basic logic and a physical
system of components. They help discover the cause of a condition in the least time.
Diagnostic charts combine many areas of diagnosis into one visual display:
Probability of certain things occurring in a system.

Speed of checking certain components or functions before others.
Simplicity of performing certain tests before others.
Elimination of checking huge portions of a system by performing simple tests.
Certainty of narrowing down the search to a small portion before performing in-depth
testing.
The fastest way to find a condition is to work with the tools that are available. This means
working with proven diagnostic charts and the correct special equipment for the system.

Noise, Vibration and Harshness - Noise,
Vibration and Harshness (NVH)
Print
Diagnosis and Testing
1. 1. Verify the customer concern.
2. 2. Visually inspect for obvious signs of mechanical or electrical damage.
3. 3. If an obvious cause for an observed or reported concern is found, correct the cause
(if possible) before proceeding to the next step.
4. 4. If the concern is not visually evident, verify the symptom and REFER to the
Symptom Chart.
How to Use this Diagnostic Procedure Section
Noise, vibration and harshness (NVH) concerns have become more important as vehicles
have become more sensitive to these vibrations. This section is designed to aid in
identifying these concerns.
The section provides diagnostic procedures based on symptom. If the condition occurs at
high speed, for instance, the most likely place to start is under Shake and Vibration While
Driving.
The road test procedure will tell how to sort the conditions into categories and how to tell
a vibration from a shake.
A series of Road Test Quick Checks are provided to make sure that a cause is either
pinpointed or eliminated.
Name the condition, proceed to the appropriate section and locate the correct diagnosis.
When the condition is identified, the job is partly done.
Follow the diagnostic procedure as outlined.
Quick Checks are described within the step, while more involved tests and adjustments
are outlined in General Procedures.
Always follow each step exactly and make notes to recall important findings later.
Customer Interview
The road test and customer interview (if available) provide information that will help
identify the concern and will provide direction to the correct starting point for diagnosis.
Identify the Condition
NVH usually occur in four areas:
tires
engine accessories
suspension
driveline
It is important, therefore, that an NVH concern be isolated into its specific area(s) as soon
as possible. The easiest and quickest way to do this is to carry out the Road Test as
outlined. To assist in the diagnosis and testing procedure(s), use a suitable approved NVH
diagnosis tester.
Noise Diagnostic Procedure
Non-Axle Noise
The five most common sources of non-axle noise are exhaust, tires, roof racks, trim panels
and transmission.

Therefore, make sure that none of the following conditions are the cause of the noise
before proceeding with a driveline teardown and diagnosis.
In certain conditions, the pitch of the exhaust may sound very much like gear noise. At
other times, it can be mistaken for a wheel bearing rumble.
Tires, especially snow tires, can have a high pitched tread whine or roar, similar to gear
noise. Radial tires may have this characteristic. Also, any non-standard tire with an
unusual tread construction may emit a roar or whine noise.
Trim panels can also cause whistling or whining noise.
Clunk may be a metallic noise heard when the automatic transaxle is engaged in
"R" (REVERSE) or "D" (DRIVE) or it may occur when the throttle is applied or released. It
is caused by backlash somewhere in the driveline.
Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a
damaged wheel bearing.
Noise Conditions
Gear noise is typically a howling or whining due to gear damage or incorrect bearing
preload. It can occur at various speeds and driving conditions, or it can be continuous.
Chuckle is a particular rattling noise that sounds like a stick against the spokes of a
spinning bicycle wheel. It occurs while decelerating from 64 km/h (40 mph) and can
usually be heard all the way to a stop. The frequency varies with vehicle speed.
Knock is very similar to chuckle, though it may be louder and occurs on acceleration or
deceleration. The teardown will disclose what has to be corrected.
Clicking, popping or grinding noises may be caused by the following:
worn, damaged or incorrectly installed wheel bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items before disassembling the transmission to
diagnose and correct gear noise.
The noises described under Road Test usually have specific causes that can be diagnosed
by observation as the unit is disassembled. The initial clues are the type of noise heard on
the road test and driving conditions.
Vibration Conditions
Vibration at highway speeds may be caused by the following:
out-of-balance front or rear wheels.

out-of-round tires.
Shudder or vibration during acceleration may be caused by the following:
damaged powertrain/drivetrain mounts.

excessively high constant velocity (CV) joint operating angles caused by incorrect ride
height. Check ride height, verify correct spring rate and check items under inoperative
conditions.
Road Test
A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and
may be audible at certain speeds or under various driving conditions, as on a newly paved
asphalt road. The slight noise is in no way detrimental and must be considered normal.
The road test and customer interview (if available) provide information needed to identify
the condition and give direction to the correct starting point for diagnosis.
1. 1. Make notes throughout the diagnosis routine. Make sure to write down even the

smallest bit of information, because it may turn out to be the most important.
2. 2. Do not touch anything until a road test and a thorough visual inspection of the
vehicle have been carried out. Leave the tire pressures and vehicle load just where
they were when the condition was first observed. Adjusting tire pressures, vehicle
load or making other adjustments may reduce the condition(s) intensity to a point
where it cannot be identified clearly. It may also inject something new into the
system, preventing correct diagnosis.
3. 3. Make a visual inspection as part of the preliminary diagnosis routine, writing down
anything that does not look right. Note tire pressures, but do not adjust them yet.
Note leaking fluids, loose nuts and bolts, or bright spots where components may be
rubbing against each other. Check the load space for unusual loads.
4. 4. Road test the vehicle and define the condition by reproducing it several times
during the road test.
5. 5. Carry out the Road Test Quick Checks as soon as the condition is reproduced. This
will identify the correct diagnostic procedure. Carry out the Road Test Quick Checks
more than once to verify they are providing a valid result. Remember, the Road
Test Quick Checks may not tell where the concern is, but they will tell where it is
not.
Road Test Quick Checks
1. 1. 24-80 km/h (15-50 mph): with light acceleration, a moaning noise is heard and
possibly a vibration felt in the front floor panel. It is usually worse at a particular
engine speed and at a particular throttle setting during acceleration at that speed. It
may also produce a moaning sound, depending on what component is causing it.
REFER to Tip-in Moan in the Driveline Noise and Vibration Symptom Chart.
2. 2. Acceleration/Deceleration: With slow acceleration and deceleration, a shake is

sometimes noticed in the steering wheel/column, seats, front floor panel, front door
trim panel or front end sheet metal. It is a low frequency vibration (around 9-15
cycles per second). It may or may not be increased by applying the brakes lightly.
REFER to Idle Boom/Shake/Vibration in the Driveline Noise and Vibration Symptom
Chart.
3. 3. High Speed: A vibration is felt in the front floor panel or seats with no visible
shake, but with an accompanying sound or rumble, buzz, hum, drone or booming
noise. Coast with the clutch pedal depressed (manual transmission) or shift control
selector lever in "N" (NEUTRAL) (automatic transmission) and engine idling. If
vibration is still evident, it may be related to wheels, tires, front brake discs, wheel
hubs or front wheel bearings. REFER to Shake and Vibration While Driving in the
Driveline Noise and Vibration Symptom Chart.
4. 4. Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular
rpm. It will disappear in neutral coasts. The vibration can be duplicated by operating
the engine at the problem rpm while the vehicle is stationary. It can be caused by
any component, from the accessory drive belt to the clutch or torque converter
which turns at engine speed when the vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise and Vibration Symptom Chart.
5. 5. Noise and Vibration While Turning: Clicking, popping or grinding noises may be
due to the following:
worn, damaged or incorrectly installed front wheel bearing.

damaged powertrain/drivetrain mounts.
Road Conditions
An experienced technician will always establish a route that will be used for all NVH
diagnosis road tests. The road selected should be reasonably smooth, level and free of
undulations (unless a particular condition needs to be identified). A smooth asphalt road
that allows driving over a range of speeds is best. Gravel or bumpy roads are unsuitable
because of the additional road noise produced. Once the route is established and
consistently used, the road noise variable is eliminated from the test results.
NOTE: Some concerns may be apparent only on smooth asphalt roads.
If a customer complains of a noise or vibration on a particular road and only on a particular
road, the source of the concern may be the road surface. If possible, try to test the vehicle
on the same type of road.
Vehicle Preparation
Carry out a thorough visual inspection of the vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust any condition until the road test is
carried out, unless the vehicle is inoperative or the condition could pose a hazard to the
technician. After verifying that the condition has been corrected, make sure all components
removed have been installed.
Power Steering Conditions
Check for the noise in the following conditions to verify the customer concern.
Check for the noise in several temperature conditions.

Is the noise from when the vehicle was new?
Can the noise be repeated constantly or is it random?
Check the condition of the vehicle age, mileage and service record.
Interview the customer to find the operating condition in which the noise will occur. Test
the vehicle based on the detail(s) from the customer interview.
Follow the power steering operation noise condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check

Step 1: Check for NVH concerns from non-steering components, which may sound like
noises coming from the steering system.
Power assisted steering operating condition

Parking Driving
Steering central/slightly Steering at a steering Driving straight ahead Cornering condition
off center lock stop
REFER to NVH concerns REFER to NVH REFER to NVH REFER to NVH
from other components concerns from other concerns from other concerns from other
column A components column B components column C components column D
NVH concerns from other components
NVH concerns from other condition (column A to D)

Noise Driving Condition ABCD
Pedal box knocking Drive off, stop driving and slow cornering over XXOX
uneven roads
Stabilizer bar link knocking Drive off, driving and cornering XOOX
Engine support insulator knocking Drive off, driving, acceleration and deceleration X X
Air conditioning knocking Engine on, activate switch for air conditioning X X OO
Suspension knocking (Subframe, Drive off, driving, cornering, acceleration and X OX
Springs) deceleration
Constant velocity (CV) joint Drive off, driving, cornering, acceleration and XO X

knocking deceleration
Washer bottle Deceleration, acceleration and single impact O X
Loose suspension bolts All driving conditions O OX
Instrument panel rattle/squeak All driving conditions. Engine rpm dependant XXXX
X = Noise will most likely occur in this operating condition.

O = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
Step 2: Check for steering system NVH concerns according to operation condition described
at the customer interview.
Power assisted steering operating condition

Vehicle stationary with engine
Parking Driving off
Steering Steering at a Steering Steering at a Steering Steering at a
central/slightly off steering lock central/slightly off steering lock central/slightly off steering lock
center stop center stop centre stop
REFER to steering REFER to REFER to steering REFER to REFER to steering REFER to
system NVH steering system NVH steering system NVH steering
concerns column system NVH concerns column system NVH concerns column system NVH
A concerns C concerns E concerns
column B column D column F
Steering system NVH concerns
Steering System operation condition (column A to F)

Noise Driving condition ABCDE F
Moan Parking between lock stops, at engine idle and also XO
increased engine speed
Whine Driving, high engine rpm. Must be present from new OO X X
Hiss a) Parking between lock stops. Must be present from new X X OO
b) Holding steering wheel against lock stops. Must be X
present from new
Lock stop impact knock a) Parking at lock stop. Must be present from new X X
Mechanical knock b) Parking between lock stops, engine OFF. Must be present X
(power assisted from new
steering (PAS) off)
Mechanical Knock (PAS c) Parking between lock stops, engine ON (ball joint knock) X
on)
Hammer knock d) Parking into lock stop and release (vehicle with hydraulic X
power assisted steering (HPAS) only, not for vehicles with
electro-hydraulic power assisted steering (EHPAS))
Hydraulic knock (clonk) e) Driving, cobble stones, rough road (clonk). Must be OX
present from new
Column knock f) Parking, driving. cobble stones and rough roads XXOX XX
Column rattle Mainly driving on rough roads O XXO
Toc-toc Steering left and right at high frequency. Must be present X
from new
Grinding When turning steering wheel X OX
Zip At engine start, low temperatures below -10°C only XO
X = Noise will most likely occur in this operating condition.

O = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
Step 3: According to each identified operating condition (Column A, B, C, D, E, F), check

each possible Steering System NVH concern with the detail symptom charts below.

Before conducting a vehicle test to identify a NVH concern carry out the following checks.
1. 1. Check the tire pressures and adjust to specification, as necessary.
2. 2. Make sure the steering system fluid is correct, the system is free of leaks and is
operating correctly.
3. 3. Make sure the vehicle steering system temperature is the same as described at the
customer interview.
4. 4. All evaluations must take place in a relatively quiet location.
5. 5. The heating - air conditioning (A/C) fan and radio must be turned off during
evaluations and the windows closed.
Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle parked, transmission in neutral and all
windows closed in the following test conditions.
1. 1. Engine speed at idle with no steering action.
2. 2. Engine speed at idle with slow 90 degrees per second turning of the steering
wheel.
3. 3. Engine speed at 1250 +/- 50 rpm with no steering action.
4. 4. Engine speed at 1250 +/- 50 rpm with slow 90 degrees per second turning of the
steering wheel.
Possible
Symptom Sources Action
CHECK the routing of the power
steering lines.
CHECK the power steering line
Power
clamps are secure.
steering
CHECK the power steering lines
lines.
for clearance from the vehicle
body, front axle crossmember
and steering gear.
Power steering system moan noise – A FLUSH the power steering system.
continuous low pitched humming noise REFER to:
occurs when the steering wheel is turned Power Steering System Flushing -
and the steering system is loaded. Noise 1.8L Duratec-DOHC (85kW/115PS)
frequency changes with engine rpm - Zetec (211-00 Steering System -
Incorrect
changes. Particularly annoying at lower General Information, General
power
engine speed. Procedures),
steering
Power Steering System Flushing -
fluid.
1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx)
Diesel (211-00 Steering System -
General Information, General
Procedures).
Power Pressure pulses from the power steering

steering pump. Certain amount of noise level
pump. acceptable, not a safety critical item.
Power Steering Whine Noise
Test Condition
Listen for steering whine noise with the vehicle parked, transmission in neutral and all
2. 2. Engine speed at 1800 +/- 50 rpm with slow 90 degrees turning of the steering
wheel.
4. 4. Engine speed at 3000 +/- 50 rpm with slow 90 degrees turning of the steering
wheel.
Symptom Possible Sources Action

BLEED the power steering system.
REFER to: Power Steering System
Power steering
Bleeding (211-00 Steering System -
fluid aeration.
Procedures).
FLUSH the power steering system.
REFER to:
1.8L Duratec-DOHC (85kW/115PS)
- Zetec (211-00 Steering System -
Incorrect power
Procedures),
steering fluid.
Power steering system whine noise –
a high pitched buzzing sound like an
electric motor or drill. Whine occurs
Procedures).
at the higher engine rpm, 1500 -
FLUSH the power steering system.
5000 rpm, frequency does not
REFER to:
change if system is loaded or not
loaded.
1.8L Duratec-DOHC (85kW/115PS)
- Zetec (211-00 Steering System -
Overheated General Information, General
power steering Procedures),
fluid. Power Steering System Flushing -
Procedures).
Hydraulic
operating
Certain amount of noise level
condition of the
acceptable, not a safety critical item.
power steering
pump.
Power Steering Hiss Noise
Test Condition

Listen for steering hiss noise with the vehicle parked, transmission in neutral and all
Possible
NOTE: Engine speed at idle turning the steering wheel CHECK the
slowly lock to lock. installation and
Floor seal.
Power steering system hiss noise – a high frequency, potential damage of
continuous rush or swish noise like escaping air from a the floor seal.
balloon. Hiss occurs while turning between the steering Certain amount of
Power
lock stops, all steering angles. Noise does not change with noise level
steering gear
engine rpm and is worse at high operating temperatures. acceptable, not a
valve design.
safety critical item.
Power
Certain amount of
steering
noise level
system
acceptable, not a
hydraulic
design.
NOTE: Engine speed at idle holding the steering wheel
against a steering lock for three seconds. Do not hold Power Certain amount of
for more than five seconds. steering pump noise level
Power steering system hiss noise – a continuous noise like pressure relief acceptable, not a
escaping air occurs while holding the steering against a valve. safety critical item.
steering lock stop.
Power Steering Lock Stop Impact Knock Noise
Test Condition
Listen for steering knock noise with the engine speed at idle in the following test conditions
(noise also apparent with engine off).
1. 1. Turn the steering wheel to the left-hand and right-hand steering locks and listen
for the impact noise.

Power steering system knock noise – a Power steering gear
Certain amount of noise
heavy loud sound like a knock on a door mechanical noise, metal to
level acceptable, not a
that occurs in parking condition when metal at end of steering
hitting the lock stop. travel.
Power Steering Mechanical Knock Noise (PAS off)
Test Condition
Listen for steering knock noise with the engine off in the following test conditions (no power
assist).
1. 1. Turn the steering wheel 90 degrees to the right, hold and then quickly release.
2. 2. Turn the steering wheel 90 degrees to the left, hold and then quickly release.

Power steering system knock noise –
Certain amount of
a damped, metallic knock noise
noise level
Power steering system knock noise which only occurs at steering
acceptable, not a
– a heavy loud repeating sound like condition with engine off (very high
a knock on a door that occurs in efforts).
several driving and steering Certain amount of
conditions. Tolerances in the steering gear noise level
components. acceptable, not a

Power Steering Mechanical Knock Noise (PAS on)
Test Condition
(power assist).
1. 1. Turn the steering wheel to a steering lock and return to center quickly.
2. 2. Turn the steering wheel 90 degrees to the left and then 90 degrees to the right
quickly.

Power steering system knock REFER to Steering System.
Worn tie-rod ball
noise – clear knock noise from REFER to: Steering System (211-00
joints (inner and
steering gear linkage area. Steering System - General
outer ball joints).
Information, Diagnosis and Testing).
Power Steering Hammer Knock (Hydraulic) Noise
Test Condition
(for vehicles with hydraulic power assisted steering only, not electro-hydraulic power
steering).
1. 1. Turn the steering wheel to a steering lock position and return quickly.

Power steering system knock noise – loud, metallic Hydraulic noise Certain amount of
sound if hitting the suspension crossmember with a created by noise level acceptable,
hammer (sounds like metallic noise but is created by pressure not a safety critical
pressure impulse in gear and return line). impulses. item.
Power Steering Hydraulic Knock/Clonk Noise
Test Condition
Listen for steering knock/clonk noise in the following test conditions with the windows
closed.
1. 1. Drive over cobbled roads at low speed 10-30 km/h (6-20 mph) with and without
turning.
2. 2. Drive over straight tar strips road rails or 25 mm tall harshness strips at low speed
10-30 km/h (6-20 mph) both driving straight and with moderate turning.

Certain amount
of noise level
Power steering
acceptable, not a
return lines.
Power steering system knock/clonk noise – sounds safety critical
almost identical to column knock that occurs when item.
driving and cornering over cobbled stones or rough High power assist
Certain amount
roads. Noise may appear to emanate from a location gain of power
of noise level
closer to the floor than that for column knock (Sounds steering gear
acceptable, not a
like metallic noise but is created by pressure impulse in valve (steering
safety critical
gear and return line – similar to a sound like quickly gear design - no
item.
turning off a water tap). quality issue).
Certain amount
High power of noise level
steering pump acceptable, not a

flow rate (by safety critical
design). item.
Power Steering Column Knock Noise
Test Condition
Listen for steering knock noise in the following test conditions with windows closed.
1. 1. Drive over cobbled stones at low speed 16-40 km/h (10-25 mph) with and without
steering input carefully listening for knock sounds.
2. 2. Drive over straight tar strips, road rails or 25 mm tall harshness strips at low
speed 16-40 km/h (10-25 mph) both driving straight and with moderate cornering.
Possible
CHECK the steering column retaining
bolts and attachments to the
steering column and secure if
necessary.
Power steering system column knock REFER to: Specifications (211-04
Steering column
noise – a loose sounding rattle or Steering Column, Specifications).
or steering
vibration coming from the column. Check steering column and
column shaft.
Noticeable by hearing and touch. intermediate shaft for free play or
loose components.
REFER to: Steering System (211-00
Steering System - General
Power Steering Toc-Toc Noise
Test Condition
Listen for steering toc-toc noise with the engine speed at idle and the vehicle parked,
automatic transmission in "P" (PARK) or manual transmission in neutral and the windows
closed.
1. 1. Turn the steering wheel from left to right abruptly changing direction.
2. 2. Drive the vehicle for low speed parking manoeuvres constantly changing steering
direction.

Power steering system toc-toc noise – a metallic
Steering gear Certain amount of noise
noise created when changing direction of
(design tolerance level acceptable, not a
steering wheel rotation during parking
in steering rack). safety critical item.
manoeuvre or at standstill.
Power Steering Grinding Noise
Test Condition
Listen for steering grinding noise with the engine speed at idle and the vehicle parked,
automatic transmission in "P" (PARK) or manual transmission in neutral and the windows
closed.
1. 1. Slowly turn the steering wheel from lock to lock.
2. 2. Tilt and extend the steering column in various positions and slowly turn the
steering wheel from lock to lock.

Steering wheel to
acceptable, not a safety critical
shroud interference.
item.
Steering column
acceptable, not a safety critical
bearing.
item.
CHECK if floor covering is
Power steering system grinding noise – Foreign material in
obstructing the steering gear
an abrasive noise (like sand paper contact with the
pinion.
rubbing against wood) occurs between steering column
moving components such as steering CHECK the installation of the
shaft.
wheel and the steering column shroud. floor seal.
CHECK the clockspring and
secure if necessary.
REFER to: Clockspring -
Clockspring. Vehicles Built From: 04/2009
(501-20B Supplemental
Restraint System, Removal and
Installation).
Power Steering Zip Noise

High viscosity of
Certain amount of noise
power steering
level acceptable, not a
fluid at low
Power steering system zip noise – occurs when safety critical item.
temperature.
hydraulic fluid does not flow freely through the
BLEED the power steering
power steering pump supply hose from steering
system.
fluid reservoir to power steering pump causing
Aeration of the REFER to: Power Steering
cavitation at the pump. Zip is primarily a cold
power steering System Bleeding (211-00
weather start-up phenomenon (below -10°C).
fluid. Steering System -
General Information,
General Procedures).
Driveline Noise and Vibration

Wheel end vibration.
Shake and vibration while driving GO to Pinpoint Test A.
Engine/transmission.
Air cleaner.
Power assisted steering.
Tip-in moan Powertrain. GO to Pinpoint Test B.
Powertrain/drivetrain mounts.
Exhaust system.
Cable(s)/hose(s).
Powertrain/drivetrain mounts.
Idle boom/shake/vibration/shudder GO to Pinpoint Test C.
Exhaust system.
Belt/pulleys.
Suspension Noise and Vibration

Suspension.
Wheel end vibration analysis GO to Pinpoint Test D.
Wheel bearings.
Trim panels.
Non-axle noise Air conditioning (A/C) system. GO to Pinpoint Test E.
Accessories.
Pinpoint Tests
NOTE: These Pinpoint Tests are designed to take the technician through a step-by-step
diagnosis procedure to determine the cause of a condition. It may not always be
necessary to follow the chart to its conclusion. Carry out only the pinpoint test steps

necessary to correct the condition. Then check the operation of the system to make sure
the condition has been corrected.
After verifying that the condition has been corrected, make sure all components removed
have been installed.
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
Does the vibration disappear during the neutral coast test?
Yes
GO to A2.
No
GO to Pinpoint Test D.
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neutralizing procedure
Are the mounts OK?
Yes
Vehicle condition corrected. ROAD TEST as necessary.
No
INSTALL new powertrain/drivetrain mounts as necessary. ROAD TEST as
necessary.
PINPOINT TEST B : TIP-IN MOAN

CONDITIONS
B1: CHECK THE AIR CLEANER
1 Check the condition of the air cleaner mounts, inlet tube, outlet tube,
resonators and all other components associated with the air induction
system for correct installation and tightness of all connections.
Are the components OK?
Yes
GO to B2.
No
REPAIR or INSTALL new components as necessary. ROAD TEST as
necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing procedure.
REFER to in this section.
Is the exhaust system OK?
Yes
GO to B3.
No
REPAIR as necessary. ROAD TEST as necessary.
B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for tip-in moan. REFER to: (303-
05 Accessory Drive)
Accessory Drive Belt - 1.8L Duratec-DOHC (85kW/115PS) - Zetec
(Removal and Installation),
Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L
Duratorq-TDDi (Lynx) Diesel (Removal and Installation).
Is the tip-in moan OK?

Yes
REPAIR the power steering as necessary.
REFER to: Steering System (211-00 Steering System - General
No

GO to B4.
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
Are the powertrain/drivetrain mounts OK?
Yes
No
necessary.
PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER

CONDITIONS
C1: CHECK THE CABLE/HOSES
1 Check the engine compartment for any component that may have a touch
condition between the engine and body or chassis. For example: control
cable, air conditioning (A/C) hoses, acceleration cable.
Are the components OK?
Yes
GO to C2.
No
necessary.
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings and bushings for security and
condition. Check the radiator installation for any component that may have
a touch condition.
Is the installation and bushings OK?
Yes
GO to C3.
No
necessary.
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing procedure.
REFER to in this section.
Is the exhaust system OK?
Yes
GO to C4.
No
REPAIR as necessary. ROAD TEST as necessary.
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
Are the powertrain/drivetrain mounts OK?
Yes
No
necessary.
PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS

CONDITIONS
D1: INSPECT THE WHEELS AND TIRES
1 Inspect the wheels and tires.
REFER to: Wheels and Tires (204-04 Wheels and Tires, Diagnosis and
Testing).
Are the wheels and tires OK?

Yes
GO to D2.
No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).
ROAD TEST as necessary.
D2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
REFER to: Wheel Bearing Inspection (204-00 Suspension System -
General Information, General Procedures).
Are the wheel bearings OK?
Yes
GO to D3.
No
INSTALL new wheel bearings as necessary. REFER to:
Front Wheel Bearing (204-01 Front Suspension, Removal and
Installation),
Wheel Hub (204-02 Rear Suspension, Removal and Installation).
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
Is the wheel and tire runout OK?
Yes
Balance the wheels and tires. Refer to the wheel balance equipment
manufacturer's instructions. ROAD TEST as necessary.
No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).
PINPOINT TEST E : NON-AXLE NOISE

CONDITIONS
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see if they are the source of
the noise.
Are the vehicle trim components causing the noise?
Yes
INSTALL new trim components or REPAIR as necessary. ROAD TEST as
necessary.
No
GO to E2.
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Ignition switch in position III.
2 Ignition switch in position II.
3 Check the A/C system components for noise by turning the A/C system on
and off.
Is the A/C system causing the noise?
Yes
INSPECT the A/C system. REFER to: (412-00 Climate Control System -
General Information)
Climate Control System (Diagnosis and Testing),
No
GO to E3.
E3: CHECK NON-FACTORY FITTED ACCESSORIES

1 Check any non-factory installed accessories for being the source of the
noise. For example: touch condition body-to-frame, antennas, deflectors
and fog lights.
Are the accessories the cause of the noise?
Yes
ADJUST, REPAIR, or INSTALL new accessories or fasteners as required.
No
VERIFY the customer concern.

Noise, Vibration and Harshness -
Powertrain/Drivetrain Mount Neutralizing
Print
General Procedures
NOTE: There is no procedure for neutralizing the powertrain/drivetrain mounts. To check

the alignment of the powertrain mounts visually, proceed as follows.
1. Loosen the rear support insulator retaining bolts
(if equipped).
2. Loosen the powertrain/drivetrain mount retaining
bolts.
3. NOTE: Support the powertrain/drivetrain in
an approximate position and height.
NOTE: Make sure that the right-hand mount
and left-hand insulator align over the studs
on the powertrain and drivetrain to allow the
fixings to be assembled through the large
holes in the support insulator bracket without
overstraining.
Check the powertrain/drivetrain mount
alignment.
4. Tighten the powertrain/drivetrain mount to
powertrain/drivetrain mount bracket retaining
bolts.
5. Tighten the powertrain/drivetrain mount to body
retaining bolts.
6. Tighten the rear support insulator retaining bolts
(if equipped).

Suspension System - General Information
- Specifications
Print
Front Wheel Alignment (at curb weight) — Caster
Model Decimal Degrees Degrees and Minutes

Nominal Tolerance Range Nominal Tolerance Range
All variants +1.80° +2.30° to +1.30° +1°48' +2°18' to +1°18'
Maximum variance left-hand side to right-hand side Caster 1.00° (1°00')
Front Wheel Alignment (at curb weight) — Camber

Short wheelbase van -0.61° -0.11° to -1.11° -0°37' -0°07' to -1°07'
Short wheelbase kombi -0.70° -0.20° to -1.20° -0°42' -0°12' to -1°12'
Long wheelbase van -0.52° -0.02° to -1.02° -0°31' -0°01' to -1°01'
Long wheelbase kombi -0.61° -0.11° to -1.11° -0°37' -0°07' to -1°07'
Maximum variance left-hand side to right-hand side Camber 0.50° (0°30')
Front Wheel Alignment (at curb weight) — Total Toe Setting - Short Wheelbase Van
Derivative Tolerance Range Setting Adjustment, If Required

All variants (decimal degrees) 0.22° (Toe-in) ± 0.15° -
All variants (degrees and minutes) 0°13' (Toe-in) ± 0°09' -
All variants (mm) 1.5 (Toe-in) ± 1.0 -
Front Wheel Alignment (at curb weight) — Total Toe Setting - Short Wheelbase Kombi

Front Wheel Alignment (at curb weight) — Total Toe Setting – Long Wheelbase Van

Front Wheel Alignment (at curb weight) — Total Toe Setting – Long Wheelbase Kombi

Rear Wheel Alignment (at curb weight) — Camber

All variants -1.00° -0.50° to -1.50° -1°00' -0°30' to -1°30'
Maximum variance left-hand side to right-hand side Camber 0.50° (0° 30')
Rear Wheel Alignment (at curb weight) — Total Toe Setting

All variants (decimal degrees) 0 Toe to 0.60° (Toe-in) -
All variants (degrees and minutes) 0 Toe to 0°36' (Toe-in) -
All variants (mm) 0 Toe to 4.0 (Toe-in) -

Torque Specifications
Description Nm lb-ft lb-in

Tie-rod end locknut 47 35 -

Front Suspension - Front Suspension Transit/Tourneo Connect 2002.5 (06/2002-)
Print
A newly developed Mc-Pherson front suspension with L-shaped lower arms is used. These
lower suspension arms are linked via two horizontal rubber mountings to a reinforced and
extremely rigid front axle crossmember.
Depending on the vehicle variant, a stabiliser may be installed. This is connected to the
suspension strut by two stabiliser link rods. The ball heads of the stabiliser link rods are
provided with an Allen screw fixing.
Overview

1 - McPherson strut
2 - Stabiliser link rod
3 - Front axle crossmember
4 - Stabiliser (depending on vehicle variant)
5 - Mounting for L-shaped suspension lower arm
6 - L-shaped suspension lower arm
The front track for all vehicle variants is 1505 mm. Depending on vehicle variant, the wheel
base is 2665 mm (short wheel base) or 2912 mm (long wheel base). The turning circle on
short wheel base vehicles is 11.01 metres, on long wheel base vehicles 11.91 metres.
Toe-in is adjusted via adjustable track rods. The lower suspension arms can only be
replaced as a complete unit.
Suspension strut

1 - Suspension strut top mount
2 - Spring
3 - Spindle carrier
4 - Ball head
5 - Heat shield
6 - Wheel bearing
7 - Studs
8 - Wheel hub
9 - Nut
NOTE: During installation of the front wheel bearing it is important to adhere to the
specified installation position, as the Anti-lock Brake System (ABS) sensor ring is located
in the wheel bearing. A coloured rubber ring is provided to indicate the correct installation
position. If the wheel bearing were to be installed incorrectly then this would cause failure
of the ABS . Refer to the current service literature for further information.
The suspension strut turret support bearings have two separate routes for independently
deflecting the spring and shock absorber forces into the body. This reduces the level of
noise transmitted from the road surface.
Springs with various ratings may be installed, depending on the vehicle variant. The shock
absorbers are twin-tube gas shock absorbers. Dampers with various characteristics may be
installed, depending on the vehicle variant.
The ball joint between the suspension arm and the strut can be changed separately. A
revised special tool is available for this in service.
There is also a heat shield installed on the ball joint. Pay particular attention here, because
any damage to the heat shield of the ball joint means that the ball joint must be replaced.
The wheel hub has five studs for securing the wheel.

Front Suspension - Front Suspension Transit/Tourneo Connect 2002.5 (06/2002-)
Print
REFER to Section 204-00 Suspension System - General Information.

Front Suspension - Front Wheel Bearing Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal and Installation
Special Tool(s)
Adaptor for 204-158 (Thrust Pad)
204-158-01 (14-038-01)
Installer, Front Wheel Bearing

204-160 (14-040)
Adapter for 205-074

205-074-01 (15-064)
Installer, Rear Hub Oil Seal

205-075 (15-036)
Remover, Bearing/Gear
204-348
Installer/Aligner, Crankshaft Rear Oil Seal

303-172-03 (21-102-03)
Removal
1. Remove the wheel knuckle.
For additional information, refer to: Wheel
Knuckle (204-01 Front Suspension, Removal and
Installation).
2. Using the special tools, remove the wheel hub
from the wheel knuckle.
3. Remove the circlip from the wheel knuckle.

4. Using the special tools, remove and discard the
wheel bearing.
Installation
CAUTIONS:
Avoid any impact on the wheel speed sensor ring.
Make sure the wheel speed sensor ring is clean.
Avoid any contact between the wheel speed sensor ring and a magnetic surface.
1. CAUTION: Make sure the wheel bearing

is installed into the wheel knuckle with the
wheel speed sensor ring, colored black,
towards the inner face of the wheel knuckle.
NOTE: Install a new wheel bearing.
Using the special tool, install the new wheel
bearing.
2. NOTE: Make sure the circlip does not cover

the wheel speed sensor.
Install the circlip.
3. Using the special tools, install the wheel hub.

4. Install the wheel knuckle.
Installation).

Front Suspension - Lower Arm Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Two leg puller
Removal
1. Remove the wheel and tire. For additional
information, refer to Section 204-04 Wheels and
Tires.
2. NOTE: Use a T50 Torx driver to prevent the
ball joint from rotating.
Loosen the lower arm ball joint retaining nut.
3. CAUTIONS:
Leave the lower arm ball joint retaining

nut in place to protect the ball joint stud.
Protect the ball joint seal using a soft

cloth to prevent damage.
Protect the heat shield using a soft cloth

to prevent damage.
Using a suitable two leg puller, detach the lower
arm from the wheel knuckle.
1. Use a soft faced hammer to strike the
lower arm.
2. Remove and discard the retaining nut.
4. Remove the lower arm.
1. Remove and discard the front retaining
bolt.
2. Remove and discard the rear clamp
retaining nuts, bolts and ball bearing
washer.
Installation
1. Check the lower arm ball joint heat shield for
damage. Install a new heat shield if necessary.
For additional information, refer to Lower Arm
Ball Joint in this section.
2. CAUTION: Make sure the ball bearing

washer is installed correctly.
NOTE: Install new nuts, bolts and ball

bearing washer.
NOTE: Do not fully tighten the lower arm
retaining bolts at this stage.
Install the lower arm.
3. Tighten the lower arm retaining bolts in the

sequence shown.
1. The front retaining bolt.
2. The rear clamp upper retaining bolt.
3. The rear clamp lower retaining bolt.
4. WARNING: Install a new lower arm ball

joint retaining nut. Failure to follow this
instruction may result in personal injury.
CAUTION: Protect the heat shield using

a soft cloth to prevent damage.
NOTE: Use a T50 Torx driver to prevent the
Attach the lower arm to the wheel knuckle.
5. Install the wheel and tire. For additional
Tires.
6. Check the toe setting and adjust as necessary.
For additional information, refer to Section 204-
00 Suspension System - General Information.

Front Suspension - Front Stabilizer Bar Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Alignment Pins, Subframe
205-316 (15-097A)
Separator, Ball Joint

211-020 (13-006)
General Equipment
Two leg puller
Transmission jack
Securing strap
Removal
1. NOTE: Make sure the road wheels are in the
straight ahead position.
Centralize the steering and lock it in position.
2. Disconnect the steering column shaft from the

steering gear pinion extension.
Discard the bolt.
3. Remove the front wheels and tires. For additional

Tires.
4. CAUTION: Leave the tie-rod end

retaining nut in place to protect the ball joint
stud.
NOTE: Use a 5 mm Allen key to prevent the
ball joint stud from rotating.
Loosen the tie-rod end retaining nut on both
sides.

5. CAUTION: Protect the ball joint seal
using a soft cloth to prevent damage.
Using the special tool, detach the tie-rod end
from the wheel knuckle on both sides.
1. Release the tie-rod end.
2. Remove and discard the tie rod end
retaining nut.

Loosen the lower arm ball joint retaining nut on
both sides.
7. CAUTIONS:



to prevent damage.
lower arm.
8. NOTE: Use a 5 mm Allen key to prevent the
Detach the stabilizer bar connecting link from
the stabilizer bar on both sides.
9. Remove the engine support insulator center bolt.
10. Using a suitable transmission jack and a suitable

wooden block, support the crossmember.
11. Using a suitable securing strap, secure the
crossmember to the transmission jack.
12. Remove the crossmember retaining bolts
(transmission jack removed for clarity).
13. Lower the crossmember approximately 100 mm.

14. Remove and discard the crossmember ball
bearing washers.
15. Remove the stabilizer bar clamp on both sides.
16. Remove the stabilizer bar.

17. Remove the stabilizer bar bushing on both sides.
Installation
2. CAUTION: The stabilizer bar bushings

must be located correctly on the flats of the

stabilizer bar with no lubricant.
Install the stabilizer bar bushings.
3. Position the stabilizer bar on the crossmember.

4. NOTE: Do not fully tighten the stabilizer bar
clamp retaining bolts at this stage.
Install the stabilizer bar clamp on both sides.
5. WARNING: When installing the stabilizer

bar, the measurement must be taken in a
vertical plane between the crossmember and
the stabilizer bar. Failure to follow this
Set the stabilizer bar to the installation setting.
Using cable ties, support the stabilizer bar
on both sides.
6. Install the stabilizer bar.
7. Remove the cable ties.
8. CAUTION: Make sure the crossmember

ball bearing washers are installed correctly.
NOTE: Install new ball bearing washers.
Using a suitable transmission jack and the
special tool, position and align the crossmember.
1. Insert the alignment pins through the
crossmember alignment holes and the
washers.
2. Slide the locking plates on top of the
washers and into the groove of the tool
and tighten the alignment pin sleeve.
3. Raise the crossmember engaging the
alignment pins into the chassis aligning

holes.
9. CAUTION: While tightening the

crossmember retaining bolts, make sure the
crossmember does not move.
Install the crossmember retaining bolts
(transmission jack removed for clarity).
10. Remove the securing strap and the transmission

jack.
11. Install the engine support insulator center bolt.

Attach the stabilizer bar connecting links to the
stabilizer bar on both sides.


Attach the lower arm to the wheel knuckle on
both sides.
14. WARNING: Install a new tie-rod end

retaining nut. Failure to follow this
Attach the tie-rod end to the wheel knuckle on
both sides.
15. Install the front wheels and tires. For additional

Tires.
16. WARNING: Install a new steering

column shaft retaining bolt to the steering
gear pinion extension. Failure to follow this
NOTE: Make sure the road wheels are in the
Connect the steering column shaft to the


Front Suspension - Wheel Knuckle Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Lever, Wheel Knuckle
204-052 (14-026 A)
Installer, Halfshaft
204-161 (14-041)

211-020 (13-006)
General Equipment
Two leg puller
Three leg puller
Removal
All vehicles
1. Loosen the wheel hub retaining nut.
2. Loosen the strut and spring assembly top mount

retaining nuts by five turns.

Tires.
4. CAUTION: Suspend the brake caliper

and anchor plate to prevent load being
placed on the brake hose.
Detach the brake caliper and anchor plate from
the wheel knuckle.

5. Remove the brake disc.
Remove and discard the retaining washer
(if equipped).
Vehicles with anti-lock brakes

6. Detach the wheel speed sensor from the wheel
knuckle.
All vehicles

stud.
Loosen the tie-rod end retaining nut.

2. Remove and discard the tie rod end
retaining nut.
9. Remove and discard the wheel hub retaining nut.

11. CAUTIONS:



to prevent damage.
lower arm.
12. CAUTION: Support the halfshaft. The

inner joint must not be bent more than 18
degrees. The outer joint must not be bent
more than 45 degrees.
Using a suitable three leg puller, detach the
wheel hub from the halfshaft.
13. Remove the wheel knuckle to suspension strut

pinch bolt.
14. Using the special tool, remove the wheel

knuckle.
Installation
All vehicles
3. CAUTION: Make sure the halfshaft is

completely installed into the wheel hub.
Using the special tool, attach the wheel hub to
the halfshaft.



Attach the tie-rod end to the wheel knuckle.

6. Attach the wheel speed sensor to the wheel
knuckle.
All vehicles
7. Install the brake disc.
8. Attach the brake caliper and anchor plate to the
wheel knuckle.
9. WARNING: Install a new wheel hub

With the aid of another technician, apply the
brakes and pre-load the wheel bearing by
installing the new wheel hub retaining nut.

Tires.
11. Tighten the wheel hub retaining nut.

12. Tighten the strut and spring assembly top mount
retaining nuts.

Front Suspension - Front Strut and Spring
Assembly
Print
Special Tool(s)
Lever, Wheel Knuckle
204-052 (14-026 A)
Removal
Tires.
Detach the stabilizer bar connecting link from the
suspension strut.
3. Remove the wheel knuckle to suspension strut

pinch bolt.
4. Using the special tool, detach the suspension

strut from the wheel knuckle.
5. CAUTION: With the aid of another

technician, support the strut and spring
assembly.
Remove the strut and spring assembly.

Installation
1. CAUTION: With the aid of another

technician, support the strut and spring
assembly.
Install the strut and spring assembly.
2. Attach the suspension strut to the wheel

knuckle.

Attach the stabilizer bar connecting link to the
suspension strut.

Tires.

Front Suspension - Lower Arm Ball Joint Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Remover/Installer, Ball Joint
204-288A (14-063A)
Adapter for 204-288A

204-288A-01
General Equipment
Two leg puller
Removal
1. Remove the wheel knuckle.
Installation).
2. CAUTION: Make sure that vise jaw

protectors are used.
Secure the wheel knuckle in a vise.
3. Remove the circlip.
4. Using the special tools, remove the lower arm

ball joint and heat shield.
Installation
1. CAUTION: Make sure that the heat shield

is correctly located to prevent damage to the
ball joint.
Using the special tools, attach the lower arm ball
joint and heat shield to the wheel knuckle.

2. Using the special tool and a suitable two leg
puller, install the lower arm ball joint.
3. Install the circlip.
4. Remove the wheel knuckle from the vise.

Installation).
For additional information, refer to: (204-00
Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).

Front Suspension - Front Strut and Spring
Assembly
Print
Disassembly and Assembly

Special Tool(s)
Compressor, Coil Spring
204-167 (14-042)
Adapter for 204-167

204-167-01 (14-042-01)
Disassembly
1. WARNING: The spring is under extreme

tension; care must be taken at all times.
Failure to follow this instruction may result in
personal injury.
Using the special tools, compress the spring.
2. CAUTION: Use an Allen key to prevent

the piston rod from rotating.
Loosen the thrust bearing retaining nut.
3. Disassemble the strut and spring assembly.

1. Remove the thrust bearing retaining nut.
2. Remove the top mount.
3. Remove the thrust bearing.
4. Remove the boot.
5. Remove the bump stop.
6. Remove the spring.

Assembly
1. CAUTION: The ends of the spring must

locate correctly against the spring seats.
To assemble, reverse the disassembly procedure.

Rear Suspension - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
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Shock absorber lower mounting retaining bolt 85 63 -
Shock absorber upper mounting retaining nuts 120 89 -
Spring U-bolt retaining nuts 125 92 -
Spring rear mounting retaining bolts 115 85 -
Wheel spindle retaining bolts 115 85 -
Wheel hub retaining nut 340 251 -
Brake hose to brake caliper union 15 11 -
Wheel speed sensor retaining bolt 9 - 80
Stabilizer bar to connecting link retaining nut 100 74 -
Stabilizer bar connecting link to beam axle retaining nut 100 74 -
Stabilizer bar clamp retaining bolts 70 52 -
Spring front mounting retaining bolts 150 111 -

Rear Suspension - Rear Suspension Transit/Tourneo Connect 2002.5 (06/2002-)
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Rear axle
The rear axle consists of a steel tube which acts as the axle body and at the end of which
the mountings for the wheel suspensions are welded. Good lateral guidance is achieved by
this construction.
The axle body is secured to the vehicle body by leaf springs each attached at two mounting
points. The front mounting is fixed, the rear mounting is moveable, in order to cater for the
variation in the length of the leaf springs as they deflect under vehicle movement.

1 - Leaf spring (shown: two-fold spring)
2 - Rear leaf spring mounting (movable)
3 - Stabiliser mounting
4 - Shock absorber (variant for long wheel base)
5 - Shock absorber (variant for short wheel base)
6 - Front leaf spring mounting (not moveable)
7 - Stabiliser bar
8 - Mounting for load dependent brake pressure apportioning valve (LAV)
only on vehicles without Anti-lock Brake System (ABS)
The rear track for all vehicle variants is 1552 mm. Two twin tube gas shock absorbers are
installed.

The mounting points and the characteristics differ, depending on the wheel base.
Furthermore, leaf springs with different ratings are installed, depending on the vehicle
construction and wheel base.
These may be either single or double leaf springs.
All vehicle variants are equipped with a stabiliser. This is connected to the vehicle body by
link rods, one on the left and one on the right.
Depending on the vehicle variant, drum or disk brakes may be installed on the rear axle.
Furthermore, on vehicles without ABS a bracket for a load dependent brake pressure
apportioning valve (LAV) is provided on the rear axle.
Wheel suspension

1 - Rubber bump stop
2 - Securing bolt for stub axle
3 - Steel tube
4 - Mounting for stub axle
5 - Stub axle
6 - Wheel studs
7 - Wheel hub
8 - Nut
9 - Dust cap
The mounting for the stub axle is permanently joined to the axle body and cannot be
changed separately. The stub axle is secured to the mounting by four bolts.
The nut securing the wheel hub is equipped with a dust cap to prevent dirt from entering.
The stub axles on vehicles with disc or drum brakes are different.
Two rubber bump stops are mounted on the outer ends of the rear axle.

Rear Suspension - Rear Suspension Transit/Tourneo Connect 2002.5 (06/2002-)
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REFER to Section 204-00 Suspension System - General Information.

Rear Suspension - Wheel Spindle Transit/Tourneo Connect 2002.5 (06/2002-)
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Removal
Vehicles with rear drum brakes
1. Remove the brake drum. For additional
information, refer to Section 206-02 Drum
Brake.
Vehicles with rear disc brakes

2. Remove the brake disc. For additional
information, refer to Section 206-04 Rear Disc
Brake.
All vehicles
3. Remove the wheel hub.
For additional information, refer to Wheel Hub in
this section.
4. Remove the wheel spindle.
Installation
1. To install, reverse the removal procedure.

Rear Suspension - Rear Stabilizer Bar Transit/Tourneo Connect 2002.5 (06/2002-)
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Removal
NOTE: Note the position of each component before removal.
1. Raise and support the vehicle.
For additional information, refer to: Jacking
(100-02 Jacking and Lifting, Description and
Operation) /
Lifting (100-02 Jacking and Lifting, Description
and Operation).
Discard the retaining nuts.
3. Remove the stabilizer bar clamp on both sides.
4. Remove the stabilizer bar.

5. Remove the stabilizer bar bushings.
Installation
NOTE: Make sure that these components are installed to the noted removal position.
1. CAUTIONS:
Do not lubricate the stabilizer bar

bushings.
The stabilizer bar bushings must be

positioned as shown.
Install the stabilizer bar bushings.

2. Install the stabilizer bar.
3. Install the stabilizer bar clamp on both sides.
4. NOTE: Install new stabilizer bar connecting

link to stabilizer bar retaining nuts.
5. Lower the vehicle.

Rear Suspension - Spring Transit/Tourneo Connect 2002.5 (06/2002-)
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General Equipment
Transmission jack
Removal
1. Raise and support the vehicle. For additional
information, refer to Section 100-02 Jacking and
Lifting.
2. Using a suitable transmission jack, support the
beam axle.
3. Remove the spring U-bolts.
4. Remove the guide plate.
5. Remove the spring rear locknut and retaining

bolt.
Discard the locknut.
6. NOTE: When removing the right-hand spring

front locknut and retaining bolt, take note of
the position of the spacer to aid installation.
Remove the spring front locknut and retaining
bolt.
Discard the locknut.
7. CAUTION: To avoid damage to the brake

hose, make sure the beam axle is only
lowered sufficiently to allow removal of the
spring.
Using a suitable transmission jack, lower the
beam axle.
8. Remove the spring.
Installation
NOTE: Final tightening of the rear suspension components should be carried out when the
vehicle weight is on the road wheels.
1. WARNING: Install a new locknut. Failure

to follow this instruction may result in
personal injury.
CAUTIONS:
The right-hand spring front retaining bolt

must be installed from the inboard side of
the spring.
When installing the right-hand spring

front locknut and retaining bolt, make sure
that the spacer is correctly positioned to
prevent damage to the fuel tank.
NOTE: Do not fully tighten the spring front
locknut at this stage.
Install the spring front locknut and retaining bolt.
2. WARNING: Install a new locknut. Failure

personal injury.
NOTE: Do not fully tighten the spring rear
locknut at this stage.
Install the spring rear locknut and retaining bolt.
3. Install the guide plate.
4. NOTE: Install new spring U-bolt retaining

nuts.
NOTE: Do not fully tighten the spring U-bolt
retaining nuts at this stage.
Install the spring U-bolts.
Install the retaining nuts.

5. Lower and remove the transmission jack.
7. Tighten the spring front locknut.
8. Tighten the spring rear locknut.
9. Tighten the spring U-bolt retaining nuts.

Rear Suspension - Beam Axle Transit/Tourneo Connect 2002.5 (06/2002-)
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General Equipment
Transmission jack
Removal
All vehicles
1. Remove the brake backing plates. For additional
Brake.
2. WARNING: Make sure the beam axle is

secured to the transmission jack. Failure to
follow this instruction may result in personal
injury.
Using a suitable securing strap, secure the beam
axle to a transmission jack.
3. Detach the shock absorbers from the beam axle.
Vehicles without anti-lock brakes

4. Detach the brake load sensor proportioning valve
from the beam axle.
All vehicles
Detach the stabilizer bar connecting link from
the beam axle on both sides.
6. Remove the spring U-bolts on both sides.


7. Remove the guide plate.
8. Remove the beam axle.

9. Remove the beam axle spacer (if equipped).
Installation
NOTE: Final tightening of the beam axle components should be carried out when the
vehicle weight is on the road wheels.
All vehicles
1. Install the beam axle spacer (if equipped).
2. Using a suitable transmission jack, locate the
beam axle.
3. Install the guide plate.
4. NOTE: Install new spring U-bolt retaining

nuts.
NOTE: Do nut fully tighten the spring U-bolt
Install the beam axle.
Install the retaining nuts.
5. NOTE: Do nut fully tighten the stabilizer bar

connecting link to beam axle retaining nuts
at this stage.

beam axle on both sides.

6. Attach the brake load sensor proportioning valve
to the beam axle.
All vehicles
7. NOTE: Do not fully tighten the shock
absorber retaining nuts at this stage.
Attach the shock absorbers to the beam axle.
8. Remove the securing strap.

9. Lower and remove the transmission jack.
10. Install the brake backing plates. For additional
Brake.
11. Tighten the spring U-bolt retaining nuts.

Tighten the stabilizer bar connecting link to
beam axle retaining nuts.

13. Tighten the shock absorber lower mounting
retaining nuts.

14. Adjust the brake load sensor proportioning valve.
00 Brake System - General Information.

Rear Suspension - Wheel Hub Transit/Tourneo Connect 2002.5 (06/2002-)
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Removal
1. Remove the brake drum. For additional
Brake.

Brake.
All vehicles
3. Remove the dust cap.
4. Remove the wheel hub.
Remove and discard the wheel hub
retaining nut.
Installation

retaining nut. Failure to follow this instruction
NOTE: If the dust cap is damaged a new dust
cap must be installed.
To install, reverse the removal procedure.

Rear Suspension - Rear Stabilizer Bar Link Transit/Tourneo Connect 2002.5 (06/2002-)
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Removal
NOTE: Removal steps in this procedure may contain installation details.
Refer to: Jacking (100-02 Jacking and Lifting,

Description and Operation).
Refer to: Lifting (100-02 Jacking and Lifting,
2. CAUTION: Make sure that the ball joint

ball does not rotate.
NOTE: Note the position of the component
before removal.
Torque: 100 Nm
Installation
1. NOTE: Make sure that this component is

installed to the noted removal position.

Wheels and Tires - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
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Wheel nuts - Alloy wheel 120 89 -
Wheel nuts - Steel wheel 90 66 -

Wheels and Tires - Wheels and Tires Transit/Tourneo Connect 2002.5 (06/2002-)
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General
A considerable amount of information is shown on the side wall of a tyre, and part of it can
be very important for the installation or maintenance of the tyre.

1 - Manufacturer
2 - Symbol (North American D epartment 0 f T ransportation
3 - Manufacturer code for product, size and design
4 - Date of production (week/year)
5 - Theoretical width of the tyre profile in millimetres
6 - Height to width ratio in %
7 - Tyre construction type (arrangment of the carcass in the tyre, earlier
also diagonal)
8 - Rim diameter in inches
9 - Load index
10 - Speed rating
11 - Mark showing running direction (optional)
-

-
12 Tyre type (radial)

13 - Tubeless tyre
14 - Approval character and number according to EEC (Economic
Commission for Europe)
15 - Manufacturer code (according to DOT)
16 - Country of manufacture
17 - Product name of tyre
18 - Maximum load (according to DOT in lbs)
19 - Maximum pressure (according to DOT in psi)
20 - Marking for TWI (Tread Wear Indicator)
21 - Details on the construction of the tyre (according to DOT)
22 - M&S (Slush and Snow = winter tyres) (optional)
23 - Note "Reinforced" (optional)
24 - Marking "Outside" (optional)
Additional tyre identification markings
Correct installation of modern high-speed tyres is absolutely vital in order to ensure

optimum driving characteristics.
Running direction dependent tyres

only install in the direction given on the sidewall (arrow mark).
Asymmetrical tyres
must always be installed in the correct position in relation ot the axle, i.e. acccording to
the marking on the sidewall.
Example: SIDE FACING INWARDS, this means that this tyre wall must be towards the
centre of the vehicle.
Example: OUTSIDE, this means that this tyre wall must be towards the outside of the
vehicle.
Directional tyres/asymmetrical tyres

pay attention to the relevant markings on the sidewall of the tyre.
Speed symbol L M N P Q R S
Speed in km/h 120 130 140 150 160 170 180
Speed symbol T U H V W Y ZR
Speed in km/h 190 200 210 240 270 300 over 300
Tyre cross section

1 - Profile width
2 - Rim flange
3 - Rim width
4 - Width overall
5 - Rim diameter
6 - Side wall
7 - External diameter
Maximum speed rating
If an emergency tyre is used, whose size differs from the tyres usually mounted on the
vehicle, a marking showing the maximum speed of 80 km/h (50 mph) must be present on
the tyre.
Winter tyres
When using winter tyres, it is a requirement that the maximum permitted speed for the
winter tyres should be displayed in an obvious position in the field of vision of the driver.
In order to comply with the regulations, a sticker must be used to advise the vehicle driver
of the maximum speed of the winter tyres being used.

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Wheels and Tyres

195/65 R 15 tyres are standard equipment. Depending on payload, tyres with the load
rating of 91T or 95T are used.
The wheel size is 6Jx15, the hole pitch circle 107.95 mm. These are also available as light
alloy wheels. No special wheel bolts are needed for these. It is possible however to secure
the wheels against theft using special wheel bolts (91AB-1A043-AA).
All tyres can be driven with snow chains.

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Visual Inspection Chart
Mechanical
Wheel(s)
Tire(s)
Tire pressure(s) *
Wheel nuts
Wheel studs
* Vehicles equipped with a tire pressure monitoring system must be inspected for correct
operation using the diagnostic tool.
To maximize tire performance, inspect the tires for signs of incorrect inflation and uneven
wear which may indicate a need for balancing, rotation or suspension alignment. Tires
should also be checked frequently for cuts, stone bruises, abrasions, blisters and for objects
that may have become embedded in the tread. More frequent inspections are
recommended when rapid or extreme temperature changes occur or when road surfaces
are rough or occasionally littered with foreign material.
As a further visible check of tire condition, tread wear indicators are molded into the bottom
of the tread grooves. When these indicator bands become visible, new tires must be
installed.
Tire Wear Diagnosis
Uneven wear is usually caused by either excessive camber or excessive toe on tires.
Sometimes incorrect toe settings or worn struts will cause severe `cupping' or `scalloped'
tire wear on non-driven wheels.
Severely incorrect toe settings will also cause other unusual wear patterns.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure always begins with a road test. The road test and
customer interview (if available) will provide much of the information needed to find the
source of a vibration.
During the road test, drive the vehicle on a road that is smooth and free of undulations. If
vibration is apparent, note and record the following:
the speed at which the vibration occurs.

what type of vibration occurs in each speed range.
- mechanical or audible
how the vibration is affected by changes in the following:
- engine torque
- vehicle speed
- engine speed
type of vibration - sensitivity:
- torque sensitive
- vehicle speed sensitive
- engine speed sensitive
The following explanations help isolate the source of the vibration.

Torque Sensitive
This means that the condition can be improved or made worse by accelerating,
decelerating, coasting, maintaining a steady vehicle speed or applying engine torque.

Vehicle Speed Sensitive
This means that the vibration always occurs at the same vehicle speed and is not affected
by engine torque, engine speed or the transmission gear selected.
Engine Speed Sensitive
This means that the vibration occurs at varying vehicle speeds when a different
transmission gear is selected. It can sometimes be isolated by increasing or decreasing
engine speed with the transmission in NEUTRAL or by stall testing with the transmission in
gear. If the condition is engine speed sensitive, the cause is probably not related to the
tires.
If the road test indicates that there is tire whine, but no shake or vibration, the noise
originates with the contact between the tire and the road surface.
A thumping noise usually means that the tire is flat or has soft spots making a noise as
they slap the roadway. Tire whine can be distinguished from axle noise. Tire whine remains
the same over a range of speeds.
A complete road test procedure is described in Section 100-04. REFER to: Noise, Vibration
and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).
Symptom Chart

Tire(s) show * Tire(s) under- * ADJUST the tire pressure(s).
excess wear on inflated.
edge of tread * Vehicle * CORRECT as necessary.
overloaded.
* Incorrect wheel * ADJUST the wheel alignment. REFER to: (204-00
alignment. Suspension System - General Information)
Tire(s) show * Tire(s) over- * ADJUST the tire pressure(s).
excess wear in inflated.
center of tread
Other * Incorrect tire * ADJUST the tire pressure(s).
excessive tire pressure(s).
wear concerns * Wheel and tire * ROTATE the wheel and tire assemblies.
assemblies need
rotating.
* Incorrect wheel * ADJUST the wheel alignment. REFER to: (204-00
alignment. Suspension System - General Information)
* Vehicle * CORRECT as necessary.
overloaded.
* Loose or leaking * TIGHTEN or INSTALL new suspension components as
front strut and necessary. REFER to: Front Strut and Spring Assembly
spring assembly. (204-01 Front Suspension, Removal and Installation).
* Wheel bearings * INSTALL new wheel bearings as necessary. REFER to:
worn. Front Wheel Bearing (204-01 Front Suspension,
Removal and Installation),
* Suspension * CHECK or INSTALL new suspension components as
components, necessary.
bushings and ball
joints.
* Excessive lateral * BALANCE the wheel and tire assemblies. Using a
or radial runout of suitable dial indicator gauge and holding fixture,
wheel or tire. CHECK lateral and radial runout of the wheel and tire
assemblies. INSTALL new wheel and tire assemblies as

necessary. REFER to: (204-04 Wheels and Tires)
Wheel and Tire (Removal and Installation).
Wobble or * Damaged wheel. * INSPECT the wheel rims for damage. BALANCE the
shimmy wheel and tire assemblies. Using a suitable dial
affecting wheel indicator gauge and holding fixture, CHECK lateral and
runout radial runout of the wheel and tire assemblies.
INSTALL new wheel and tire assemblies as necessary.
REFER to: (204-04 Wheels and Tires)
* Front wheel * CHECK or INSTALL new wheel bearings as necessary.
bearing. REFER to: Front Wheel Bearing (204-01 Front
Suspension, Removal and Installation).
Excessive * Suspension * CHECK or INSTALL new suspension components as
vehicle components. necessary.
vibration,
rough steering
Vehicle * Incorrect tire * ADJUST the tire pressure(s).
vibrations from pressure(s).
wheels and * Wheel or tire * BALANCE the wheel and tire assemblies.
tires imbalance.
* Uneven tire wear. * INSTALL a new tire(s) as necessary. REFER to: Wheel
and Tire (204-04 Wheels and Tires, Removal and
Installation).
* Brake disc * CHECK the brake disc for foreign material.
imbalance.
* Water in tire(s). * REMOVE the water.
* Bent wheel. * INSTALL a new wheel and tire assembly. REFER to:
Wheel and Tire (204-04 Wheels and Tires, Removal
and Installation).
* Incorrectly seated * SPIN the wheel on the vehicle. EXAMINE the area
tire bead. where the tire and the wheel meet. If that section of
the tire appears to waver while being rotated, the tire
bead may not be correctly seated on the wheel.
REMOVE the tire and CLEAN the bead seat areas on
both wheel and tire.
* Excessive lateral * BALANCE the wheel and tire assemblies. Using a
or radial runout of suitable dial indicator gauge and holding fixture,
wheel or tire. CHECK the lateral and radial runout of the wheel and
tire assemblies. INSTALL new wheel and tire
assemblies as necessary. REFER to: (204-04 Wheels
and Tires)
* Foreign material * CLEAN mounting surfaces.
between wheel
mounting face and
hub mounting
surface.
* Front wheel * CHECK or INSTALL new wheel bearings as necessary.
bearing. REFER to: Front Wheel Bearing (204-01 Front
Suspension, Removal and Installation).
Rust streaks * Wheel nuts. * REMOVE the wheel and tire assembly. Inspect the
from the wheel wheel nuts and wheel and tire assembly for damage.
stud holes in INSTALL new wheel nuts and wheel and tire
the wheel assemblies as necessary. REFER to: (204-04 Wheels
and Tires)

Seized wheel * Corrosion. * CAUTION: Do not permit lubricant to get on cone sets
nuts of stud holes or on cone angle of wheel nuts. If
corrosion is slight, wire brush away. If corrosion is
excessive, INSTALL new wheel studs and nuts. REFER
to: (204-04 Wheels and Tires)
If the condition persists, LUBRICATE the first three
threads of each wheel stud with a graphite-based
lubricant.
* Vehicle overloaded * CORRECT as necessary.

Wheels and Tires - Wheel and Tire Transit/Tourneo Connect 2002.5 (06/2002-)
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Removal
CAUTIONS:
Do not use heat to loosen a seized wheel nut. Heat may damage the wheel and
wheel hub.
Do not use power tools on locking wheel nuts.

1. Loosen the wheel nuts.
For additional information, refer to: Lifting (100-
02 Jacking and Lifting, Description and
Operation).
3. Remove the wheel and tire.
Installation
1. WARNING: Remove any corrosion or dirt

from the mounting surfaces of the wheel,
wheel hub, brake drum or brake disc.
Corrosion or dirt on the mounting surfaces
may cause the wheel nuts to loosen and the
wheel to come off while the vehicle is in
motion. Failure to follow this instruction may
Clean the wheel hub and mating surfaces.
2. Install the wheel and tire.
4. Tighten the wheel nuts in the sequence shown.
For additional information, refer to:
Specifications (204-04 Wheels and Tires,
Specifications).

Front Drive Halfshafts - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
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Item Nm lb-ft lb-in

Intermediate shaft center bearing 25 18 -
Wheel hub retaining nut 320 236 -
Strut and spring assembly top mount nuts 25 18 -
Constant velocity (CV) joint boot retaining clamps 21 15 -
Tie-rod end retaining nut 47 35 -
Lower arm ball joint retaining nut 150 111 -

Front Drive Halfshafts - Front Drive
Halfshafts
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NOTE: New front wheel drive halfshafts should not be installed unless disassembly and
inspection reveals unusual wear.
1. 1. Inspect front wheel driveshaft joint boots for evidence of cracks, tears or splits.
NOTE: While inspecting the front wheel driveshaft CV joint boots, watch for indentations
(dimples) in the boot convolutions. If an indentation is observed, it must be removed.
2. 2. Inspect the underbody for any indication of grease splatter in the vicinity of the
front wheel driveshaft CV joint boots outboard and inboard locations, which is an
indication of front wheel driveshaft CV joint boot and/or front wheel driveshaft CV
joint boot clamp damage.
3. 3. Inspect for inboard CV joint stub shaft pilot bearing housing seal leakage at the
front wheel driveshaft CV joint.
4. 4. Make sure front axle wheel hub retainer is the correct prevailing torque type.
5. 5. The silicone front wheel driveshaft CV joint boot will sweat during operation,
causing a light film of grease to show on the outside of the front wheel driveshaft
CV joint boot. This condition is normal.
NOTE: Halfshafts are not balanced and do not contribute to rotational vibration.
6. 6. If the concerns remain after the inspection, determine the symptoms and go to the
Symptom Chart. For additional Noise, Vibration and Harshness (NVH). REFER to
Section 100-04 Noise, Vibration and Harshness.
Symptom Chart

Clicking, Popping * Inadequate or contaminated * INSPECT, CLEAN and LUBRICATE as
or Grinding Noises lube in outboard/inboard front necessary.
While Turning wheel driveshaft CV joint.
* Another component * INSPECT and REPAIR as necessary.
contacting driveshaft
assembly.
* Wheel bearings, brakes, * INSPECT and REPAIR as necessary.
suspension or steering REFER to Section 204-00 Suspension
components. System - General Information / 206-00
Brake System - General Information /
211-00 Steering System - General
Information.
Vibration at * Out of balance front wheels * REPAIR or INSTALL new as necessary.
Highway Speeds or tires. REFER to Section 204-04 Wheels and
Tires.
* Out-of-round tires. * REPAIR or INSTALL new as necessary.
REFER to Section 204-04 Wheels and
Tires.
* Incorrectly seated outboard * REPAIR or INSTALL new as necessary.
front wheel driveshaft CV joint REFER to Halfshaft Disassemblv and

in front wheel hub. Assembly in this section.
Shudder Vibration * Excessively high CV joint * CHECK ride height, VERIFY correct
During operating angles caused by spring rate and CHECK items under
Acceleration. incorrect ride height. Halfshaft Joint Pullout. REPAIR or
INSTALL new as necessary.
* Excessively worn or damaged * INSPECT and INSTALL new as
inboard front wheel driveshaft necessary.
joint or outboard front wheel
driveshaft joint.
Halfshaft Joint * Inboard driveshaft bearing * INSPECT and REPAIR or INSTALL new
Pullout retainer circlip missing or not as necessary.
correctly seated in differential
side gear.
* Engine/transaxle assembly * CHECK engine mounts for damage or
mispositioned. wear. REPAIR or INSTALL new as
necessary.
* Frame rail or strut tower out * CHECK underbody dimensions. REFER
of position or damaged. to REFER to Section 501-00 Body
System - General Information.
* Front suspension components * CHECK for worn bushings or bent
worn or damaged. components (front stabilizer bar, front
suspension lower arm). REPAIR or
INSTALL new as necessary.

Front Drive Halfshafts - Front Halfshaft LH Transit/Tourneo Connect 2002.5 (06/2002-)
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Special Tool(s)
204-161 (14-041)
Remover, Halfshaft
204-226 (16-092)
Adapter for 204-226

204-226-01 (16-092-01)
Slide Hammer
205-047 (15-011)

211-020 (13-006)
General Equipment
Three leg puller
Two leg puller
Materials
Name Specification
Manual transmission WSD-M2C200-C
fluid
Removal
nuts by five turns.
2. CAUTION: Use a socket to loosen the

wheel hub retaining nut to prevent damage.
Remove the wheel hub retaining nut.
Discard the nut.

3. Remove the front wheel and tire. For additional
Tires.

stud.
Loosen the tie-rod end retaining nut.
5. CAUTION: Protect the ball joint seal,

2. Remove the tie-rod end retaining nut.
Discard the nut.

7. CAUTIONS:


lower arm.

8. CAUTION: Support the halfshaft. The
inner joint must not be bent more than 18
degrees. The outer joint must not be bent
halfshaft from the wheel hub.
9. CAUTIONS:
Support the halfshaft. The inner joint

must not be bent more than 18 degrees.
The outer joint must not be bent more than
45 degrees.
Do not damage the halfshaft seal.
Plug the transaxle to prevent oil loss

and dirt ingress.
Using the special tool, remove the halfshaft.
Discard the snap ring.
Allow the oil to drain into a suitable
container.
Installation
1. CAUTIONS:

must not be bent more than 18 degrees. The
outer joint must not be bent more than 45
degrees.
Make sure that the snap ring is correctly

seated.
NOTE: Install a new snap ring.
Attach the left-hand halfshaft to the transaxle.
2. Using the special tool, install the halfshaft.


4. NOTE: Install a new tie-rod end retaining

nut.

brakes and preload the wheel bearing by
6. Check the transmission fluid level. For additional

information, refer to Section 308-03 Manual
Transmission/Transaxle.
7. Install the front wheel and tire. For additional
Tires.
8. CAUTION: Use a socket to tighten the

Tighten the wheel hub retaining nut.

nuts.

Front Drive Halfshafts - Front Halfshaft
RH
Print

Special Tool(s)
204-161 (14-041)

211-020 (13-006)
General Equipment
Three leg puller
Two leg puller
Removal
nuts by five turns.
2. CAUTION: Use a socket to loosen the

Loosen the wheel hub retaining nut.
Discard the nut.

Tires.

stud.
Loosen the tie-rod end retaining nut (left-hand
side shown).
5. CAUTION: Protect the ball joint seal,

from the wheel knuckle (left-hand side shown).
2. Remove the tie-rod end retaining nut.
Discard the nut.

7. CAUTIONS:


lower arm.
8. CAUTION: Secure the halfshaft to

prevent damage to the CV joints. The inner
CV joint must not be bent more than 18
degrees. The outer CV joint must not be bent
halfshaft from the wheel hub.
9. CAUTIONS:
Secure the halfshaft to prevent damage

to the CV joints. The inner CV joint must not
be bent more than 18 degrees. The outer CV
joint must not be bent more than 45
degrees.
Make sure that the inner CV joint boot is

not damaged.
NOTE: Discard the grease filling.
Remove the halfshaft.
Remove and discard the CV joint boot
retaining clamps.

Installation
1. CAUTION: Make sure that the amount of

grease in the CV joint does not exceed 100
grams.
Fill the CV joint with grease.

prevent damage to the CV joints. The inner
CV joint must not be bent more than 18
degrees. The outer CV joint must not be bent
Attach the halfshaft to the intermediate shaft.
3. CAUTION: Make sure that the inner CV

joint boot is not damaged.
Install the inner CV joint boot (halfshaft shown
removed for clarity).
1. Use a suitable screwdriver under the boot
to allow air to escape.
2. Insert the CV joint as far as it will go,
then pull it back approximately 20 mm.
4. CAUTION: Make sure the halfshaft is

completely installed into the wheel hub.
Using the special tool, install the halfshaft.
5. CAUTION: Protect the heat shield using

NOTE: Install a new lower arm ball joint
retaining nut.
6. NOTE: Install a new tie-rod end retaining

nut.


brakes and preload the wheel bearing by
8. Check the transmission fluid level. For additional

Tires.
10. Tighten the wheel hub retaining nut.

nuts.

Front Drive Halfshafts - Intermediate
Shaft
Print

Special Tool(s)
211-020 (13-006)
General Equipment
Grip Wrench (Hazet 1847-1)
Materials
Name Specification
Grease – inner joint XS4C-M1C230-A
Removal
1. Loosen the strut top mount retaining nuts by
four turns.
2. Remove the wheel.For additional information,

refer to Section 204-04 Wheels and Tires.
3. CAUTION: Do not unscrew the track rod

end retaining nut from the ball joint in order
to protect the thread.
NOTE: Counterhold the ball joint with a 5
mm Allen key.
Loosen the left track rod end retaining nut.
4. CAUTION: Protect the ball joint gaiter

Detach the track rod end from the spindle carrier
using the special tool (left-hand side shown).
1. Loosen the track rod end.
2. Remove and discard the track rod end
retaining nut.
5. Loosen the lower suspension arm ball joint

retaining nut.

6. CAUTIONS:
Do not unscrew the lower arm ball joint

retaining nut in order to protect the thread.
Protect the ball joint gaiter using a soft


to prevent damage.
Using a suitable two-legged puller, detach the
lower suspension arm from the spindle carrier.
1. Use a soft faced hammer to release the
lower suspension arm.
7. NOTE: Ensure that the gaiter is not
damaged.
Remove the gaiter clamping strap for the
halfshaft joint.

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

to the constant velocity joints. The inner
constant velocity joint must not be bent by
more than 18 degrees. The outer constant
velocity joint must not be bent by more than
45 degrees.
Ensure that the halfshaft oil seal is not

damaged.

Close off the transmission openings to
prevent fluid loss or dirt ingress.
Remove the intermediate shaft.
Collect the fluid in a suitable container.
Remove and discard the center bearing
cap and locknuts.
Pull the intermediate shaft out of the
transmission.
Installation
1. CAUTION: Ensure that the halfshaft oil

seal is not damaged.
Install the intermediate shaft in the
transmission.
2. NOTE: Install a new intermediate shaft

center bearing cap and new locknuts.
NOTE: Insert the intermediate shaft into the
transmission until the intermediate shaft
bearing contacts the rib of the intermediate
shaft bracket.
Install the intermediate shaft in the
transmission.
Install the center bearing cap and
locknuts.

prevent damage to the constant velocity
joints. The inner constant velocity joint must
not be bent by more than 18 degrees. The
outer constant velocity joint must not be
bent by more than 45 degrees.
Attach the right halfshaft to the tripode housing.
4. Install the gaiter clamping strap for the halfshaft

joint.
Push a small screwdriver under the gaiter
seat to allow air to escape.
Install the tripode housing and pull it
backwards 20 mm.
5. WARNING: Use a new lower suspension

arm ball joint retaining nut. Failure to
observe this instruction can lead to injury.

NOTE: Do not tighten the lower suspension
arm ball joint retaining nut for the moment.
Attach the lower suspension arm to the spindle
carrier.
6. Tighten the lower suspension arm ball joint

retaining nut.
7. NOTE: Install a new track rod end retaining

nut.
mm Allen key.
Attach the track rod end to the spindle carrier.
8. Check the transmission fluid level and top up the

manual transmission fluid if necessary.For
additional information, refer to Section 308-03
Manual Transmission/Transaxle.
9. Install the wheel.For additional information, refer
to Section 204-04 Wheels and Tires.
10. Tighten the strut top mount retaining nuts.

Front Drive Halfshafts - Inner Constant
Velocity (CV) Joint Boot
Print

Special Tool(s)
Boot clamp tightening tool
204-169 (14-044)
Separating tool, bearing/gear wheel

205-310 (15-091)
Puller, bearing/gear wheel

205-311 (15-092)
Installer, bushing and oil seal, transmission extension

308-046 (16-016)
General Equipment
Grip wrench (Hazet 1847-1)
Expanding pliers, snap-ring
Materials
Name Specification
Grease, inner joint XS4C-M1C230-BA
Removal
1. Remove the drive halfshaft.
For additional information, refer to Left-hand
drive halfshaft /
Right-hand drive halfshaft in this section.
2. CAUTION: Use a vice with protective

jaw covers.
NOTE: Hold the intermediate shaft in a vice.
Clamp the constant velocity joint into the vice
and detach the tripod housing.
1. Cut and discard the boot clamps.
2. Slide the boot back.
3. Pull apart the tripod joint.

Remove the grease.

4. Remove the snap-ring.
5. Detach the tripod using the special tool.

Take off the boot and discard it.
Installation
1. Insert a new boot.
2. NOTE: Renew the boot clamp.

Install a new inner boot clamp using the special
tool.
3. NOTE: Chamfer points towards front drive

halfshaft.
Attach the tripod using the special tool.
Slide on the boot.

Drive the tripod home onto the front drive
halfshaft.
4. NOTE: Use a new snap-ring.

Install the tripod snap-ring.
5. CAUTION: The constant velocity joint

must not be packed with more than 120 g of
grease.
Pack the constant velocity joint with grease .
6. Assemble the constant velocity joint.
1. Slide a small screwdriver under the boot
seat to allow the air to escape.
2. Slide the constant velocity joint in as far
as it will go, then pull it back out 20 mm.
7. NOTE: Renew the boot clamp.

Install a new outer boot clamp using a grip
wrench .
8. Install the drive halfshaft.

For additional information, refer to Left-hand
drive halfshaft /
Right-hand drive halfshaft in this section.

Front Drive Halfshafts - Outer Constant
Velocity (CV) Joint Boot
Print
Special Tool(s)
Clamping Tool, Boot Retaining Clamp
204-169 (14-044)
General Equipment
Expanding pliers, snap-ring
Materials
Name Specification
Constant velocity joint ESP-M1C207-A
high-temperature grease
Removal
1. Remove the inner CV joint boot.
For additional information, refer to: Inner
Constant Velocity (CV) Joint Boot (205-04 Front
Drive Halfshafts, Removal and Installation).
2. CAUTION: Use a vice with protective jaw

covers.
Remove the outer CV joint boot.
Cut and discard the boot clamps.
Remove and discard the rubber boot.
Remove the grease packing.
Installation
1. NOTE: Install a new rubber boot.
Install the outer CV joint boot.
Pack the CV joint with grease.
Specifications (205-04 Front Drive
Halfshafts, Specifications).
Press the rubber boot into the groove of
the CV joint.
1. Insert a small screwdriver under the boot
seat to allow the air to escape.
2. Position the rubber boot.
Remove the screwdriver.
2. NOTE: Install a new clamping strap.
Insert the inner clamping strap into the ring
groove of the rubber boot and tighten with the
special tool.

3. NOTE: Install a new clamping strap.
Insert the outer clamping strap into the ring
groove of the rubber boot and tighten with the
special tool.
4. Install the inner CV joint boot.

For additional information, refer to: Inner
Constant Velocity (CV) Joint Boot (205-04 Front
Drive Halfshafts, Removal and Installation).

Front Drive Halfshafts - Halfshaft Bearing Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
204-169
Clamping Tool, Boot Retaining Clamp
205-080
Installer, Differential Bearing
205-310
303-255
Installer, Timing Cover Seal
Materials
Name Specification
Grease FD-R WSS-M1C259-A1 / 3M5J-M1C259-AA
General Equipment
Flat-bladed screwdriver
Hydraulic press
Removal
1.
2.

3. Special Tool(s): 205-310
General Equipment: Hydraulic press
Installation
1. Special Tool(s): 205-080, 303-255

General Equipment: Hydraulic press
2. Material: Grease FD-R (WSS-M1C259-A1 /

3M5J-M1C259-AA)

3.
1. Release any trapped air.
General Equipment: Flat-bladed

screwdriver
4. General Equipment: Flat-bladed
screwdriver

Brake System - General Information -
Brake System
Print
Brake system, general information

A - Brake system without Anti-lock Brake System (ABS)
B - Brake system with ABS
1 - Tandem brake master cylinder
2 - Reservoir
3 - Brake servo
4 - Wheel speed sensors
5 - Internally ventilated front brake discs
6 - Rear disk brake
7 - MK 25 ABS
8 - Drum Brake
9 - Load dependent brake pressure apportioning valve
The brake pressure regulating valve is mounted on the chassis and regulates the brake
pressure applied to each rear wheel depending on the vehicle load. This ensures that the
braking forces applied to the front wheels are always greater than those applied to the rear
wheels.

Brake System
Print

General Equipment
Pressure/vacuum gauge set
The Ford approved diagnostic tool
The brake system operates by transferring effort applied to the brake pedal by the driver to
the brakes at each wheel.
The braking effort is distributed to each wheel, using a hydraulic system. The system is
assisted using a vacuum brake booster that reduces pedal effort and increases hydraulic
pressure.
The parking brake operates on the rear wheels and is applied using a hand operated
control.
NOTE: Before carrying out any diagnosis, make sure that the brake system warning
indicator is functional.
Mechanical Electrical
Tire pressure(s) Electrical connector(s)
Wheels and tires Wiring harness(s)
Fluid leak(s) Switch(es)
Brake pipe(s)
3. 3. If an obvious cause for an observed or reported concern is found, correct the case
4. 4. If the cause if not visually evident, verify the symptom and refer to the Symptom
Chart.
Road Test
Carry out a road test to compare actual vehicle braking performance with the performance
standards expected by the driver. The ability of the test driver to make valid comparisons
and detect performance deficiencies will depend on experience.
The driver should have a thorough knowledge of the brake system operation and accepted
general performance guidelines to make good comparisons and detect performance
concerns.
An experienced technician will always establish a route that will be used for all brake
diagnosis road tests. The road selected will be reasonably smooth and level. Gravel or
bumpy roads are not suitable because the surface does not allow the tires to grip the road
equally. Crowned roads should be avoided because of the large amount of weight shifted to
the low set of wheels on this type of road. Once the route is established and consistently
used, the road surface variable can be eliminated from the test results.
Before a road test, get a complete description of the customer concerns or suspected
condition. From the description, the technician will be able to match possible causes with

symptoms. Certain components will be identified as possible sources while others will be
eliminated by the evidence. More importantly, the customer description can reveal unsafe
conditions which should be checked or corrected before a road test. The description will also
help form the basic approach to the road test by narrowing the concern to specific
components, vehicle speed or conditions.
Begin the road test with a general brake performance check. Using the description of the
concern, test the brakes at different vehicle speeds using both light and heavy pedal
pressure. Determine if the concern is in the front or rear braking system. First use the foot
brake and then the parking brake. If the condition (i.e. pull, vibration, pulsation) occurs
only on operation of the parking brake, the concern is in the rear brake system. If the
condition occurs when the foot brake is depressed, the concern is in the front brake system.
Avoid locking the brakes and sliding the tires. This condition will not indicate brake
efficiency. A heavily braked but turning wheel will stop the vehicle in a shorter distance
than locked wheels.
If the concern becomes evident during this check, make sure it fits the description given
before the road test. If the concern is not evident, attempt to duplicate the condition using
the information from the description.
If a concern exists, use the Brake System Symptom Chart in order to isolate it to a specific
sub-system and condition description. From this description, a list of possible sources can
be used to further narrow the cause to a specific component or condition.
Symptom Chart

Brakes pull or * Worn or damaged brake shoes or * INSTALL new brake shoes or brake
drift brake pads and linings. pads.
REFER to: Brake Shoes (206-02 Drum
Brake, Removal and Installation) /
Brake Pads (206-03 Front Disc Brake,
Removal and Installation).
* Abnormal wear or distortion of front * INSTALL a new front brake disc.
brake disc. REFER to: Brake Disc (206-03 Front
Disc Brake, Removal and
Installation).
* Malfunctioning rear brake shoe * CHECK the automatic brake shoe
adjuster. adjuster.
* Incorrectly adjusted parking brake. * ADJUST the parking brake cable.
REFER to: Parking Brake Cable
Adjustment (206-05 Parking Brake
and Actuation, General Procedures).
* Incorrect wheel alignment * ADJUST the wheel alignment.
adjustment.
* Incorrect wheel bearing preload * INSTALL a new wheel bearing as
adjustment. necessary.
REFER to: Front Wheel Bearing (204-
01 Front Suspension, Removal and
Installation).
* Grease or fluid on the brake shoes * INSTALL new brake shoes or brake
or brake pads; glazed linings. pads.
* Stuck or seized wheel cylinders or * INSTALL a new wheel cylinder or
brake calipers. brake caliper.
REFER to: Wheel Cylinder (206-02
Drum Brake, Removal and

Installation) /
Brake Caliper (206-03 Front Disc
Brake, Removal and Installation).
Brake warning * Low brake fluid level. * FILL the reservoir. CHECK the brake
indicator is and clutch system for leaks including
always on brake fluid in the brake booster.
* Leak in the hydraulic system. * REPAIR the leak. CHECK the entire
hydraulic system. FILL and BLEED the
brake system.
REFER to: Brake System Bleeding
(206-00 Brake System - General
Information, General Procedures) /
Brake System Pressure Bleeding
Information, General Procedures).
* Leaking brake master cylinder * CARRY OUT a brake master cylinder
primary piston cup. bypass condition test. REFER to Brake
Master Cylinder Component Test in
this procedure.
* Parking brake control not fully * FREE UP and ADJUST the parking
released. brake cable.
INSTALL new components as
necessary.
* Malfunctioning anti-lock braking * REFER to: Anti-Lock Brake System
system (ABS). (ABS) Module (206-09A Anti-Lock
Control, Removal and Installation) /
Anti-Lock Brake System (ABS) Module
(206-09A Anti-Lock Control, Removal
and Installation).
* Shorted indicator circuit. * REPAIR as necessary.
Vibration when * Grease or fluid on the brake shoes * INSTALL new brake shoes or brake
the brakes are or brake pads; glazed linings. pads.
applied REFER to: Brake Shoes (206-02 Drum
Brake Pads (206-04 Rear Disc Brake,
* Worn or damaged brake shoes or * INSTALL new brake shoes or brake
brake pads. pads.
* Loose caliper mounting bolt(s). * TIGHTEN the caliper mounting bolt
(s).
* Insufficient grease on sliding parts. * APPLY grease where necessary.
* Damaged brake drum contact * INSTALL a new brake drum.
surface. REFER to: Brake Drum (206-02 Drum
Brake, Removal and Installation).
* Excessive brake disc thickness * CARRY OUT a brake disc runout
variation or brake disc runout. check.
REFER to: Brake Disc Runout Check
* Wheels and tires. * CHECK the tires. BALANCE or
INSTALL new tires as necessary.
* Loose or missing wheel hub bolts. * TIGHTEN or INSTALL new wheel hub

bolts as necessary.
* Worn or damaged brake drums or * INSTALL new brake drums or brake
brake discs. discs.
REFER to: Brake Pads (206-04 Rear
Installation) /
Brake Shoes (206-02 Drum Brake,
Pedal goes * Low brake fluid level. * FILL the reservoir. CHECK the brake
down fast and clutch system for leaks including
brake fluid in the brake booster.
* Leak in the hydraulic system. * REPAIR the leak. CHECK the entire
hydraulic system. FILL and BLEED the
brake system.
* Air in the system. * CHECK for leaks. BLEED the brake
system.
* Brake disc “brake knock * CARRY OUT a brake disc runout
back” (Brake pads push the brake check.
caliper piston back into the brake REFER to: Brake Disc Runout Check
caliper. Caused by excessive brake (206-00 Brake System - General
disc lateral runout or loose wheel Information, General Procedures).
bearings.)
* Worn brake shoes or brake pads. * INSTALL new brake shoes or brake
pads.
* Worn brake master cylinder piston * GO to Pinpoint Test A.
cups or scored cylinder bore.
Pedal eases * Air in the system. * BLEED the brake system.
down slowly REFER to: Brake System Bleeding
* Malfunctioning brake master * GO to Pinpoint Test B.
cylinder.
* Low engine vacuum (stationary).
Pedal is low or * Worn brake shoes or brake pads. * INSTALL new brake shoes or brake
feels spongy pads.
Removal and Installation) /

GO to Pinpoint Test B.
* Air in the system. * CHECK for leaks. BLEED the brake
system.
Brake lockup * Glazed or worn brake shoes or * INSTALL new brake shoes or brake
during light brake pads. pads.
brake pedal REFER to: Brake Shoes (206-02 Drum
force Brake, Removal and Installation) /
* Brake booster. * GO to Pinpoint Test C.
* Low engine vacuum.
Excessive or * Worn brake shoes or brake pads. * INSTALL new brake shoes or brake
erratic pedal pads.
travel REFER to: Brake Shoes (206-02 Drum
* Wheel bearings * CARRY OUT brake disc runout check.
REFER to: Brake Disc Runout Check
Brake drag * Incorrectly adjusted stop lamp * ADJUST the stop lamp switch. GO to
switch. Pinpoint Test B.
* Incorrectly adjusted speed control * ADJUST the speed control
deactivation switch (if equipped). deactivation switch. GO to Pinpoint
Test B.
* Incorrectly adjusted parking brake. * ADJUST the parking brake cable.
* Brake booster. * REFER to brake booster operation
check in this procedure.
* Seized brake caliper or wheel * INSTALL a new brake caliper or wheel
cylinder. cylinder.
REFER to: Wheel Cylinder (206-02
Drum Brake, Removal and
Installation).
* Seized brake caliper slide pins. * INSTALL a new brake caliper.
REFER to: Brake Caliper (206-04 Rear
Installation).
* Seized parking brake cables. * INSTALL new parking brake cables.
Excessive * Worn or contaminated brake shoes * INSTALL new brake shoes or brake
brake pedal or brake pads. pads.
effort REFER to: Brake Shoes (206-02 Drum

* Malfunctioning vacuum pump * INSTALL a new brake vacuum pump.
(diesel). REFER to: Brake Vacuum Pump (206-
07 Power Brake Actuation, Removal
and Installation).
* Disconnected or damaged brake * CONNECT or INSTALL a new brake
booster vacuum pipe. booster vacuum pipe as necessary.
* Brake booster. * GO to Pinpoint Test D.
Brake noise * Worn or damaged brake shoes or * INSTALL new brake shoes or brake
brake pads. pads.
* Brake booster. * GO to Pinpoint Test E.
Slow or * Brake booster. * GO to Pinpoint Test F.
incomplete * Seized brake pedal pivot.
brake pedal
return
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST

CONDITIONS
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
Does the brake pedal height build up and then hold?
Yes
CHECK parking brake adjustment and ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment (206-05 Parking Brake and
Actuation, General Procedures).
If the condition still exists. BLEED the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General
Brake System Pressure Bleeding (206-00 Brake System - General
TEST the system for normal operation.
No
GO to A2.
A2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system leaks. Refer to Brake Master
Cylinder Component Test in this procedure.
Are any leaks present?
Yes
REPAIR as necessary. ADD fluid and BLEED the brake system.
No
GO to A3.
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a Brake Master Cylinder Bypass Condition Test. Refer to the
Brake Master Cylinder Component Test in this procedure.
Was a concern found?

Yes

INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - RHD FWD (206-06 Hydraulic Brake
Actuation, Removal and Installation) /
Brake Master Cylinder - LHD FWD (206-06 Hydraulic Brake Actuation,
No
PINPOINT TEST B : PEDAL EASES DOWN SLOWLY

CONDITIONS
B1: CHECK THE BRAKE PEDAL OPERATION
1 Depress the brake pedal.
Does the pedal ease slowly?
Yes
GO to B2.
No
Refer to the Brake Master Cylinder Component Test in this procedure.
B2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks.
Are any leaks present?
Yes
REPAIR as necessary. ADD fluid and BLEED the brake system.
No
GO to B3.
B3: CHECK THE AIR INTAKE FILTER
1 Check the air intake filter.
Is the filter damaged in any way
Yes
REPAIR as necessary. TEST the system for normal operation.
No
GO to B4.
B4: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass Condition Test. Refer to the
Brake Master Cylinder Component Test in this procedure.
Was a concern found?
Yes
No
GO to B5.
B5: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve vacuum hose at the manifold.
2 Blow into the hose attached to the brake booster check valve.
Does air pass through the valve?

Yes
INSTALL a new brake booster check valve.
No

GO to B6.
B6: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
2 Using a suitable vacuum gauge, check the vacuum pressure.
Is the vacuum pressure above 40.5 kPa (0.4 bar) with the brake booster non-
operational?
Yes
No
INSTALL a new brake booster check valve vacuum hose. TEST the system
for normal operation.
B7: CHECK THE MASTER CYLINDER
1 Carry out a master cylinder condition test. Refer to the Brake Master
Cylinder Component Test in this procedure.
was a concern found?
Yes
No
GO to B2.
PINPOINT TEST C : BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE

CONDITIONS
C1: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment and pedal travel.
Is the push rod and pedal travel OK?
Yes
TEST the brake pedal application. GO to Pinpoint Test D.
No
INSTALL a new brake booster.
REFER to: Brake Booster - LHD FWD (206-07 Power Brake Actuation,
Brake Booster - RHD FWD (206-07 Power Brake Actuation, Removal and
Installation).
PINPOINT TEST D : EXCESSIVE BRAKE PEDAL EFFORT

CONDITIONS
D1: CHECK BRAKE APPLICATION
1 With the engine off, apply and release the brake pedal five times to
deplete all vacuum from the brake booster. Apply the brake pedal, hold
with light pressure. Start the engine.
Does the brake pedal hold?
Yes
GO to D2.
No
GO to D3.
D2: CHECK THE BRAKE BOOSTER FOR LEAKS
1 Run the engine at approximately 1000rpm, release the accelerator pedal
and turn the engine off. Wait 90 seconds and apply the brakes. Two or
more brake applications should be power assisted.
Does the brake booster work?

Yes
No
GO to D4.
D3: CHECK THE BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin and fully depress the brake
pedal.
Did the pedal move freely?
Yes
No
INSTALL new brake pedal and bracket.
REFER to: Brake Pedal and Bracket - Vehicles Built Up To: 04/2009 (206-
06 Hydraulic Brake Actuation, Removal and Installation).
D4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve vacuum hose at the manifold.
2 Blow into the hose attached to the brake booster check valve.
Does air pass through the valve?
Yes
INSTALL a new brake booster check valve. TEST the system for normal
operation.
No
GO to D5.
D5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
2 Using a suitable vacuum gauge, check the vacuum pressure.
Is the vacuum pressure above 40.5 kPa (0.4 bar) with the brake booster non-
operational?
Yes
GO to D6.
No
INSTALL a new vacuum hose and fittings. TEST the system for normal
operation.
D6: CHECK THE BRAKE BOOSTER
1 Check the brake booster. REFER to the Brake Booster Operation Check in
this procedure.
Is the brake booster OK?
Yes
No
Installation).
PINPOINT TEST E : BRAKE NOISE

CONDITIONS
E1: CHECK VACUUM
1 Disconnect the brake vacuum hose from the brake booster.
2 Connect a vacuum/pressure tester to the vacuum hose.
4 Run the engine at normal operating temperature.
5 Record the vacuum reading.

Is the vacuum reading 40.5kPa (12in - Hg)?
Yes
GO to E2.
No
LOCATE and REPAIR the source of low vacuum. TEST the system for
normal operation.
E2: INSPECT SYSTEM
1 Ignition switch in position 0.
2 Reconnect the vacuum hose.
Inspect the brake booster, rubber grommet, and all vacuum plumbing for
3
cracks, holes, bad connections, or missing clamps.
4 Pump the brake pedal five times to exhaust the vacuum. Push down on
the brake pedal and hold.
Does the brake pedal move down when the engine is started?
Yes
Vacuum system is OK.
No
GO to E3.
E3: CHECK POWER BRAKE BOOSTER CHECK VALVE
1 Check the brake booster check valve.
Is the power brake booster check valve OK?
Yes
CHECK the brake booster. Refer to Brake Booster Component Test in this
procedure. INSTALL a new brake booster as necessary. TEST the system
No
INSTALL a new brake booster check valve. TEST the system for normal
operation.
PINPOINT TEST F : SLOW OR INCOMPLETE BRAKE PEDAL RETURN

CONDITIONS
F1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at approximately 1200rpm whilst making several brake
applications.
2 Pull the brake pedal upwards with approximately 44.5 N (10 lbs) force.
3 Release the brake pedal and measure the distance to the floor panel and
note the reading.
4 Make a hard brake application.
5 Release the brake pedal and measure the distance to the floor panel and
note the reading.
6 Compare the measurements.
Did the brake pedal return to its original position?
Yes
No
GO to F2.
F2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal for free operation.
Did the brake pedal operate freely?

Yes
Installation).

No
INSTALL new brake pedal and bracket.
REFER to: Brake Pedal and Bracket - Vehicles Built Up To: 04/2009 (206-
06 Hydraulic Brake Actuation, Removal and Installation).
Component Tests
Hydraulic Leak Check
NOTE: There is a common clutch and brake fluid reservoir, therefore it is possible that a
clutch leak can lead to reduction in the reservoir level.
It is possible that all evidence of fluid leakage may have washed off if the vehicle has been
operated in rain or snow, as brake fluid is water-soluble. Refill the system, bleed then apply
the brakes several times. Examine the system to verify that the reservoir fluid level is
actually dropping. Locate and repair the external leak. If the fluid level drops and no
external leak can be found, check for a brake master cylinder bore end seal leak.
Brake System Check
Brake Pedal Reserve Check
Where a low brake pedal or the feel of a bottomed-out condition exists, check for brake
pedal reserve.
1. 1. Operate the engine at idle with the transaxle in the NEUTRAL position.
2. 2. Apply the brake pedal lightly three or four times.
3. 3. Allow 15 seconds for the vacuum to replenish the brake booster.
NOTE: This increased resistance may feel like something has bottomed out.
4. 4. Apply the brake pedal until it stops moving downward or an increased resistance to
the pedal travel occurs.
5. 5. Hold the brake pedal in the applied position and raise the engine speed to
approximately 2000 rpm.
NOTE: The additional movement of the brake pedal is the result of the increased engine
manifold vacuum which exerts more force on the brake booster during engine rundown.
This means that additional stroke is available in the brake master cylinder and the brake
system is not bottoming out.
6. 6. Release the accelerator pedal and observe that the brake pedal moves downward
as the engine returns to idle speed.
Brake Booster Functional Test

Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses
and their connections should be correctly secured and in good condition with no holes and
no collapsed areas. Inspect the check valve on the brake booster for damage.
Brake Booster Operation Check
1. 1. Check the hydraulic brake system for leaks or low fluid.
2. 2. With the transaxle in the NEUTRAL position, stop the engine and apply the parking
brake. Apply the brake pedal several times to exhaust all the vacuum in the system.

3. 3. With the engine turned off and the vacuum in the system exhausted, apply the
brake pedal and hold it down. Start the engine. If the vacuum system is operating,
the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the vacuum booster system is not functioning.
4. 4. Remove the vacuum hose from the brake booster. Manifold vacuum should be
available at the brake booster end of the hose with the engine at idle speed and the
transaxle in the NEUTRAL position. Make sure that all unused vacuum outlets are
correctly capped, hose connectors are correctly secured and vacuum hoses are in
good condition. When it is established that manifold vacuum is available to the
brake booster, connect the vacuum hose to the brake booster and repeat Step 3. If
no downward movement of the brake pedal is felt, install a new brake booster.
REFER to: Brake Booster - LHD FWD (206-07 Power Brake Actuation, Removal and
Installation) /
Installation).
5. 5. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine and let
the vehicle stand for 10 minutes. Then, apply the brake pedal with approximately
89 N (20 lb) force. The pedal feel (brake application) should be the same as that
noted with the engine operating. If the brake pedal feels hard (no power assist),
install a new vacuum check valve and then repeat the test. If the brake pedal still
feels hard, install a new brake booster.
REFER to: Brake Booster - LHD FWD (206-07 Power Brake Actuation, Removal and
Installation) /
Installation).
If the brake pedal movement feels spongy, bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information,
General Procedures) /
Brake System Pressure Bleeding (206-00 Brake System - General Information,
Brake Master Cylinder
Usually, the first and strongest indicator of anything wrong with the braking system is a
feeling through the brake pedal. In diagnosing the condition of the brake master cylinder,
check pedal feel as evidence of a brake concern. Check for the brake warning indicator
illumination and the fluid level in the master cylinder reservoir.
Normal Conditions
The following conditions are considered normal and are not indications that the brake
master cylinder is in need of service.
Modern brake systems are not designed to produce as hard a pedal effort as in the past.
Complaints of light pedal efforts should be compared to pedal efforts of another vehicle,
of the same model and year.
During normal operation of the brake pedal, the fluid level in the reservoir will rise during
brake pedal application and fall during release. The net fluid level (i.e., after brake pedal
application and release) will remain unchanged.
A trace of brake fluid will exists on the brake booster shell below the master cylinder
mounting flange. This results from the normal lubricating action of the master cylinder
bore end seal.
The fluid level will fall with brake shoe and lining wear.
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make sure the brake system warning indicator
is functional.

Changes in brake pedal feel or travel are indicators that something could be wrong with the
braking system. The diagnostic procedure and techniques use brake pedal feel, warning
indicator illumination and low brake fluid level as indicators in diagnosing braking system
concerns. The following conditions are considered abnormal and indicate that the brake
master cylinder is in need of service.
The brake pedal goes down fast. This could be caused by an external or internal leak.
The brake pedal eases down slowly. This could be caused by an external or internal leak.
The brake pedal is low and or feels spongy. This condition may be caused by no fluid in
the brake master cylinder reservoir, reservoir cap vent holes clogged or air in the
hydraulic system.
The brake pedal effort is excessive. This may be caused by a bind or obstruction in the
pedal or linkage, clogged fluid control valve or insufficient booster vacuum.
The rear brakes lock up during light pedal force. This may be caused by incorrect tire
pressures, grease or fluid on the brake shoes and linings, damaged brake shoes and
linings, incorrectly adjusted parking brake, or damaged or contaminated brake pressure
control valves.
The brake pedal effort is erratic. This condition could be caused by a brake booster
malfunction, extreme caliper piston knock back or incorrectly installed brake shoes and
linings.
The brake warning indicator is ON. This may be caused by low fluid level, ignition wire
routing too close to the fluid level indicator assembly, or float assembly damage.
Bypass Condition Test
1. 1. Check the fluid in the brake master cylinder reservoir. Fill the brake master
cylinder reservoir if low or empty.
2. 2. Observe the fluid level in the brake master cylinder reservoir. If after several brake
applications, the fluid level remains the same, measure the wheel turning torque
required to rotate the wheels with the brakes applied as follows:
Place the transaxle in the NEUTRAL position. Raise and support the vehicle.
REFER to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
Lifting (100-02 Jacking and Lifting, Description and Operation).
Apply the brakes with a minimum of 445 N (100 lb) and hold for approximately 15 seconds.
With the brakes still applied, exert a torque on the front wheels of 10.1 Nm (75 lb ft). If
either wheel rotates, install a new brake master cylinder.
REFER to: Brake Master Cylinder - LHD FWD (206-06 Hydraulic Brake Actuation, Removal
and Installation) /
Brake Master Cylinder - RHD FWD (206-06 Hydraulic Brake Actuation, Removal and
Installation).
Non-Pressure Leaks
Any empty brake master cylinder reservoir condition may be caused by two types of non-
pressure external leaks.
Type 1: An external leak may occur at the brake master cylinder reservoir cap because of
incorrect positioning of the gasket and cap. Reposition the cap and gasket.
Type 2: An external leak may occur at the brake master cylinder reservoir mounting seals.
Service such a leak by installing new seals.

Brake System Bleeding
Print
General Procedures
General Equipment
Worldwide Diagnostic System (WDS)
Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush
the eyes for 15 minutes with cold running water. Get medical attention if irritation
persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instructions may result in personal injury.
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be
immediately washed down with cold water.
NOTE: Make sure that the vehicle is standing on a level surface.
NOTE: The system consists of separate circuits for each front and diagonally opposite rear
wheel. Each circuit can be bled independently.
1. CAUTION: The brake fluid reservoir must

remain full with new, clean brake fluid at all
times during bleeding.
Install the bleed tube to the bleed nipple.
2. Immerse the end of the bleed tube in a bleed jar
containing a small quantity of approved brake
fluid.
3. Position the bleed jar base at least 300 mm
above the bleed nipple to maintain fluid pressure
and prevent air leaking past the threads of the
bleed nipple.
4. Loosen the bleed nipple by one-half turn.
5. Operate the brake pedal fully (pumping brake
fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position.
6. Fill the brake fluid reservoir to the MAX mark.
7. Continue operating the brake pedal until air-free
fluid is being pumped into the bleed jar.
8. With the brake pedal fully depressed tighten the
bleed nipple.
9. CAUTION: Make sure that the bleed

nipple cap is installed after bleeding the
brake line(s). This will prevent corrosion to
the bleed nipple. Failure to follow this
instruction may result in the bleed nipple
becoming seized.
Repeat the procedure for the remaining brake
lines.

Brake System Leak Check
Print
General Procedures
Check
1. NOTE: Brake fluid is water soluble and it is
possible that all evidence of fluid leakage has
been washed off if the vehicle has been
operated in rain or snow.
Check the brake fluid level. Add brake fluid as
necessary.
2. Apply the brakes several times and make sure
the pedal feel is not spongy. If necessary, bleed
the brake system.
For additional information, refer to Brake System
Bleeding in this section.
3. Check the brake fluid level and verify that the
fluid level is actually dropping.
4. NOTE: If the brake fluid level drops and no
external leak is evident, check for a brake
master cylinder bore end seal leak.
Locate and correct the external leak.

Brake Load Sensor Proportioning Valve Transit/Tourneo Connect 2002.5 (06/2002-)
Adjustment
Print
General Procedures
Special Tool(s)
Wrench, Hydraulic Line Union Nut
211-268A (13-026A)
WARNINGS:
When installing a new brake load sensor proportioning valve, remove the rubber
band from the tension spring. Failure to follow this instruction may result in personal
injury.
The brake load sensor proportioning valve adjustment must be carried out with the
vehicle in an unladen ride height condition. Failure to follow this instruction may result in
personal injury.
1. Loosen the tension spring coupling link setting
screw.
2. WARNING: Incorrect adjustment of the

brake load sensor proportioning valve will
result in inefficient braking. The brake load
sensor proportioning valve adjustment lever
must be set in the correct position. Failure to
injury.
CAUTIONS:
Whilst depressing the valve adjustment

lever, make sure that excessive force is not
placed on the special tool.
Whilst tightening the tension spring

coupling link setting screw, make sure that
the valve adjustment lever does not move.
NOTE: Make sure that the tension spring
coupling link is correctly located on the
tension spring.
NOTE: Make sure that the rounded end of
the tension spring coupling link correctly
engages with the valve adjustment lever.
Using the special tool, set the valve adjustment
lever to the correct position.
1. Fully depress the valve adjustment lever.
2. Tighten the tension spring coupling link
setting screw.

Brake Disc Runout Check
Print
General Procedures
Special Tool(s)
Dial Indicator Gauge (Metric)
205-069 (15-046)
Holding Fixture, Dial Indicator Gauge

205-070 (15-022A)
Holding Fixture, Dial Indicator Gauge (Disc Brake)

206-003 (12-003)
General Equipment
Micrometer 0-125 mm
Check
1. NOTE: The total dial indicator gauge reading
should not exceed 0.05 mm.
Using the special tools, measure the brake disc
runout on the inner face of the brake disc (wheel
and tire shown removed for clarity).
1. Position the dial indicator gauge so that it
contacts the brake disc approximately 10
mm from the outer edge.
2. Slowly rotate the wheel and tire and note
the readings.
2. NOTE: Using paint or typing correction fluid,

mark the position of the wheel in relation to
the wheel hub.
Remove the wheel and tire. For additional
Tires.
3. Remove the brake pads. For additional
information, refer to Section 206-03 Front Disc
Brake / 206-04 Rear Disc Brake.
4. Install the wheel nuts and tighten the wheel nuts
to 10 Nm, to hold the brake disc in place.
5. NOTE: The total dial indicator gauge reading
should not exceed 0.05 mm.
Using the special tools, measure the brake disc
runout on the inner and outer faces of the brake
disc (outer face measurement shown).
1. Position the dial indicator gauge so that it
contacts the brake disc approximately 10
mm from the outer edge.
2. Slowly rotate the brake disc and note the
readings.
6. NOTE: If any of the readings vary by more

than 0.015 mm or the brake disc thickness is

less than the specified minimum, a new
brake disc must be installed and the brake
disc runout re-checked.
Check the brake disc thickness variation.
Using a suitable micrometer, measure the
brake disc thickness at eight positions, 45
degrees apart and approximately 15 mm
from the outer edge of the brake disc.
7. If all the brake disc runout measurements and

the thickness variation are within the
specifications, check the wheel balance.
8. If just the brake disc runout measurement with
the wheel and tire fitted exceeds the
specification, the wheel and tire must be rotated
through 90 degrees in relation to the brake disc
and the brake disc runout re-checked.
If the brake disc runout measurement still
exceeds the specification, repeat the wheel
and tire rotation and checking process until
the measurement is within specification.
9. If the brake disc runout measurement without
the wheel and tire fitted is outside the
specification, check the wheel hub face runout.
10. NOTE: Using paint or typing correction fluid,
mark the position of the brake disc in relation
to the wheel hub.
Remove the brake disc. For additional
information, refer to Section 206-03 Front Disc
Brake / 206-04 Rear Disc Brake.
11. NOTE: Make sure that the wheel hub face is
clean and free of rust and foreign material.
NOTE: Re-position the dial indicator gauge
so that it contacts the wheel hub
approximately 10 mm from the outer edge of
the wheel hub.
Check the wheel hub face runout.
Slowly rotate the wheel hub and note the
readings.
12. If the wheel hub runout exceeds 0.03 mm, install

a new wheel hub. For additional information,
refer to Section 204-01 Front Suspension / 204-
02 Rear Suspension.
13. If the wheel hub face runout is within
specification, install a new brake disc. For
Front Disc Brake / 206-04 Rear Disc Brake.

Drum Brake - Specifications Transit/Tourneo Connect 2002.5 (06/2002
Print
Lubricants, Fluids, Sealers and Adhesives
Specification
Silicon dielectric compound ESA-M1C171-A
Grease–brake shoe adjuster ESE-M1C171-A
Super DOT 4 brake fluid ESD-M6C57-A
Drum Brake Dimensions
Description mm
New brake drum nominal diameter 228.3
Worn brake drum discard diameter* 230.2
Brake shoe width 55
Worn brake shoe lining discard thickness* 1
Brake shoe adjuster pre-set diameter 228
* When the discard thickness has been reached, install a new brake drum/brake shoes.

Wheel spindle retaining bolts 115 85 -
Wheel cylinder retaining bolts 10 - 89
Brake hose to wheel cylinder union 18 13 -

Drum Brake - Drum Brake Transit/Tourneo Connect 2002.5 (06/2002-)
Print
REFER to Section 206-00 Brake System - General Information.

Drum Brake - Brake Shoes Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Materials
Name Specification
Silicon dielectric ESA-M1C171-A
compound
Grease–brake shoe ESE-M1C171-A
adjuster
Removal
1. Remove the brake drum.
For additional information, refer to: Brake Drum
(206-02 Drum Brake, Removal and Installation).
2. Remove the hold down springs (wheel spindle
shown removed for clarity).
3. CAUTION: Do not damage the wheel

cylinder boots.
NOTE: Hold the wheel cylinder pistons in
place with a rubber band.
Detach the brake shoes from the wheel cylinder
(wheel spindle shown removed for clarity).
4. NOTE: Fully release the brake shoe

adjuster.
Remove the brake shoe return springs (wheel
spindle shown removed for clarity).
5. Remove the brake shoe adjuster from the brake

shoes (wheel spindle shown removed for
clarity).

6. Disconnect the parking brake cable from the
brake shoe.
7. Remove the brake shoes.
Installation
1. CAUTION: Make sure that the brake

shoe adjuster is pre-set to give a brake shoe
diameter of 228 mm before installing the
brake drum.
NOTE: Install a new parking brake cable
retaining clip.
Apply grease to the brake shoe adjuster
strut.
Clean the backing plate and apply silicon
dielectric compound to the brake shoe
contact points.
2. Adjust the parking brake cable.
For additional information, refer to: Parking
Brake Cable Adjustment (206-05 Parking Brake

Drum Brake - Wheel Cylinder Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Brake hose clamp
Removal
1. Remove the brake shoes.
For additional information, refer to Brake Shoes
in this section.
2. Loosen the brake hose to wheel cylinder union.
1. Using a suitable brake hose clamp, clamp
the brake hose.
2. Loosen the union.
3. Detach the wheel cylinder from the brake

backing plate.
4. CAUTION: Cap the brake hose to

Remove the wheel cylinder.
Installation
2. Bleed the brake system. For additional
information, refer to Section 206-00 Brake

Drum Brake - Brake Drum Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1. Remove the parking brake control boot.
2. Release the parking brake.

3. Loosen the parking cable adjustment nut to the
end of the thread.
Discard the retaining clip.

Tires.
(if equipped).
Installation
1. NOTE: Install a new parking brake cable
retaining clip.
2. Adjust the parking brake cable. For additional
information, refer to Section 206-05 Parking
Brake and Actuation.

Drum Brake - Brake Backing Plate Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Electric hand drill
Blind rivet gun-hand
Removal
1. Remove the wheel spindle. For additional
information, refer to Section 204-02 Rear
Suspension.
2. Remove the wheel cylinder.
For additional information, refer to Wheel
Cylinder in this section.
3. Detach the parking brake cable from the brake
backing plate.
1. Depress the retaining clip.
2. Detach the cable.
4. Remove the brake backing plate.

Using a suitable electric hand drill remove
the rivets.
Installation
1. NOTE: Using a suitable blind rivet gun-hand,
install new rivets.

Front Disc Brake - Specifications Transit/Tourneo Connect 2002.5 (06/2002-
Print
Specifications
Front Disc Brake Dimensions
Description mm
Brake disc diameter 278
New brake disc nominal thickness 24
Worn brake disc discard thickness* 22
Worn brake pad discard thickness* 2
* When the discard thickness has been reached, install a new brake disc/brake pads.

Brake caliper anchor plate retaining bolts 133 98 -
Brake caliper retaining bolts 30 22 -

Front Disc Brake - Front Disc Brake Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Front Disc Brake - Brake Pads Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Retractor, Caliper Piston
206-005 (12-014)
Materials
Name Specification
High temperature grease ESE-M12A4-A
Removal
Tires.
2. Detach the brake caliper retaining clip.
3. CAUTION: Suspend the caliper to

prevent load being placed on the brake hose.
Detach the brake caliper from the brake caliper
anchor plate.
1. Remove the bolt covers (if equipped).
2. Remove the retaining bolts.
4. Remove the outer brake pad.
5. Remove the inner brake pad.

Installation
1. CAUTION: When the brake caliper

pistons are retracted into the piston housing,
brake fluid will be displaced into the brake
fluid reservoir.
Using the special tool, fully retract the brake
caliper pistons.

Apply high temperature grease to the
brake pad contact points.
3. Depress the brake pedal, check the fluid level in
the brake fluid reservoir and top up if necessary
with brake fluid.

Front Disc Brake - Brake Caliper Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Brake hose clamp
Materials
Name Specification
Removal
Tires.
2. Remove the brake caliper retaining clip.
3. Loosen the brake hose to brake caliper union.

the brake hose.
4. Detach the brake caliper from the brake caliper

anchor plate.

6. Remove the inner brake pad.

Disconnect the brake hose from the caliper.
Rotate the caliper counterclockwise.
8. Remove the brake caliper.
Installation

Front Disc Brake - Brake Disc Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
Tires.

the wheel knuckle.

(if equipped).
Installation

Front Disc Brake - Brake Caliper Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Disassembly
1. Remove the caliper.
For additional information, refer to Caliper -
Front Brake in this section.
2. CAUTION: Place a block of wood or some

shop rags between the caliper piston and the
caliper housing as damage to the caliper
piston may result.
Extract the caliper piston from the caliper
housing using compressed air.
3. Remove the caliper piston.
4. Remove and discard the dust seal.
5. Remove and discard the piston seal.
6. Inspect the caliper piston and the piston bore for

pitting or scoring and install a new piston as
necessary.
Assembly
1. Lubricate the piston bore, piston seal and the
caliper piston with high performance super DOT
4 brake fluid meeting Ford specification ESD -
M6C57 - A.
2. NOTE: The caliper seal fits into a machined

groove in the piston bore.
Install a new piston seal into the piston bore.
3. Install a new dust seal onto the caliper piston.
4. CAUTION: Do not scratch or damage the

caliper piston when installing it into the
caliper bore.
Install the caliper piston into the caliper bore.
5. Seat the dust seal

6. Install the caliper.
For additional information, refer to Caliper -
Front Brake in this section.

Rear Disc Brake - Specifications Transit/Tourneo Connect 2002.5 (06/2002-
Print
Specifications
Rear Brake Disc Specifications
Description mm
Brake disc diameter 278
New brake disc nominal thickness 11
Worn brake disc discard thickness * 9
Worn brake pad discard thickness* 2
* When the discard thickness has been reached, install a new brake disc/brake pads.

Brake caliper anchor plate retaining bolts 133 98 -
Brake caliper retaining bolts 28 21 -

Rear Disc Brake - Rear Disc Brake Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Rear disc brake

1 - Brake disc
2 - Combination caliper
3 - Brake cylinder piston
On vehicles with Anti-lock Brake System (ABS), brake discs with a diameter of 278 mm and
a thickness of 11 mm are used together with a combination caliper.
The hand brake operates through the combination caliper on the brake disc.

Rear Disc Brake - Rear Disc Brake Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Rear Disc Brake - Brake Caliper Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Brake hose clamp
Removal
1. Remove the brake pads.
For additional information, refer to Brake Pads -
in this section.
2. Loosen the brake hose to brake caliper union.
the brake hose.

Disconnect the brake hose from the brake
caliper.
Rotate the caliper counterclockwise.
4. Remove the brake caliper.
Installation

Rear Disc Brake - Brake Pads Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Retractor, Rear Brake Caliper Piston
206-085 (12-025)
Materials
Name Specification
Removal

3. Loosen the parking brake cable adjustment nut
to the end of the thread.

Tires.
brake caliper lever.
6. Remove the brake caliper retaining clip.

7. CAUTION: Suspend the brake caliper to
prevent load being placed on the brake hose.
Detach the brake caliper from the brake caliper
anchor plate.
8. NOTE: The inner brake pad is secured to the

brake caliper piston by a spring clip.
Remove the inner brake pad.
Slide the brake pad out.
Installation
1. CAUTIONS:
When the brake caliper piston is

retracted into the piston housing, brake fluid
will be displaced into the brake fluid
reservoir.
Support the brake caliper piston during

brake caliper retraction.
NOTE: To retract the left-hand or the right-
hand brake caliper piston, the piston must be
rotated clockwise whilst applying pressure.
Using the special tool, retract the brake caliper

piston.
3. Depress the brake pedal, check the fluid level in
the brake fluid reservoir and top up if necessary
with brake fluid.

Rear Disc Brake - Brake Disc Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal


Tires.
5. Detach the parking brake cable from the brake
caliper lever.

the wheel spindle (brake caliper shown removed
for clarity).

Remove and discard the retaining clip (if
equipped).
Installation


Parking Brake and Actuation -
Specifications
Print

Parking brake cable adjusting nut 2.6 - 24
Parking brake control retaining nuts 20 15 -
Parking brake cable clips retaining bolts 7 - 62
Parking brake cable support bracket retaining bolts 11 8 -

Parking Brake and Actuation - Parking
Brake
Print
Parking brake

1 - Parking brake cable
2 - Brake disc
3 - Combination caliper
4 - Variant with drum brakes
5 - Balance arm
6 - Adjusting screw
7 - Contact switch, parking brake lever

Depending on the equipment level, the vehicle may have drum or disc brakes on the rear
axle.
On the parking brake system with disc brakes, the parking brake operates on the brake disc
through a combination caliper.
Parking brake adjustment is carried out at the adjustment screw on the left beside the
parking brake lever.
Two separate cables run from the balance arm to the brakes.

Brake
Print
1. 1. Verify the customer concern by operating the parking brake system.
Parking brake control Parking brake warning circuit.
REFER to: Parking Brake Control (206-05 REFER to: Instrument Cluster (413-
Parking Brake and Actuation, Removal and 01 Instrument Cluster, Diagnosis and
Installation). Testing).
Cable and conduit
REFER to: Parking Brake Cable (206-05
Parking Brake and Actuation, Removal and
Installation).
4. 4. If the concern is not visually evident, verify the symptom and refer to the
Symptom Chart.
Symptom Chart
Symptom Chart

The parking brake will not apply * Parking brake control. * GO to Pinpoint Test A.
* Cable and conduit.
The parking brake will not release * Parking brake control. * GO to Pinpoint Test B.
* Cable and conduit.
Pinpoint Tests
PINPOINT TEST A : THE PARKING BRAKE WILL NOT APPLY

CONDITIONS
A1: CHECK FOR MISADJUSTED REAR PARKING BRAKE CABLE
1 Operate the parking brake control several times to adjust the cable.
Does the parking brake now engage correctly?
Yes
Vehicle OK
No
GO to A2.
A2: CHECK FOR WORN BRAKE SHOES OR PADS
1 Inspect the brake shoes or pads for excessive wear.
REFER to /
Brake Shoes (206-02 Drum Brake, Removal and Installation) /
Brake Pads (206-04 Rear Disc Brake, Removal and Installation).
Are the brake shoe linings or brake pads OK?
Yes
GO to A3.

No
INSTALL new brake shoes or pads.
REFER to: Brake Shoes (206-02 Drum Brake, Removal and Installation) /
Brake Pads (206-04 Rear Disc Brake, Removal and Installation).

A3: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables and conduits for damage, rust or
fraying.
Are the parking brake cables and conduits OK?
Yes
CHECK for other causes such as loose parking brake control or
conventional brake system components.
No
REPAIR or INSTALL cables and conduit as necessary. TEST the system for
normal operation.
PINPOINT TEST B : THE PARKING BRAKE WILL NOT RELEASE

CONDITIONS
B1: CHECK PARKING BRAKE CONTROL
1 Raise and support the vehicle on a lift with the parking brake fully
applied.
REFER to: Lifting (100-02 Jacking and Lifting, Description and Operation).
With the aid of another technician, release the parking brake and check
the operation of the brake cables and levers.
Did the parking brake release?
Yes
CHECK the other causes such as conventional brake system components.
REPAIR or INSTALL new components as necessary.
No
GO to B2.
B2: CHECK PARKING BRAKE CABLES
1 Loosen the parking brake cable tension.
Rotate the rear wheels by hand.

Did the rear wheels turn freely?
Yes
INSTALL a new parking brake control.
REFER to: Parking Brake Control (206-05 Parking Brake and Actuation,
No
GO to B3.
B3: CHECK FRONT PARKING BRAKE CABLE
1 Disconnect the parking brake front cable and conduit from the rear brake
cable and conduit at the equalizer.
Rotate the rear wheels by hand.

Did the rear wheels turn freely?
Yes
INSTALL a new front parking brake cable and conduit.
REFER to: Parking Brake Cable (206-05 Parking Brake and Actuation,
No
GO to B4.

B4: CHECK REAR PARKING BRAKE CABLES
1 Disconnect the parking brake at the rear brakes, one at a time.
Rotate the wheel affected by the disconnected parking brake.

Did the wheel turn freely?
Yes
INSTALL a new parking brake control lever on the rear drum brakes or
caliper assembly on rear disc brakes.
REFER to: Brake Shoes (206-02 Drum Brake, Removal and Installation) /
Brake Caliper (206-04 Rear Disc Brake, Removal and Installation).
No
REFER to: Brake System (206-00 Brake System - General Information,
Diagnosis and Testing).

Brake Cable Adjustment
Print
General Procedures
All vehicles

Remove and discard the retaining clip.
4. NOTE: The right-hand cable can be identified

by a sleeve on the outer cable.
Make sure the parking brake cable is correctly
located.
5. NOTE: Prior to carrying out adjustment to a
new or relocated parking brake cable, settle
the parking brake system.
Settle the parking brake system in three stages.
Stage 1: Raise the parking brake control
seven notches.
Stage 2: Tighten the adjustment nut to 6
Nm.
Stage 3: Loosen the adjustment nut to the
end of the thread.

6. Using a suitable rolling road, carry out a brake
test. For additional information, refer to Section
100-00 General Information.
7. Start the engine.
8. Depress and release the brake pedal firmly
fifteen times.
9. Raise the parking brake control seven notches.
10. Tighten the parking brake cable adjustment nut.
Install a new retaining clip.

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

Brake Control
Print
Removal
Lifting.
3. Remove the floor console. For additional
information, refer to Section 501-12 Instrument
Panel and Console.
4. Disconnect the electrical connector.
5. Remove the parking brake cable adjustment nut.

1. Remove the clip.
2. Remove the adjustment nut.
6. Remove the parking brake control.
Installation
1. NOTE: After installation, adjust the parking
brake.
For additional information, refer to Parking
Brake Cable Adjustment in this section.

Brake Cable
Print
Removal
All vehicles

4. Remove the rear wheels and tires. For additional

Tires.
5. Detach the center section of the exhaust system
heat shield from the floor panel.
6. Detach the right-hand section of the exhaust

system heat shield from the floor panel.
7. Detach the fuel tank section of the exhaust

system heat shield from the floor panel.

8. Remove the brake drums. For additional
Brake.
brake shoes on both sides (wheel hub shown
1. Release the actuating lever.
2. Detach the cable.
3. Depress the clip.

brake caliper lever.
All vehicles
11. Detach the parking brake cable from the parking
brake equalizer.
1. Detach the cables from the bracket.
2. Detach the cables from the equalizer.
12. NOTE: There is a sleeve on the cable outer to

indicate the right-hand cable. Note the
position of the sleeve to aid installation.
Detach the parking brake cable from the floor
panel and chassis on both sides.

13. NOTE: Make a note of the position of the
parking brake cable support bracket to aid
installation.
Detach the parking brake cable support bracket
from the chassis on both sides.
14. Remove the parking brake cable.
Installation
1. NOTE: The parking brake cable support
bracket cable carrier must face the front of
the vehicle.
NOTE: The right-hand cable can be identified
by a sleeve on the cable outer.
2. Adjust the parking brake.
For additional information, refer to Parking Brake
Cable Adjustment - in this section.

Hydraulic Brake Actuation - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Specifications
Super DOT 4 brake fluid ESD–M6C57–A

Brake master cylinder retaining nuts 25 18 -
Brake tube to master cylinder unions (M10) 14 10 -
Brake booster retaining nuts 25 18 -
Brake pedal retractor retaining nuts 48 35 -
Brake pedal shaft nut 23 17 -
Clutch master cylinder retaining nuts 9 - 80
Bleed nipple 5 - 44
Wiring harness bracket to brake booster retaining nut 20 15 -

Hydraulic Brake Actuation - Hydraulic
Brake Actuation
Print
Brake pedal
WARNING: In the case of an accident due to which the instrument cluster or the
brake booster are damaged or severely displaced on vehicles with a brake pedal return
lever, the brake pedal must be replaced. Failure to observe this instruction can lead to
injuries.

1 - Retaining bolt
2 - Noise Vibration and Harshness (NVH) weight
3 - Lever mechanism
4 - Spindle
5 - Brake pedal
The brake pedal is equipped with a safety device which moves the brake pedal downwards
by up to 8 cm if a severe frontal collision occurs, to reduce the risk of injury to the driver.
This is achieved by a mechanism which joins the brake pedal stop to the vehicle body.
If a severe collision occurs, the brake pedal stop will be slid over a lever mechanism,
through which the end position of the pedal also changes.

Hydraulic Brake Actuation - Hydraulic
Brake Actuation
Print

Hydraulic Brake Actuation - Brake Pedal
and Bracket—Vehicles Built Up To: Transit/Tourneo Connect 2002.5 (06/2002-)
04/2009
Print
Removal
WARNING: In the event of a frontal impact to a vehicle equipped with a decoupler

brake pedal in which damage to, or significant movement of, the instrument panel or the
brake booster has occurred, a new brake pedal and bracket must be installed. Failure to
follow this instruction may result in personal injury.
All vehicles
1. Detach the instrument panel lower panel from
the instrument panel.
1. Remove the retaining screws.
2. Release the clips.
2. Remove the instrument panel lower panel.

Disconnect the headlamp control switch
electrical connector.
3. Disconnect the electrical connectors from the

pedal position switches.
1. Speed control deactivation switch (if
equipped).
2. Stop lamp switch.
3. Clutch position switch.
4. CAUTION: Make sure the clutch pedal is

depressed to avoid damage to the clutch
pedal switch.
Depress the clutch pedal and hold it in the
depressed position.
5. Remove the pedal position switches.
1. Speed control deactivation switch (colored
green) (if equipped).
2. Stop lamp switch (colored grey).
3. Clutch position switch (colored red).

6. Detach the brake booster actuating rod from the
brake pedal.
1. Depress the brake pedal.
3. Remove the brake booster actuator rod
pin.
1. Discard the pin.
7. Remove the brake booster retaining nuts.
Right-hand drive vehicles

9. Detach the steering column shaft from the

1. Remove the bolt.
1. Discard the retaining bolt.
2. Release the pinion shaft extension from

the steering column.
All vehicles
10. Detach the clutch master cylinder from the pedal
bracket.

1. Remove the clip.
2. Remove the bolts.
11. Detach the clutch master cylinder actuating rod

from the clutch pedal.
12. Remove the brake pedal retractor retaining bolt

(if equipped).
13. Remove the brake pedal bracket.
Installation
All vehicles
1. NOTE: Make sure the brake pedal locates
into the brake booster actuator rod clevis.
Install the brake pedal bracket.
2. NOTE: Do not fully tighten the brake booster
Install the brake booster retaining nuts.
3. NOTE: Do not fully tighten the brake pedal

retractor arm retaining bolt at this stage.
Install the brake pedal retractor arm retaining
bolt (if equipped).

4. Attach the clutch master cylinder actuating rod
to the clutch pedal.
5. NOTE: Locate the clutch master cylinder into

the pedal bracket holes.
Attach the clutch master cylinder to the pedal
bracket.
1. Install the bolts.
2. Install the clip.
6. NOTE: Install a new brake booster actuating

rod pin.
Install the brake booster actuating rod pin.
2. Install the brake booster actuating rod pin.
7. CAUTION: Make sure there is clearance

between the brake pedal and the brake pedal
retractor to allow free movement.
Align the brake pedal retractor arm to the brake
pedal bracket (if equipped).
8. Tighten the brake booster retaining nuts.

9. Tighten the brake pedal retractor arm retaining
bolt (if equipped).
10. With the engine running depress the brake pedal

three times to make sure the brake pedal moves
freely and returns to the full brake off position.

column pinch bolt. Failure to follow this
Attach the steering column shaft to the steering
gear pinion extension.
All vehicles
12. NOTE: The clutch position switch (colored
red) is not adjustable.
NOTE: From 08/2003 only non-adjustable
stop lamp switches are available.
Pull out the speed control deactivation switch (if
equipped) and the stop lamp switch (if equipped
with an adjustable stop lamp switch) plungers
until they are fully extended.
Measure the plunger length.
1. Speed control deactivation switch
(colored green) XX mm = 24 mm.
2. Stop lamp switch (colored grey) XX
mm = 21 mm.
13. CAUTIONS:
When installing the switches, the stop

lamp switch is rotated counterclockwise and
the remaining switches are rotated
clockwise. Failure to follow this instruction
will result in the switch plungers binding

inside the switch.
Make sure the switches are correctly

installed.
NOTE: The speed control deactivation switch
(if equipped) and the stop lamp switch (if
equipped with an adjustable stop lamp
switch) are automatically adjusted during
installation.
NOTE: A slight ratcheting noise and feel
during installation of the speed control
deactivation switch (if equipped) and the
stop lamp switch (if equipped with an
adjustable stop lamp switch) is normal.
Install the pedal position switches.
14. NOTE: The colors of the electrical connectors
and switches are identical.
Connect the electrical connectors to the pedal
switches.
equipped).
15. Connect the headlamp control switch electrical

connector.
16. Install the instrument panel lower panel.

1. Install the retaining screws.
2. Install the clips.

Hydraulic Brake Actuation - Brake Pedal
and Bracket—Vehicles Built From: Transit/Tourneo Connect 2002.5 (06/2002-)
04/2009
Print
Removal
1.
2.
3.
4.

5.
6.
7.
8.

Installation
1. NOTE: Only tighten the nuts and bolt finger

tight at this stage.
2. Torque: 9 Nm

3.
2. Torque: 50 Nm
3. Torque: 23 Nm
4.
5. Torque: 28 Nm

6.
7.
8.

Hydraulic Brake Actuation - Brake Master
Cylinder—LHD FWD
Print
Removal
All vehicles
1. CAUTION: The brake fluid reservoir cap

must not become contaminated.
Remove the brake fluid reservoir cap.
Disconnect the low brake fluid warning
indicator switch electrical connector.
2. NOTE: It will be necessary to carry out this

step on both sides in order to completely
drain the brake fluid reservoir.
Drain the brake fluid reservoir.
1. Connect one end of a suitable piece of
clear plastic pipe to the bleed nipple and
place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all the brake
fluid is drained from the brake fluid
reservoir.
4. Tighten the bleed nipple.
3. Install the brake fluid reservoir cap.
4. Remove the air cleaner.
For additional information, refer to: Air Cleaner
(303-12 Intake Air Distribution and Filtering,
5. Remove the air cleaner outlet tube.
6. Disconnect the battery junction box (BJB)
electrical connectors.
7. Remove the BJB retaining screw.

8. Detach the BJB from the BJB support bracket
and position to one side.
Depress the locking tangs.
9. CAUTION: Cap the brake master

cylinder feed hose to prevent fluid loss or
dirt ingress.
Disconnect the brake master cylinder feed hose
from the brake master cylinder.
10. CAUTION: Cap the brake tubes to

Disconnect the brakes tubes from the brake
master cylinder.

master cylinder.
All vehicles

12. Remove the brake master cylinder.
Discard the nuts
Installation
CAUTION: Make sure the brake master cylinder vacuum seal is correctly positioned
before installation.
2. Bleed the brake system.
For additional information, refer to: Brake
System Bleeding (206-00 Brake System -

Hydraulic Brake Actuation - Brake Master
Cylinder—RHD FWD
Print

General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing oven
Removal
All vehicles
1. Remove the polyurethane (PU) adhesive cap and
heat the PU adhesive for a minimum of 30
minutes.


container.
reservoir.
5. Detach the brake fluid reservoir from the cowl
panel.

Vehicles with diesel engine
6. Detach the fuel filter and position it to one side.
All vehicles
7. Detach the coolant expansion tank from the
wheelhouse assembly and position it to one side.
1. Remove the retaining bolt.
2. Detach the coolant expansion tank.
8. Detach the power steering reservoir from the

wheelhouse assembly and position it to one side.
9. Remove the cowl panel grille.

For additional information, refer to: Radiator
Grille Opening Panel - Vehicles Built Up To:
04/2009 (501-02 Front End Body Panels,
Radiator Grille Opening Panel - Vehicles Built
From: 04/2009 (501-02 Front End Body Panels,
10. Disconnect the vacuum hoses and the electrical
connector from the exhaust gas recirculation
(EGR) electronic vacuum regulator.

11. Disconnect the intake air volume sensor hose
and intake air volume sensor electrical connector
from the intake air volume sensor.
12. Detach the brake vacuum pipe support bracket

from the cowl panel.
13. WARNING: Wear ear protectors when

working with the glass cutting tool. Failure to
injury.
Remove the water guide.
Using a suitable direct glazing cutter, cut
the PU adhesive.
14. Remove the pollen filter.
15. Detach the cowl panel from the fender on both

sides.

16. Remove the cowl panel (reverse side shown,
cowl panel removed for clarity).
17. CAUTION: Cap the brake master

cylinder feed hose to prevent fluid loss or
dirt ingress.
Disconnect the brake master cylinder feed hose
from the brake master cylinder.

master cylinder.

master cylinder.
All vehicles

20. Detach the main engine wiring harness bracket
from the master cylinder.
21. Remove the brake master cylinder.

Discard the nuts
Installation
1. CAUTION: Make sure the brake master

cylinder vacuum seal is correctly positioned
2. CAUTIONS:
Do not touch the adhesive surface as re-

bonding will be impaired.
To make sure that the PU adhesive

cures, it is essential that all bonding surfaces
are free of moisture.
NOTE: Discard the first 100mm of PU
adhesive as this may have a reduced working
time.
NOTE: To avoid water leaks and breakage in
the continuous bead, the continuous bead
must be over lapped by 20 mm.
NOTE: Before installing the water guide,
apply the PU adhesive in a continuous bead
of between 8 and 10mm in height to the
windshield glass flange along the bond line.
Using a hot air gun, apply warm air to the
windshield glass flange and glass bond line to
remove all moisture.
4. Bleed the brake system.
For additional information, refer to: Brake
System Bleeding (206-00 Brake System -

Hydraulic Brake Actuation - Brake Fluid
Reservoir
Print
Removal
All Vehicles
1. CAUTION: If brake fluid is spilt on the

paintwork, the affected are must be
Disconnect the electrical connector from the filler
cap.
1. Pull back the tab.
2. Depress the clips.
2. CAUTION: Make sure the filler cap does

not become contaminated.
Remove the brake fluid reservoir filler cap.
3. Using a suitable clean suction device drain the

reservoir.
4. Install the brake fluid reservoir filler cap.

5. Detach the reservoir.
6. Detach the central electrical box screw.

7. Detach the electrical connector clip.
8. CAUTION: Cap the hose connections to

prevent fluid loss or dirt contamination.
Disconnect the brake master cylinder feed hose.
Vehicles with manual transaxle
9. CAUTION: Cap the hose connections to

prevent fluid loss or dirt contamination.
Disconnect the clutch master cylinder feed hose.
All Vehicles
10. Disconnect the brake fluid reservoir wiring
harness.
Installation

1. NOTE: After installation, bleed the brake
system. For additional information, refer to
Section 206-00 Brake System - General
Information.

Power Brake Actuation - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Specifications

Brake booster retaining nuts 25 18 -
Brake pedal retractor retaining nuts 48 35 -
Engine support insulator center bolt 50 37 -
Engine front mount bracket retaining bolts 48 35 -

Power Brake Actuation - Power Brake
System
Print

Power Brake Actuation - Brake Booster—
LHD FWD
Print
Removal
All vehicles
1. Remove the brake master cylinder. For additional
information, refer to Section 206-06 Hydraulic
Brake Actuation.

2. Remove the hydraulic control unit (HCU). For
additional information, refer to Section 206-09A
Anti-Lock Control / 206-09B Anti-Lock Control -
Traction Control / 206-09C Anti-Lock Control -
Stability Assist.
All vehicles


equipped)


brake pedal.
3. Remove the brake booster actuating rod
pin.
9. Remove the brake booster.

Discard the gasket.
Installation
1. CAUTIONS:
Make sure that the brake booster

actuating rod is correctly positioned through
the bulkhead rubber boot.
Make sure the brake booster gasket is

correctly positioned on the brake booster
NOTE: Install a new gasket.

Power Brake Actuation - Brake Booster—
RHD FWD
Print

Special Tool(s)
Lifting bracket,Engine
303-122 (21-068A)
Disconnect tool, Spring-Lock Coupling 5/8 inch (black)

412-038 (34-003)
General Equipment
Engine hoist.
Removal
1. Remove the brake master cylinder. For additional
information, refer to Section 206-06 Hydraulic
Brake Actuation.
2. Remove the charge air cooler (if equipped). For
Intake Air Distribution and Filtering.
equipped).

1. Speed control switch (colored green) (if
equipped).

brake pedal.
3. Remove the brake booster actuating rod
pin.

7. Drain the air conditioning system. For additional

information, refer to Section 412-00 Climate
Control System - General Information.
8. Remove the right-hand fender splash shields
(wheel and tire shown removed for clarity).
9. Disconnect the high-pressure cut off switch

10. Disconnect the low-pressure cut off switch

11. CAUTION: Cap the refrigerant line

connections to prevent fluid loss and dirt
ingress.
Using the special tool, disconnect the refrigerant
line to the accumulator at the evaporator.
Discard the O-rings.

ingress.
Using the special tool, disconnect the refrigerant
line to the condenser at the evaporator.
13. Detach the refrigerant line bracket from the

radiator crossmember.

ingress.
Detach the refrigerant line from the condenser.
15. Detach the refrigerant lines from the wheelhouse

assembly.
16. Detach the dehydrator from the fender.

1. Disconnect the refrigerant line from the
dehydrator.
2. Remove the dehydrator bolts and nut.
17. NOTE: Pull the refrigerant lines through the

hole in the fender.
Remove the refrigerant lines from the engine
compartment.

Lifting.
19. Remove the auxiliary drive belt cover.
20. Remove the engine support insulator centre bolt.

22. Disconnect the headlamp wiring harness ground
cable.
23. Using the special tool and a suitable engine

hoist, support the engine.
24. Detach the engine front mount bracket from the

side member.
25. CAUTION: Make sure excessive force is

not placed on the remaining engine mount
when moving the engine forwards.
Move the engine front mount towards the front
of the vehicles to its maximum deflection.
26. Remove the brake booster.

Rotate the booster through 180 degrees to
aid removal.
Discard the gasket.
Installation
1. CAUTIONS:
Make sure that the brake booster

actuating rod is correctly positioned through
the bulkhead rubber boot.
Make sure the brake booster gasket is

correctly positioned on the brake booster
NOTE: Install a new brake booster gasket.
NOTE: Install new O-rings on the refrigerant
lines.
NOTE: Coat the O-rings for the refrigerant
lines with clean refrigerant oil prior to
installation.

Power Brake Actuation - Brake Vacuum
Pump
Print
Removal
1. Remove the air intake cover.
2. Detach the air intake hose clips.
3. Detach the intercooler.
4. Disconnect the intercooler electrical connector.
5. Remove the intercooler.

6. Detach the vacuum hose from the vacuum
pump.

7. Detach the upper and lower oil separator hoses.
8. Detach the glow plug electrical connector.
9. Disconnect the oil pressure switch.
10. Detach the oil separator.

1. Detach the engine coolant temperature
sensor electrical connector.
2. Detach the oil separator drain hose.
3. Remove the bolt.
11. Detach the vacuum pump oil drain hose.

12. Loosen the vacuum pump retaining bolts by 2
1/2 turns.
13. Select fourth gear.

15. Move the car forwards, rotating the engine, until
the vacuum pump becomes loose.
16. Remove the vacuum pump.
1. Loosen the lower retaining bolt.
2. Remove the upper retaining bolt.
3. Remove the vacuum pump.
17. Remove the vacuum pump seal.

Discard the seal
Installation
1. Install a new vacuum pump seal.

2. Install the brake vacuum pump.
3. Attach the vacuum pump oil drain hose.
4. Attach the oil separator.

1. Install the retaining bolt.
2. Attach the oil separator drain hose.
3. Attach the engine coolant temperature
5. Connect the oil pressure switch
6. Attach the glow plug electrical connector.

7. Attach the oil seperator upper and lower hoses.
8. Attach the vacuum hose to the brake vacuum

pump.
9. Install the intercooler.
10. Connect the intercooler electrical connector.
11. Attach the air intake hose clips.

12. Install the air intake cover.

Anti-Lock Control - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Specifications

Hydraulic control unit (HCU) support bracket retaining bolts 25 18 -
HCU retaining bolts 9 - 80
HCU to anti-lock brake system (ABS) module retaining bolts 2 - 18
Brake tube to HCU unions (M10) 14 10 -

Anti-Lock Control - Anti-Lock Control Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Diagnostic Tool FDS2000
2. 2. Visually inspect for obvious signs of damage. Refer to the following chart:
Check the condition and attachment of all Loose or corroded connections to
sensors and sensor indicators. sensors.
Wiring harness(s)
Loose or corroded hydraulic
actuator multiplug.
3. 3. If the inspection reveals an obvious concern rectify this before continuing.
4. 4. If the concern remains after the inspection, use FDS 2000 to diagnose the system.

Anti-Lock Control - Hydraulic Control Unit
(HCU)
Print

General Equipment
Transmission jack
Securing straps
Removal
All vehicles


container.
reservoir.
4. Remove the air cleaner. For additional
information, refer to Section 303-12 Intake Air
Distribution and Filtering.
6. Remove the battery tray. For additional
information, refer to Section 414-01 Battery,
Mounting and Cables.
7. Detach the transaxle breather assembly from the
air cleaner bracket.

8. Detach the air cleaner bracket from the
wheelhouse assembly.
9. Detach the engine wiring harness from the air

cleaner bracket.
10. NOTE: Use suitable wooden blocks to protect

the transaxle.
NOTE: Secure the transaxle with securing
straps.
Using a suitable transmission jack support the
transaxle.
11. Remove and discard the engine rear mount

center retaining nut.
12. Remove the engine rear mount retaining nuts.
13. Remove the air cleaner bracket.

Detach the transaxle breather tube from
the bracket.


17. Disconnect the anti-lock braking system (ABS)

module electrical connector.
1. Release the retainer.

NOTE: Make a note of the position of the
brake tubes, to aid installation.

Disconnect the brake tubes from the hydraulic
control unit (HCU).
19. Remove the booster heater (if equipped). For

Heating and Ventilation / 412-02B Auxiliary
Heating.
20. Detach the brake tubes from the bulkhead.
Left-hand drive vehicles

Remove the master cylinder to HCU brake tubes.
All vehicles
22. Detach the HCU and ABS module assembly from
the support bracket.
23. Remove the HCU to ABS module retaining bolts.

24. Remove the HCU.
Installation
1. NOTE: Install a new engine rear mount

Anti-Lock Control - Rear Wheel Speed
Sensor
Print
Removal
All vehicles
Tires.
3. Detach the wheel speed sensor wiring harness
from the wheel knuckle and floor panel.
2. Detach the clips.

Brake.
All vehicles
5. NOTE: The wheel speed sensor wiring
harness is routed through the wheel knuckle.
Detach the wheel spindle and wheel hub
assembly from the wheel knuckle.
6. Remove the wheel speed sensor.
Installation
1. CAUTIONS:
Do not damage the wheel speed sensor

wiring harness or electrical connector.

Make sure that the wheel speed sensor
housing is free from contamination and
moisture.

Anti-Lock Control - Rear Wheel Speed
Sensor Ring
Print
Removal
1. Remove the rear hub. For additional information,
refer to Section 204-02 Rear Suspension.

2. Remove the wheel and tire assembly. For
Wheels and Tires.
3. NOTE: If the dust cap is damaged on
removal a new dust cap must be used on
installation.
Remove the dust cap.

1. Remove the hub retaining nut.
All vehicles
6. Remove the wheel speed sensor ring (drum
brake shown, disc brake similar).
Discard the wheel speed sensor ring.
Installation
All vehicles
1. CAUTIONS:
Make sure the wheel speed sensor ring is

not knocked, damaged and keep free from

metal fragments.
Protect the face of the wheel speed

sensor ring with a suitable non-ferrous flat
block to prevent damage.
Make sure the brake drum is adequately

supported and do not allow it to rest on the
wheel studs.
Make sure the wheel speed sensor ring is

pressed on slowly and squarely until fully
seated.
Do not exceed a maximum load of 10

kn.
Using a suitable hydraulic press install a new
wheel speed sensor ring.

2. Install the rear wheel hub. For additional
information, refer to Section 204-02 Rear
Suspension.
3. CAUTION: Rotate the drum in the

opposite direction when tightening the hub
nut to prevent damage to the bearing.
Install the brake drum.
4. Install the dust cap.
5. Install the wheel and tire assembly. For

Wheels and Tires.

Anti-Lock Control - Anti-Lock Brake
System (ABS) Module
Print

General Equipment
Transmission jack
Securing straps
Removal
All vehicles


container.
reservoir.


cleaner bracket.

the transaxle.
straps.
Using a suitable transmission jack, support the
transaxle.


the bracket.





control unit (HCU).
19. Remove the booster heater (if equipped). For

Heating and Ventilation / 412-02B Auxiliary
Heating.

All vehicles
23. Remove the ABS module to HCU retaining

screws.

24. Remove the ABS module.
Installation

Anti-Lock Control - Traction Control -
Specifications
Print
Specifications

Hydraulic control unit (HCU) support bracket retaining bolts 25 18 -
HCU retaining bolts 9 - 80
HCU to anti-lock brake system (ABS) module retaining bolts 2 - 18

Anti-Lock Control - Traction Control
Print
General
The MK 25- Anti-lock Brake System (ABS) is a further development of the MK 20- ABS.
The MK 25 ABS performs the following control functions:

Anti-lock control
Traction Control System (TCS)
Electronic Brake Distribution
This further development is a compact smaller design and weighs less.
The new MK 25- ABS complies in all functions with the MK 20- ABS:
Anti-lock control prevents the wheels from locking during braking and therefore the
keeps the vehicle stabile (can be steered and kept on track).
TCS prevents the driven wheels from spinning if too much power is applied.
Electronic brake distribution ensures optimum distribution of the braking force between
the front and rear wheels.
The MK 25- ABS differs from the MK 20- ABS in having a faster response, an improved
software, a revised connector and a new board.
The MK 25- ABS can be delivered with a variety of operating features, depending on the
system requirements of the manufacturer.
At present it will only be installed with ABS and TCS.
Overview

1 - Integral MK 25- ABS -control unit
2 - Data Link Connector (DLC)
3 - Active wheel sensors
-

-
4 Ignition lock
5 - Stoplamp switch
6 - Valve block
7 - Pump motor
8 - Warning lamp ABS
9 - Warning lamp TCS
10 - Braking system warning lamp (warning lamp for electronic brake
distribution)
Function
Solenoid valves in the hydraulic control unit
Item Part Number Description

1 - Separation valves and changeover valves
2 - Outlet solenoid valves
3 - Inlet solenoid valves
The hydraulic control unit comprises the valve block with the electric motor (pump).
Each having one inlet and outlet valve, the brake pressure is modulated for each individual
wheel brake.
These is also one separation valve and one changeover valve for each brake circuit, in order
to allow braking intervention for the driven wheels during traction control (brake pressure is
created without the driver operating the brakes).
The relay (semiconductor relay) for system changeover and for the pump motor, and also
the relay (semiconductor relay) for the solenoid valves are integrated in the electronic
control unit as electronic components.
The pump motor and the electronic controller with the relays as drivers are bolted directly
to the hydraulic control unit.
Inlet and outlet solenoid valve pairs for one wheel brake
On vehicles with ABS if the electronic control unit detects a rapid decrease in the speed of
revolution of a wheel, which is characteristic when a wheel locks (the wheel deceleration is
greater than the maximum possible wheel deceleration), it outputs the corresponding
signals for brake pressure modulation to the valves.

This modulation is carried out by each of two solenoid valves, the inlet valve (open when no
current is applied), and the outlet valve (closed when no current is applied).
All controlled brake circuits are equipped with two such valves.
Electronic control unit
The coils integrated in the control unit housing are connected directly to the solenoid valves
during assembly.
The connector plug for the pump motor is not visible from the outside, instead it is passed
through the aluminium block and joined directly to the motor.
On the printed circuit board of the electronic control unit there is a 32 bit microcontroller,
an input/output driver with fixed voltage regulator and two semiconductor relays as drivers
for the valves and the pump motor.
The reliability is increased by the extreme integration and the very small number of chips.
The microcontroller prepares the signals of the wheel sensors and of the brake light switch
and then processes the wheel speed information and control algorithms.
The connection to the vehicle electronics is made through just one wiring harness
connector.
The MK 25- ABS control unit can be diagnosed using WDS.
Schematic diagram of the MK 25 ABS control unit

1 - Pump motor
2 - Valve block
3 - Separation valves, changeover valves, outlet valves and inlet valves
distribution)
7 - Input/output driver
-

8 Microcontroller
9 - Stoplamp switch
11 - Pump motor semiconductor relay
12 - Valve semiconductor relay
13 - Fixed voltage regulator
Block circuit diagram

distribution)
4 - Stoplamp switch
5 - Electronic control unit (MK 25 ABS control unit)
6 - Pump motor
7 - Separation valves, changeover valves, outlet valves and inlet valves
8 - Ground
9 - DLC
11 - Power supply
Warning lamps in the instrument cluster

Warning lamp ABS

The warning lamp ABS illuminates:
after the ignition is switched on until the end of the self-test
continuously, if the MK 25 ABS control unit has detected a fault in the anti-locking
control.
Warning lamp TCS
The warning lamp TCS illuminates:

continuously, if the MK 25 ABS control unit has detected a fault in the traction control.
Braking system warning lamp (warning lamp for electronic brake distribution)
The braking system warning lamp (warning lamp for electronic brake distribution)
illuminates:
continuously, if the MK 25 ABS control unit has detected a fault in the electronic brake
distribution,
continuously, if the handbrake is applied,
continuously if the brake fluid level is too low.

Anti-Lock Control - Traction Control
Print
REFER to Section 206-09A Anti-Lock Control / 206-09B Anti-Lock Control - Traction

Control / 206-09C Anti-Lock Control - Stability Assist.

Anti-Lock Control - Traction Control - Rear
Wheel Speed Sensor
Print
Removal
1. For additional information, refer to Section 206-
09A Anti-Lock Control / 206-09B Anti-Lock
Control - Traction Control / 206-09C Anti-Lock
Control - Stability Assist.

Anti-Lock Control - Stability Assist - Anti-
Lock Control - Stability Assist - System Transit/Tourneo Connect 2002.5 (06/2002-)
Operation and Component Description
Print
Control Diagram
Item Description
1 Brake Booster.
2 Primary hydraulic circuit
3 Secondary hydraulic circuit
4 Pulsation damper
5 Pulsation damper
6 HCU.
7 Damping chamber
8 Dual circuit hydraulic pump
9 D.C. motor
10 Solenoid-operated pilot valve (2 off)
11 Solenoid-operated priming valve (2 off)

12 One-way check valve
13 Low-pressure accumulator (2 off)
14 Solenoid-operated inlet valve (RH rear brake)
15 Solenoid-operated inlet valve (LH front brake)
16 Solenoid-operated outlet valve (LH front brake)
17 Solenoid-operated outlet valve (RH rear brake)
18 Pressure sensor (5 off)
19 LH front brake (secondary circuit)
20 RH rear brake (secondary circuit)
21 LH rear brake (primary circuit)
22 RH front brake (primary circuit)
23 Solenoid-operated outlet valve (RH front brake)
24 Solenoid-operated outlet valve (LH rear brake)
25 Solenoid-operated inlet valve (LH rear brake)
26 Solenoid-operated inlet valve (RH front brake)
System Operation
The HCU features 3 operating modes:
Normal braking: Initially, no current is supplied to any of the solenoid-operated valves.
Operating the brake pedal produces a corresponding increase or decrease of pressure in the
brakes, through the open pilot valves and inlet valves. If the ABS module determines that
EBD is necessary, it energizes the inlet valves for both the rear brakes, to isolate the brakes
from any further increase in hydraulic pressure.
ABS braking:If the ABS module determines that ABS braking is necessary, it actuates the
inlet and outlet valves of the relevant brake and starts the hydraulic return pump. The inlet
valve closes to isolate the brake from pressurized fluid; the outlet valve opens to release
pressure from the brake into the accumulator, and the return pump circuit. The brake
releases slightly and the wheel starts to turn again. The ABS control unit then operates the
inlet and outlet valves to regulate the hydraulic pressure acting on the brake in order to
maximize braking effect without the wheel locking up. Control of the valves for each wheel
takes place individually.
Active braking: With active braking, pressure is generated for other braking functions than
the normal and ABS braking systems, e.g. for the ESP and TCS systems. For active braking,
the ABS module energizes the pilot valves and priming valves, starts the return pump and
energizes all of the inlet valves. Brake fluid, drawn from the reservoir through the master
cylinder and priming valve, is pressurized by the return pump and supplied to the inlet
valves. The ABS control unit then actuates the inlet and outlet valves in order to regulate
the pressure for the individual brakes. Some noise may be generated during active braking.
Principles of Operation

Item Description
1 Battery.
2 Battery junction box (BJB) in the engine compartment
3 Generic electronic module (GEM)
4 Powertrain Control Module (PCM)
5 Instrument Cluster
6 Data link connector (DLC)
7 Steering Wheel Rotation Sensor
8 ABS/ESP module or hydraulic control unit (HCU)
9 Combined yaw rate sensor and lateral acceleration sensor / longitudinal acceleration
sensor
10 Front wheel sensor

11 Rear wheel sensor
12 Rear wheel sensor
13 Front wheel sensor
14 ESP switch
15 Rear brakes
16 Front brake
The ABS monitors the different wheel speeds of the vehicle with the aid of wheel speed
sensors. Using the data from all of the wheel speed sensors, the ABS module calculates the
so-called reference speed, which is a measure of the actual road speed. The ABS module
compares the individual circumferential wheel speeds with this reference speed when the
driver initiates braking. If one or more of the circumferential wheel speeds deviates too far
from the reference speed, this means that slip at the affected wheels is so great that
steering stability of the vehicle is no longer ensured. The ABS module actuates electro-
mechanical valves which influence the brake pressure at the relevant wheels.
Like the traction control system (TCS), the ESP system uses a large proportion of the ABS
components. In addition, there are sensors which pick up the steering angle, the
acceleration forces acting on the vehicle and the yaw rate or yaw moment. The sensors
transmit these signals to the combined ABS/ESP module. Using the wheel speed and
steering angle data, the ABS/ESP module calculates the direction of travel planned by the
driver and determines the corresponding speed-dependent lateral acceleration and yaw
moment. These values are compared with those actual measured. If the actual lateral
acceleration and the yaw moment deviate excessively from the target values (unstable
driving characteristics), the ABS/ESP module actuates individual brakes selectively via the
HCU (hydraulic control unit). In addition, the engine speed is reduced by intervention in the
engine management system.
How the system works for understeer: In the event of understeer, brake intervention
occurs at the wheels on the inside of the curve. The rear wheel is braked heavily, so that a
high amount of slip is caused. In this way, the cornering force of the rear axle is heavily
reduced and the centrifugal force that now becomes effective turns the rear of the vehicle
back into the curve. The front wheel is not braked as hard. The braking force that is
transmitted via the front wheel to the road surface generates a torque with the aid of the
lever arm (vertical tire force to the vehicle's centre of gravity), which supports the yaw
moment of the vehicle. Both measures together result in the vehicle reverting back to the
curved path intended by the driver.
How the system works for oversteer: In the event of oversteer the wheels on the
outside of the curve are braked. This time, the front wheel is subjected to a high level of
slip so that the cornering force at the front axle is reduced. The rear wheel is not braked as
heavily and, together with the effective lever arm, results in a reduction in the vehicle yaw
moment. Both measures together result in the vehicle being stabilized and reverting back to
the curved path intended by the driver.
If ESP control occurs, possible ABS interventions will be overridden as the ESP works at
higher slip rates than the ABS.
Emergency brake assist (EBA): The emergency brake assist helps drivers in emergency
braking situations by automatically applying the brakes with the maximum possible braking
force.
If the brake pedal is pressed very suddenly, the ABS module increases the hydraulic
pressure to all of the brakes until the threshold for ABS intervention is reached. This action
applies the maximum braking effort for the available traction. The ABS control unit monitors
inputs from the brake pedal switch and from the pressure sensor within the HCU to check
for sudden actuation of the brakes. With the brake pedal pressed, the ABS module triggers
emergency braking if the rate of increase of hydraulic pressure exceeds the predetermined
limit.

If the brake pedal is pressed so hard that the ABS becomes active on the front wheels then
the ABS control unit increases the pressure to the rear wheel brakes up to the ABS
intervention threshold.
EBA operation continues until the driver releases the brake pedal sufficiently for the
hydraulic pressure in the HCU to drop below a threshold value stored in the ABS module.
Trailer stability control: If the vehicle is ordered with a trailer coupling then the Trailer
Stability Control function is integrated in the ESP. The ESP detects snaking when driving
with a trailer and reduces the speed of the vehicle and trailer through adapted braking and,
if necessary, by also reducing the engine output until the snaking movement of the trailer is
corrected.
Emergency brake light:The emergency brake light automatically switches on the hazard
flasher system to warn drivers of other vehicles that emergency braking is being initiated.
Based on a defined delay value, the ABS/ESP module sends a signal to the generic
electronic module (GEM) via the CAN data bus. The GEM activates the hazard flasher
system, that then flashes 7 times.
Prerequisites for activation of the emergency brake light are:

The speed is higher than 50 km/h.
The brake pedal is being actuated.
The deceleration is greater than 9 m/s².
To prevent activation on snow or ice, for example, the following prerequisites must be
met:
The speed is higher than 50 km/h.
The brake pedal is being actuated.
ABS regulation takes place.
The deceleration is greater than 6 m/s².
Component Description
Opto-electronic steering wheel rotation sensor
The opto-electronic steering wheel rotation sensors use light barriers for contactless
scanning of a segment disk which is connected fixedly to the steering shaft.

Item Description
1 Segment disk
2 Photoelectric barrier
3 Electronics
4 Electrical connection
Use is made of opto-electronic types of sensors with relative and absolute steering angle
sensing. For relative steering angle sensing, changes in the steering angle are measured
exclusively by the sensor and transmitted to the ABS/ESP module. With the aid of other
vehicle status signals (e.g. wheel speed sensors) the module calculates the straight ahead
position of the steering. For absolute steering angle sensing, the sensor transmits a specific
signal to the module for each steering angle position (in relation to one turn of the steering
wheel). The straight ahead position of the steering is therefore defined in the sensor. On an
absolute steering angle sensor, several photoelectric barrier modules are distributed around
the segment disk at varying distances. The gaps between segments of the segment disk are
also unequal. For each specific steering angle there is therefore a specific switch status of
all photoelectric barriers.
ABS/ESP module or hydraulic control unit (HCU)
Item Description
1 ABS Pump Motor
2 Valve block (with low-pressure accumulators)
3 ABS/ESP module

The HCU comprises the ABS/ESP module, the valve block (with low-pressure accumulators)
and the ABS pump.
The valve block combines all of the brake pressure control valves in one unit. Depending on
the system, either simple changeover valves or proportioning valves (e.g. on EBD
(electronic brake force distribution) systems) are installed. The low-pressure accumulators
store the brake fluid that is returned from the wheel brakes during the pressure reduction
phase until it is drawn back into the system by the ABS pump.
The ABS pump is designed as a dual piston pump. This means that two separate pump
elements assure an increase in brake pressure during control interventions. A direct current
motor drives the pump pistons via an eccentric shaft.
The ABS/ESP module monitors the input signals of all sensors and actuates the electro-
magnetic brake pressure valves and the ABS pump as required. For reasons of safety, the
module is of the redundant type, whereby processing of the signals is carried out via two
separate processors that also monitor each other.
Combined yaw rate sensor and lateral acceleration sensor
The heart of the combined yaw rate sensor and lateral acceleration sensor is a small,
double-sided tuning fork made of a piezo crystal (A). The exciter side of this tuning fork is
set to a resonance of 11 kHz with the aid of an alternating current. The measuring side of
the tuning fork features a resonance frequency of 11.33 kHz and therefore does not vibrate
(B). Since, under influence of an external accelerating force, a vibrating mass reacts slower
than a comparable mass that is not vibrating, the tuning fork twists within itself with
rotational movement being imparted on the sensor (C). This rotation results in a change in
the charge distribution in the Piezo element, which is subsequently picked up and converted
into an electronic signal by electronics integrated into the sensor. This electronic signal is
then sent to the ESP module. The ESP module evaluates these data and takes into account
the other input data (vehicle speed, wheel speed) before deciding whether the ESP function
is required.
Item Description
1 Tuning fork exciter

2 Suspension
3 Measuring side
Due to the special way in which it works. the combined yaw rate sensor and lateral
acceleration sensor must be installed the right way up in the designated location specified
by the manufacturer. Any slight deviation in the installation position and/or installation
location could lead to impaired functionality and thereby possible failure of the stability
assist.
Front wheel sensor
Active sensors are used to determine the rotational speeds of the wheels at the hub. After
the ignition is switched on, the ABS module supplies the sensors with power. The sensors
work in accordance with the Hall effect principle and generate a square wave output signal.
The signal acts in proportion to the rotational speed of the sensor ring. The ABS sensor
rings are built into the seals in the front wheel bearings. The ABS/ESP module evaluates the
signals from all four sensors to calculate a vehicle speed signal based on the rotational
speeds of all wheels. The road speed is transmitted on the CAN bus. The powertrain control
module (PCM) uses this signal and the programmed tire size to calculate the vehicle speed.
The calculated vehicle speed is forwarded on the CAN bus and is requested by other control
units that need this input information.
Rear wheel sensor
The sensors are joined to the main wiring harness using a separate connecting cable.

Anti-Lock Control - Stability Assist -
Hydraulic Control Unit (HCU)
Print

General Equipment
Transmission jack
Securing straps
Removal
All vehicles


container.
reservoir.
6. Remove the battery tray.
For additional information, refer to: Battery Tray
(414-01 Battery, Mounting and Cables, Removal
and Installation).


cleaner bracket.

the transaxle.
straps.
transaxle.


the bracket.


17. Remove the booster heater (if equipped).

For additional information, refer to: Booster
Heater (412-02B Auxiliary Heating, Removal and
Installation).

Vehicles built up to 08/2006

control unit (HCU).

NOTE: Left-hand drive vehicles only.

23. Remove the HCU to ABS module retaining bolts.

24. Remove the HCU.
Vehicles built 08/2006 onwards


control unit (HCU).

NOTE: Left-hand drive vehicles only.
Remove the master cylinder to HCU brake tubes
(left-hand drive vehicles only).
28. Remove the HCU and ABS module assembly and



Installation
information, refer to: (206-00 Brake System -
General Information)
Brake System Bleeding (General
Procedures),
Brake System Pressure Bleeding (General
Procedures).

Anti-Lock Control - Stability Assist - Yaw
Rate Sensor
Print
Removal
1. Refer to: Floor Console (501-12 Instrument Panel
and Console, Removal and Installation).
Refer to: Floor Console - Vehicles Built From:
04/2009 (501-12 Instrument Panel and Console,
2. Torque: 9 Nm
Installation

Anti-Lock Control - Stability Assist -
Steering Wheel Rotation Sensor
Print
Removal
1. Refer to: Clockspring - Vehicles Built From:

04/2009 (501-20B Supplemental Restraint
System, Removal and Installation).
Installation

Steering System - General Information -
Specifications
Print
Specifications
Power steering fluid WSA-M2C195-A
Turning Circle
Meters
Wall to wall
Short wheelbase 10.68
Long wheelbase 11.55
Steering Wheel Alignment
Degrees
Maximum allowable steering wheel mis-alignment ± 3.00

Steering System
Print
Tire pressure(s) Power steering pressure (PSP) switch
Accessory drive belt
Wheels and tires
Power steering line fluid leaks
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.
Symptom Chart

Steering is very * Loose or worn * CHECK the accessory drive belt. REFER to
difficult/very easy accessory drive belt. Section 303-05 Accessory Drive.
* Power steering hose * CHECK the power steering hoses for
restriction. damage, kinks or restrictions. INSTALL new
components as necessary. REFER to
Section 211-02 Power Steering.
* Fluid contamination. * FLUSH the power steering system.
REFER to Power Steering System Flushing /
Power Steering System Flushing in this

section.
* Fluid aeration. * BLEED the power steering system. REFER
to Power Steering System Bleeding in this
section.
* Seized suspension ball * CARRY OUT the suspension ball joint
joints. component test. REFER to Section 204-00
Suspension System - General Information.
* Worn steering gear. * INSTALL a new steering gear. REFER to
Section 211-02 Power Steering.
* Worn steering column. * CARRY OUT the steering linkage
component test. REFER to Steering Linkage
Component Test.
* Worn power steering * INSTALL a new power steering pump.
pump. REFER to Section 211-02 Power Steering.
Steering does not * Worn tie-rod ends. * CHECK and INSTALL new components as
vary with increased necessary. REFER to Section 211-03
wheel rotation Steering Linkage.
* Worn front suspension * CHECK and INSTALL new components as
bushings. necessary. REFER to Section 204-01 Front
Suspension.

* Worn suspension ball
* CARRY OUT the suspension ball joint
joints. inspection component test. REFER to
Section 204-00 Suspension System -
General Information.
* Worn strut and spring * INSTALL a new strut and spring assembly
assembly top mount. top mount. REFER to Section 204-01 Front
Suspension.
* Steering gear insulator * CHECK and INSTALL new components as
bushings worn or necessary. REFER to Section 211-02
perished. Power Steering.
* Loose steering gear * CHECK and INSTALL new bolts as
retaining bolts. necessary. REFER to Section 211-02
Power Steering.
* Loose steering column * CHECK and INSTALL new bolts as
retaining bolts. necessary. REFER to Section 211-04
Steering Column.
* Loose steering column * CHECK and INSTALL a new bolt as
to steering gear pinion necessary. REFER to Section 211-04
retaining bolt. Steering Column.
* Excessive steering gear * INSTALL a new steering gear. REFER to
backlash. Section 211-02 Power Steering.
Steering assist does * Power steering * For additional information, refer to the
not vary with vehicle pressure (PSP) switch. Wiring Diagram.
speed * Circuit.
Components Tests
Steering Linkage
Inspect the steering gear boots for cuts, deterioration, twisting or distortion. Make sure the
boots are secure. Install new boots or clamps as necessary.
1. 1. Park the vehicle on a dry, even surface and apply the parking brake. Place the
steering in the straight-ahead position.
2. 2. With the engine running, gently turn the steering wheel to the right and left to
check free play. Free play is measured at the steering wheel rim and should be
within the limits stated in the specifications. If free play exceeds the limit stated the
steering linkage or the steering column is worn, or the backlash of the steering gear
is excessive.
3. 3. With the engine OFF, hold the steering wheel firmly with both hands. Attempt to
move the steering wheel up and down and also to the left and right without turning
the wheel, to check the steering column bearing wear, steering column shaft joint
play and steering wheel or steering column looseness. If free play is detected, check
the correct torque of the steering column, coupling shaft and steering wheel
retaining bolts. The steering column cannot be repaired, install a new steering
column. REFER to Section 211-04 Steering Column.
4. 4. If the steering linkage is worn, install new components as necessary. REFER to

Section 211-03 Steering Linkage. The steering column cannot be repaired, install a
new steering column. REFER to Section 211-04 Steering Column. Steering gear
backlash cannot be adjusted, install a new steering gear. REFER to Section 211-02
Power Steering.

Steering Gear Checks After a Collision
Print

General Equipment
Feeler gauge
Straight edge
Items to be observed when checking the steering system
The following list of steering gear conditions and the methods of testing should be taken
into account when carrying out checks to the steering system:
If the steering gear has no faults after completing the following checks, do not install a
new steering gear.
Surface corrosion and marks on the tie-rod are acceptable.
When checking for turning effort torque peaks in the steering gear, turn the steering
wheel from steering lock stop to steering lock stop in approximately 15 seconds.
A steady increase of turning effort torque from steering center to steering lock stop is
acceptable.
When checking for power steering fluid leaks, turn the steering wheel to the steering lock
stop in approximately 10 seconds.
Noises from the power steering, for example the power steering pump relief valve, are
acceptable.
STEERING GEAR HOUSING

Raise and support the vehicle.
REFER to: Lifting (100-02 Jacking and Lifting, Description and Operation).
Visually inspect the steering gear housing for cracks and damage. If the steering gear
housing is cracked or damaged, install a new steering gear.
REFER to: Steering Gear (211-02 Power Steering, Removal and Installation).
TIE-RODS
Using a straight edge and feeler gauge, check the tie-rods to see if they are straight. If
the distance between the tie-rod and straight edge is greater than 0.5 mm, install a new
steering gear.
Check the tightening torque of the tie-rod end to wheel knuckle nut.
REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).
Check the tightening torque of the tie-rod end locking nut.
REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).
CHECK FOR TURNING EFFORT TORQUE PEAKS IN THE STEERING GEAR

Lower and support the vehicle making sure that the road wheels are just clear of the
floor.
With the ignition switch in position I, slowly turn the steering wheel from steering lock
stop to steering lock stop. If a turning effort torque peak or judder is felt while turning
the steering wheel, detach the tie-rods from the wheel knuckles.
Slowly turn the steering wheel from steering lock stop to steering lock stop. If a turning
effort torque peak or judder is felt while turning the steering wheel, install a new steering
gear.
CHECK FOR POWER STEERING FLUID LEAKS

Lower the vehicle.
Run the engine at a fast idle and slowly turn the steering wheel to the left-hand steering
lock stop. Hold the steering wheel in this position for 5 seconds with a turning effort

torque of 15 Nm at the steering wheel rim.
Turn the steering wheel away from the left-hand steering lock stop for 30 seconds.
Run the engine at a fast idle and slowly turn the steering wheel to the right-hand
steering lock stop. Hold the steering wheel in this position for 5 seconds with a turning
effort torque of 15 Nm at the steering wheel rim.
Turn the steering wheel away from the right-hand steering lock stop.
Check for power steering fluid leaks at the steering gear housing and the power steering
line connections to the steering gear. If there is a power steering fluid leak at the
steering gear, install a new steering gear.

Power Steering System Flushing—1.8L Transit/Tourneo Connect 2002.5 (06/2002-)
Duratec-DOHC (85kW/115PS) - Zetec
Print
General Procedures
Special Tool(s)
Socket, Spark Plug
303-499 (21-202)
Materials
Name Specification
Power Steering Fluid WSA-M2C-195-A
Lifting.
2. Disconnect the crankshaft position (CKP) sensor
3. Lower the vehicle until the wheels are clear of

the floor to allow the steering wheel to be
rotated from lock to lock.
wheelhouse assembly and position to one side.
1. Remove the bolt.
5. Detach the power steering fluid reservoir from

the wheelhouse assembly.
6. NOTE: Using a suitable blanking cap, cap the

power steering fluid reservoir.
Disconnect the power steering fluid cooler return
line from the power steering fluid reservoir.

Allow the fluid to drain into a suitable
container.
7. Place the end of the power steering fluid cooler

return line into a suitable container.
8. Disconnect the spark plug wires.
9. Using the special tool remove the spark plugs.
10. NOTE: When filling the power steering fluid

reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The
fluid should be poured slowly into the
reservoir to minimize the possibility of
aeration. The fluid level should be checked
with the fluid cold.
Fill the power steering fluid reservoir to the MAX
mark with clean Power Steering Fluid.
11. CAUTION: Do not continuously crank the

engine for more than 30 seconds, as damage
to the starter motor may result.
NOTE: When flushing the power steering
system, make sure that the power steering
fluid in the reservoir does not fall below the
minimum mark.
While cranking the engine for no more than 30
seconds turn the steering from lock to lock.
With the aid of another technician add 1
liter of clean Power Steering Fluid.
12. Wait 60 seconds to allow the starter motor to
cool.

minimum mark.
While cranking the engine for a further 30
With the aid of another technician add a
further 1 liter of clean Power Steering
Fluid.
14. When all the fluid has been used, turn the
ignition switch to the OFF position.
15. Using the special tool install the spark plugs.
16. Connect the spark plug wires.
17. Remove the blanking cap from the power

steering fluid reservoir and connect the power
steering fluid cooler return line.
18. Attach the power steering fluid reservoir to the

19. Attach the coolant expansion tank to the

1. Attach the coolant expansion tank.
2. Install the bolt.

Lifting.
21. Connect the CKP sensor electrical connector.

23. Fill and bleed the power steering system.
For additional information, refer to Power
Steering System Bleeding in this section.

Power Steering System Flushing—1.8L
Duratorq-TDCi (Lynx) Diesel/1.8L
Duratorq-TDDi (Lynx) Diesel
Print
General Procedures
Materials
Name Specification
Power Steering Fluid WSA-M2C-195-A
All vehicles
wheelhouse assembly and position to one side.
1. Remove the bolt.
2. Detach the coolant expansion tank

3. NOTE: Using a suitable blanking cap, cap the

Disconnect the power steering fluid cooler return
container.
4. Place the end of the power steering fluid cooler

return line into a suitable container.
5. CAUTION: Isolate the glow plugs to

prevent damage to the glow plug electrical
connectors.
Remove the glow plug relay fuse from the
Battery Junction Box (BJB).
6. Detach the oil level indicator tube from the

engine.
7. Disconnect the positive crankcase ventilation

(PCV) hose from the valve cover and position to
one side.
Vehicles without common rail fuel injection

8. Disconnect the glow plug electrical connectors.
9. Remove the glow plugs.
10. Disconnect the fuel injection pump electrical

connector.
1. Pull out the locking handle.
Vehicles with common rail fuel injection

11. Disconnect the glow plug electrical connectors.

13. Disconnect the fuel injector electrical connectors.
All vehicles
14. NOTE: The vehicle must be raised until the
wheels are clear of the floor to allow the
steering wheel to be rotated from lock to
lock.
Raise and support the vehicle. For additional
Lifting.
reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The
fluid should be poured slowly into the
reservoir to minimize the possibility of
aeration. The fluid level should be checked
with the fluid cold.
mark with clean Power Steering Fluid .

minimum mark.

With the aid of another technician add 1
liter of clean Power Steering Fluid .
17. Wait 60 seconds for the starter motor to cool.

minimum mark.
With the aid of another technician add a
further 1 liter of clean Power Steering
Fluid .
19. When all the fluid has been used, turn the
ignition switch to the OFF position.
21. Remove the blanking cap from the power
steering fluid reservoir and connect the power
steering fluid cooler return line.

23. Attach the coolant expansion tank to the

1. Attach the coolant expansion tank.

24. Connect the fuel injection pump electrical
connector.

1. Connect the electrical connector.
2. Push in the locking handle.
25. Install the glow plugs.
26. Connect the glow plug electrical connectors.

28. Connect the glow plug electrical connectors.
29. Connect the fuel injector electrical connectors.

All vehicles
30. Connect the PCV hose to the valve cover.
31. Attach the oil level indicator tube to the engine.
32. Install the glow plug relay fuse.

For additional information, refer to Power
Steering System Bleeding in this section.

Power Steering System Bleeding
Print
General Procedures
Special Tool(s)
Adapter, Power Steering Bleeding
211-189 (13-016)
Hand Vacuum Pump/Pressure Pump

416-D001 (23-036A)
Bleeding
reservoir, make sure that the power steering
fluid is clean and not agitated prior to use.
The power steering fluid should be poured
slowly into the reservoir to minimize the
possibility of aeration. The power steering
fluid level should be checked with the power
steering fluid cold.
mark with the appropriate power steering fluid.
Specifications (211-00 Steering System - General
Information, Specifications).
2. Raise and support the vehicle making sure that
the road wheels are just clear of the floor. For
additional information, refer to: (100-02 Jacking
and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
3. NOTE: Do not start the engine at this stage.
NOTE: Make sure that the power steering
fluid in the power steering fluid reservoir
does not fall below the MIN mark, as air
could enter the system.
Slowly turn the steering wheel from lock to lock
and add power steering fluid until the power
steering fluid in the power steering fluid reservoir
stops dropping.
4. Check the power steering fluid level. Fill the
power steering fluid reservoir to the MAX mark
with the appropriate power steering fluid.
5. NOTE: When bleeding the power steering
system the vacuum will decrease. Using the
special tools, maintain a sufficient vacuum of
38cm-Hg. If the vacuum decreases by more
than 5cm-Hg in 5 minutes, the system
should be checked for leaks.
Using the special tools, bleed the power steering

system in the following sequence.
1. Slowly turn the steering wheel from lock to
lock once; then turn the steering wheel to
the right, just off the stop.
2. Using the special tools, create a vacuum of
38cm-Hg. Maintain the vacuum until the
air is evacuated from the system
(minimum of five minutes).
3. Release the vacuum.
4. Repeat the power steering bleeding
procedure, turning the steering wheel to
the left, just off the stop.
6. Remove the special tools. Fill the power steering
fluid reservoir to the MAX mark with the
appropriate power steering fluid as necessary.
7. NOTE: Make sure that the power steering
Start the engine and slowly turn the steering
wheel from lock to lock and add power steering
fluid until the power steering fluid in the power
steering fluid reservoir does not drop.
8. Switch OFF the engine and examine the power
steering hose connections, steering gear boots,
power steering valve body and power steering
pump for external leaks.
9. Check the power steering fluid level. Fill the
power steering fluid reservoir to the MAX mark
with the appropriate power steering fluid.
10. NOTE: When bleeding the power steering
system the vacuum will decrease. Using the
special tools, maintain a sufficient vacuum of
38cm-Hg. If the vacuum decreases by more
than 5cm-Hg in 5 minutes, the system
should be checked for leaks.
Using the special tools, bleed the power steering
system in the following sequence.
1. Start the engine and slowly turn the
steering wheel from lock to lock once;
then turn the steering wheel to the right,
just off the stop.
2. Switch OFF the engine.
3. Using the special tools, create a vacuum of
38cm-Hg. Maintain the vacuum until the
air is evacuated from the system
(minimum of five minutes).
4. Release the vacuum.
5. Repeat the power steering bleeding
procedure, turning the steering wheel to
the left, just off the stop.

12. Start the engine, turn the steering wheel from
lock to lock. If excessive noise is apparent,
repeat the power steering bleeding procedure.
14. If the noise level is still unacceptable, leave the
vehicle standing overnight then repeat the power
steering system bleeding procedure.

Power Steering System Filling
Print
General Procedures
Special Tool(s)
Adapter, Power Steering Bleeding
211-189 (13-016)
Hand Vacuum Pump/Pressure Pump

416-D001 (23-036A)
Refill
reservoir, make sure that the power steering
fluid is clean and not agitated prior to use.
The power steering fluid should be poured
slowly into the reservoir to minimize the
possibility of aeration. The power steering
fluid level should be checked with the power
steering fluid cold.
mark with the appropriate power steering fluid.
2. Raise and support the vehicle making sure that
the road wheels are just clear of the floor. For
additional information, refer to: (100-02 Jacking
and Lifting)
3. NOTE: Do not start the engine at this stage.
NOTE: Make sure that the power steering
Slowly turn the steering wheel from lock to lock
and add power steering fluid until the power
steering fluid in the power steering fluid reservoir
stops dropping.
4. NOTE: Make sure that the power steering
Start the engine and slowly turn the steering
wheel from lock to lock and add power steering
fluid until the power steering fluid in the power
steering fluid reservoir stops dropping.
5. Switch the engine OFF and using the special
tools, create a vacuum of 62cm-Hg - 75cm-Hg
for 30 seconds.

6. Observe the vacuum gauge reading.
If the vacuum decreases by more than
5cm-Hg in 5 minutes, the system should
be checked for leaks.

Power Steering - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Item Specifications
Power steering fluid WSA-M2C195-A
lb- lb-
Item Nm ft in
Steering gear mounting bolts 80 59 -
Power steering line to steering gear valve body retaining bolt 18 13 -
Power steering line to cylinder head support bracket retaining nuts - vehicles with 23 17 -
1.8L Zetec engine
Power steering line to power steering pump union – vehicles with 1.8L Zetec 22 16 -
engine
Power Steering pump retaining bolts – vehicles with 1.8L Zetec engine 23 17 -
Power steering line to transmission housing retaining bolt. 22 16 -
Power steering line to valve cover retaining nut – vehicles with 1.8L Zetec engine 9 - 80
Power steering line to cylinder head retaining nut – vehicles with 1.8L Zetec 23 17 -
engine
Power steering line to crankcase breather assembly - vehicles with 1.8L diesel 22 16 -
engine
Power steering line to power steering pump union vehicles with 1.8L diesel 22 16 -
engine.
Power steering pump retaining bolts - vehicles with 1.8L diesel engine. 23 17 -
Steering column shaft to steering gear pinion extension retaining bolt 28 21 -
Steering gear pinion extension to steering gear pinion retaining bolt 28 21 -
Connecting link to stabilizer bar retaining nut 50 37 -
Front crossmember rear retaining bolts 200 148 -
Front crossmember front retaining bolts 125 92 -
Engine support insulator center retaining bolt. 50 37 -

Power Steering - Power Steering Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Power steering
All vehicle variants are equipped with power steering. The location of the power steering
pump and the route of the corresponding lines vary depending on the engine
(petrol/diesel).
There is a power steering fluid cooler located in the line between the steering gear and the
reservoir. This is mounted below the bumper at the front of the vehicle.
The reservoir is located in the engine compartment at the front right-hand side.
The steering column is horizontally and vertically adjustable as standard.

A - Vehicles with petrol engine
B - Vehicles with diesel engine
1 - Power steering pump
2 - Power Steering Pressure (PSP) switch
3 - PAS reservoir
4 - Pressure line to steering gear
5 - Steering gear
6 - Line to reservoir
7 - Fluid cooler - power steering

Power Steering - Power Steering Transit/Tourneo Connect 2002.5 (06/2002-)
Print
REFER to Section 211-00 Steering System - General Information.

Power Steering - Power Steering Pump—
1.8L Duratec-DOHC (85kW/115PS) - Transit/Tourneo Connect 2002.5 (06/2002-)
Zetec
Print
Removal
1. Remove the accessory drive belt.
For additional information, refer to: Accessory
Drive Belt - 1.8L Duratec-DOHC (85kW/115PS) -
Zetec (303-05 Accessory Drive, Removal and
Installation).
2. Disconnect the power steering pressure (PSP)
switch electrical connector.
3. CAUTIONS:
Do not disconnect the power steering

pump pressure adapter from the power
steering pump.
Cap the power steering line to prevent

fluid loss or dirt ingress.
Cap the power steering pump pressure

adapter to prevent fluid loss or dirt ingress.
Disconnect the power steering line from the
power steering pump.
1. Using a suitable wrench, hold the power
steering pump pressure adapter.
2. Disconnect the union.
container.
Discard the O-ring seal.
4. Remove the power steering pump lower
retaining bolts.

6. Detach the power steering line from the engine
block.

7. Detach the coolant hoses from the radiator grille
opening panel.
8. CAUTIONS:
Cap the power steering fluid supply hose

to prevent fluid loss or dirt ingress.
Cap the power steering pump connection

to prevent fluid loss or dirt ingress.
Disconnect the power steering fluid supply hose
from the power steering pump.
9. Detach the oil level indicator from the engine

block and position to one side.
10. Detach the air-conditioning (A/C) pipe from the

radiator grille opening panel and position it to
one side.
11. Remove the power steering pump upper

retaining bolts.

12. Remove the power steering pump.
13. Remove the PSP switch.
Installation
1. CAUTION: Care must be taken to

prevent dirt ingress.
Install a new O-ring seal onto the power steering
pump to steering gear line union.

For additional information, refer to: Power
Steering System Filling (211-00 Steering System
- General Information, General Procedures) /
Power Steering System Bleeding (211-00
Steering System - General Information, General
Procedures).

Power Steering - Power Steering Pump—
1.8L Duratorq-TDCi FGT (55kW/75PS) -
Lynx/1.8L Duratorq-TDDi (55kW/75PS) -
Lynx/1.8L Duratorq-TDCi (66kW/90PS) -
Lynx/1.8L Duratorq-TDCi FGT Transit/Tourneo Connect 2002.5 (06/2002-)
(66kW/90PS) - Lynx/1.8L Duratorq-TDCi
VNT (66kW/90PS) - Lynx/1.8L Duratorq-
TDCi VNT (55kW/75PS) - Lynx/1.8L
Duratorq-TDCi (81kW/110PS) - Lynx
Print
Removal
Drive Belt - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (303-05
Accessory Drive, Removal and Installation).
2. Remove the power steering pump lower
retaining bolts.

wheelhouse assembly and position it to one
side.
1. Remove the bolt.

6. CAUTIONS:
Cap the power steering fluid reservoir

hose to prevent fluid loss or dirt ingress.
Cap the power steering fluid reservoir

connection to prevent fluid loss or dirt
ingress.
Disconnect the power steering fluid reservoir
hose from the power steering fluid reservoir.
container.
7. Detach the fuel filter from the wheelhouse

assembly and position it to one side.
8. Remove the charge air cooler outlet hose.

1. Remove the retaining nuts.
2. Release the retaining clips.
9. NOTE: Note the position of the power

steering line to aid installation.
Detach the power steering line from the
camshaft cover.

Detach the power steering line from the engine
lifting eye.
11. CAUTIONS:

steering pump.


Disconnect the power steering line union from
the power steering pump.
container.
13. Remove the power steering hose.
Installation


Procedures).

Power Steering - Power Steering Fluid
Cooler—Vehicles Built Up To: 08/2006
Print
Removal
All vehicles
1. Remove The front bumper cover
For additional information, refer to: Front
Bumper Cover - Vehicles Built Up To: 08/2006
(501-19 Bumpers, Removal and Installation).
wheelhouse assembly and position it to one
side.
2. Release the clip.

4. Disconnect the power steering fluid cooler return

container.

Operation).

6. Detach the power steering fluid reservoir to
power steering fluid cooler line from the

7. Disconnect the steering gear to power steering
fluid cooler hose quick release coupling from the
power steering fluid cooler.
1. Press the power steering fluid cooler hose
quick release coupling locking tangs.
2. Disconnect the power steering fluid cooler
hose quick release coupling.
container.

8. Detach the power steering fluid reservoir to
power steering fluid cooler line from the

fluid cooler hose from the power steering fluid
cooler.
container.
All vehicles
10. Remove the radiator splash shield.
11. Remove the power steering fluid cooler (front

bumper cover shown removed for clarity).

Installation
1. NOTE: Make sure the collar on the hose is
inserted fully into the quick release coupling.
2. Fill the power steering system.
- General Information, General Procedures).
3. Bleed the power steering system.
Steering System Bleeding (211-00 Steering
System - General Information, General
Procedures).

Power Steering - Power Steering Fluid
Cooler—Vehicles Built From: 08/2006
Print

Special Tool(s)
307-242
Remover, Transmission Fluid Cooler
Removal
1. Refer to: Front Bumper Cover - Vehicles Built
From: 08/2006 (501-19 Bumpers, Removal and
Installation).
2.
3. Torque: 15 Nm
4. WARNING: Be prepared to collect

escaping fluids.
CAUTION: Make sure that all openings

are sealed.
5.

escaping fluids.
CAUTION: Make sure that all

openings are sealed.
Special Tool(s): 307-242
2. Torque: 10 Nm
6.


8.
9.
Installation

2.
Refer to: Power Steering System Filling

(211-00 Steering System - General
Refer to: Power Steering System Bleeding

(211-00 Steering System - General

Power Steering - Power Steering Pump to
Steering Gear Pressure Line—1.8L Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
Operation) /
and Operation).
steering lines to aid installation.
Detach the power steering lines from the
steering gear.
3. CAUTIONS:
Cap the power steering lines to prevent

Cap the steering gear valve body to

Disconnect the power steering lines from the
steering gear valve body (left-hand drive
shown).
2. Rotate the clamp plate.
container.
Discard the O-ring seals.
Detach the power steering pump to steering gear
pressure line from the cylinder block.
6. CAUTIONS:

steering pump.


Disconnect the power steering line from the
power steering pump (shown from underneath
for clarity).
7. Remove the power steering pump to steering
gear pressure line.
Installation

2. Install new O-ring seals onto the power steering

lines.
3. To install reverse the removal procedure.

Procedures).

Steering Gear Pressure Line—1.8L
Duratorq-TDCi FGT (55kW/75PS) -
Lynx/1.8L Duratorq-TDDi (55kW/75PS) -
Lynx/1.8L Duratorq-TDCi (66kW/90PS) -
Lynx/1.8L Duratorq-TDCi FGT
Duratorq-TDCi (81kW/110PS) - Lynx
Print
Removal
Operation) /
and Operation).
steering lines to aid installation.
Detach the power steering lines from the
steering gear.
3. CAUTIONS:
Cap the power steering lines to prevent

Cap the steering gear valve body to

Disconnect the power steering lines from the
steering gear valve body.
container.
5. Remove the charge air cooler inlet pipe.
1. Loosen the retaining clips.
6. Remove the charge air cooler outlet pipe.

1. Loosen the retaining clips.

pressure line from the transaxle.

pressure line from the engine lifting eye.

pressure line from the valve cover.
11. CAUTIONS:

steering pump.


Disconnect the power steering line union from

container.
Remove the power steering pump to steering
gear pressure line.
Installation


lines.
3. To install reverse the removal procedure.

Procedures).

Steering Gear Pressure Line—Vehicles Transit/Tourneo Connect 2002.5 (06/2002-)
Built From: 08/2006
Print
Removal


2. Torque: 7 Nm
3. NOTE: Note the position of the component

before removal.
Torque: 7 Nm

before removal.
Torque: 7 Nm
All vehicles
before removal.
Torque: 8 Nm

escaping fluid.

are sealed.
1. Torque: 18 Nm
container.

escaping fluid.

are sealed.
Installation
1.
2.
3.
1. Torque: 22 Nm
2. Torque: 22 Nm

Refer to: Power Steering System Filling (211-00


Procedures).
Refer to: Power Steering System Bleeding (211-

00 Steering System - General Information,

Power Steering - Steering Gear Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
211-020 (13-006)

205-316 (15-097A)
General Equipment
Transmission jack
Removal
Centralize the steering wheel and lock it in
position.

Discard the retaining bolt.

Lifting.
fluid hose quick release coupling from the power
steering fluid cooler.
1. Press the power steering fluid cooler hose
quick release coupling locking tangs.
2. Disconnect the power steering fluid cooler
hose quick release coupling.
container.


stud.
Loosen the tie-rod end retaining nut on both
sides.

from the wheel knuckle on both sides.
2. Remove and discard the tie-rod end
retaining nut.

strut and spring assembly on both sides.
8. Remove the engine support insulator center

retaining bolt.
9. Remove the steering gear heat shield.
10. Detach the power steering lines from the

steering gear.

11. Disconnect the power steering lines from the
steering gear valve body.
container.
12. Using a suitable transmission jack and a wooden

block, support the crossmember.
(transmission jack shown removed for clarity).
14. Using the transmission jack and the wooden

block, support the crossmember.
15. Lower the front crossmember to gain access to
the steering gear.
16. Remove and discard the crossmember ball
bearing washers.
17. Remove the steering gear pinion extension shaft.

1. Detach the floor seal from the steering
gear.
2. Remove and discard the retaining bolt.

18. Remove the steering gear.
Installation
gear lines.
2. Install the steering gear.
3. WARNING: Install a new steering gear

pinion extension shaft to steering gear pinion
pinch bolt. Failure to follow this instruction
Install the steering gear pinion extension shaft.
2. Attach the floor seal to the steering gear.
4. Connect the power steering lines to the steering

gear valve body.

5. Attach the power steering lines to the steering

gear.

ball bearing washers are installed correctly.
NOTE: Install new ball bearing washers.
Using a suitable transmission jack, wooden block
and the special tool position and align the
crossmember.
washers.
washers and into the groove of the tool
and tighten the alignment pin sleeve.
alignment pins into the chassis aligning
holes.

does not move while tightening the
crossmember retaining bolts.
Install the crossmember assembly (transmission
jack shown removed for clarity).
8. Remove the special tools.

9. Remove the transmission jack.
10. Install the steering gear heat shield.

11. Install the engine support insulator center
retaining bolt.
12. WARNING: Install new tie-rod end

retaining nuts. Failure to follow this
Attach the tie-rod end to the wheel knuckle on
both sides.

strut and spring assembly on both sides.
14. NOTE: Make sure the collar on the hose is

inserted fully into the quick release coupling.
Connect the power steering reservoir return hose
quick release coupling to the power steering fluid
cooler.

column shaft to steering gear pinion
extension pinch bolt. Failure to follow this

Attach the steering column shaft to the steering
gear pinion extension.
17. Fill and bleed the power steering system. For

Steering System - General Information.

Power Steering - Steering Gear Bushing Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Installer, Wheel Hub
204-148 (14-037)
Remover/Installer, Pivot Bushing

205-297 (15-086)
Materials
Name Specification
Rubber suspension E25J-19553-A
insulator lubricant
Removal
1. Remove the steering gear.
For additional information, refer to Steering Gear
in this section.
2. CAUTIONS:
Make sure vise jaw protectors are used.
Clamp the steering gear reinforcement

boss. Do not clamp the steering gear body.
Secure the steering gear in a vise.
3. Using the special tools remove the steering gear

insulator bushing on both sides.
Installation
1. Lubricate the steering bushing with rubber
suspension insulator lubricant prior to
installation.
2. Using the special tools install the steering gear
insulator bushing on both sides.

3. Install the steering gear.
For additional information, refer to Steering Gear
in this section.

Steering Linkage - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Tie-rod end locknut 63 46 -
Tie-rod to steering gear 80 59 -

Steering Linkage - Steering Linkage Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Steering Linkage - Tie Rod End Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
211-020 (13-006)
Removal
1. Raise and support the vehicle.For additional
information, refer to: (100-02 Jacking and
Lifting)

stud.
Loosen the tie-rod end locknut and the tie-rod
end retaining nut.
1. Loosen the locknut.
2. Loosen the retaining nut.

2. Remove and discard the tie-rod end
retaining nut.
4. NOTE: Make a note of the number of turns

used to remove the tie-rod end.
Remove the tie-rod end.
Installation
1. NOTE: Install the tie-rod end using the same
number of turns used to remove it.
Install the tie-rod end.

retaining nut. Failure to follow this instruction
Tighten the tie-rod end locknut and the tie-rod
end retaining nut.
1. Tighten the retaining nut.
2. Tighten the locknut.
For additional information, refer to: (204-00
Suspension System - General Information)

Steering Linkage - Tie Rod Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Socket, Tie-Rod End, Steering Gear
211-245 (13-025)
General Equipment
Pipe wrench
Vise jaw protectors
Pincers
Materials
Name Specification
Grease ESB-M1C119-B
Removal
1. Remove the steering gear. For additional
information, refer to Section 211-02 Power
Steering.
2. NOTE: Make a note of the number of turns
used to remove the tie-rod end.
Remove the tie-rod end and the tie-rod end
locknut.
1. Remove the tie-rod end.
2. Remove the tie-rod end locknut.
3. NOTE: Make sure the tie-rod is clean before

removing the steering gear boot.
Remove and discard the steering gear boot
clamps.
4. Remove and discard the steering gear boot.
5. Rotate the steering gear pinion to expose the

rack.

6. CAUTIONS:
Do not clamp the steering rack on

exposed hydraulic sealing surfaces.
Make sure vise jaw protectors are used.
To counter the extensive torque forces

required to remove the tie-rod, clamp the
steering rack teeth in a suitable vise. Do not
clamp the steering gear body.
Secure the steering rack in a vise and using a
suitable pipe wrench, remove the tie-rod.
Installation
1. Using the special tool, install the tie-rod.
2. NOTE: Lubricate the steering gear boot.

Install a new steering gear boot.
3. Using a suitable pair of pincers, install a new

steering gear boot inner clamp.

4. NOTE: Make sure the steering gear boot
outer clamp is located over the recess in the
tie-rod.
Using a suitable pair of pincers, install a new
steering gear boot outer clamp.
5. NOTE: Install the tie-rod end using the same

number of turns used to remove it.
Install the tie-rod end and the tie tie-rod end
locknut.
6. Install the steering gear. For additional

information, refer to Section 211-02 Power
Steering.

Steering Linkage - Steering Gear Boot Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Pincers
Materials
Name Specification
Grease ESB-M1C119-B
Removal
1. Remove the tie-rod end.
For additional information, refer to Tie-Rod End
in this section.
2. Remove the tie-rod end locknut.
3. NOTE: Make sure the tie-rod is clean before

removing the steering gear boot.
Remove the steering gear boot.
Discard the clamps.
Installation
1. NOTE: Lubricate the steering gear boot.
Install the steering gear boot.
2. Using a suitable pair of pincers, install a new

steering gear boot inner clamp.

3. NOTE: Make sure the steering gear boot
outer clamp is located over the recess in the
tie-rod.
Using a suitable pair of pincers, install a new
steering gear boot outer clamp.
4. Install the tie-rod end locknut.
5. Install the tie-rod end.

For additional information, refer to Tie-Rod End
in this section.

Steering Column - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Item Nm lb-ft lb-in

Steering wheel retaining bolt 48 35 -
Steering column retaining nuts 16 12 -
Steering column retaining screw 17 13 -
Steering column shaft to steering gear pinion extension retaining bolt 28 21 -

Steering Column - Steering Column Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Print
Removal
1. Remove the driver air bag module. For additional
information, refer to Section 501-20A Safety
Belt System / 501-20B Supplemental Restraint
System.


5. Detach the steering column upper shroud from

the steering column lower shroud.
Using a thin bladed screwdriver, release
the two clips (one each side).
6. Detach the audio control switch from the

steering column lower shroud (if equipped).
the locking tang.

7. Remove the audio control switch (if equipped).
Disconnect the electrical connector.
8. Remove the steering column lower shroud.

1. Release the steering column locking lever.
9. Disconnect the passive anti-theft system (PATS)

transceiver, windshield wiper/washer switch and
clockspring electrical connectors.
10. Disconnect the ignition switch and turn

signal/flash to pass electrical connectors.
11. Detach the wiring harness from the steering

column.
1. Release the locating pin.
2. Detach the wiring harness.

Discard the retaining bolt.
13. Remove the steering column.

Discard the retaining screw.
Installation
WARNINGS:
Make sure the steering column adjustment lever is in the locked position. Failure to
Install a new steering column shaft to steering gear pinion extension retaining bolt.
Failure to follow this instruction may result in personal injury.
Install new steering column shaft to cross car beam retaining nuts and screw. Failure
to follow this instruction may result in personal injury.

Steering Column - Steering Wheel Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1. Remove the driver air bag module.
For additional information, refer to: Driver Air
Bag Module (501-20B Supplemental Restraint
2. NOTE: Make sure that the road wheels are in
the straight ahead position.
3. Remove the steering wheel.
Installation

Print
Disassembly
1. Remove the steering wheel.
2. Remove the spacing collar.
3. NOTE: Make sure the clockspring is not

allowed to rotate. Secure in the central
position with a piece of suitable tape.
Remove the clockspring.
4. Remove the multifunction switches.

1. Depress the retaining tangs.
2. Lift the switches upwards.
5. Remove the passive anti-theft system (PATS)

transceiver.

6. Remove the ignition switch.
Release the locking tangs.
7. CAUTION: Never rotate the ignition

switch camshaft from position I when the
ignition lock cylinder has been removed. If
the ignition lock mechanism is moved the
anti-theft feature is activated. The steering
column will be permanently locked and can
not be recovered.
Remove the ignition lock cylinder.
1. Insert and turn the ignition key to position
I.
2. Using a thin bladed screwdriver depress
the detent.
Assembly

switch camshaft from position I if the ignition
lock dummy cylinder has been removed. If
the ignition lock mechanism is moved when
the ignition lock dummy cylinder is not in
place the anti-theft feature is activated. The
steering column will be permanently locked
and can not be recovered.
Using a suitable screwdriver to push in and
rotate the ignition switch camshaft from the 0
position to position I.
Item Description
1 Ignition switch camshaft
2 Ignition lock dummy cylinder

switch camshaft from position I if the ignition
lock cylinder has been removed. If the
ignition lock mechanism is moved when the
lock cylinder is not in place the anti-theft
feature is activated. The steering column will
be permanently locked and can not be
recovered.
Using a suitable Allen key, remove the ignition
dummy lock cylinder.
1. Insert the Allen key and turn the ignition
dummy lock cylinder from the 0 position to
position I.
2. Remove and discard the ignition dummy
lock cylinder.

3. CAUTIONS:
Remove the tape from the clockspring

before installing the steering wheel.
Make sure the spacing collar is correctly

located when installing the steering wheel.
Do not install the steering wheel if the
spacing collar is missing.
4. CAUTIONS:
Make sure the ignition lock cylinder is

correctly installed.
A new steering column must be installed

if the ignition lock cylinder fails to operate
correctly.
Check the operation of the ignition lock cylinder
twice in the following sequence:
1. Turn the ignition key to the 0 position and
make sure the steering column is free to
rotate.
2. Remove the ignition key and make sure
the steering column is locked.
3. Insert the ignition key and turn the ignition
key to position I and make sure the
steering column is free to rotate.

Steering Column Switches - Ignition
Switch
Print
Removal
1. Disconnect the battery ground cable. For
Battery, Mounting and Cables.
2. Fully extend the steering column.
3. Detach the steering column upper shroud from
the steering column lower shroud.
4. Detach the audio control switch from the

steering column lower shroud (if equipped).
the locking tang.


7. Disconnect the ignition switch and turn

signal/flash to pass electrical connectors.

8. Remove the ignition switch.
Installation
1. WARNING: Make sure the steering

column adjustment lever is in the locked
position. Failure to follow this instruction may
CAUTION: Make sure the ignition switch

and lock housing are in the OFF position.

Engine System - General Information -
Engine
Print
Engine/transmission combinations

1 - 1.8L Zetec E
2 - 1.8L Duratorq DI
3 - 1.8L Duratorq TDCi
4 - MTX-75

Engine
Print
1. 1. Verify the customer concern by operating the system
Coolant leaks Fuse(s)
Oil leaks Loose or corroded connector(s)
Fuel system leaks Control module
Visibly damaged or worn parts Damaged or worn switch(es)
Loose or missing nuts or bolts
Symptom Chart.
Symptom Chart

Loss of oil * Use of the wrong type of * Determine the engine oil last filled (e.g.
engine oil. last invoice or receipt). Compare the
specifications and renew if necessary.
* Poor sealing between * Screw the compressed air lines into the
combustion chamber and spark plug hole of each cylinder in turn,
crankcase. apply compressed air and check for
escaping air when the oil filler cap is
removed. If there is a perceptible flow of
air, inspect the cylinder liner surfaces
and pistons for damage. REFER to
General Procedures in this section.
* Leaking as a result of * Check the alignment of the oil seal
damaged oil seal or incorrect carrier, and re-align if necessary. Renew
oil seal carrier alignment. the oil seal.
- Camshaft oil seal.
- Front or rear crankshaft oil
seal.
* Damaged gaskets or mating * Check gaskets and mating faces for
faces. damage.
* Cylinder head gasket or * Open the coolant expansion tank cap
mating face is damaged, and check for oil sludge or a film of oil
engine oil can escape from the on the surface of the coolant.
engine between cylinder head *
and cylinder block or get into Remove the cylinder head. 1.8L engine -
the cooling system. REFER to Section 303-01A Engine /
303-01B Engine.1.8L diesel engine -
REFER to Section 303-01A Engine /
303-01B Engine.
- Check the mating faces and cylinder
head gasket, and check the flatness of
the cylinder head mating face. REFER to

- Renew the cylinder head if necessary.
* Oil leaks on components that * Locate cracks in oil-carrying
are either coated in oil or have components or the basic engine by
oilways, oil leaks on ancillary means of a UV leak test, and renew the
components. relevant components or seals.
* Faulty PCV system * Check that the PCV system works
- Hoses or ventilation/breather correctly, repair it if necessary.
valve are blocked. This causes
excessive pressure in the
crankcase which causes more
oil to enter the combustion
chamber.
- The PCV system oil separator
is faulty and engine oil can
enter the combustion chamber
through the intake manifold.
* Damaged cylinder liners or too * Check the running surfaces and
much clearance on engine clearances of the individual engine
components. components, and renew if necessary.
Renew the cylinder block if necessary.
* Pistons. * Pistons.
* Piston rings (ring clearances * Piston rings.
and ring gap).
* Cylinder liners. * Cylinder liners.
* Valve stems and guides. * Valve stems and guides.
* Damaged gaskets or mating * Check gaskets and mating faces for
faces damage.
* Cylinder head gasket or *
mating face is damaged, and Remove the cylinder head. 1.8L engine -
engine oil can enter the REFER to Section 303-01A Engine /
combustion chamber. 303-01B Engine. 1.8L diesel engine -
303-01B Engine.
- Check the mating faces and cylinder
* Valve stem oil seals are * Renew the valve stem oil seals. 1.8L
damaged and engine oil can engine - REFER to Section 303-01A
enter the combustion chamber Engine / 303-01B Engine. 1.8L diesel
between valve stem and valve engine - REFER to Section 303-01A
guide. This becomes Engine / 303-01B Engine.
particularly apparent on
overrun.
* Cracks in engine components * Add the engine oil additive for the UV
with oilways or engine leak test and bring the engine oil to at
components coated in oil, e.g. least 80°C so that the engine oil additive
cylinder liners, pistons and oil can enter any existing cracks. Allow the
galleries and passages. engine to cool to ambient temperature,
remove the affected component and
dismantle it if necessary. Check the
engine component using the UV leak test
procedure, and renew it if necessary.
Coolant * Damaged gaskets or mating *
consumption faces Remove the cylinder head. 1.8L engine -
- The cylinder head gasket or REFER to Section 303-01A Engine /
mating face is damaged. 303-01B Engine. 1.8L diesel engine -
Coolant can enter the REFER to Section 303-01A Engine /

combustion chamber or the 303-01B Engine.
crankcase. - Check the mating faces and cylinder
* Cracks or material breaks in * Determine the damaged engine
engine components around component and renew it.
which coolant flows, such as
cylinder liner surfaces and the
cylinder head.
Engine will not * Battery or wiring is faulty. * Check the battery, electrical connections
start and cables. REFER to Section 414-00
Charging System - General Information.
* Starter motor or wiring is * Check the starter system. REFER to
faulty. Section 303-06 Starting System.
* Fault in fuel system. * Check the fuel system. 1.8L engine -
303-01B Engine. 1.8L diesel engine -
303-01B Engine.
* Fuel tank is empty. * Check the fluid level.
* Fault in ignition system (petrol * Check the ignition system. REFER to
engines only). Section 303-07A Engine Ignition / 303-
07B Glow Plug System.
* Fault in engine management * Check the engine management system.
system. REFER to Section 303-14 Electronic
Engine Controls.
* Intake system is faulty. * Check the intake system. REFER to
- Intake system air leak. Section 303-12 Intake Air Distribution
- Blocked air cleaner. and Filtering.
- Faulty idle air control valve.
* Fault in valve train. * Connect compressed air to the
- Burned out exhaust valve. cylinders. If air flows out through the
- Timing incorrectly adjusted. intake manifold or the exhaust pipe,
- Cracked or damaged timing check the valve train.
belt.
* Faulty engine components. * Connect the compressed air line to the
- Burned through piston. cylinder. If air is escaping from the
- Piston rings. opened oil filler cap, remove the cylinder
- Cylinder head gasket. head in accordance with the operation
- Big-end and/or main bearing and check the components. 1.8L engine
journals. - REFER to Section 303-01A Engine /
303-01B Engine.
Very poor power * Fault in fuel system. * Check the fuel system. 1.8L engine -
output / fuel REFER to Section 303-01A Engine /
consumption too 303-01B Engine. 1.8L diesel engine -
high / rough REFER to Section 303-01A Engine /
engine running 303-01B Engine.
* Fault in ignition system (petrol * Check the ignition system. 1.8L engine -
engines only). REFER to Section 303-07A Engine
Ignition / 303-07B Glow Plug System.
* Fault in engine management * Check the engine management system.
system. REFER to Section 303-14 Electronic
Engine Controls.
* Intake system is faulty. * Check the intake system. REFER to
- Intake air leak. Section 303-12 Intake Air Distribution

- Air cleaner is blocked. and Filtering.
- Faulty idle air control valve.
* Fault in valve train. * Connect compressed air to the
- Burned out exhaust valve. cylinders. If air flows out through the
- Timing incorrectly adjusted. intake manifold or the exhaust pipe,
- Cracked or damaged timing check the valve train.
belt.
* Engine components faulty. * Connect the compressed air line to the
- Piston burned through. cylinder. If air is escaping from the
- Piston rings. opened oil filler cap, remove the cylinder
- Cylinder head gasket. head and check the components.
- Big-end and/or main bearing Dismantle the engine if necessary and
journal. check the components. 1.8L engine -
303-01B Engine.
Noisy running * Misfiring/backfiring * Determine the cause of the misfiring
- Fuel has wrong octane and rectify it.
number (petrol engines only), - Determine which type of fuel was last
or the wrong type of fuel is put in the tank (note the country specific
filled. fuel specifications).
- Fault in ignition system (petrol - Check the ignition system. 1.8L engine -
engines only). REFER to Section 303-07A Engine
- Engine temperature too high. Ignition / 303-07B Glow Plug System.
- Carbon deposits in the - Check the engine cooling. REFER to
combustion chamber start to Section 303-03 Engine Cooling.
glow and cause misfiring. - Remove the carbon deposits by using
- Timing incorrect, which causes fuel additives and driving the vehicle
misfiring in the intake/exhaust carefully
system. - Check the valve timing.
* Fault in valve train. * Check the valve train.
* Valve clearance too large, * Set the valve clearance (if possible) or
resulting from faulty bucket replace the faulty bucket tappet.
tappet or incorrect valve
clearance setting.
* Valve timing incorrectly * Check and set the valve timing if
adjusted - valves and pistons required. 1.8L engine - REFER to
are touching. Section 303-01A Engine / 303-01B
Engine. 1.8L diesel engine - REFER to
Section 303-01A Engine / 303-01B
Engine.
* Cracked or damaged timing * Check the timing belt. In addition, check
belt. the pistons and valves for damage and
renew all faulty parts.
* Engine components faulty. * Disassemble the engine and check
- Pistons. components. 1.8L engine - REFER to
- Piston rings. Section 303-01A Engine / 303-01B
- Cylinder head gasket. Engine. 1.8L diesel engine - REFER to
- Big-end and/or main bearing Section 303-01A Engine / 303-01B
journals. Engine.
* Engine components or * Check the condition of the engine
ancillary components are components and check that they are
broken or loosened. tight and seated correctly. If necessary,
tighten to the prescribed torque. Renew
the broken components.
* Dual mass flywheel faulty * Check the dual mass flywheel.
REFER to Flywheel Inspection - vehicles
with Dual Mass Flywheel in this section.

Engine Oil Leaks
NOTE: Before installing new gaskets or oil seals, make sure that the fault is clearly
established.
If the oil leak cannot be identified clearly by a visual inspection, carry out a UV test:
Ultraviolet (UV) Testing
1. 1. Clean the engine and transaxle with a suitable cleaning fluid.
2. 2. Pour the UV test fluid in accordance with the quantity specified by the
manufacturer through the oil filler neck into the engine and install the oil filler cap.
3. WARNING: On manual transaxles put the transaxle into NEUTRAL. Failure to

follow these instructions may result in personal injury.
3. Start the engine and let it run for about five minutes.
4. 4. Switch off the engine.
5. NOTE: If no leak can be found, road test the vehicle under various loads and again
check the engine for leaks.
5. Check the engine for oil leaks using a suitable UV leak tester.
6. 6. Rectify any leaks found and recheck the engine for oil leaks.
Measure the compression pressure (21 111 0).

NOTE: The powertrain control module (PCM) receives an error message when the relay is
removed out or electrical components are disconnected. This error message must be
deleted from the fault memory by connecting WDS after completing the measurement.
NOTE: Valve clearance must be set correctly before performing a compression test. Make
sure engine is at the normal operating temperature.
NOTE: The varying design of compression checking devices and fluctuating starter motor
speeds normally only allows to check if the compression is even in all cylinders.
Measure the compression pressure (1.8L engine)
1. 1. Open the central junction box (CJB) and remove the fuel pump relay.
2. NOTE: The engine will start, run for a few seconds and then stops.
2. Start the engine.

NOTE: Turn the spark plug connector slightly before disconnecting it. Pull the connector
and not the lead.
3. 3. Detach the spark plug connectors and remove the spark plugs.
4. 4. Disconnect the ignition coil (EI) electrical connector.
NOTE: Operate the starter motor with wide open throttle until the pointer on the
measuring device stops rising.
5. 5. Using a suitable compression pressure recorder carry out the measurement on

every cylinder.
6. 6. Refit the components in reverse order, observing the prescribed torques. Coat the
spark plug connector seal with silicone grease (A960-M1C-AA) before fitting. Coat
the spark plug thread with lubricant (ESE-M1244-A). Valve cover torque: Stage 1: 2
Nm; stage 2: 7 Nm. Spark plug torque: 15 Nm.
7. 7. Reset the PCM fault memory.
Measure the compression pressure (1.8L diesel engine - without common rail fuel
injection)
WARNING: Do not smoke or carry lighted tabacco or open flame of any type when

working on or near any fuel related components. Highly flammable mixtures are always
present and can ignite. Failure to follow these instructions may result in personal injury.
1. 1. Open the central junction box (CJB) and remove the glow plug relay.
2. 2. Remove the engine upper cover.
3. 3. Remove the charge air cooler inlet and outlet pipes.
4. 4. Remove the charge air cooler air guide.

5. 5. Disconnect the intake air temperature sensor (IAT) electrical connector.
6. 6. Remove the charge air cooler.
7. 7. Disconnect the fuel injection pump electrical connector.
8. 8. Remove the glow plug power supply.

9. 9. Remove the glow plugs.
10. 10. Install the compression tester with adapter into the glow plug bore.
NOTE: Crank the engine with the starter motor until the reading on the compression
tester stops rising.
11. 11. Carry out the measurement on all cylinders, following the measuring equipment
manufacturer's instructions.
12. 12. Detach the compression tester and adapter.
13. 13. Install the glow plugs.

14. 14. Install the glow plug power supply.
15. 15. Connect the fuel injection pump electrical connector.
16. 16. Install the charge air cooler.
17. 17. Connect the IAT sensor electrical connector.

18. 18. Install the charge air cooler air guide.
19. 19. Install the charge air cooler inlet and outlet pipes.
20. 20. Install the engine upper cover.
21. 21. Install the glow plug relay.
Measure the compression pressure (1.8L diesel engine - with common rail fuel
injection)

WARNINGS:
Do not smoke or carry lighted tobacco or open flame of any type when working on or
near any fuel related components. Highly flammable mixtures are always present and can
ignite. Failure to follow these instructions may result in personal injury.
Do not carry out any repairs to the fuel injection system without checking the fuel
pressure has dropped to zero and that the fuel temperature is below 30° C. Failure to
1. 1. Using datalogger in world wide diagnostic system (WDS), check that the fuel
pressure has dropped to zero and that the fuel temperature is below 30° C.
2. 2. Open the central junction box (CJB) and remove the glow plug relay.
4. 4. Remove the charge air cooler inlet and outlet pipes.

5. 5. Remove the charge air cooler air guide.
6. 6. Disconnect the intake air temperature sensor (IAT) electrical connector.
7. 7. Remove the charge air cooler.
8. 8. Disconnect the fuel injector electrical connectors.

9. 9. Remove the glow plug power supply.
10. 10. Remove the glow plugs.
11. 11. Install the compression tester with adapter into the glow plug bore.
NOTE: Crank the engine with the starter motor until the reading on the compression
tester stops rising.
12. 12. Carry out the measurement on all cylinders, following the measuring equipment
13. 13. Detach the compression tester and adapter.

14. 14. Install the glow plugs.
15. 15. Install the glow plug power supply.
16. 16. Connect the fuel injector electrical connectors.
17. 17. Install the charge air cooler.

18. 18. Connect the intake air temperature sensor (IAT) electrical connector.
19. 19. Install the charge air cooler air guide.
20. 20. Install the charge air cooler inlet and outlet pipe.

22. 22. Install the glow plug relay.
Measure the oil pressure (21 113 0)

The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
NOTE: Measure the oil pressure at the specified engine speed. Measure the oil pressure at
an oil temperature of 80° C.
Measure the oil pressure (1.8L engine)
1. 1. Raise and support the vehicle. REFER to Section 100-02 Jacking and Lifting.
2. 2. Disconnect the oil pressure switch electrical connector and remove the oil pressure
switch.
3. 3. Attach the oil pressure gauge with oil pressure gauge connector, and arrange it so
that the reading can be made from above.
4. 4. Lower the vehicle.
5. 5. Check the oil pressure.
6. 6. Raise and support the vehicle. REFER to Section 100-02 Jacking and Lifting.
7. 7. Detach the oil pressure gauge and connector.
8. 8. Coat the oil pressure switch with oil pressure switch sealer (WSK-M2G349-A7).
9. 9. Install the oil pressure switch and connect the oil pressure switch electrical
connector.

10. 10. Lower the vehicle.
Measure the oil pressure (1.8L diesel engine)
2. 2. Detach the charge air cooler inlet and outlet pipe.
3. 3. Detach the charge air cooler air guide.
4. 4. Disconnect the oil pressure switch electrical connector from the oil pressure switch.

5. 5. Remove the oil pressure switch.
NOTE: Measure the oil pressure at idle speed and at 2000 rev/min.
6. 6. Attach the oil pressure gauge with the oil pressure gauge connector.
7. 7. Check the oil pressure.
8. 8. Detach the oil pressure gauge and the oil pressure gauge connector.
9. 9. Coat the oil pressure switch with sealer (WSK-M2G349-A7)
10. 10. Install the oil pressure switch.

11. 11. Connect the oil pressure switch electrical connector to the oil pressure switch.
12. 12. Attach the charge air cooler air guide.
13. 13. Attach the charge air cooler inlet and outlet pipe.
Valve train analysis - static (engine off)

Detach the valve cover.
Check all valve train components for damage and wear. Ensure that only original
components are installed and that all bolts and nuts have been tightened to the correct
tightening torque.

Camshaft Bearing Journal Diameter
Print
General Procedures
1. Determine the diameter of the camshaft

journals.
Using a micrometer measure the diameter
at 90 degrees intervals to determine if the
journals are out-of-round.
Measure at two different points on the
journal to determine if there is any
tapering.
If the measurements are out of the
specified range, install a new camshaft.

Camshaft Bearing Journal Clearance
Print
General Procedures
1. NOTE: Make sure that the following stages

are followed exactly. The tappets or followers
must be removed to carry out this
measurement.
NOTE: Make sure that the camshaft is to
specification.
NOTE: The bearing caps and journals should
be free from engine oil and dirt.
Position on a width of plastigage on the bearing
cap.
Insert the camshaft, without lubrication,
into the cylinder head.
Position a plastigage strip, which should be
equal to the width of the bearing cap, on
the bearing journal.
2. Following the tightening specification, install the
camshaft bearing caps. Refer to the
corresponding Section 303-01.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps, refer to the
corresponding Section 303-01.
4. Using the Plastigage, read off the measurement.
Compare the width of plastigage with the
plastigage scale.
The value that is read off is the bearing
clearance.

Camshaft End Play
Print
General Procedures
1. NOTE: Make sure that the camshaft is to

specification.
Using a Dial Indicator Gauge, measure the end
play.
Slide the camshaft in both directions. Read
and note the maximum and minimum
values on the Dial Indicator Gauge.
1. End play = maximum value minus
minimum value
If the measurement is out of specification,

install new components.

Camshaft Surface Inspection
Print
General Procedures
1. Inspect the camshaft lobes for pitting or damage

in the active area. Minor pitting is acceptable
outside the active area.

Camshaft Lobe Lift
Print
General Procedures
1. Determine the cam lift.

Using a micrometer measure the cam in
two directions.
The difference between the two
measurements is the cam lift.

Crankshaft Main Bearing Journal Diameter
Print
General Procedures
General Equipment
Micrometer
1. Measure the diameter of the main bearing
journals and the big-end bearing journals.
Repeat the measurement with the
micrometer offset by 90°, in order to
determine any eccentricity which may be
present.
Measure the journal at two different
positions to determine any conicity which
may be present.

Crankshaft End Play
Print
General Procedures
General Equipment
Dial indicator
Dial indicator fixture
1. Determine the end float
Place on the dial indicator and bracket .
Determine the end float by raising the
crankshaft with the aid of a screwdriver.
If necessary, correct the end float by using
new thrust half washers.

Cylinder Bore Taper
Print
General Procedures
1. NOTE: The main bearing caps or lower

crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
Carry out the measurements in different
directions and at different heights to
determine if there is any out-of-roundness
or tapering.
If the measurement is out of the specified
range, install a new block or hone out the
cylinder block (if aplicable/allowed).

Piston Inspection
Print
General Procedures
1. CAUTION: Do not use any aggressive

cleaning fluid or a wire brush to clean the
piston.
Carry out a visual inspection.
Clean the piston skirt, pin bush, ring
grooves and crown and check for wear or
cracks.
If there are signs of wear on the piston
skirt, check whether the connecting rod is
twisted or bent.

Piston Pin to Bore Diameter
Print
General Procedures
1. NOTE: The piston and piston pin form a

matched pair. Do not mix up the
components.
Measure the diameter of the piston pin bore.
Measure the diameter in two directions.
If the values are not to specification, install
both a new piston and a new piston pin.

Piston Diameter
Print
General Procedures
General Equipment
Micrometer
1. NOTE: Mark the piston to make sure the
piston is installed correctly.
Using a Micrometer measure the piston
diameter.

Piston Ring End Gap
Print
General Procedures
1. CAUTION: Do not mix up the piston

rings. Install the piston rings in the same
position and location.
Take the piston ring and use a piston without
rings to push the piston ring about 30 mm into
the cylinder bore.
2. Using the Feeler Gauge, measure the piston ring

gap.

Piston Ring-to-Groove Clearance
Print
General Procedures
General Equipment
Feeler Gauge
1. NOTE: The piston ring must protrude from
the piston groove. To determine the piston
ring clearance, insert the Feeler Gauge right
to the back of the groove, behind the wear
ridge.
Using the Feeler Gauge , measure the piston ring
clearance.

Piston Pin Diameter
Print
General Procedures
1. NOTE: The piston and piston pin are a

matched pair. Do not mix up the
components.
Measure the piston pin diameter.
Measure the diameter in two directions.
If the values are not to specification, install
a new piston and a new piston pin.

Connecting Rod Large End Bore
Print
General Procedures
1. Measure the bearing bore in two directions. The

difference is the connecting rod bore out-of-
round. Verify the out-of-round and the bearing
bore is within specification.

Valve Stem Diameter
Print
General Procedures
1. Using a micrometer measure the diameter of the

valve stems.
If the measurements are not to
specification, install a new valve.

Flywheel Inspection
Print
General Procedures
1. Inspect the flywheel. If there is evidence of the

following, install a new flywheel.
1. Cracks.
2. Worn ring gear teeth.
3. Chipped or cracked ring gear teeth.

Flywheel Inspection—Vehicles With: Dual Transit/Tourneo Connect 2002.5 (06/2002-)
Mass Flywheel
Print
General Procedures
CAUTIONS:
Do not rework the flywheel if it is distorted.
Do not clean the dual mass flywheel with any kind of fluid. Clean the flywheel with a
dry cloth only.
Do not clean the gap between the primary and secondary mass. Only clean the bolt
connection surface and the clutch surface.
1. Inspect the flywheel, if there is evidence of the
following install a new flywheel:
Cracks.
Worn ring gear teeth.
Chipped or cracked ring gear teeth.
2. Check the flywheel for lateral movement.
Rotation movement in either one or both
directions, or rock on it's axis in relation to
the primary mass is acceptable.
If there is any lateral movement, install a
new flywheel.
3. CAUTION: Make sure that the three

locating dowels are installed.
Check if the locating dowels are touching the
primary mass of the flywheel.
If the locating dowels are touching the
primary mass of the flywheel, install a new
flywheel.
4. Inspect for grease along the welding.

If grease is evident, install a new flywheel.

Cylinder Head Distortion
Print
General Procedures
General Equipment
Feeler gauge
Straight edge
1. Using a straight edge and feeler gauge, measure
the cylinder head distortion.
Measure the mating face distortion.
Refer to Specifications in the appropriate
engine section.

Cylinder Block Distortion
Print
General Procedures
1. Using a Straight Edge and a Feeler Gauge,

measure the cylinder block/cylinder head
distortion.
Measure the mating face distortion.
If the value is not to specification rework
the mating face (if allowed).

Exhaust Manifold Cleaning and Inspection
Print
General Procedures
1. Inspect the cylinder head joining flanges of the

exhaust manifold for evidence of exhaust gas
leaks.
2. Inspect the exhaust manifold for cracks,
damaged gasket surfaces, or other damage that
would make it unfit for further use.

Bearing Inspection
Print
General Procedures
1. Inspect bearings for the following defects.

1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or
bearing not seated.

Valve Seat Inspection
Print
General Procedures
General Equipment
Valve seat width scale
1. Measure the width of the valve seat.
Measure the valve seat width using the
Valve seat width scale.
If the value is not to specification rework
the valve seat.

Engine - 1.8L Duratec-DOHC
(85kW/115PS) - Zetec - Specifications
Print
Engine Data
Description
Engine code EYPA
Emission standard Stage 3
Firing order 1-3-4-2
Bore 80.6 mm
Stroke 88.0 mm
Cubic capacity 1796 cc
Compression ratio 10.0:1
Power output at 5750 rpm 85 kW
Torque at 3750 rpm 158 Nm
Idle speed 800 rpm
Maximum permissible engine speed 7100
Number of main bearings 5
Camshaft drive Belt
Engine Oil
Viscosity/Ambient
temperature Type Specification
Recommended engine oil:
SAE 5W30 / below -20°C to WSS-M2C913-A or WSS-
above 40°C Ford Formula E Economy Motor Oil M2C912-A1
Alternative engine oils:
SAE 10W40 / -20°C to above Ford XR+ High-performance High- ACEA A3/B3
40°C lubricity Engine Oil
SAE 5W40 / below -20°C to Ford Formula S Synthetic Engine Oil ACEA A3/B3
above 40°C
Capacities
Litres
Engine oil, initial fill including filter 4.35
Engine oil, including filter change 4.25
Engine oil, excluding filter change 3.75
Item Specification
Sealant WSK-M2G348-A5
Sealant WSK-M4G320-A
Sealant ESW-1C155-A
Sealant WSE-M4G323-A6
Thread locking compound SDM-M4G9107-A
Lubricant WSD-M13P8-A
Lubricant WSEM-2C903-A1
Silicone grease A696-M1C171-AA
Crankshaft
Clearance between cylinder block and lower Required spacer shim thickness
crankcase: (mm)
0.26 mm - 0.50 mm 0.25
0.51 mm - 0.75 mm 0.50
Valves

Description mm
Valve stem to valve guide clearance (intake) 0.017 - 0.064
Valve stem to valve guide clearance (exhaust) 0.035 - 0.081
Valve clearance (intake) 0.110 - 0.180
Valve clearance (exhaust) 0.270 - 0.340
Oil System
Description bar
Oil pressure at 800 - 850 rpm 1.3 - 2.5
Oil pressure at 4000 rpm 3.7 - 5.5
Cylinder Head
Description mm
Maximum distortion (mating face) 0.1
Height of sealing surface 2.0 +0.12 -
0.24
Sealing surface roughness (reference length 2.5 mm vertical to groove R3z= 6.0 µ m
direction)

Intake manifold retaining bolts 18 13 -
Exhaust manifold heat shield retaining bolts 10 - 89
Exhaust manifold studs 5 - 44
Exhaust manifold retaining nuts 16 11 -
Catalytic converter rear support strap retaining bolt 22 16 -
Catalytic converter front support strap retaining bolt 23 17 -
Catalytic converter retaining bolt 48 30 -
Catalytic converter retaining bolt 47 35 -
Intermediate shaft center bearing retaining nuts 25 18 -
Generator retaining bolts 25 18 -
Generator retaining bracket retaining nut 25 18 -
Generator retaining bracket retaining bolts 65 48 -
Transaxle retaining bolts 47 35 -
Starter motor retaining bolts 35 26 -
Engine rear mount center retaining nut 133 98 -
Engine front mount retaining nuts 80 59 -
Engine front mount retaining bolts 48 35 -
Engine front mount bracket retaining bolts 50 37 -
Suspension strut nuts 48 35 -
Power steering pump retaining bracket retaining bolts 48 35 -
Power steering pump retaining bracket retaining nuts 48 35 -
Cylinder head bolts a) - -
Valve cover retaining bolts a) - -
Spark plugs 15 11 -
Timing belt tensioner retaining bolt 25 18 -
Timing belt idler pulley retaining bolt 23 17 -
Timing belt upper cover retaining bolts 10 - 89
Camshaft timing pulleys retaining bolts 68 50 -
Camshaft bearing caps retaining bolts a) - -
Ignition retaining bracket retaining bolts 21 15 -
Thermostat housing retaining bolts 20 15 -
Front engine lifting eye 47 35 -
Engine oil drain plug 25 18 -

Cylinder block oil gallery blanking plug 23 17 -
Oil pressure switch 27 20 -
Oil pan retaining bolts a) - -
Oil pump retaining bolts a) - -
Oil pick up pipe retaining bolts 10 - 89
Oil level indicator tube retaining bolt 10 - 89
Main bearing retaining bolts 85 63 -
Connecting rod retaining bolts a) - -
Water pump retaining bolts 18 13 -
Lower crankcase retaining bolts 30 22 -
Crankshaft rear oil seal carrier retaining bolts 20 15 -
Crankcase ventilation pipe retaining bracket 23 17 -
Positive crankcase ventilation housing 10 - 89
Crankshaft pulley retaining bolt 115 85 -
Crankshaft position (CKP) sensor mounting bracket retaining bolt 21 15 -
CKP sensor retaining bolt 8 - 71
Accessory drive belt idler pulley 40 30 -
Air conditioning (A/C) compressor retaining bracket retaining bolts. 25 18 -
Air conditioning (A/C) compressor retaining bracket retaining nuts. 25 18 -
a) Refer to procedure in this section.

(85kW/115PS) - Zetec - Engine
Print
Overview
The 1.8L Zetec E engine used in the Ford Transit belongs to the Zetec-Upgrade engine
range and has largely been taken over from the Ford Focus.
Engine
Transversely mounted straight 4 engine with 16 valves
1.8L capacity producing 85 kW (115 PS)
Double overhead camshafts driven by a timing belt
Mechanical bucket tappet operated valves
Cylinder head and lower crankcase made of aluminium
Engine management
ECC V engine management system
PCM with 60 pins
Sequential fuel injection
Mass Air Flow (MAF) sensor with integrated Intake Air Temperature (IAT) sensor
Cylinder Head Temperature (CHT) sensor for measurement of the engine temperature
Pre-cat and post-cat heated oxygen sensors (HO2S1 and HO2S2) designed to determine
sensor faults and discrepancies in the air/fuel supply, as well as to monitor the catalytic
converter efficiency
'Smart charge' alternator control system

European On-Board Diagnosis (EOBD) for the monitoring of emissions-relevant control
systems.
Engine emission control

Meets the European level III emissions standard
3-way catalytic converter
EVAPorative emission (EVAP) system
Diagnosis
Can be diagnosed via the Data Link Connector (DLC) in the passenger compartment
Engine power and torque

1 - Torque curve
2 - Power curve

Print
REFER to Section 303-00 Engine System - General Information.

(85kW/115PS) - Zetec - Valve Clearance Transit/Tourneo Connect 2002.5 (06/2002-)
Adjustment
Print
General Procedures
Special Tool(s)
Compressor, Valve Adjustment
303-563 (21-218)
General Equipment
Feeler gauges
1. Remove the valve cover.
For additional information, refer to Valve Cover
in this section.
2. CAUTION: Only turn the engine in the

normal direction of rotation.
Turn the engine until each piston is at top dead
center (TDC) and measure the valve clearances.
3. NOTE: Note down each cylinder number and
the valve clearances measured.
Using a suitable set of feeler gauges, measure
the valve clearances.
4. NOTE: Only carry out the following steps

when the valve clearance must be adjusted.
For additional information, refer to
Specifications in this section.
Install the special tool.
5. NOTE: The number on the shim indicates the

shim thickness.
Remove the adjusting shim from the tappet and
read the thickness from the underside.

6. Determine the shim thickness required.
Shim thickness required = thickness of
currently installed shim + the measured
valve clearance - the required valve
clearance.
Specifications in this section.
7. Install the correct shim.
8. Remove the special tool.
9. Check the valve clearance after adjustment is

complete.
10. Install the valve cover.
For additional information, refer to Valve Cover
in this section.

(85kW/115PS) - Zetec - Intake Manifold
Print
In-vehicle Repair
Removal
Lifting.
3. Remove the intake manifold lower retaining bolts
(engine shown removed for clarity).

5. Detach the accelerator cable from the throttle
body and position it to one side.
1. Detach the accelerator outer cable from
the accelerator cable bracket.
2. Detach the accelerator inner cable from
the throttle body lever.
6. Disconnect the camshaft position (CMP) sensor

7. Disconnect the cylinder head temperature (CHT)

sensor and the powertrain control module (PCM)
8. Disconnect the vacuum hoses from the throttle

body.

9. Disconnect the brake booster vacuum pipe from
the brake booster.
10. Disconnect the fuel supply line and fuel return

line from the fuel rail.
11. Remove the intake manifold (engine shown

Installation
1. NOTE: Clean and inspect the intake manifold
gasket. Install a new intake manifold gasket
if necessary.
Install the intake manifold (engine shown

Lifting.

3. Install the intake manifold lower retaining bolts

5. Connect the fuel supply line and fuel return line
to the fuel rail.
6. Connect the brake booster vacuum pipe to the

brake booster.
7. Connect the vacuum hoses to the throttle body.
8. Connect the cylinder head temperature (CHT)

9. Connect the camshaft position (CMP) sensor


10. Attach the accelerator cable to the throttle body.
1. Attach the accelerator outer cable to the
accelerator cable bracket.
2. Attach the accelerator inner cable to the
throttle body lever.
11. Install the air cleaner. For additional information,

refer to Section 303-12 Intake Air Distribution
and Filtering.

(85kW/115PS) - Zetec - Crankshaft Front Transit/Tourneo Connect 2002.5 (06/2002-)
Seal
Print
In-vehicle Repair
Special Tool(s)
Remover, Crankshaft Oil Seal
303-293 (21-143)
Installer, Crankshaft Oil Seal

303-395 (21-171)
Installer, Front Crankshaft Oil Seal

303-684 (21-243)
Removal
1. Remove the timing belt.
For additional information, refer to Timing belt in
this section.
2. NOTE: FRONT marking and installation
position of the timing pulley thrust washer.
Remove the crankshaft timing pulley.
1. Pull off the crankshaft timing pulley.
2. Remove the timing pulley key and thrust
washer.
3. Remove the crankshaft front oil seal.
Installation
1. NOTE: Correct seating of sealing lip on the
installation sleeve.
Push crankshaft front oil seal to approx. the
middle position on the special tool.

2. Push the special tool fully home onto the
crankshaft.
3. Push the crankshaft front oil seal by hand, over
the special tool, until it is fully home on the oil
seal carrier, on the crankshaft.

5. NOTE: Use the bolt of the crankshaft
vibration damper.
Draw in the crankshaft front oil seal using the
special tool to the fully home position.
6. NOTE: FRONT marking and installation

position of the timing pulley thrust washer.
Install the crankshaft timing pulley.
1. Push on the timing pulley thrust washer
and key.
2. Attach the crankshaft timing pulley.
7. Install the timing belt.

this section.

(85kW/115PS) - Zetec - Valve Springs
Print
In-vehicle Repair
Special Tool(s)
Valve Spring Compressor
303-361A (21-155 A)

303-361-02 (21-155-02)
Connector, Air Supply (Cylinder Head)

303-363 (21-157)
Materials
Name Specification
Engine oil WSS-M2C912-A1
Removal
1. Remove the camshafts.
For additional information, refer to Camshafts in
this section.
Remove the valve tappets and lay them in
order, to one side.
2. WARNING: Always wear protective

goggles when working with compressed air.
Failure to do so can result in injury.
Remove the spark plug from cylinder no. 1 and
attach the special tool.
3. CAUTION: Use compressed air at 7 to

10 bar.
Attach the special tools and apply compressed
air to the cylinder.
1. Compress the valve spring.
2. Remove the valve collets.
Take out the valve spring retainer and the
valve spring.
Installation
1. NOTE: Check that the valve collets are
correctly seated.
Install the valve springs with the valve spring
retainers.

1. Compress the valve springs.
2. Install the valve collets.
2. Detach Special Tool 303-363 and screw in the

spark plug.
3. Repeat the operations for all the other cylinders.
4. Coat the valve tappets with engine oil and insert.
5. Install the camshafts.
this section.

(85kW/115PS) - Zetec - Valve Seals
Print
In-vehicle Repair
Special Tool(s)
303-361 (21-155)

303-361-02 (21-155-02A)
Connector, Air Supply (Cylinder Head)

303-363 (21-157)
Remover, Valve Stem Oil Seal

303-374 (21-160)
Materials
Name Specification
Removal
this section.
Remove the valve tappets and lay them in
order, to one side.
2. WARNING: Always wear protective

goggles when working with compressed air.
Failure to do so can result in injury.
Unscrew the spark plug from cylinder no. 1 and
attach the special tool.
3. CAUTION: Use compressed air at 7 to

10 bar.
Attach the special tools and apply compressed
air to the cylinder.
Take out the valve spring retainer and the
valve spring.
4. Remove the valve stem oil seal.

1. Insert the special tool.

2. Turn the special tool clockwise and pull it
out.
Installation
1. Install the valve stem oil seal.
Coat the valve stem with engine oil .
Cover the valve stem grooves with the oil
seal installation sleeve.
Slide the valve stem oil seals onto the
valve stem and remove the oil seal
installation sleeve.

correctly seated.
retainers.
1. Compress the valve springs.
3. Detach Special Tool 303-363.

4. Repeat the operations for all the other cylinders.
5. Coat the valve tappets with engine oil and insert.
this section.

(85kW/115PS) - Zetec - Valves
Print
In-vehicle Repair
Special Tool(s)
303-361 (21-155)

303-361-02 (21-155-02A)
Remover, Valve Stem Oil Seal

303-374 (21-160)
Materials
Name Specification
Lubricant ESR-M99C80-A
Valve grinding paste Proprietary
Engine oil WSS-M2-C912-A1
Removal
1. NOTE: Lay the cylinder head on the
workbench on a clean surface.
Remove the cylinder head.
For additional information, refer to Cylinder head
in this section.
2. NOTE: Place wooden wedges in the
combustion chamber recesses of the
cylinder head to hold the valves in place
during removal.
Remove the valve.
3. NOTE: Lay all parts in order, to one side.

Remove the valves springs.
4. Remove the valve stem oil seal.
1. Insert the special tool.
2. Turn the special tool clockwise and pull it
out.

5. Repeat the removal steps for the remaining
valves.
Installation
1. NOTE: Follow the procedure recommended
by the grinding paste manufacturer.
NOTE: Install all parts in the same position
from which they were removed.
Regrind the valves usinggrinding paste .
2. Thoroughly clean all components to remove any
traces of grinding paste.
3. Coat valve stem withlubricant and insert.
4. Install the valve stem oil seal.
Cover the grooves in the valve stems with
the oil seal installation sleeve.
Slide the valve stem seal onto the valve
stem and remove the installation sleeve.

correctly seated.
retainers.
6. Repeat the installation steps for the remaining

valves.

7. Install the cylinder head.
For additional information, refer to Cylinder Head
in this section.

(85kW/115PS) - Zetec - Camshafts
Print
In-vehicle Repair
Special Tool(s)
Flange Holding Wrench, Universal
205-072 (15-030A)
Installer, Timing Cover Seal

303-039 (21-009B)
General Equipment
M10 x 70 mm bolt
Materials
Name Specification
Sealer WSK-M2G348-A5
Engine Oil WSS-M2C912-A1
Removal
For additional information, refer to Timing Belt in
this section.
2. NOTE: Only carry out the following step if
reusing the original valve train components.
Check the valve clearance.
For additional information, refer to Valve
Clearance Adjustment in this section.
3. Using the special tool, remove the camshaft
pulleys.
4. CAUTION: Loosen the camshaft bearing

cap retaining bolts in the sequence shown.
NOTE: Working in several stages, release
each camshaft bearing cap retaining bolt two
turns at a time.
Remove the camshafts.
Discard the seals.
Installation
1. Apply sealer to camshaft bearing caps number 0
and 5 in the areas as shown.

2. NOTE: Only rotate the crankshaft in the
Rotate the crankshaft until piston No. 1 is
approximately 60 degrees before top dead center
(TDC).
3. NOTE: Identification numbers are provided
on the outer face of the camshaft bearing
caps.
NOTE: Coat the camshaft and the camshaft
bearing caps with clean engine oil.
Install the camshafts.
4. NOTE: Install the camshafts so that none of

the cams are at full lift.
NOTE: Working in several stages, tighten
each camshaft bearing cap retaining bolt
two turns at a time.
Install the camshaft bearing cap retaining bolts.
Tighten the bolts in the sequence shown
in two stages.
Stage 1: 10 Nm.
Stage 2: 19 Nm.
5. NOTE: Only carry out the following step if

using new valve train components.
Check and adjust the valve clearance.
For additional information, refer to Valve
Clearance Adjustment in this section.
6. NOTE: Coat the camshaft and the oil seal lip
with clean engine oil.
Using the special tool and a M10 x 70 mm bolt,
install the camshaft seals.
7. NOTE: Do not tighten the bolts at this stage.

Using the special tool, install the camshaft
pulleys.

this section.

(85kW/115PS) - Zetec - Camshaft Seal
Print
In-vehicle Repair
Special Tool(s)
205-072 (15-030A)
Installer, Engine Front Cover Oil Seal

303-039 (21-009B)
Materials
Name Specification
Removal
this section.
2. Detach the timing pulleys from the camshafts
using the special tool.
Unscrew the bolts.
3. Detach both front camshaft bearing caps.

Discard the camshaft oil seals.
Installation
1. Thinly coat the camshaft bearing caps with
sealant .

2. Attach both front camshaft bearing caps.
Stage 1: 10 Nm.
Stage 2: 19 Nm.
3. Install the camshaft oil seals using the special

tool.
Lubricate the camshaft and the sealing lip
of the oil seals with engine oil .
Install new oil seals using the special tool,
a washer and an M10x70 bolt.
NOTE: The camshaft timing pulleys
must be able to turn freely on the
camshafts. Do not tighten the bolts.
Attach the camshaft timing pulleys.
4. Install a new timing belt.

this section.

(85kW/115PS) - Zetec - Timing Belt
Print
In-vehicle Repair
Special Tool(s)
205-072 (15-030A)
Alignment Plate, Camshaft

303-376 (21-162B)
Socket, Spark Plug

303-499 (21-202)
Timing Peg, Crankshaft TDC

303-574 (21-163)
General Equipment
Trolley jack
Materials
Name Specification
Removal
1. Disconnect the battery ground cable.
For additional information, refer to: Battery
Disconnect and Connect (414-01 Battery,
Mounting and Cables, General Procedures).
For additional information, refer to: Valve Cover
(303-01A Engine - 1.8L Duratec-DOHC
(85kW/115PS) - Zetec, In-vehicle Repair).
Installation).
Rotate the crankshaft until piston No. 1 is at top
dead center (TDC).
5. Remove the blanking plug and install the special

tool.

6. Remove the crankshaft pulley.
7. Remove the timing belt lower cover.

wheel housing and position it to one side.

the wheel housing and position it to one side.
11. Using a trolley jack and a suitable wooden block

under the oil pan, raise the engine so that the
engine front mount is free from load.
12. Remove the engine front mount.

13. Remove the engine front mount retaining
bracket.
14. Remove the timing belt upper cover.
15. Using the special tool, remove the spark plugs.
16. Slacken the timing belt tensioner.

1. Loosen the bolt and rotate the timing belt
tensioner washer clockwise.
2. Remove the bolt and the timing belt
tensioner and discard it.
17. Remove the timing belt (engine shown removed

for clarity).
Discard the timing belt.

Installation
1. Using the special tool, loosen the camshaft pulley
retaining bolts.
2. Install the special tool.
3. CAUTIONS:
Do not kink the timing belt, the bend

diameter must not be less than 35 mm.
Do not rotate the crankshaft. If

necessary check if the crankshaft is touching
the timing peg.
NOTE: The clip of the timing belt tensioner
must not be hooked into the pressed steel
cover.
NOTE: Install a new timing belt.
Install the timing belt.

Beginning with the crankshaft timing
pulley, working counterclockwise.
4. Make sure that piston No. 1 is still at top dead

center (TDC).
5. NOTE: Make sure that a new component is
installed.
Rotate the timing belt tensioner washer
counterclockwise, tension the timing belt.
1. Hook the timing belt tensioner into the
pressed steel cover.
2. Rotate the timing belt tensioner washer
counterclockwise until the arrow points the
mark and tighten the bolt.
3. Check if the arrow points the mark after
tightening the bolt.
6. Using the special tool, tighten the camshaft
pulley retaining bolts.


Operation).

Using the crankshaft pulley, rotate the
crankshaft two revolutions until piston No. 1 is at
TDC.

Rotate the crankshaft against the special
tool.
12. Remove the crankshaft pulley.

14. CAUTION: It is possible that the timing

belt tensioner marks do not align after
rotating the crankshaft. Do not re-tighten
the timing belt if the timing belt tensioner
marks do not align.
Install the special tool, check the valve timing.
Loosen the camshaft pulleys, correct the
camshaft alignment if necessary.

Operation).

18. Install the blanking plug.

20. Apply sealer to the camshaft front bearing caps.
21. Using the special tool, install the spark plugs.
22. NOTE: Do not tighten the bolts at this stage.

Install the timing belt upper cover.
23. Install the engine front mount retaining bracket.

24. Install the engine front mount.

wheel housing.
26. Attach the coolant expansion tank to the wheel

housing.
27. Remove the trolley jack .

Operation).
29. Install the timing belt lower cover.

30. Install the crankshaft pulley.
31. Install the accessory drive belt.

Installation).
(303-01A Engine - 1.8L Duratec-DOHC
(85kW/115PS) - Zetec, In-vehicle Repair).
33. Connect the battery ground cable.
Installation).

(85kW/115PS) - Zetec - Exhaust Manifold
Print
In-vehicle Repair
Removal
1. Raise the vehicle.For additional information, refer
to Section 100-02 Jacking and Lifting.
2. Detach the exhaust manifold bracket and
disconnect the plugs for the heated oxygen
sensor (H02S).

4. Detach the heat shield.
5. Detach the exhaust manifold from the catalytic

converter.
6. Detach the exhaust manifold from the cylinder

head.
Installation
1. Attach the exhaust manifold to the cylinder
head.

2. NOTE: Renew the gasket.
Attach the exhaust manifold to the catalytic
converter.
3. Attach the heat shield.

5. Tighten the exhaust manifold bracket and
connect the HO2S plugs.

(85kW/115PS) - Zetec - Cylinder Head
Print
In-vehicle Repair
Special Tool(s)
Socket Wrench, Cylinder Head Bolts
303-392 (21-167)
Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
General Equipment
Spatula
Materials
Name Specification
Engine Oil WSS-M2C912-A1
Removal
1. Release the fuel system pressure. For additional
information, refer to Section 310-00A Fuel
System - General Information / 310-00B Fuel
2. Drain the cooling system. For additional
information, refer to Section 303-03 Engine
Cooling.
3. Using a suitable splint or wrap, support the
exhaust flexible pipe.
4. Detach the catalytic converter bracket from the

engine.
5. Disconnect the oil pressure switch electrical

connector.

6. Disconnect the brake booster pipe from the
intake manifold.

8. Disconnect the fuel supply and return line quick

release couplings. For additional information,
refer to Section 310-00A Fuel System - General
Information / 310-00B Fuel System - General
Information.
9. Disconnect the ground cable from the engine

front lifting eye.

body.

11. Remove the exhaust manifold heat shield.
12. Detach the power steering pipe bracket and the

oil level indicator tube from the cylinder head.
13. Detach the catalytic converter from the exhaust

manifold and secure it to the radiator grille
opening panel.
Discard the gasket.
14. Detach the electronic ignition (EI) coil from the

cylinder head.
15. Detach the thermostat housing from the cylinder

head.

(PCV) hose from the PCV tube.
17. Detach the coolant distribution pipe from the

radiator grille opening panel.
Detach the degas hose from the coolant
distribution pipe.
18. Remove the power steering pump bracket upper

retaining bolts.
19. Remove the exhaust manifold (engine shown

Discard the gasket.
20. Detach the generator from the generator

bracket.
1. Loosen the bolt.
2. Remove the bolt.

21. Remove the generator bracket upper retaining
bolt.

this section.
23. CAUTIONS:
The cylinder head bolts can only be

reused twice. Stamp the bolts to indicate
usage.
The cylinder head must have cooled to

below 30°C before removal.
Using the special tool, remove the cylinder head
bolts in the sequence shown.
Discard the cylinder head gasket.
Discard the cylinder head bolts as
necessary.
24. NOTE: Place the cylinder head on a clean
surface.
Installation
1. Check the cylinder head for distortion. For
Engine System - General Information.
2. Fabricate two locating studs as shown.

3. CAUTION: The choice of cylinder head
gasket depends on the cast cylinder block
number.
Check the cylinder block number.
4. Position a new cylinder head gasket on the
cylinder block.
Check that the guide bushes are correctly
seated.
5. Install the fabricated locating studs.

Remove the locating studs.
7. NOTE: Install new cylinder head bolts as
necessary.
Using the special tool, tighten the cylinder head
bolts in the sequence shown in three stages.
Stage 1: 20 Nm.
Stage 2: 40 Nm.
Stage 3: 90 degrees.

this section.
9. NOTE: Install a new exhaust manifold
gasket.
NOTE: Install new spacers to the outer
studs.
Install the exhaust manifold (engine shown
10. Install the power steering pump bracket upper

retaining bolts.

11. Install the generator bracket upper retaining
bolt.
12. Attach the generator to the generator bracket.
13. NOTE: Install a new O-ring seal.

Attach the thermostat housing to the cylinder
head.
14. Connect the positive crankcase ventilation (PCV)

hose to the PCV tube.
15. Attach the coolant distribution pipe to the

radiator grille opening panel.
Attach the degas hose to the coolant
distribution pipe.

16. Attach the electronic ignition (EI) coil to the
cylinder head.
17. Attach the oil level indicator tube and the power
steering pipe bracket to the cylinder head.
18. NOTE: Install a new catalytic converter

gasket.
Attach the catalytic converter to the exhaust
manifold.
19. Install the exhaust manifold heat shield.
20. Connect the fuel supply and return line quick

release couplings. For additional information,
Information.

21. Connect the ground cable to the engine front
lifting eye.

23. Connect the vacuum hoses to the throttle body.

Lifting.
25. Connect the oil pressure switch electrical
connector.
26. Connect the brake booster pipe to the intake

manifold.

27. Attach the catalytic converter bracket to the
engine.
28. Detach the wrap from the exhaust flexible pipe.
29. Fill and bleed the cooling system. For additional

Cooling.
30. NOTE: Install a new oil filter.
Change the engine oil .

(85kW/115PS) - Zetec - Oil Pump
Print
In-vehicle Repair
General Equipment
Knife-edge straight-edge
Removal
1. Remove the crankshaft front oil seal.
For additional information, refer to Crankshaft
front oil seal - in this section.
2. Detach the air conditioning compressor from the
bracket and secure it on the radiator
crossmember.
3. Remove the A/C compressor bracket (engine

4. Remove the intermediate shaft centre bearing

bracket.
5. Remove the oil pan.

For additional information, refer to Oil Sump in
this section.
6. Remove the oil intake tube.

7. CAUTION: Make a note of the
installation position of the adjusting shims
between the transmission and lower
crankcase for use during installation. The
adjusting shims must be put back in their
original positions when the oil pump is
installed.
Remove the lower crankcase (shown with engine
Discard the gasket.
8. Remove the auxiliary drive belt tensioner.
9. Remove the oil pump (shown with engine

Discard the gasket.
Installation
1. NOTE: Renew the oil pump gasket.
NOTE: Do not fully tighten the oil pump
Install the oil pump (shown with engine removed
for clarity).
2. Align the oil pump on both sides using a knife-

edge straight-edge so that the contact surface
lies 0,3 mm - 0,8 mm above the lower edge of
the cylinder block.
3. Tighten the oil pump bolts in two stages (engine

Stage 1: 6 Nm

4. Install the auxiliary drive belt tensioner.
5. CAUTION: Make sure that all the

adjustment shims between the transmission
and lower crankcase are reinstalled in their
original positions.
NOTE: First tighten the bolts on the
transmission.
NOTE: Install a new ladder frame gasket.
Install the lower crankcase (shown with engine
6. NOTE: Renew the oil intake tube O-ring.

Install the oil intake.
7. Install the oil sump.

For additional information, refer to Oil Sump in
this section.
8. Install the intermediate shaft centre bearing
bracket.
9. Install the A/C compressor bracket (engine


10. Install the air conditioning compressor on the
bracket
11. Install the front crankshaft oil seal.

For additional information, refer to Crankshaft
front oil seal - in this section.

(85kW/115PS) - Zetec - Crankshaft Rear Transit/Tourneo Connect 2002.5 (06/2002-)
Seal
Print
In-vehicle Repair
Special Tool(s)
Centring tool, clutch disc
308 - 204 (16067)
Locking tool, flywheel

303 - 254 (21135)
Puller, oil seal

303 - 291 (21141)
Remover, oil seal

303 - 293 (21143)
Materials
Name Specification
High-temperature ESD - M1C220 - A
grease
Removal
1. Detach the clutch.
Lock the flywheel using Special Tool 303-
254.
Slacken the bolts of the clutch pressure
plate evenly.
Detach the clutch pressure plate and the
clutch disc.
2. NOTE: Mark the installation position.

Detach the flywheel.
Remove Special Tool 303-254.
3. Remove the oil seal.

Installation
1. CAUTION: The oil seal must be installed

in Special Tool 303-291 as far as the stop.
Fit the new crankshaft rear seal in the Special
Tool.
To ensure correct installation, place the
special tool on a vice and press in the oil
seal using a hammer handle.
1 Incorrect installation
2 Correct installation
2. Draw in the oil seal.

Draw in the oil seal with the special tool
and two flywheel bolts.
3. NOTE: Clear the remainder of the locking

compound from the threaded holes on the
crankshaft.
NOTE: Use new bolts.
Attach the flywheel.
4. NOTE: Apply a layer of high-temperature

grease. This should be so thin that no grease
is expelled from the splines when the clutch

disc is pushed on to the transmission input
shaft.
Coat the drive splines of the clutch disk evenly
with high-temperature grease.
5. Center the clutch disc on the clutch pressure
plate.
6. Install the clutch.

1. Install the clutch pressure plate with
centered clutch disc.
2. Working diagonally, tighten the bolts in
several stages one turn at a time.
3. Check the centering and correct if
necessary.
7. Detach the special tools.

(85kW/115PS) - Zetec - Valve Cover
Print
In-vehicle Repair
Removal
the throttle body bracket.
2. Disconnect the spark plug electrical connectors.

(PCV) hose from the valve cover.
4. NOTE: Do not remove the timing belt upper

cover at this stage.
Loosen the timing belt upper cover retaining
bolts.

Installation
1. NOTE: Install a new valve cover gasket if
necessary.

(85kW/115PS) - Zetec - Oil Pan
Print
In-vehicle Repair
Special Tool(s)
Slide Hammer
205-047 (15-011)
Adapter for 205-047

303-633 (21-227)
General Equipment
Ten M6 x 20 mm studs
Materials
Name Specification
Sealer WSE-M4G323-A6
Removal
1. Remove the catalytic converter. For additional
information, refer to Section 309-00 Exhaust
System.
2. Drain the engine.
container.
3. Remove the oil pan retaining bolts.
4. CAUTION: To prevent damage to the

sealing surface, only use the special tool
shown to remove the oil pan.
NOTE: Tighten the locknut against the oil
pan and tap the special tool several times to
release the oil pan from the lower crankcase.
Using the special tool, remove the oil pan.
Installation
1. NOTE: Do not damage the mating faces.
Clean the mating faces.
2. NOTE: The mating faces must be free from
oil and sealer residue.

Clean all traces of oil residue from the oil pan.
3. CAUTION: The lower crankcase may be

damaged if sealer enters the blind holes.
Install ten M6 x 20 mm studs into the indicated
blind holes (engine shown removed for clarity).
4. NOTE: Install the oil pan within ten minutes

of applying the sealer.
Apply a 3 mm diameter bead of sealer to the oil
pan mating face.
5. NOTE: The oil pan must not be removed once

it comes into contact with the lower
crankcase housing.
Install the oil pan.
Remove the ten M6 x 20 mm studs.
6. Install the oil pan retaining bolts.
Tighten the bolts in the sequence shown in
two stages.
Stage 1: 6 Nm.
Stage 2: 10 Nm.
7. NOTE: Inspect the oil drain plug seal for

damage. Install a new oil drain plug and seal
if necessary.
Install the oil pan drain plug.
8. Install the catalytic converter. For additional

information, refer to Section 309-00 Exhaust
System.
9. Fill the engine with engine oil.
For additional information, refer to Specification
in this section.

Print
Removal
Special Tool(s)
Lifting Bracket, Engine
303-122 (21-068A)
Remover/Installer, Hose Clamp

303-397 (24-003)
Remover, Halfshaft
308-192 (16-057)
General Equipment
Workshop table
Retaining straps
Engine hoist
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable vapors are always
present and may ignite. Failure to follow these instructions may result in personal injury.
nuts by three turns on both sides.
4. Disconnect the ground cable from the body.


the accelerator cable bracket.
6. Disconnect the ignition coil electrical connector.
7. Disconnect the transaxle wiring harness electrical

connector.

line from the fuel rail.
9. Disconnect the ground cable from the engine

front lifting eye.
10. Disconnect the powertrain control module (PCM)


11. Disconnect the generator electrical connector.
12. Disconnect the brake booster vacuum pipe from

the brake booster.

body.
14. Disconnect the power steering hose from the

container.
15. Disconnect the transaxle ventilation hose from

the transaxle.

paintwork, the affected area must be
Disconnect the clutch slave cylinder hydraulic
fluid supply line from the transaxle.
Remove the spring clip.
17. Disconnect the reversing lamp switch electrical

connector.
18. Disconnect the catalyst monitor sensor electrical

connector.
19. Disconnect the heated oxygen (HO2S) sensor


Cooling.
21. Remove the accessory drive belt. For additional
information, refer to Section 303-05 Accessory
Drive.

22. Remove the crossmember. For additional
information, refer to Section 502-00 Uni-Body,
Subframe and Mounting System.
23. Remove the flexible exhaust pipe.
Discard the gaskets.
24. Detach the air conditioning (A/C) compressor

from the bracket and secure it to one side.
25. Disconnect the power steering pressure (PSP)

26. Using the special tool, disconnect the coolant

hose from the water pump.
27. Remove the intermediate shaft center bearing

cap.
Discard the center bearing cap and
locknuts.
28. CAUTIONS:

degrees.
Cap the transaxle to prevent oil loss or

dirt ingress.
Detach the right-hand halfshaft and the
intermediate shaft from the transaxle and secure
it to one side.
container.
29. CAUTIONS:

degrees.
Cap the transaxle to prevent oil loss and

dirt ingress.
Using the special tool, detach the left-hand
halfshaft from the transaxle and secure it to one
side.
container.
30. Disconnect the vehicle speed sensor (VSS)
31. Disconnect the crankshaft position (CKP) sensor

32. Detach the gearshift cables from the transaxle.

1. Detach the gearshift cable (colored white)
and the selector cable (colored black) from
the selector levers.
2. Turn the abutment sleeves clockwise and

detach the cables from the bracket.
33. WARNING: Support the engine and

transaxle assembly on wooden blocks and
secure it with suitable retaining straps.
Failure to follow these instructions may
Position the workshop table under the vehicle
and carefully lower the vehicle, until the engine
and transaxle assembly is supported by the
workshop table.
34. Using the special tool, disconnect the coolant

hoses from the thermostat housing.
35. Disconnect the coolant hose from the coolant

distribution pipe.
36. Remove the engine rear mount center retaining

nut.
Discard the nut.
37. Remove the engine front mount retaining nuts.

Discard the nuts.

38. Raise the vehicle and remove the engine and
transaxle assembly.
39. Using the special tool, attach the engine and
transaxle assembly to the engine hoist.
40. Remove the starter motor and the ground cable.
41. Remove the transaxle left-hand retaining bolts.
42. Remove the transaxle right-hand retaining bolts.
43. Remove the transaxle.

Print
Disassembly
Special Tool(s)
Slide hammer
205-047 (15-011)

205-072 (15-030A)
Lifting bracket, engine

303-122 (21-068A)
Immobiliser, flywheel
303-254 (21-135)
Socket, cylinder head cover

303-293 (21-143)
Mounting Bracket for 303-435

303-435-04 (21-064)
Mounting Plate for 303-435-04

303-435-12A (21-150B)
Adapter for 205-047

303-633 (21-227)
Disassembly
1. Disconnect the plug of the oil pressure switch.
2. Remove the oil pressure switch.

3. Remove the lower bolts from the intake
manifold.
4. Remove the intake manifold.
5. Remove the generator.

1. Remove the positive cable.
2. Unscrew the bolt.
3. Undo the bolt.
6. Remove the generator bracket.
7. Remove the oil filter.

Discard the oil filter.

10. Attach the engine to the assembly stand.

11. Remove the special tool .
12. Remove the catalytic converter support bracket.

14. Remove the front retaining strap of the catalytic
converter.
15. Remove the catalytic converter.
16. Remove the oil level indicator and tube.
17. Remove the power steering pump bracket.
18. Remove the A/C compressor bracket.

19. Remove the positive crankcase ventilation (PCV)
housing.
20. Remove the water pump pulley.
21. Remove the auxiliary drive belt idler pulley.
22. Remove the front engine mounting bracket.
23. Remove the upper timing belt cover.

24. Immobilize the flywheel with the special tool.
25. Remove the crankshaft belt pulley.
26. Remove the lower timing belt cover.
27. Lock the flywheel using the special tool and

undo the clutch disc and pressure plate bolts by
two turns.
28. Remove the clutch disc and pressure plate.

29. Using the special tool, immobilize the flywheel
and remove the flywheel.
Discard the bolts.

31. CAUTION: Do not pull the cable when

removing the spark plug connector. If
necessary, remove the ignition cables from
the ignition coil to avoid kinking the cables.
Turn the spark plug connector slightly before
removing to loosen the seal.
Detach the ignition cables from the spark plugs.
32. Remove the spark plugs.
33. Remove the cylinder head cover.
34. Slacken the timing belt.

1. Undo the bolts and turn the washer of the
timing belt tensioner clockwise.
2. Loosen the bolts by a further four turns
and unhook the timing belt tensioner.

36. Remove the timing belt idler pulley.

37. Remove the timing belt tensioner.
38. Detach the crankshaft timing pulley and the

timing belt thrust washer.
39. Remove the water pump.
40. Remove the camshaft timing pulley using the

special tool.
41. NOTE: Loosen the camshaft bearing cap

bolts by two turns each.
Remove the camshafts.
Discard the oil seals.

42. CAUTIONS:
Mark the bolts to be reused with one or

two punch marks as applicable. Bolts can be
reused twice. If necessary, discard the bolts.
Only undo the cylinder head bolts once

the cylinder head temperature has dropped
below 30 degrees C.
Remove the cylinder head bolts in the sequence
shown.
43. Remove the cylinder head.
Discard the cylinder head gasket.
Collect the engine oil in a suitable
container.
45. Remove the oil pan bolts.
46. Remove the oil pan using the special tool.
47. Remove the oil intake tube.


48. Remove the ladder frame.
Discard the gasket.
49. Remove the front crankshaft oil seal using the

special tool.
50. Remove the oil pump.

Discard the gasket.
51. Remove the crankshaft position (CKP) sensor

and the CKP sensor bracket.
52. Remove the crankshaft rear oil seal carrier.

Discard the gasket.
Discard the oil seal.

Print
Assembly
Special Tool(s)
205-072 (15-030A)
Installer, timing cover oil seal

303-039 (21-009B)
Lifting bracket, engine

303-122 (21-068A)
Immobiliser, flywheel
303-254 (21-135)
Installer, crankshaft rear oil seal

303-291 (21-141)
Timing Plate, Camshaft Alignment

303-376 (21-162 B)
Socket, Cylinder Head Bolt

303-392 (21-167)
Installer, crankshaft oil seal

303-395 (21-171)

303-435-04 (21-064)

303-435-12A (21-150B)
Timing Peg, Crankshaft

303-574 (21-163)
Installer, crankshaft front oil seal

303-684 (21-243)
Centering tool, clutch disc

308-204 (16-067)
General Equipment
Steel straightedge
Workshop hoist
Studs M6 x 1020
Bolt, M8 x 40
Bolt M10 x 70
Materials
Name Specification
High-temperature ESD-M1C220-A
grease
Sealant WSK-M4G320-A
Sealant WSS-M4G323-A7
Assembly
1. NOTE: Install a new oil seal in the crankshaft
rear oil seal carrier.
NOTE: Do not tighten the bolts of the
crankshaft rear oil seal carrier for the
moment.
Install the rear crankshaft oil seal carrier.
2. Install the crankshaft position (CKP) sensor and

the CKP sensor bracket.
3. CAUTION: The new crankshaft rear oil

seal must be fully installed in the special
tool.
NOTE: Install the new crankshaft rear oil
seal.
Install the crankshaft rear oil seal using the
special tool and two used flywheel bolts.

5. NOTE: Install a new oil pump gasket.
NOTE: Do not tighten the oil pump bolts for

the moment.
Install the oil pump.
6. NOTE: Align the oil pump on both sides so
that the mating face is between 0.3 mm and
0.8 mm above the lower edge of the cylinder
block.
Align the oil pump using a steel rule.
7. NOTE: Install the new crankshaft front oil

seal.
Slide the crankshaft front oil seal onto the
special tool.
8. NOTE: For the moment, do not fully install

the crankshaft front oil seal.
NOTE: The crankshaft journals must be clean
and free of oil or grease.
Slide the crankshaft front oil seal with the special
tool onto the crankshaft.

10. Install the crankshaft front oil seal and
crankshaft pulley bolt.
11. Remove the special tool and the crankshaft

pulley bolt.
12. Tighten the oil pump bolts in two stages.
Stage 1: 6 Nm
Stage 2: 45 degrees

13. NOTE: The lower crankcase must by
tightened to the specified torque within 10
minutes of applying the sealant.
NOTE: If the permissible amounts for
protrusions and/or gaps are exceeded, then
fit spacer shims as described in the next
step.
NOTE: Install a new lower crankcase gasket.
NOTE: Do not tighten the lower crankcase
bolts for the moment.
Align the lower crankcase using a steel rule.
max. protrusion: 0.10 mm
Max. gap: 0.25 mm
Apply sealant to the transitions between
the cylinder block and the oil pump and
the cylinder block and oil seal carrier.
14. If necessary, install lower crankcase spacer
shims.
with a gap of 0.26 - 0.50 mm, install 0.25
mm spacer washers.
with a gap of 0.51 - 0.75 mm, install 0.50
mm spacer washers.
15. Tighten the lower crankcase bolts.
16. NOTE: Install a new oil intake O-ring.

Install the oil intake.
17. Screw 10 M6 x 20 studs into the blind holes

shown.

18. CAUTION: Install the oil pan within ten
minutes of applying the sealant and tighten
the bolts within a further 5 minutes.
Apply a 3 mm diameter bead of sealant to the
oil pan.
19. Install the oil sump.

Remove the M6 x 20 studs.
20. Tighten the oil pan bolts in two stages.
Stage 1: 6 Nm
Stage 2: 10 Nm
21. NOTE: Check the seal of the oil drain plug for
damage. If necessary install a new oil drain
plug and seal.
Install the oil drain plug.
22. Immobilize the flywheel with the special tool.
23. NOTE: Install new flywheel bolts.

NOTE: Remove any residual thread-locking
compound from the threaded bores.
Install the flywheel.
24. NOTE: Apply a layer of high-temperature

grease. This should be so thin that no grease
is expelled from the splines when the clutch

disc is pushed on to the transmission input
shaft.
Evenly coat the splines of the clutch disc with
high-temperature grease.
25. Center the clutch disc on the clutch pressure
plate using the special tool.
26. Install the clutch disc and pressure plate.

1. Position the clutch pressure plate with the
centered clutch disc.
2. Working diagonally in several stages,
tighten the bolts a turn at a time.
3. Check the centering and correct as
necessary.
27. Make two guide studs as shown in the diagram.
28. CAUTION: The choice of cylinder head

gasket depends on the cast cylinder block
number.
Check the cylinder block number.
29. NOTE: Install a new cylinder head gasket.
Lay a new cylinder head gasket on the cylinder
block.
30. Install the prepared locating studs.

Remove the prepared locating studs.
32. CAUTION: Do not re-torque the cylinder

head bolts.
NOTE: Screw in the cylinder head bolts free
of oil.
NOTE: Install new cylinder head bolts as
necessary.
Install the cylinder head bolts.
Tighten the bolts in the sequence shown,
in three stages.
Stage 1: 20 Nm
Stage 2: 40 Nm
33. NOTE: Identification numbers are provided
on the outer face of the camshaft bearing
caps.
Apply sealant to the marked areas on camshaft
bearing caps 0 and 5.

Turn the crankshaft until piston no. 1 is approx.
60 degrees before top dead centre (TDC).
35. NOTE: The identification numbers are located
on the outside of the camshaft bearing caps.
NOTE: Lay the camshaft in place so that
none of the cams is at full lift.
NOTE: Apply clean engine oil to the
camshafts and camshaft bearing caps.
Install the camshafts.
36. NOTE: Screw in the camshaft bearing cap

bolts evenly, in the sequence shown, a half
turn at a time and tighten them in two
stages.
Tighten the camshaft bearing caps in two
stages.
Stage 1: 10 Nm

Stage 2: 19 Nm
37. NOTE: Apply clean engine oil to the

camshafts and camshaft oil seal lips.
Install the camshaft oil seals using the special
tool, a washer and a M10 x 70 bolt.
38. NOTE: Do not tighten the bolt of the

crankshaft pulley for the moment.
Install the crankshaft belt pulley.

Turn the crankshaft until no. 1 piston is at TDC.
41. NOTE: Cylinders 1 and 4 are at TDC when

the Woodruff key is pointing towards the
pistons.
Remove the lower cylinder block plug and install
the special tool.

42. Turn the camshafts until the cams of cylinder no.
1 are at TDC and insert the special tool into the
camshafts.
43. NOTE: Do not tighten the camshaft pulley

Install the camshaft timing pulleys.
44. NOTE: Install a new coolant pump gasket.

Install the coolant pump gasket.
1. Lay the gasket in place.
2. Secure the gasket by bending over the
tabs.
45. Install the water pump.
46. NOTE: Pay attention to the installation

position of the crankshaft thrust washer.
Install the crankshaft timing pulley and the
thrust washer.

installed.
NOTE: Do not tighten the bolt of the timing
belt tensioner for the moment.
Install the timing belt tensioner.
48. Install the timing belt idler pulley.
49. CAUTIONS:
Do not kink the timing belt (bend

diameter must not be less than 35 mm).
Do not turn the crankshaft. If necessary

check whether the crankshaft is touching
Special Tool 303-574.
NOTE: The clip of the timing belt tensioner
must not be hooked into the pressed steel
cover.
Starting from the crankshaft timing pulley
and working anti-clockwise, put the timing
belt in place. Pull the belt tight as you
proceed.

installed.
Tension the timing belt.
1. Hook the timing belt tensioner into the
metal cover.

2. Turn the timing belt tensioner washer anti-
clockwise until the arrow and mark line up
and tighten the bolt.
3. After tightening the bolt check whether the
marks still line up.
51. Tighten the camshaft timing pulley bolt using the

special tool.
54. NOTE: Do not tighten the bolt of the

crankshaft pulley for the moment.
Install the crankshaft belt pulley.

Turn the crankshaft two turns until no. 1 piston
is at TDC.

58. CAUTION: If the timing belt tensioner

marks do not line up, the timing belt must
not be re-tensioned.
Install the special tool and check the valve
timing.
Loosen the camshaft pulley bolts to adjust
the valve timing.

60. Install the lower cylinder block plug.
61. Apply sealant thinly to the areas of the camshaft

front bearing caps shown.

62. NOTE: Install a new cylinder head cover seal
if necessary.
Install the cylinder head cover.
Tighten the bolts in two stages.
Stage 1: 2 Nm
Stage 2: 7 Nm
63. Install the spark plugs.
64. Install the ignition cables.
65. Install the lower timing belt cover.
66. Install the crankshaft belt pulley.

68. NOTE: Do not tighten the bolts of the timing

belt upper cover for the moment.
Install the timing belt upper cover.
69. Install the front engine mounting bracket.
70. Tighten the bolts of the timing belt upper cover.
71. Install the auxiliary drive belt idler pulley.

72. Install the water pump pulley.
73. NOTE: Install a new gasket for the housing

of the positive crankcase ventilation (PCV).
Install the PCV housing.
1. Tighten the bolts of the PCV housing.
2. Tighten the bolts of the PCV pipe.
74. Install the A/C compressor bracket.
75. Install the power steering pump bracket.
76. Install the oil level indicator and tube.

77. Loosen the bolts of the rear retaining strap of the
catalytic converter.
78. NOTE: Install a new catalytic converter

gasket.
NOTE: Do not tighten the catalytic converter
Install the catalytic converter.
79. Loosely attach the catalytic converter to the

catalytic converter bracket using M8 x 40 bolts.
80. Tighten the catalytic converter bolts.
81. Install the front retaining strap of the catalytic

converter.

82. Tighten the bolts of the rear retaining strap of
the catalytic converter.
83. Remove the M8 x 40 bolts.
84. Install the exhaust manifold heat shield.
86. Detach the engine from the assembly stand.


89. NOTE: Install the new oil filter.

Install the oil filter.
90. Install the generator bracket.
91. Install the generator.

1. Screw in and tighten the bolt.
2. Tighten the bolt.
3. Install the positive lead.
92. NOTE: If necessary install a new intake

manifold gasket.
Install the intake manifold.

93. Install the lower bolts of the intake manifold.
94. Install the oil pressure switch.
95. Push on the oil pressure switch connector.

Print
Installation
Special Tool(s)
303-122 (21-068A)

303-397 (24-003)
General Equipment
Workshop table
Retaining straps
Engine hoist
working on or near any fuel related components. Highly flammable vapors are always

transaxle assembly on wooden blocks and
secure it with suitable retaining straps.
Using the special tool and the engine hoist,
position the engine and transaxle assembly on
the workshop table.
2. Install the transaxle left-hand retaining bolts.
3. Install the transaxle right-hand retaining bolts.
4. Install the starter motor and the ground cable.

5. Remove the engine hoist.
Lifting.
7. Position the engine and transaxle assembly in
the engine compartment.
Carefully lower the vehicle until the engine
and transaxle assembly is supported by
the workshop table.
8. NOTE: Install new engine front mount

retaining nuts.
NOTE: Do not tighten the engine front mount
Install the engine front mount retaining nuts.
9. NOTE: Install a new rear mount center

retaining nut.
NOTE: Do not tighten the engine rear mount
center retaining nut at this stage.
Install the engine rear mount center retaining
nut.
10. Raise the vehicle and remove the workshop

table.
11. Attach the gearshift cables to the transaxle.
Attach the gearshift cables to the bracket
and turn the abutment sleeves
counterclockwise.

12. Connect the crankshaft position (CKP) sensor
13. Connect the vehicle speed sensor (VSS)

14. CAUTIONS:

45 degrees.

NOTE: Install a new center bearing cap and
locknuts.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.
locknuts.
15. CAUTIONS:

degrees.
Make sure the snap ring is correctly

seated.

16. Using the special tool, connect the coolant hose
to the water pump.
17. Connect the power steering pressure (PSP)

18. Attach the air conditioning (A/C) compressor to

the bracket.
19. NOTE: Install new flexible exhaust pipe

gaskets.
Install the flexible exhaust pipe.
20. Install the crossmember. For additional

21. Install the accessory drive belt. For additional
Drive.
23. Tighten the engine front mount retaining nuts.

24. Tighten the engine rear mount center retaining
nut.
25. Using the special tool, connect the coolant hoses

to the thermostat housing.
26. Using the special tool, connect the coolant hose

to the coolant distribution pipe.
27. Connect the heated oxygen (HO2S) sensor

28. Connect the catalyst monitor sensor electrical

connector.

29. Connect the reversing lamp switch electrical
connector.

NOTE: Make sure the spring clip is correctly
seated.
Connect the clutch slave cylinder supply
hydraulic fluid line to the transaxle and install
the spring clip.
31. Connect the transaxle ventilation hose to the

transaxle.
32. Connect the power steering hose to the power

steering fluid reservoir.
33. Connect the vacuum hose to the throttle body.

34. Connect the brake booster vacuum pipe to the
brake booster.
35. Connect the generator electrical connector.
36. Connect the powertrain control module (PCM)

37. Connect the ground cable to the engine front

lifting eye.
38. Connect the fuel supply line and fuel return line
to the fuel rail.

39. Connect the transaxle wiring harness electrical
connector.
40. Connect the ignition coil electrical connector.
41. Attach the accelerator cable to the throttle body.

1. Attach the accelerator outer cable to the
accelerator cable bracket.
2. Attach the accelerator inner cable to the
throttle body lever.
42. Connect the ground cable to body.

nuts on both sides.

44. Check the transaxle fluid level and top up with
manual transmission fluid, if necessary. For
46. Bleed the hydraulic clutch system. For additional
Transmission/Transaxle and Clutch - General
Information.
47. Adjust the gearshift cables. For additional
Information.
48. Connect the battery ground cable. For additional
and Filtering.
Cooling.

Engine Data — 75/76 PS
Description
Code BHPA P7PA/R2PA
Emission level Stage III Stage IV
Firing order 1-3-4-2 1-3-4-2
Bore diameter 82.5 mm 82.5 mm
Stroke 82 mm 82 mm
Displacement 1753 cc 1753 cc
Compression ratio 19.4 : 1 19.4 : 1
Power output at 4000 rpm 55 kW (75 PS) 56 kW (76 PS)
Torque at 1800 rpm 175 Nm 175 Nm
Idle speed 825 rpm 825 rpm
Maximum oil consumption 0.1L/1000km 0.1L/1000km
Engine Data — 90/91 PS
Code HCPA P9PA/R3PA

Emission level Stage III Stage IV
Firing order 1-3-4-2 1-3-4-2
Bore diameter 82.5 mm 82.5 mm
Stroke 82 mm 82 mm
Displacement 1753 cc 1753 cc
Compression ratio 19.4 : 1 19.4 : 1
Power output at 4000 rpm 66 kW (90 PS) 67 kW (91 PS)
Torque at 2000 rpm 200 Nm 200 Nm
Idle speed 900 rpm 900 rpm
Maximum oil consumption 0.1L/1000km 0.1L/1000km
Engine Data — 110 PS
Description
Engine code RWPA
Emission level Stage IV
Firing order 1-3-4-2
Bore diameter 82.5 mm
Stroke 82 mm
Displacement 1753 cc
Compression ratio 17 : 1
Maximum power output at 3700 rpm 81 kW (110 PS)
Torque at 1250 rpm 196 Nm
Maximum torque at 1900 rpm 280 Nm
Idle speed 850 rpm
Maximum oil consumption 0.1L/1000 km
Engine Oil Capacity
Description Liters
Initial fill including oil filter 6.1
Service fill including oil filter 5.6
Service fill without oil filter 5.0
Cylinder Block Dimensions
Description mm
Cylinder bore diameter — Class 1 82.500 - 82.515
Cylinder bore diameter — Class 2 82.515 - 82.530
Main bearing parent bore diameter 57.683 - 57.696
Piston Dimensions
Description mm
Piston diameter — Class 1 82.410 - 82.425
Piston diameter — Class 2 82.425 - 82.440
Piston ring end gaps
— upper compression ring 0.310 - 0.500
— lower compression ring 0.310 - 0.500
— oil control ring 0.250 - 0.580
Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring gaps at 120 degrees to each other.
Crankshaft Dimensions
Description mm
Main bearing journal end float 0.110 - 0.370
Main bearing journal diameter 53.970 - 53.990
Connecting rod bearing journal diameter 48.970 - 48.990
Connecting Rod Dimensions
Description mm
Large end bore diameter 52.000 - 52.020
Small end bore diameter 26.012 - 26.020
Connecting rod bearing radial clearance 0.016 - 0.074
Piston Pin Dimensions
Description mm
Piston pin diameter 27.996 - 28.000
Camshaft Dimensions
Description mm
Camshaft end float 0.100 - 0.240
Camshaft bearing journal diameter 27.960 - 27.980
Cylinder Head Dimensions
Description mm
Valve guide inner diameter 8.000 - 8.025
Intake valve clearance 0.300 - 0.400
Exhaust valve clearance 0.450 - 0.550
Camshaft bearing parent bore diameter 30.500 - 30.525
Maximum distortion — measured longitudinally and diagonally 0.600
Thickness of cylinder head gasket with piston protrusion of 0.550 mm - 0.600 mm 1.270 (two tooth marks)
Thickness of cylinder head gasket with piston protrusion of 0.601 mm - 0.650 mm 1.320 (three tooth marks)
Thickness of cylinder head gasket with piston protrusion of 0.651 mm - 0.700 mm 1.370 (four tooth marks)
Thickness of cylinder head gasket with piston protrusion of 0.701 mm - 0.750 mm 1.420 (five tooth marks)
Thickness of cylinder head gasket with piston protrusion of 0.751 mm - 0.800 mm 1.470 (six tooth marks)
Thickness of cylinder head gasket with piston protrusion of 0.801 mm - 0.850 mm 1.520 (seven tooth marks)
Oil Pressure Specifications
Description bar
Minimum oil pressure at idle speed 0.75
Minimum oil pressure at 2000 rpm 1.50

Lower arm ball joint retaining nuts 83 61 -
Tie-rod end retaining nuts 26 19 -
Stabilizer bar retaining nuts 47 35 -
Halfshaft center bearing cap retaining nut 27 20 -
Halfshaft center bearing bracket to cylinder block 48 35 -
Engine front mount retaining nuts 80 59 -
Engine front mount to body retaining bolts 90 66 -
Engine rear mount center retaining bolt 148 109 -
Engine rear mount to body retaining nuts 48 35 -
Wiring loom retaining bracket to transaxle 12 9 -
Engine support insulator retaining bracket to subframe 48 35 -
Engine support insulator center retaining bolt 120 89 -
Engine support insulator retaining bracket to transaxle 84 62 -
Radiator support bracket retaining bolts 10 - 89
Water pump retaining bolts (M8) 23 17 -
Water pump retaining bolts (M6) 10 - 89
Vacuum line bracket to thermostat housing 9 - 80
Air conditioning (A/C) compressor to retaining bracket 25 18 -
Charge air cooler retaining bolts 5 - 44
Turbocharger retaining bracket to cylinder block 24 18 -
Power steering pipe retaining bracket to body 10 - 89
Power steering pump to retaining bracket 24 18 -
Accessory drive belt tensioner retaining bolt 23 17 -
Accessory drive belt tensioner to power steering pump bracket 24 18 -
Engine mount bracket to cylinder block 47 35 -
Engine lifting eye to cylinder head 23 17 -
Exhaust manifold to catalytic converter 40 30 -
Catalytic converter to exhaust flexible pipe 40 30 -
Catalytic converter support bracket retaining bolts 24 18 -
Vacuum line to brake booster vacuum pump 18 13 -
Brake booster vacuum pump to cylinder head 22 16 -
Transaxle retaining bolts 40 30 -
Starter motor retaining bracket 20 15 -
Power steering high pressure pipe to lifting eye 10 - 89
Fuel filter to bracket 23 17 -
Oil pressure switch to cylinder head 20 15 -
Oil drain plug 25 18 -
Oil intake pipe bracket to cylinder block 10 - 89
Oil pan retaining bolts 10 - 89
Oil level indicator tube retaining bolts 10 - 89
Crankshaft main bearing caps a - -
Connecting rod bearing cap retaining bolts a - -
Timing chain housing to cylinder block (M6) 10 - 89
Timing chain housing to cylinder block (M8) 23 17 -
Crankshaft rear oil seal carrier retaining bolts 20 15 -
Clutch disc pressure plate retaining bolts 29 21 -
Crankshaft position (CKP) sensor retaining bracket 10 - 89
Generator bracket to cylinder block 42 31 -
Generator to generator bracket (M8) 24 18 -
Generator to generator bracket (M10) 50 37 -
Tensioning pulley bracket to generator bracket 24 18 -
Generator tensioning pulley bolt 24 18 -
Vacuum line bracket to cylinder head 22 16 -
Oil baffle retaining nuts 20 15 -
Camshaft bearing cap retaining nuts 20 15 -
Valve cover retaining bolts 5 - 44
Fuel injection pump to rear timing chain housing 20 15 -
Fuel injection pump retaining bracket 23 17 -
Fuel filter bracket to cylinder head 23 17 -
High pressure fuel-supply lines to fuel injectors 28 21 -
High pressure fuel-supply lines to fuel injection pump 28 21 -
Fuel injection pump pulley retaining bolts 42 31 -
Camshaft pulley retaining bolt 50 37 -
Timing belt tensioner to cylinder head 50 37 -
Blanking plug 24 18 -
Crankshaft pulley retaining bolt a - -
Turbocharger oil supply and return pipe retaining bolts 10 - 89
Catalytic converter retaining bracket 24 18 -
Timing belt cover retaining bolts 7 - 70
Coolant pipe bracket 25 18 -
Oil pump to cylinder block 23 17 -
Intake manifold to cylinder head 23 17 -
Exhaust manifold to cylinder head 24 18 -
Coolant expansion tank retaining bolt 10 - 89
Fender splash shield retaining bolts 11 8 -
Exhaust gas recirculation (EGR) pipe to intake manifold 20 15 -
Air cleaner bracket 23 17 -
Cylinder head bolts a - -
Fuel injector clamp bolt a - -
Cylinder head temperature (CHT) sensor 20 15 -
Glow plug 15 11 -
Glow plug power supply to glow plug 3 - 19
Timing belt rear cover 10 - 89
Injection pump oil seal carrier 10 - 89
Injection pump pulley 42 31 -
Engine mount to cylinder block 28 21 -
Engine mount bracket studs 13 10 -
Water pump pulley retaining bolts 23 17 -
http://vnx.su
Intake manifold retaining nuts and bolts 23 17 -
Downloaded from www.Manualslib.com manuals search engine

Intake manifold studs
Exhaust manifold studs
10
13
-
10
89
-
Turbocharger oil supply pipe retaining bracket to cylinder block 48 35 -
Flywheel retaining bolts a - -
Vehicle speed sensor (VSS) retaining bolt 10 - 89
Positive crankcase ventilation retaining bolt 23 17 -
Exhaust manifold retaining bracket 51 38 -
a) Refer to the procedure in this section
Item Specification
Ford Formula E SAE 5W-30 engine oil (vehicles without common rail fuel injection) WSS-M2C912-A
Ford Formula E SAE 5W-30 engine oil (vehicles with common rail fuel injection) WSS-M2C913-A
Coolant WSS-M97B44-D
Transmission fluid (MTX) WSD-M2C200-C
Power steering hydraulic fluid WSA-M2C195-A
Sealer — oil pan to ladder frame WSE-M4G323-A6
Sealer — ladder frame to cylinder block Hylomar SPM-4G9112-H
Sealer — camshaft bearing cap no. 1 WSK-M2G348-A5
Sealer — injection pump pulley WSK-M2G348-A5

Engine - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel -
Engine—1.8L Duratorq-TDDi (Lynx) Diesel
(75 PS)
Print
Alongside the Duratec-DOHC (Zetec) engine, the vehicle is also available with a latest
generation diesel engine. This assembly is called the Endura-DI engine.
This diesel engine, is available with 55 kW (75 PS), is based on the familiar swirl chamber
diesel, but has been brought to the latest state of the technology with charge air cooling
and direct injection.
This engine therefore complies with EEC emissions standard D3 and all other requirements
made on latest generation assemblies with regard to fuel consumption, quiet running,
flexibility and power output.
Engine codes
The engine codes for the Endura-DI engines installed are:
55 kW / 75 PS - BHPA
55 kW / 75 PS - BHPB (Turkey only)
Location of the engine code on the cylinder block of the Endura-DI engine:
Crankshaft
The five main bearing crankshaft has thrust half rings on the third main bearing that control
the crankshaft end float.
Crankshaft timing sprocket
The crankshaft timing sprocket drives the injection pump sprocket by means of a chain
drive. The crankshaft timing sprocket is held in position only by the clamping pressure of
the center bolt.
Timing belt drive

1 - Timing belt tensioner
2 - Timing belt
3 - Camshaft pulley
4 - Injection pump pulley
The timing belt is driven by the injection pump pulley and transmits the valve timing to the
overhead camshaft.
CAUTION: Because a new timing belt stretches considerably when it is first installed,
the instructions for adjustment must be followed.
The tension of the timing belt drive is maintained by an automatic timing belt tensioner.
The initial setting of the timing belt tension is carried out by the adjustment cam.
The camshaft timing pulley is retained on the camshaft by a taper. The required frictional
force is applied to the camshaft by the center bolt.
Valve tappet, adjusting shims
The camshaft timing is transmitted to the valve springs by eight bucket tappets.
CAUTION: The lettering must face the tappets when the adjusting shims are
installed.
Adjusting shims are available for adjusting the valve clearance. The thickness of these is
indicated on the underside.
Cylinder head

1 - Guide sleeve hole
2 - Identification of seal thickness
Cylinder head gaskets of various thicknesses are available. Dependent on the piston
protrusion, a certain thickness is assigned to the engine. This is indicated by indentations
on the cylinder head gasket.
CAUTION: Thoroughly clean the gasket and mating faces. Do not use any sharp
object for cleaning.
The cylinder head gasket is an MLS (multi-layered steel) gasket. The gasket consists of
three steel layers. The steel layers have an outer covering of rubber. Because of this
design, the longevity of the gasket is increased, and because the gasket does not settle
during installation, the cylinder head bolts can be installed with lower clamping force.
However, because of the rubber surface, the gasket is also more susceptible to grooves,
and therefore it must be cleaned without using sharp objects.
Crankshaft oil seals
NOTE: The crankshaft rear oil seal is supplied with an alignment sleeve. It aligns the oil
seal to the crankshaft rear flange.
NOTE: The crankshaft rear oil seal carrier must be aligned with the special tool.
CAUTION: If the alignment sleeve is removed too soon, the oil seal will be
compressed and made unusable.
The front and rear oil seals are made of PTFE and must be free from oil when installed.
Both oil seals are supplied with an alignment sleeve. This must not be removed until after
assembly.
Crankcase ventilation

The crankcase ventilation valve is located on the top of the valve cover. To provide optimal
engine performance, this valve and all positive crankcase ventilation (PCV) hoses must be
free of contaminants at all times.
Oil Sump
The oil pan is made of steel. It is sealed using silcone based sealant (WSE-M4G-323-A6).
CAUTIONS:
When removing the engine front mount, do not place a workshop jack under the
sump to support the engine.
Support the engine and transaxle on wooden blocks on the oil pan flange, so that the
oil pan is not under load.

Engine—1.8L Duratorq-TDCi (Lynx) Diesel
(90 PS)
Print
The Duratorq-TDCi diesel engine, which is available as a 66kW (90PS) version, is based on
the familiar Endura-DI diesel engine, but has been brought to the latest state of the
technology with a high-pressure fuel supply manifold.
This engine therefore complies with EEC emissions standard Stage III and all other
requirements made on latest generation assemblies with regard to fuel consumption, quiet
running, flexibility and power output.
Engine codes
The engine code for the Duratorq-TDCi is:
66 kW / 90 PS - HCPA (Stage III / LDT 2)

66 kW / 90 PS - HCPB (Stage III Car / LDT 1)
66 kW / 90 PS - HCPC (Stage I)
Location of the engine code on the cylinder block of the Duratorq-TDCi engine:
Crankshaft
The five main bearing crankshaft has thrust half rings on the third main bearing that control
the crankshaft end float.
Crankshaft timing sprocket
The crankshaft timing sprocket drives the injection pump sprocket by means of a chain
drive.
Timing belt drive

1 - Timing belt tensioner
2 - Timing belt
3 - Timing belt pulley
4 - Injection pump timing pulley
The camshaft timing belt is driven by the injection pump pulley and transmits the valve
timing to the overhead camshaft.
CAUTION: Because a new timing belt stretches considerably when it is first installed,
the instructions for adjustment must be followed exactly.
The tension of the timing belt is maintained by an automatic timing belt tensioner.
The timing pulley is retained on the camshaft by a taper. The required frictional force is
applied to the camshaft by a central bolt.
Valve tappet, adjusting shims
The camshaft timing is transmitted to the valve springs by eight bucket tappets.
CAUTION: The lettering must face the tappets when the adjusting shims are
installed.
Adjusting shims are available for adjusting the valve clearance. The thickness of these is
indicated on the underside.
Cylinder head

1 - Guide sleeve hole
2 - Identification of gasket thickness
Cylinder head gaskets of various thicknesses are available. Dependent on the piston
projection, a certain thickness is assigned to the engine. This is indicated by indentations
on the cylinder head gasket.
CAUTION: Thoroughly clean the gasket and mating faces. Do not use any sharp
object for cleaning.
The cylinder head gasket is an MLS (multi-layered steel) gasket. The gasket consists of
three steel layers. The steel layers have an outer covering of rubber. Because of this
design, the longevity of the gasket is increased, and because the gasket does not settle
during installation, the cylinder head bolts can be inserted with lower clamping force.
However, because of the rubber surface, the gasket is also more susceptible to grooves,
and therefore it must be cleaned without using sharp objects.
Crankshaft oil seals
NOTE: The rear crankshaft oil seal is supplied with an oil seal carrier. It must be aligned
using the tool shown.
CAUTION: If the support ring is removed too soon, the oil seal will be compressed
and made unusable.
The front and rear oil seals are made of PTFE and must be free from oil when installed.
Both oil seals are supplied with a support ring as a spare part. This must not be removed
until after assembly, when it may drop out of the oil seal of its own accord.
Crankcase ventilation

The crankcase ventilation valve is located on the top of the cylinder head cover. To ensure
optimal engine performance, this valve and all PCV hoses must be free of contaminants at
all times.
Oil Sump
The oil pan is made of steel. It is sealed using silcone based sealant (WSE-M4G-323-A6).
CAUTIONS:
When removing the engine front mount, do not place a workshop jack under the oil
pan to support the engine.
Support the engine and transmission on wooden blocks on the subframe/oil pan
flange, so that the oil pan is not under load.
The oil pan will be pushed in if the engine is supported on a workshop jack. This can cause
the oil supply to the oil intake pipe to be obstructed.
The oil drain plug is provided with an O-ring seal, and can be re-used many times.

Engine—1.8L Duratorq-TDCi (Lynx) Diesel Transit/Tourneo Connect 2002.5 (06/2002-)
(75 PS/90 PS/110 PS), Vehicles Built
From: 08/2006
Print
1.8L Duratorq TDCi
Engine
Transversely-mounted 4-cylinder in-line turbo diesel engine with direct fuel injection,
based on the 1.8L Duratorq DI.
1.8L capacity with 55 kW (75 PS), 66 kW (90 PS) or 81 kW (110 PS).
Turbocharger with variable turbine geometry and intercooler.
Common rail fuel injection system.
Dual mass flywheel for the reduction of drive noise.
Steel crankshaft in the 110 PS variant. Cast iron crankshaft in the 75 PS and 90 PS
variants.
Common rail fuel injection system

High-pressure pump for the generation of pressure in the fuel rail with an integrated
transfer pump for fuel supply.
Fuel rail for constant fuel pressure.
Piezo fuel injectors for optimized metering of the fuel quantity.

Variable pilot and main injection for optimization of noise emissions.
Engine management
A Siemens powertrain control module (PCM) (one box design) with 128 pins, for fuel
quantity regulation, fuel injector control and exhaust gas recirculation, with integrated
immobilizer.
camshaft position (CMP) sensor for determination of the injection sequence.
knock sensor (KS) for reducing combustion noise.
Electrical actuator for turbocharger guide vane adjustment for optimisation of boost
pressure control.
Emission control
Meets the European level IV emissions standard.
Oxidation catalytic converter.
Actuator motor controlled exhaust gas recirculation (EGR) valve with integral position
sensor.
EGR cooler for reduction in oxides of nitrogen (NOx) emissions.
Vacuum-controlled intake manifold flap with position sensor for optimization of exhaust
gas recirculation rate.

Diesel/1.8L Duratorq-TDDi (Lynx) Diesel - Transit/Tourneo Connect 2002.5 (06/2002-)
Engine
Print
REFER to Section 303-00 Engine System - General Information.

Valve Clearance
Print
General Procedures
Special Tool(s)
Compressor, Valve Spring
303-195
Pliers, Valve Shim

303-196
General Equipment
Feeler gauge
(303-01B Engine - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, In-
vehicle Repair).
2. Remove the oil baffle.
3. Install the camshaft bearing cap retaining nuts.
4. Using a suitable feeler gauge, measure the valve

clearance.
Rotate the crankshaft until the cam pair of
the cylinder to be adjusted are pointing
upwards.
Check the valve clearance and note the
values.
If the values of one or more adjustment
shims are outside the tolerance range,
renew the adjustment shim as described in
the following step.
5. NOTE: Rotate the crankshaft by a further 90
degrees.
NOTE: The piston of the cylinder to be

adjusted must not be at TDC.
Install the adjustment shim.
1. Using the special tool, push down the two
valve tappets at the same time.
2. Using the special tool, remove the
adjustment shim.
Note the thickness of the adjustment
shim, marked on the underside of the
shim.
Install the new adjustment shim to obtain
the correct valve clearance.
6. Remove the camshaft bearing cap retaining nuts.
7. Install the oil baffle.

vehicle Repair).

Exhaust Manifold
Print
In-vehicle Repair
1. NOTE: The exhaust manifold and

turbocharger are serviced as one component
and can not be renewed separately.
Remove the turbocharger.
For additional information, refer to: Turbocharger
- 1.8L Duratorq-TDCi FGT (55kW/75PS) -
Lynx/1.8L Duratorq-TDCi FGT (66kW/90PS) -
Lynx/1.8L Duratorq-TDCi VNT (66kW/90PS) -
Lynx (303-04C Fuel Charging and Controls -
Turbocharger, Removal and Installation).

Intake Manifold
Print
In-vehicle Repair
NOTE: The intake manifold and exhaust gas recirculation (EGR) valve are one component
and can not be serviced separately.
1. Remove the EGR valve.
For additional information, refer to: Exhaust Gas
Recirculation (EGR) Valve - 75 PS/90 PS (303-
08B Engine Emission Control - 1.8L Duratorq-
TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx)
Diesel, Removal and Installation) /
Exhaust Gas Recirculation (EGR) Valve - 110 PS
(303-08B Engine Emission Control - 1.8L
Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi
(Lynx) Diesel, Removal and Installation).

Intake Manifold—1.8L Duratorq-TDCi Transit/Tourneo Connect 2002.5 (06/2002-)
(Lynx) Diesel (75 PS/90 PS/110 PS),
Vehicles Built From: 08/2006
Print
In-vehicle Repair
NOTE: The intake manifold and exhaust gas recirculation (EGR) valve are one component
and can not be serviced separately.
1. Remove the EGR valve.
For additional information, refer to: Exhaust Gas
Recirculation (EGR) Valve - 75 PS/90 PS (303-
08B Engine Emission Control - 1.8L Duratorq-
Diesel, Removal and Installation).

Valve Cover
Print
In-vehicle Repair
Removal
All vehicles
1. Remove the engine upper cover.

charge air cooler outlet hose retaining clamp.
Remove the charge air cooler outlet pipe.
1. Remove and discard the charge air cooler
outlet hose retaining clamp.
2. Detach the charge air cooler outlet hose
retaining clamp.
3. Remove the charge air cooler outlet pipe
retaining nuts.

turbocharger outlet hose and clamps.
Remove the charge air cooler intake pipe.
intake hose retaining clamp.
2. Remove and discard the turbocharger
outlet hose clamp.
3. Remove the charge air cooler intake pipe
retaining nuts.

(PVC) hoses from the valve cover.

All vehicles
Installation
All vehicles
necessary.
Install the valve cover.
Lubricate the valve cover gasket with
clean engine oil before installation.


All vehicles
3. Connect the positive crankcase ventilation (PVC)
hoses to the valve cover.
4. Install the turbocharger outlet hose to the charge

air cooler intake pipe.
1. Install a new turbocharger outlet hose
clamp.
5. CAUTION: The charge air cooler intake

hose retaining clamp must be installed in the
same position as removed. Failure to follow
this instruction may cause premature failure
of adjacent components.
NOTE: Make sure that the inside of the
charge air cooler intake hose is clean and
free from any oil residue, as this will reduce
the installation grip of the hose to the charge
air cooler.
NOTE: Install a new charge air cooler intake
hose retaining clamp.
Install the charge air cooler intake pipe.
Clean the inside of the charge air cooler
intake hose.
Install a new charge air cooler intake hose
retaining clamp in the same position as
when removed.
6. CAUTION: The charge air cooler to

intake manifold hose retaining clamp must be
installed in the same position as removed.

Failure to follow this instruction may cause
premature failure of adjacent components.
Install the charge air cooler to intake manifold
hose and retaining clamp.
Install the hose retaining clamp in the
same position as when removed.
7. CAUTION: The charge air cooler outlet

charge air cooler outlet hose is clean and free
from any oil residue, as this will reduce the
installation grip of the hose to the charge air
cooler.
NOTE: Install a new charge air cooler outlet
Install the charge air cooler outlet pipe.
outlet hose.
Install the charge air cooler outlet hose
when removed.
8. Install the engine upper cover.

Valve Seals
Print
In-vehicle Repair
Special Tool(s)
Installer, Valve Stem Seal
303-037

303-060
Adapter for 303-060

303-060-05
Installer, Valve Stem Collets

303-362
Pliers, Valve Stem Seal

303-390
Materials
Name Specification
Engine Oil - 5W-30 WSS-M2C912-A1
Removal
1. Remove the camshaft.
For additional information, refer to: Camshafts
vehicle Repair).
2. Position the apropriate piston at top dead center
(TDC).
3. Using the special tools, remove the valve
springs.
4. Using the special tool, remove the valve stem

seals.

Installation
1. NOTE: Cover the collet grooves with
adhesive tape during installation of the valve
stem seals.
Using the special tool, install the valve stem
seals.
Coat the valve stem seals with clean
engine oil.
2. Using the special tools, install the valve springs.
3. Install the camshaft.

For additional information, refer to: Camshafts
vehicle Repair).

Camshaft Seal
Print
In-vehicle Repair
Special Tool(s)
Remover, Crankshaft Seal
303-293
Installer, Camshaft Seal

303-199A
Removal
For additional information, refer to: Timing Belt -
1.8L Duratorq-TDCi (Lynx) Diesel (75 PS/90
PS/110 PS), Vehicles Built From: 08/2006 (303-
01B Engine - 1.8L Duratorq-TDCi (Lynx)
vehicle Repair).
2. Remove the camshaft pulley.
3. Using the special tool, remove the camshaft seal.

Discard the camshaft seal.
Installation
1. NOTE: Install a new camshaft seal.
Using the special tool, install the camshaft seal.

2. NOTE: Do not fully tighten the camshaft
pulley retaining bolt at this stage.
Install the camshaft pulley.

vehicle Repair).

Camshafts
Print
In-vehicle Repair
Materials
Name Specification
Gasket Eliminator WSK-M2G348-A5
Sealant
Removal
1. Remove the camshaft seal.
For additional information, refer to: Camshaft
Seal (303-01B Engine - 1.8L Duratorq-TDCi
(Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel,
In-vehicle Repair).
2. Check the valve clearances.
For additional information, refer to: Valve
Clearance (303-01B Engine - 1.8L Duratorq-TDCi
3. CAUTION: Loosen the nuts of camshaft

bearing caps number one, three, and five by
one turn each until the camshaft is released.
NOTE: Keep the nuts and camshaft bearing
caps in order.
Remove the camshaft.
4. NOTE: Keep the valve tappets and

adjustment shims in order.
Remove the valve tappets and adjustment
shims.
Installation
1. NOTE: Coat the valve tappets and
adjustment shims with clean engine oil.
Install the valve tappets and adjustment shims.
2. NOTE: The larger semi-circle points upwards.

Install the camshaft.

3. NOTE: Coat the camshaft bearing caps with
clean engine oil.
Install the camshaft bearing caps.
Coat bearing cap number one with sealant
on the marked surfaces.
4. Check the valve clearances.

For additional information, refer to: Valve
Clearance (303-01B Engine - 1.8L Duratorq-TDCi
5. Install the camshaft seal.
For additional information, refer to: Camshaft
Seal (303-01B Engine - 1.8L Duratorq-TDCi
In-vehicle Repair).

Crankshaft Front Seal
Print
In-vehicle Repair
Special Tool(s)
Universal Flange Holding Wrench
205-072 (15-030A)
Gauge, Bolt Angle

303-174 (21-540)

303-293 (21-143)
Aligner, Oil Pump

303-652 (21-230)
Removal
2. Using the special tool, remove the crankshaft
pulley.
Discard the bolt.

seal.
Discard the seal.
Installation
1. NOTE: Install a new crankshaft front seal.
Using the special tool, install the crankshaft front
seal.

2. NOTE: Install a new crankshaft pulley
retaining bolt.
Using the special tool, install the crankshaft
pulley.
Tighten the crankshaft pulley retaining bolt
in two stages.
Stage 1: 100 Nm.


Crankshaft Rear Seal
Print
In-vehicle Repair
Special Tool(s)
Gauge, Bolt Angle
303-174 (21-540)
Locking Tool, Flywheel

303-393 (21-168)
Removal
1. Remove the clutch disc and pressure plate.
For additional information, refer to: Clutch Disc
and Pressure Plate (308-01 Clutch, Removal and
Installation).
2. Using the special tool, lock the flywheel in
position.
3. Remove the flywheel.

Discard the bolts.
4. Remove the crankshaft rear seal carrier.

Discard the carrier.
Installation
All vehicles

1. NOTE: A new crankshaft rear seal carrier is
supplied with an alignment sleeve that must
be removed following installation.
NOTE: Do not fully tighten the crankshaft
rear seal carrier retaining bolts at this stage.
Install the crankshaft rear seal carrier.
2. Tighten the crankshaft rear seal carrier
retaining bolts.
3. Remove the crankshaft rear seal carrier

alignment sleeve.

NOTE: Do not fully tighten the flywheel bolts
at this stage.
Install the flywheel.
5. Using the special tool, lock the flywheel in

position.

6. Using the special tools, install the flywheel.
Tighten the bolts in three stages.
Stage 1: 18 Nm.
Stage 3: 45 degrees


8. Using the special tools, install the dual mass
flywheel.
Stage 1: 35 Nm.

10. Inspect the dual mass flywheel.
For additional information, refer to: Flywheel
Inspection - Vehicles With: Dual Mass Flywheel
(303-00 Engine System - General Information,
All vehicles
11. Install the clutch disc and pressure plate.
For additional information, refer to: Clutch Disc
and Pressure Plate (308-01 Clutch, Removal and
Installation).

Timing Belt—75 PS/90 PS
Print
In-vehicle Repair
Special Tool(s)
205-072 (15-030A)

303-193 (21-104)
Support Bar, Engine

303-290A (21-140A)

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)

303-376 (21-162B)

303-393 (21-168)
Remover, Camshaft Sprocket

303-651 (21-229)
Materials
Name Specification
Coolant ESDM-97B49-A
Removal

All vehicles
1. CAUTIONS:
Never install a used timing belt.
Only install the timing belt after the

engine has cooled to workshop temperature.
Disconnect the battery ground cable.
vehicle Repair).
3. Detach the coolant expansion tank and position
it to one side.
4. Remove the charge air cooler cover.
5. Disconnect the intake air temperature (IAT)

6. Remove the charge air cooler.

7. Detach the power steering pipe retaining bracket
from the cylinder head.
8. Using the camshaft groove as a guide, turn the

crankshaft to five degrees before top dead
center (TDC).


10. Remove the generator drive coupling.
1. Driveshaft intermediate bearing retaining
bolts.
2. Vibration damper retaining bolts.

For additional information, refer to: Generator -
1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles Built
From: 05/2007 (414-02 Generator and
Regulator, Removal and Installation).
12.

All vehicles
Remove the cylinder block blanking plug
and install the special tool.
14. Detach the starter motor and position it to one

side.
15. NOTE: Only turn the crankshaft in the normal

direction of rotation.
Turn the crankshaft to TDC.
Turn the crankshaft slowly until the
crankshaft stops.
16. CAUTIONS:
Make sure that the crankshaft does not

rotate during installation of the special tool.
Make sure crankshaft is at the TDC

position before locking the special tool.
Make sure that the special tool engages

correctly.
Using the special tool, lock the crankshaft.
18. Install the special tools.


All vehicles
21. Remove the engine front mount stud.
22. Remove the timing belt cover.

Engines with mechanical timing belt tensioner

25. Discard the timing belt tensioner.
All vehicles
26. Remove and discard the timing belt.
27. Using the special tool, loosen the camshaft
pulley retaining bolt by five turns.

pulley.
Installation
All vehicles
1. NOTE: Install only latest level timing belts.
These are identified by a laser etched Ford
logo.
Check the new timing belt.

2. Install a new automatic timing belt tensioner.
All vehicles
3. Check the automatic timing belt tensioner.
1. Make sure that the tensioner pointer
rotates clockwise freely.
2. Arrow denotes counter clockwise rotation
of tensioner.
4. NOTE: Move timing belt tensioner

adjustment arm to 3 o'clock position.
Install the timing belt tensioner and tighten the
bolt finger tight.
5. CAUTIONS:
Install the timing belt with the direction

arrows in the direction of engine rotation.

6. NOTE: The camshaft pulley must be able to
turn freely on the camshaft taper.
Tighten the camshaft pulley bolt finger tight and
then loosen by 1/2 a turn.

7. NOTE: Using an allen key, maintain tension
until the tensioner bolt is tightened.
1. Turn the timing belt tensioner adjustment
arm counter clockwise to tension the
timing belt slightly.
2. The pointer must be positioned between
the sides of the window.
3. Tighten the timing belt tensioner retaining
bolt.

pulley retaining bolt.

Operation).
11. Release the special tool.
13. NOTE: Only turn the crankshaft in the

NOTE: Using paint or typing correction fluid,
mark the crankshaft pulley to show top dead
center (TDC).
Turn the crankshaft six revolutions.

crankshaft stops.
16. CAUTIONS:



correctly.
18. NOTE: The auto tensioner pointer may move
slightly upwards in the window.
Check that the autotensioner pointer is
positioned in between the sides of the window.
1. If the pointer is in the window, go to the
following step.
2. If the pointer is not in the window, repeat
procedure from the previous steps.

If the special tool cannot be installed,
repeat the procedure from the previous
steps.

21. CAUTION: Do not damage the timing

belt cover.
NOTE: Only rework the timing belt cover, if
there was a mechanical timing belt tensioner
installed.
Using a suitable file, modify the timing belt
cover.
22. Install the timing belt cover.
23. Install the engine front mount stud.


All vehicles

Operation).
28. Remove the special tool and install the blanking
plug.
29. Attach the starter motor.

30. Install the generator drive coupling.

31.

1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles Built
From: 05/2007 (414-02 Generator and
Regulator, Removal and Installation).
All vehicles
information, refer to: Accessory Drive Belt - 1.8L
(Lynx) Diesel (303-05 Accessory Drive, Removal
and Installation).
34. Attach the power steering pipe retaining bracket
to the cylinder head.
35. Install the charge air cooler.
36. Connect the intake air temperature (IAT) sensor


37. Install the charge air cooler cover.
38. Install the coolant expansion tank.

vehicle Repair).
Vehicles with front and rear power windows

41. Initialize the door window motors.

Timing Belt—1.8L Duratorq-TDCi (Lynx) Transit/Tourneo Connect 2002.5 (06/2002-)
Diesel (75 PS/90 PS/110 PS), Vehicles
Built From: 08/2006
Print
In-vehicle Repair
Special Tool(s)
205-072 (15-030A)

303-193 (21-104)
Support Bar, Engine

303-290A (21-140A)

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)

303-376 (21-162B)

303-393 (21-168)

303-651 (21-229)
Materials
Name Specification
Coolant ESDM-97B49-A

Removal
All vehicles
1. CAUTIONS:

vehicle Repair).
it to one side.
4. Remove the charge air cooler cover.


7. Detach the power steering pipe retaining bracket
8. Using the camshaft groove as a guide, turn the

crankshaft to five degrees before top dead
center (TDC).

10. Remove the generator drive coupling.
1. Driveshaft intermediate bearing retaining
bolts.
2. Vibration damper retaining bolts.
11. Detach the starter motor and position it to one

side.

Remove the cylinder block blanking plug
and install the special tool.

crankshaft stops.
14. CAUTIONS:



correctly.
18. Remove the engine front mount stud.


All vehicles
23. Remove and discard the timing belt.
pulley retaining bolt by five turns.

pulley.
Installation
All vehicles
1. NOTE: Install only latest level timing belts.
logo.
Check the new timing belt.

All vehicles
3. Check the automatic timing belt tensioner.
2. Arrow denotes counter clockwise rotation
of tensioner.
4. NOTE: Move timing belt tensioner

adjustment arm to 3 o'clock position.
Install the timing belt tensioner and tighten the
bolt finger tight.

5. CAUTIONS:


then loosen by 1/2 a turn.
7. NOTE: Using an allen key, maintain tension

until the tensioner bolt is tightened.
arm counter clockwise to tension the
timing belt slightly.
bolt.


Operation) /
and Operation).
11. Release the special tool.

NOTE: Using paint or typing correction fluid,
mark the crankshaft pulley to show top dead
center (TDC).

crankshaft stops.
16. CAUTIONS:



correctly.
18. NOTE: The auto tensioner pointer may move
slightly upwards in the window.
Check that the autotensioner pointer is
positioned in between the sides of the window.
1. If the pointer is in the window, go to the
following step.
2. If the pointer is not in the window, repeat
procedure from the previous steps.

repeat the procedure from the previous
steps.
21. CAUTION: Do not damage the timing

belt cover.
NOTE: Only rework the timing belt cover, if
there was a mechanical timing belt tensioner
installed.
Using a suitable file, modify the timing belt
cover.

23. Install the engine front mount stud.

Operation) /
and Operation).
27. Remove the special tool and install the blanking
plug.

28. Attach the starter motor.
29. Install the generator drive coupling.

31. Attach the power steering pipe retaining bracket
to the cylinder head.


34. Install the charge air cooler cover.

vehicle Repair).

Cylinder Head—1.8L Duratorq-TDCi (Lynx) Transit/Tourneo Connect 2002.5 (06/2002-)
Diesel (90 PS), Vehicles With: Common
Rail Fuel Injection
Print
In-vehicle Repair
Special Tool(s)
303-122 (21-068A)
Gauge, Bolt Angle

303-174 (21-540)
Support Bar, Engine

303-290A (21-140A)

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)

303-397 (24-003)
Materials
Name Specification
Loctite 7070
ISO 4113 Lubricant
Removal
All vehicles
1. WARNINGS:
Do not smoke or carry lighted tobacco or

open flame of any type when working on or
near any fuel related components. Highly

flammable mixtures are always present and
may ignite. Failure to follow these
instructions may result in personal injury.
Do not carry out any repairs to the fuel

injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature is below 30 °C. Failure
to follow these instructions may result in
personal injury.

injection system with the engine running.
The fuel pressure within the system is
approximately 1600 bar. Failure to follow
these instructions may result in personal
injury.
CAUTIONS:
Diesel fuel injection equipment is

manufactured to very precise tolerances and
fine clearances. It is therefore essential that
absolute cleanliness is observed when
working with these components. Always fit
blanking plugs to any open orifices or lines.
Always carry out the cleaning process

before carrying out any repairs to fuel
injection system components to prevent
foreign material entering the components
Using datalogger in worldwide diagnostic system
(WDS), check that the fuel pressure has dropped
to zero and that the fuel temperature is below
30°C.
2. Remove the battery and the battery tray. For
Cooling.
this section.
6. Detach the timing belt rear cover (engine shown



All vehicles

11. Remove the air cleaner outlet pipe.

12. Detach the vacuum hose from the turbo charger
vacuum diaphragm unit.
13. Disconnect the Exhaust gas recirculation (EGR)

vacuum hose from the EGR valve.
14. Disconnect the EGR vacuum hose.
15. Detach the electronic vacuum regulating valve

support bracket from the intake manifold and
position it to one side.

17. Install the camshaft bearing cap nuts.

Lifting.
19. Detach the catalytic converter from the catalytic
converter bracket.
20. Detach the oil supply and return pipes from the
turbocharger.
1. Remove the oil supply pipe retaining bolt.
2. Remove the oil return pipe retaining bolts.

connector.
23. Disconnect the engine wiring harness electrical

connector.

housing.
25. Detach the power steering high pressure pipe

container.

bracket from the timing belt cover stud
connection.

bracket from the lifting eye.

from the bracket and position it to one side.

29. Detach the glow plug power supply from the
glow plug wire terminal block.
30. Detach the glow plug wire terminal block.
31. Detach the oil level indicator and secure it to one

side.
32. Detach the vacuum pipe from the brake booster

vacuum pump.
33. Using the special tool, detach the upper coolant

hose from the thermostat housing.

34. Remove the thermostat housing.
Discard the gasket.
35. Detach the power steering reservoir and secure

it to one side.
container.

converter.
Vehicles with EGR cooler

hose from the EGR cooler.
All vehicles
38. Clean the area around the fuel injection supply
manifold, high pressure fuel supply lines and

surrounding areas. For additional information,
refer to Section 303-04A Fuel Charging and
Controls / 303-04B Fuel Charging and Controls /
303-04C Fuel Charging and Controls -
Turbocharger / 303-04D Fuel Charging and
Controls.
39. WARNING: Cover the fuel injector with

lint-free material while disconnecting the fuel
return line to prevent fuel spray. Failure to
injury.
Disconnect the fuel return line from the fuel
injectors and install blanking caps to the fuel
injector return line spigots.
40. Disconnect the fuel injector electrical connectors

and protect it with lint-free material to prevent
contamination from the cleaning fluid.
41. NOTE: Make a note of the orientation of the

clamps to make sure it is positioned in
exactly the same position when installed.
Remove the high pressure fuel supply line clamp.
42. CAUTION: Make sure the tool used to

loosen the high pressure fuel supply line
unions is used at the top of the union as this
is where there is most material. Failure to
follow this instruction may result in damage
to the union.
NOTE: Maintain pressure on the high-
pressure fuel supply line to keep the olive in
contact with the fuel injector cone while
detaching the union.
NOTE: While maintaining the pressure on the
high-pressure fuel supply line, clean and
vacuum foreign material from the line and
union.
Detach the high pressure fuel supply lines from
the fuel injectors.
43. Protect the generator with lint-free material to
prevent contamination from the cleaning fluid.
44. NOTE: Protect the connector with lint free

cloth to prevent contamination from the
cleaning fluid.
Disconnect the fuel high pressure sensor
45. NOTE: Maintain pressure on the high

contact with the fuel supply manifold cone
while detaching the union.
high pressure fuel supply line, clean and
union.
Remove the high pressure fuel supply lines.
Install blanking caps to the open threaded
ports on the fuel injectors and fuel supply
manifold.
Discard the high pressure fuel supply lines.
46. Remove the high pressure fuel supply line
bracket.

contact with the fuel injection pump and fuel
supply manifold cone while unscrewing the
unions.
unions.
Remove the high pressure fuel supply line.
ports on the fuel injection pump and fuel
injection supply manifold.
clamp to make sure it is positioned in exactly
the same position when installed.
Discard the high pressure fuel supply line.

49. Remove the fuel supply manifold bracket lower
retaining bolt.
50. Remove the fuel supply manifold bracket and the

fuel supply manifold.
51. CAUTION: Remove the cylinder head

Remove the cylinder head bolts.
Discard the bolts.
52. Using the special tool, remove the cylinder head.

Discard the gasket.
Installation
All vehicles

1. WARNING: Do not smoke or carry
lighted tobacco or open flame of any type
when working on or near any fuel related
components. Highly flammable mixtures are
always present and may ignite. Failure to
follow these instructions may result in
personal injury.
CAUTIONS:


system components to prevent foreign
material entering the components
Clean the mating faces of the cylinder head and
cylinder block with Loctite 7070.
3. CAUTION: The thickness of the new

cylinder head gasket must be the same as
that of the old one (hole/tooth marked).
NOTE: "TOP/OBEN" mark.
Install a new cylinder head gasket.
4. NOTE: The pistons must not be at TDC. Make

sure that the special tool is engaged in the
camshaft groove.
Using the special tool, position the cylinder head
on the cylinder block.
Remove the special tool.
5. CAUTION: Use new, unoiled cylinder

head bolts.
Tighten the cylinder head bolts in four stages.
Using the special tool, tighten the bolts in
the sequence shown.
First stage: 20 Nm
Second stage: 54 Nm
Third stage: 90 degrees
Fourth stage, short bolts: 70 degrees, long
bolts: 90 degrees

6. NOTE: Do not tighten the fuel supply
manifold bracket retaining bolts at this
stage.
Install the fuel supply manifold bracket and the

manifold bracket retaining bolt at this stage.
Install the fuel supply manifold bracket lower
retaining bolt.
8. NOTE: Use new high pressure fuel supply

line unions.
Lubricate the high pressure fuel supply line union
threads with clean ISO 4113 lubricant from the
high pressure fuel supply line parts kit.
9. CAUTION: Do not allow the unions to hit

the olive ends of the high pressure fuel
supply line as this may damage the ends of
the line and allow foreign material to enter

the fuel injection system.
NOTE: Do not tighten the high pressure fuel
supply line unions at this stage.
NOTE: Maintain pressure on the high
contact with the injector cone while hand
tightening the union.
NOTE: The yellow colored collar is positioned
at the injector end and the blue colored
collar is positioned at the fuel injection
supply manifold end of the high pressure fuel
supply line.
Attach the high pressure fuel supply lines of
cylinder one and four to the fuel injectors.

Install the high pressure fuel supply lines of
cylinder one and four to the fuel supply manifold.
11. NOTE: Make sure the clamp is installed in
the same position as removed.
Install the high pressure fuel supply line clamp
to the high pressure fuel supply line.
12. NOTE: Use a new high pressure fuel supply

line union.
Lubricate the high pressure fuel supply line union
threads with clean ISO 4113 lubricant from the
high pressure fuel supply line parts kit.

supply line union at this stage.

supply line.
Install the high pressure fuel supply line.

supply line.
cylinder two and three to the fuel injectors.

cylinder two and three to the fuel supply
manifold.
16. Connect the fuel return line to the fuel injectors.
17. NOTE: Make sure the clamps are installed in

Install the high pressure fuel supply line clamps.

18. Install the high pressure fuel supply line bracket.
19. Install the fuel supply manifold bracket and the

20. Install the fuel supply manifold bracket lower

retaining bolt.
21. Install the high pressure fuel supply lines of

cylinder one and four to the fuel injectors.


23. Install the high pressure fuel supply line.

cylinder two and three to the fuel injectors.

manifold.
Vehicles with EGR cooler

26. Using the special tool, attach the upper coolant
hose to the EGR cooler.
All vehicles
27. Attach the exhaust manifold to the catalytic
converter.

28. Attach the power steering reservoir.
29. Connect the fuel high pressure sensor electrical

connector.
30. NOTE: Use a new gasket.

Install the thermostat housing.

hose to the thermostat housing.
32. Attach the vacuum pipe to the brake booster

vacuum pump.

33. Attach the oil level indicator.
34. Attach the glow plug wire terminal block.
35. Attach the glow plug power supply to the glow

plug wire terminal block.
36. Attach the power steering high pressure pipe to

the bracket.
37. Attach the power steering high pressure pipe

bracket to the lifting eye.

bracket to the timing belt cover stud connection.

40. Connect the engine wiring harness electrical

connector.
41. NOTE: Install the clip at a 45 degree angle to

the horizontal.

connector.

Lifting.
44. NOTE: Use new gaskets.
Attach the oil supply and return pipes to the
turbocharger.
1. Install the oil return pipe retaining bolt.
2. Install the oil supply pipe retaining bolts.
45. Attach the catalytic converter to the catalytic

converter bracket.

47. Remove the bearing cap nuts.
49. Attach the electronic vacuum regulating valves

support bracket to the intake manifold and
50. Connect the EGR vacuum hose.
51. Connect the EGR vacuum hose to the EGR valve.
52. Attach the vacuum hose to the turbo charger

53. Install the air cleaner outlet pipe.

and Filtering.


All vehicles
58. Attach the timing belt rear cover (engine shown

retaining bolt at this stage.

this section.
Cooling.
63. Install the battery tray and connect the battery.
01 Battery, Mounting and Cables.
64. Change the engine oil and the oil filter.

65. Initialize the door window motors. For additional
information, refer to Section 501-11 Glass,
Frames and Mechanisms.

Cylinder Head—75 PS/90 PS/110 PS, Transit/Tourneo Connect 2002.5 (06/2002-)
Vehicles Built From: 08/2006, Vehicles
With: Common Rail Fuel Injection
Print
In-vehicle Repair
Special Tool(s)
303-122 (21-068A)
Gauge, Bolt Angle

303-174 (21-540)
Support Bar, Engine

303-290A (21-140A)

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)

303-397 (24-003)
Materials
Name Specification
Loctite 7070
ISO 4113 Lubricant
Removal
All vehicles
1. WARNINGS:


flammable mixtures are always present and

injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature is below 30 °C. Failure
to follow these instructions may result in
personal injury.

injection system with the engine running.
The fuel pressure within the system is
approximately 1600 bar. Failure to follow
injury.
CAUTIONS:


injection system components to prevent
foreign material entering the components
Using datalogger in worldwide diagnostic system
(WDS), check that the fuel pressure has dropped
to zero and that the fuel temperature is below
30°C.
2. Remove the battery and the battery tray.
and Installation).
3. Drain the cooling system.
For additional information, refer to: Cooling
System Draining, Filling and Bleeding (303-03
Engine Cooling, General Procedures).
housing.


vehicle Repair).



12. Disconnect the electrical connectors.
1. Remove the glow plug relay to glow plug
wire terminal block cable.
2. Remove the glow plug wire terminal block
cable electrical connector retaining bolt.
3. Disconnect the oil pressure switch
13. Disconnect the heater core to exhaust gas

recirculation (EGR) cooler coolant hose from the
EGR cooler.
Vehicles with vacuum exhaust gas recirculation (EGR)

valve
14. Disconnect the Exhaust gas recirculation (EGR)
15. Detach the vacuum hose from the turbo charger

17. Detach the vacuum regulating valve support

bracket from the intake manifold and position it
to one side.

Operation) /
and Operation).
converter bracket.
20. Detach the oil supply and return pipes from the
turbocharger.
1. Remove the oil supply pipe retaining bolt.
2. Remove the oil return pipe retaining bolts.

converter.
Vehicles with electronic exhaust gas recirculation (EGR)

valve
23. Detach the wiring harness from the intake
manifold.

24. Disconnect the EGR valve electrical connector
and detach the wiring harness electrical
connector from the wiring harness support
bracket.

turbocharger to exhaust manifold retaining
clamp.
Remove the turbocharger to exhaust manifold
retaining clamp.
Discard the turbocharger to exhaust
manifold retaining clamp.
All vehicles
28. Disconnect the engine wiring harness electrical

connector.

29. Disconnect the fuel temperature sensor electrical
connector.
30. Disconnect the fuel metering valve and fuel

pressure regulator electrical connectors.
1. Fuel metering valve electrical connector.
2. Fuel pressure regulator electrical
connector.

container.

connection.



side.

vacuum pump.


Discard the gasket.

it to one side.
container.
41. Clean the area around the fuel injection supply

manifold, high pressure fuel supply lines and
surrounding areas.
For additional information, refer to: Fuel
Injection Component Cleaning - Vehicles With:
Common Rail Fuel Injection (303-04B Fuel
Charging and Controls - 1.8L Duratorq-TDCi
42. Disconnect the fuel pump fuel return line quick
release coupling.
For additional information, refer to: Quick
Release Coupling (310-00A Fuel System -
43. Disconnect the fuel injector electrical connectors.

Detach the wiring harness clips from the
cylinder head.


loosen the high pressure fuel supply line
to the union.
contact with the fuel injector cone while
detaching the union.
high-pressure fuel supply line, clean and
union.
Detach the high pressure fuel supply lines from
the fuel injectors.
prevent contamination from the cleaning fluid.
47. NOTE: Protect the connector with lint free
cloth to prevent contamination from the
cleaning fluid.
Disconnect the fuel high pressure sensor

contact with the fuel supply manifold cone
while detaching the union.

union.
Remove the high pressure fuel supply lines.
ports on the fuel injectors and fuel supply
manifold.
49. Remove the high pressure fuel supply line

bracket.

contact with the fuel injection pump and fuel
supply manifold cone while unscrewing the
unions.
unions.
Remove the high pressure fuel supply line.
ports on the fuel injection pump and fuel
clamp to make sure it is positioned in exactly
the same position when installed.
Discard the high pressure fuel supply line.
52. Remove the fuel supply manifold bracket lower

retaining bolt.
53. Remove the fuel supply manifold bracket and the


Discard the bolts.
55. NOTE: Do not discard the cylinder head

gasket at this stage.
Using the special tool, remove the cylinder head.
Installation
All vehicles

personal injury.
CAUTIONS:


material entering the components
Clean the mating faces of the cylinder head and
2. Check the cylinder head for distortion.
For additional information, refer to: Cylinder
Head Distortion (303-00 Engine System -

Discard the old cylinder head gasket.
4. NOTE: The pistons must not be at TDC. Make

sure that the special tool is engaged in the
camshaft groove.

head bolts.
the sequence shown.
First stage: 20 Nm
Second stage: 54 Nm
Third stage: 90 degrees
Fourth stage, short bolts: 70 degrees, long
bolts: 90 degrees

manifold bracket retaining bolts at this
stage.
Install the fuel supply manifold bracket and the

manifold bracket retaining bolt at this stage.
Install the fuel supply manifold bracket lower
retaining bolt.
8. CAUTIONS:
Remove the blanking caps from the

high-pressure fuel supply lines, fuel rail and
fuel injectors at the last possible moment.
foreign material ingress to the fuel injection
system.
Do not allow the unions to hit the ends

of the high-pressure fuel supply line. Failure
damage to the ends of the line and allow
foreign material to enter the fuel injection
system.

NOTE: To aid installation of the high-pressure
fuel supply line, the unions at the fuel rail
end are colored gold.
NOTE: Install new fuel injector high-pressure
fuel supply lines.
NOTE: Do not fully tighten the fuel injector
high-pressure fuel supply line unions at this
stage.
Install the fuel injector high-pressure fuel supply
lines in the sequence shown.
Remove and discard the blanking caps.
Install the unions finger tight.
9. CAUTIONS:
Remove the blanking caps from the

high-pressure fuel supply lines, the fuel rail
and fuel pump at the last possible moment.
foreign material ingress to the fuel injection
system.
Do not allow the unions to hit the ends

of the high-pressure fuel supply line. Failure
damage to the ends of the line and allow
foreign material to enter the fuel injection
system.
NOTE: Install a new fuel rail high-pressure
fuel supply line.
NOTE: Do not fully tighten the fuel rail high-
pressure fuel supply line unions at this stage.
Install the fuel rail high-pressure fuel supply line.
Remove and discard the blanking caps.
Install the unions finger tight.
10. Tighten the fuel supply manifold retaining
bracket upper retaining bolts.
11. Tighten the fuel supply manifold retaining

bracket lower retaining bolt.
12. Tighten the fuel injector high-pressure fuel

supply lines and the fuel rail high-pressure fuel
supply line unions in the sequence shown.

supply lines and the fuel rail high-pressure fuel
supply line unions in the sequence shown.
14. Connect the fuel injector electrical connectors.

Attach the wiring harness clips to the
cylinder head.
15. Connect the fuel high-pressure sensor electrical

connector.
16. Connect the fuel metering valve and fuel

pressure regulator electrical connectors.
1. Fuel metering valve electrical connector.
2. Fuel pressure regulator electrical
connector.
17. Connect the fuel temperature sensor electrical

connector.

18. Connect the fuel pump fuel return line quick
release coupling.
19. Connect the heater core to EGR cooler coolant




vacuum pump.



29. Connect the engine wiring harness electrical

connector.
30. Remove the bearing cap nuts.

valve
32.
33. Connect the exhaust gas recirculation (EGR)
valve electrical connector and attach the wiring

harness electrical connector to the wiring harness
support bracket.
34. Attach the wiring harness to the intake manifold.
35. NOTE: The turbocharger to exhaust manifold

retaining clamp must be installed in the same
position as removed.
NOTE: Install a new turbocharger to exhaust
manifold retaining clamp.
Install the turbocharger to exhaust manifold
retaining clamp.

valve
36. Attach the exhaust manifold to the catalytic
converter.

Operation) /
and Operation).
38. NOTE: Use new gaskets.
Attach the oil supply and return pipes to the
turbocharger.
1. Install the oil return pipe retaining bolt.
2. Install the oil supply pipe retaining bolts.

converter bracket.

41. Attach the vacuum regulating valves support
bracket to the intake manifold.
44. Attach the vacuum hose to the turbo charger


All vehicles
47. Attach the timing belt rear cover to the cylinder

head (engine shown removed for clarity).



vehicle Repair).
the horizontal.
51. Connect the electrical connectors.

1. Install the glow plug wire terminal block
cable electrical connector retaining bolt.
2. Install the glow plug relay to glow plug
wire terminal block cable.
connector.
52. Install the air cleaner.

54. Fill and bleed the cooling system.

Procedures).
56. Install the battery tray and connect the battery.
and Installation).

Cylinder Head—1.8L Duratorq-TDDi (Lynx) Transit/Tourneo Connect 2002.5 (06/2002-)
Diesel (75 PS), Vehicles Without:
Common Rail Fuel Injection
Print
In-vehicle Repair
Special Tool(s)
303-122 (21-068A)
Gauge, Bolt Angle

303-174 (21-540)

303-397 (24-003)
Materials
Name Specification
Loctite 7070
Removal
All vehicles

personal injury.
CAUTION: Diesel fuel injection

equipment is manufactured to very precise
tolerances and fine clearances. It is therefore
essential that absolute cleanliness is
observed when working with these
components. Always fit blanking plugs to any
open orifices or lines.
Remove the battery and the battery tray. For
Cooling.
this section.



All vehicles


diaphragm unit.

Lifting.
converter bracket.

16. Detach the turbocharger oil supply and return
pipe.
Discard the gasket

connector.
19. Remove the oil separator.

container.

connection.


24. Detach the glow plug power supply from the

glow plug wire terminal block.

side.

vacuum pump.


Discard the gasket
30. Detach the high pressure fuel supply lines from

the fuel injection pump.
31. Remove the high pressure fuel supply lines.

Discard the lines.

it to one side.

converter.
Discard the nuts.

hose from the exhaust gas recirculation (EGR)
cooler.

Discard the bolts.

36. Using the special tool, remove the cylinder head.
Discard the gasket.
Installation
All vehicles
1. Clean the mating faces of the cylinder head and

4. NOTE: Make sure that the special tool is

engaged in the camshaft groove.

head bolts.
the sequence shown.
Stage 1: 20 Nm.
Stage 2: 54 Nm.
Stage 3: 90 degrees
Stage 4, short bolts: 70 degrees.
Stage 4, long bolts: 90 degrees.

7. NOTE: Use new catalytic converter nuts.

Attach the exhaust manifold to the catalytic
converter.

9. NOTE: Use new high pressure fuel supply
lines.
Install the high pressure fuel supply lines to the
fuel injectors.
10. Attach the high pressure fuel supply lines to the

fuel injection pump.



vacuum pump.

16. Attach the glow plug power supply to the glow

plug wire terminal block.

the bracket.




connector.

the horizontal.
Install the oil separator.

Lifting.
Attach the turbocharger oil supply and return

pipe.

converter bracket.

27. Remove the camshaft bearing cap nuts.
29. Attach the vacuum hose to the vacuum

diaphragm unit.

and Filtering.


All vehicles
35. Attach the timing belt rear cover (engine shown


this section.
Cooling.
40. Install the battery tray and install the battery.
01 Battery, Mounting and Cables.

42. Initialize the door window motors. For additional
information, refer to Section 501-11 Glass,
Frames and Mechanisms.

Oil Cooler—RHD FWD
Print
In-vehicle Repair
Removal
1. Remove the oil filter element.
Refer to: Oil Filter Element - RHD FWD (303-01B

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L
Duratorq-TDDi (Lynx) Diesel, In-vehicle Repair).
2.
3. NOTE: The seals are to be reused unless

damaged.
Torque: 23 Nm
4.
Installation

Oil Filter Element—RHD FWD
Print
In-vehicle Repair
Removal
1. Torque: 80 Nm
2.
Installation

Oil Pan
Print
In-vehicle Repair
Special Tool(s)
Slide Hammer
205-047
Adapter for 205-047

303-633
Materials
Name Specification
Cleaner WSK-M5B401-A1
Silicone Sealant WSE-M4G323-A4
Engine Oil - 5W-30 WSS-M2C912-A1
Removal
Lifting)
2. Drain the engine oil.
container.
3. Remove the oil pan retaining nuts and bolts.
4. Install the special tools to the oil pan.
5. CAUTION: To avoid damaging the

mating faces, only use the special tool to
remove the oil pan.
Using the special tools, remove the oil pan

Installation
NOTE: The mating faces and blind holes must
be free of oil and sealer residue.
Clean the mating faces of the oil pan and ladder
frame with cleaner.
2. CAUTION: Make sure that the sealant

does not enter the ladder frame blind holes.
Failure to follow this procedure may result in
damage to the engine assembly.
NOTE: Attach the oil pan within 10 minutes
of applying the sealant.
NOTE: Once the oil pan is in contact with the
ladder frame it must not be removed.
Apply a 2.5 mm diameter bead of sealant to the
ladder frame (dotted line) and install the oil pan.
Tighten the nuts and bolts in the sequence
shown.
3. NOTE: Inspect the oil pan drain plug seal for

damage. Install a new oil pan drain plug and
seal if necessary.
Install the oil pan drain plug.

5. Fill the engine with engine oil

Oil Pump
Print
In-vehicle Repair
Special Tool(s)
205-072 (15-030A)

303-293 (21-143)

33-393 (21-168)
Aligner, Oil Pump

303-652 (21-230)
Materials
Name Specification
Removal
1. Remove the timing belt. For additional
information, refer to: (303-01B Engine - 1.8L
(Lynx) Diesel)
Timing Belt - 75 PS/90 PS (In-vehicle
Repair),
Timing Belt - 1.8L Duratorq-TDCi (Lynx)
Diesel (75 PS/90 PS/110 PS), Vehicles Built
From: 08/2006 (In-vehicle Repair).
pulley.
Discard the bolt.

seal.
Discard the seal.

4. Remove the accessory drive belt idler pulley.
5. Remove the fuel pump pulley.
6. Remove the fuel pump seal retainer.

Discard the seal.
7. Remove the timing belt rear cover.
8. Remove the timing chain housing cover.

Discard the gasket.

Installation
All vehicles
1. NOTE: Install a new timing chain housing
cover gasket.
Using the special tool, install the timing chain
housing cover.
2. Install the timing belt rear cover.
3. NOTE: Install a new fuel pump seal retainer.

Install the fuel pump seal retainer.
4. Attach the fuel injection pump pulley to the fuel

pump sprocket.
Apply sealer to the fuel injection pump
pulley and to the outer edge of the fuel
pump pulley bolt holes.
5. Install the fuel pump pulley.
6. Install the accessory drive belt idler pulley.

seal.

retaining bolt.
pulley.

Tighten the retaining bolts in two stages.
Stage 1: 90 Nm
Stage 2: 90 degrees

retaining bolt.
pulley.
Tighten the retaining bolts in two stages.
Stage 1: 100 Nm
Stage 2: 180 Nm
All vehicles
10. Install the timing belt. For additional information,
refer to: (303-01B Engine - 1.8L Duratorq-TDCi
(Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel)
Timing Belt - 75 PS/90 PS (In-vehicle
Repair),
Timing Belt - 1.8L Duratorq-TDCi (Lynx)
From: 08/2006 (In-vehicle Repair).

Diesel/1.8L Duratorq-TDDi (Lynx) Diesel - Transit/Tourneo Connect 2002.5 (06/2002
Cylinder Head
Special Tool(s)
303-290-01
303-290-02
303-290-03A
303-290A
Support Bar, Engine
General Equipment
Hose clamp remover/installer
Mounting table set
Pneumatic vacuum gun
Removal
1. Refer to: Timing Belt - 1.8L Duratorq-TDCi (Lynx) Diesel (75

PS/90 PS/110 PS), Vehicles Built From: 08/2006 (303
Engine - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq
TDDi (Lynx) Diesel, In-vehicle Repair).
2. NOTE: Only tighten the bolt finger tight at this stage.
3. NOTE: Only tighten the nuts finger tight at this stage.
4. Remove the following items:

1. Special Tool(s): 303-290A, 303-290-01, 303-290
303-290-03A
5. Refer to: Catalytic Converter - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (309-00 Exhaust
6.
7.
8. CAUTION: Note the position of the component

before removal.
9.
10.

11.
12. CAUTIONS:
Vacuum any foreign material from the fuel pump

and fuel rail unions before sealing the unions with
blanking caps.
Make sure that the fuel line remains in contact at

both ends until both unions nuts have been unscrewed
and the area around the joints thoroughly cleaned.
Use an open-ended wrench to prevent the

component from turning.
General Equipment: Pneumatic vacuum gun
13.
14.
15.

16. General Equipment: Hose clamp remover/installer
17.

18.

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

26. CAUTION: Note the thickness of the gasket.
Installation
1. NOTE: Make sure that a new component is installed.
2. CAUTIONS:
Take
extra care
when handling
the
component.
Make
sure that the
component is
clean, free of

foreign
material and
lubricant.
General
Equipment:
Mounting table
set
3. CAUTIONS:
Make sure that new bolts are installed.
Make sure that the component is clean, free of

foreign material and lubricant.
NOTE: Note the different lengths of the bolts.
Torque:
Stage 1: 20 Nm
Stage 2: 54 Nm
Stage 3: 90°
Stage 4: M12x137 70°
M12x177 90°
4. Torque: 10 Nm
5.
6. Torque: 20 Nm


Torque:
1: 23 Nm
2: 10 Nm
9. Torque: 10 Nm
10.

Torque: 23 Nm
12. Torque: 18 Nm

13. Torque: 23 Nm
14. CAUTIONS:

blanking caps.

both ends until both unions nuts have been unscrewed
and the area around the joints thoroughly cleaned.
Use an open-ended wrench to prevent the

component from turning.
NOTE: Make sure that new components are installed.
Torque:
1: 25 Nm
2: 38 Nm
15. NOTE: Make sure that new components are installed.

16. NOTE: Install all the bolts finger tight before final
tightening.
Torque:
1: 10 Nm
2: 10 Nm
3: 25 Nm
17. NOTE: Make

sure that the
clamp is
installed to
the same
orientation as
when
removed.
NOTE: Make
sure that a
new clamp is
installed.
1. Torque:
Nm
18. Torque:
1: 25 Nm
2: 25 Nm
19. Torque: 23 Nm

20. Refer to: Catalytic Converter - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (309-00 Exhaust
21. Install the following items:
1. Special Tool(s): 303-290A, 303-290-01, 303-290
303-290-03A
22.
23.
24. Refer to: Timing Belt - 1.8L Duratorq-TDCi (Lynx) Diesel (75
PS/90 PS/110 PS), Vehicles Built From: 08/2006 (303
Engine - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq

Engine
Print
Removal
Special Tool(s)
211-020 (13-006)

303-397 (24-003)
Remover, Halfshaft
308-192 (16-057)
General Equipment
Workshop table
Securing straps
Two leg puller
Transmission jack
Removal
All vehicles
and Installation).
4. NOTE: Make sure that the road wheels are in

Discard the bolt.

nuts by five turns.

2. Detach the charge air cooler outlet hose
retaining clamp.
3. Remove the charge air cooler outlet pipe
retaining nuts.

turbocharger outlet hose and clamps.
2. Remove and discard the turbocharger
outlet hose and clamps.
3. Remove the charge air cooler intake pipe
retaining nuts.

10. Remove the charge air cooler air guide.


14. Remove the air cleaner intake pipe.
15. Disconnect the glow plug wire from the terminal

block.
16. Disconnect the glow plug wiring harness from

the terminal block.
17. Remove the oil level indicator and oil level

indicator tube.

vacuum pump.


Discard the gasket.

21. Disconnect the fuel pressure sensor electrical
connector.
All vehicles
22. Using the special tool, detach the cooling hoses
from the thermostat housing and from the
coolant distribution pipe.
23. Disconnect the generator battery positive cable.

24. Remove the generator electrical connector
cover.

diaphragm unit.
26. Disconnect the engine wiring harness.

27. Disconnect the injector driver module electrical
connector.

28. Disconnect the exhaust gas recirculation (EGR)
30. Detach the electronic vacuum regulating valves

support bracket from the intake manifold and
All vehicles
31. Detach the upper coolant hose from the EGR
cooler.

32. Detach the vacuum hoses and the electrical
connector from the EGR valve.

33. Disconnect the fuel injection pump electrical
connector.
All vehicles

connection.


from the bracket.

it to one side.
container.
39. Detach the fuel supply and return line from the
fuel line bracket.

line quick release coupling.
41. Using the special tool, disconnect the lower
coolant hose from the coolant expansion tank.
42. Remove the coolant expansion tank and position

it to one side.

43. Disconnect the cooling fan motor electrical
connector and detach the cooling fan wiring
harness from the cooling fan shroud.
Vehicles with air conditioning

44. Using cable ties, secure the air conditioning heat
exchanger.
All vehicles
Operation) /
and Operation).
47. Disconnect the horn electrical connector and the
horn wiring harness.

48. Disconnect the air conditioning compressor
electrical connector and detach the wiring
harness from the air conditioning compressor.

49. Detach the air conditioning compressor (four
bolts) and secure it to one side.
All vehicles
50. Using the special tool, detach the coolant hose
from the oil cooler.
51. Remove the front wheel and tire.

For additional information, refer to: Wheel and
Tire (204-04 Wheels and Tires, Removal and
Installation).
52. Detach the stabilizer bar connecting link on both
sides.

stud.
Loosen the left-hand tie-rod end retaining nut.
54. CAUTION: Using a soft cloth, protect the

ball joint seal.
Using the special tool, detach the tie-rod end.
1. Discard the retaining nut.

ball joint seal.
Detach the lower arm from the wheel knuckle on
both sides (left-hand side shown).
56. Remove the left-hand fender splash shield.
57.
58. Disconnect the starter motor electrical connector

and the power supply.
59. Remove the radiator support bracket on both

sides (left-hand side shown).

60. Detach the gear shift cables from the transaxle.
1. Detach the shift cable from the gear lever.
2. Pretension the abutment collars by turning
them in a counterclockwise direction and
remove the cable assembly from the
bracket.
3. Detach the selector cable from the selector
lever.
4. Pretension the abutment collars by turning
them in a counterclockwise direction and
remove the cable assembly from the
bracket.
5. Disconnect the adjustment mechanism by
pressing it in.
61. CAUTION: Excessive bending of the

exhaust flexible pipe may cause damage
resulting in failure.
Using a support wrap or a suitable splint,
support the exhaust flexible pipe
62. Detach the exhaust flexible pipe from the

exhaust system.
1. Discard the retaining nuts.
63. Remove the engine support insulator.
64. CAUTIONS:

degrees.
Do not damage the halfshaft oil seal.

NOTE: Plug the transaxle to prevent oil loss
or dirt ingress.
Detach the right-hand halfshaft and secure it to
one side.
Remove and discard the center bearing

cap and locknuts.
container.
65. CAUTIONS:

degrees.

or dirt ingress.
Using the special tool, detach the left-hand
side.
container.
66. Detach the high-pressure line from the clutch
slave cylinder.
1. Remove the retaining clip.
2. Detach the bracket together with the
rubber grommet.
67. Detach the starter motor wiring harness bracket

and engine ground cable from the transaxle
housing.
68. Remove the steering gear heat shield.
69. Detach the power steering line from the

retaining bracket.

70. Detach the power steering line from the steering
gear (crossmember shown removed for clarity).
1. Remove the bolt.
2. Rotate the clamp clockwise.
container.

crossmember.
72. Using a suitable securing strap, secure the
crossmember and lower arm assembly to the
transmission jack.
(support shown removed for clarity).
74. Remove the crossmember.

transaxle assembly on wooden blocks.
CAUTION: Support the engine on the oil

pan flange.
Using suitable securing straps, secure the engine
and transaxle assembly on the workshop table.

76. Remove the engine rear mount.
78. Raise the vehicle and remove the engine and

transaxle assembly.
79. Remove the engine from the transaxle.

Engine—Vehicles With: Common Rail Fuel
Injection
Print
Disassembly
Special Tool(s)
Slide Hammer
205-047 (15-011)

205-072 (15-030A)

303-393 (21-168)

303-397 (24-003)
Mounting Stand
303-435 (21-187)

303-435-06 (21-031B)
Adapter for 205-047

303-633 (21-227)

303-651 (21-229)
Remover, Fuel Injection Pump Pulley

310-095 (23-067)
General Equipment
Engine vacuum cleaner
All vehicles
CAUTIONS:
Diesel fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute cleanliness is observed when working
with these components. Always fit blanking plugs to any open orifices or lines.

Do not disassemble or clean inside the fuel injection supply manifold, even with an
ultrasonic cleaner.
1. Using the special tool, attach the engine to the
mounting stand.
Attach the mounting bracket.
Mount the engine on the mounting stand.
2. Drain the engine oil.

container.
3. Detach the turbocharger oil supply tube from the
turbocharger.
Discard the sealing washers.
4. Remove the turbocharger oil supply line.

5. Detach the turbocharger oil return tube.


Discard the filter.

7. Remove the oil cooler.
Discard the gasket.
8. Using the special tool, detach the positive

crankcase ventilation (PCV) hoses from the lower
PCV pipe.
9. Using the special tool, detach the PCV hoses

from the valve cover.

1. Detach the electrical connector from the
PCV housing.
11. Remove the PCV housing.
12. Using the special tool, detach the PCV hose from
the brake booster vacuum pump.

13. Remove the brake booster vacuum pump.
14. CAUTION: Carry out the fuel injection

component cleaning procedure before
carrying out any repairs to fuel injection
material entering the components.
Detach the fuel injector return line from the fuel
injectors.
15. Remove the fuel injector return line.
16. CAUTION: Carry out the fuel injection

component cleaning procedure before
carrying out any repairs to fuel injection
material entering the components.
Disconnect the fuel injector electrical connectors.


connector.
19. Detach the oil level indicator tube bracket from

the thermostat housing.
20. Detach the glow plug wiring harness bracket

from the oil level indicator tube bracket.
21. Disconnect the knock sensor (KS) electrical

connector.
22. Disconnect the high-pressure fuel sensor

electrical connector from the fuel injection
supply manifold.

23. Disconnect the fuel pump electrical connectors.

clamps to make sure they are positioned in
Remove the high-pressure fuel supply line
clamps.
25. CAUTIONS:
Use an open-ended wrench to prevent

the component from turning.
Make sure that the high-pressure fuel

supply lines remain in contact with the fuel
injectors until all unions have been detached
and cleaned. Failure to follow this instruction
may result in foreign matter ingress to the
fuel injection system.
Cap the fuel injectors to prevent dirt

ingress.
Detach the high-pressure fuel supply lines from
the fuel injectors.
26. CAUTIONS:
Make sure that the high-pressure fuel

supply lines remain in contact with the fuel
injection supply manifold until all unions
have been detached and cleaned. Failure to
follow this instruction may result in foreign
matter ingress to the fuel injection system.

Cap the fuel injection supply manifold to
Detach the high-pressure fuel supply lines from
the fuel injection supply manifold.
27. Using the engine vacuum cleaner, vacuum
foreign material from the high-pressure fuel
supply lines and the fuel injection supply
manifold.
28. Remove the high-pressure fuel supply lines.
Discard the fuel lines.
29. Remove the high-pressure fuel supply line clamp
retaining nut.
30. CAUTION: Make sure that the high-

pressure fuel supply lines remain in contact
with the fuel pump and the fuel injection
supply manifold until all unions have been
detached and cleaned. Failure to follow this
instruction may result in foreign matter
ingress to the fuel injection system.
Detach the high-pressure fuel supply line and
clamp from the fuel pump and the fuel injection
supply manifold.
supply line, the fuel pump and the fuel injection
supply manifold.
32. Remove the high-pressure fuel supply line.
Remove the clamp from the high-pressure fuel
supply line.
Discard the high-pressure fuel supply line.

foreign material from the fuel pump and the fuel
35. Install blanking caps to the open threaded ports
on the fuel pump and the fuel injection supply
manifold.
36. Remove the fuel injectors.

37.
38. Remove the fuel injection supply manifold.
39. Remove the fuel injection supply manifold

retaining bracket.
40. Using the special tool, detach the coolant hose

from the thermostat housing.

42. Detension the timing belt.
Loosen the timing belt tensioner bolt.



pulley.
47. Using the special tool, remove the fuel pump

pulley.

48. Remove the fuel pump oil seal retainer.
Discard the seal.

Discard the gasket and the bolts.

53. Remove the engine front mount bracket.
54. Using the special tool, remove the water pump

pulley (four bolts).

Discard the gasket.

pulley.
Discard the bolt.

57. Remove the accessory drive belt idler.

Discard the gasket.
59. Remove the timing chain tensioner.
60. Detach the fuel pump sprocket.

61. Remove the timing chain, sprockets and guides.
62. Remove the fuel pump bracket.
63. Remove the fuel pump.

Discard the gasket.

64.
65.

66.
All vehicles
hose from the coolant distribution pipe.
68. Remove the coolant distribution pipe.
69. Remove the fuel pump bracket.
70. CAUTION: Loosen the clutch pressure

plate retaining bolts by two turns at a time in

the sequence shown.
Remove the clutch disc and pressure plate.
71. Using the special tool, remove the dual mass

flywheel.
Discard the bolts.
72. Remove the crankshaft position (CKP) sensor.

Discard the sensor.
73. Remove the oil pan retaining nuts and bolts (16
bolts, two nuts).
74. Using the special tools, remove the oil pan.
75. Remove the CKP sensor retaining bracket.

76. Remove the crankshaft rear oil seal retainer.
Discard the retainer.
77. Remove the oil pump connecting pipe.

78. Remove the oil pump pickup tube.

79. Remove the air conditioning (A/C) compressor

retaining bracket.
80. Remove the ladder frame (14 bolts).

Discard the gasket.

81. Remove the timing chain rear housing.
Discard the gasket.
82. NOTE: Keep the connecting rod bearings and

bearing caps in order for installation.
Remove the pistons.
83. NOTE: Keep the main bearings and main

bearing caps in order for installation.
Remove the crankshaft.

Engine—Vehicles Without: Common Rail
Fuel Injection
Print
Disassembly
Special Tool(s)
Slide Hammer
205-047 (15-011)

205-072 (15-030A)

303-393 (21-168)

303-397 (24-003)
Mounting Stand
303-435 (21-187)
Mounting Bracket for 303-435 (21-187)

303-435-06 (21-031B)
Adapter for 205-047

303-633 (21-227)

303-651 (21-229)
Remover, Fuel Injection Pump Pulley

310-095 (23-067)
General Equipment
Scraper
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances

and fine clearances. It is therefore essential that absolute cleanliness is observed when
working with these components. Always fit blanking plugs to any open orifices or lines.
All vehicles
1. Using the special tool, attach the engine to the
mounting stand.

Attach the mounting bracket.
Mount the engine on the mounting stand.

container.
3. Detach the positive crankcase ventilation (PCV)
housing.
Detach the ventilation hoses.
4. Remove the high pressure fuel supply lines.

5. Remove the power steering pump lower retaining

bolts.
7. Remove the generator with driveshaft.

8. Detach the turbocharger oil supply and oil return
lines.

Discard the filter.
10. Remove the oil cooler.

Discard the gasket.
11. Remove the generator bracket.

1. Remove the PCV hoses.
2. Remove the valve cover bolts.

Vehicles without charge air cooler
13. Remove the timing belt lower cover.
Vehicles with charge air cooler

All vehicles

17. Detension the timing belt.
Loosen the timing belt tensioner bolt.


All vehicles

pulley.
23. Remove the fuel injection pump pulley bolts.

24. Using the special tool, remove the fuel injection
pump pulley.
25. Remove the fuel injection pump oil seal retainer.

Discard the seal.
28. Remove the fuel injectors.

Discard the bolts.

Discard the gasket.
30. Using the special tool, remove the water pump

pulley.

Discard the gasket.

pulley.
Discard the bolt.

33. Remove the accessory drive belt idler.

Discard the gasket.
35. Remove the timing chain tensioner.
36. Detach the fuel injection pump sprocket.

37. Remove the timing chain, sprockets and guides.
38. Remove the fuel injection pump bracket.
39. Remove the fuel injection pump.

Discard the gasket.

hose from the coolant distribution pipe.
41. Remove the coolant distribution pipe.

42. CAUTION: Loosen the clutch pressure
plate retaining bolts by two turns at a time in
the sequence shown.
Remove the clutch disc and pressure plate.
43. Using the special tool, remove the flywheel.

Discard the bolts.
44. Remove the crankshaft position (CKP) sensor.
45. Remove the CKP sensor retaining bracket.
46. Remove the crankshaft rear oil seal retainer.

Discard the retainer.

47. Remove the oil pan retaining nuts and bolts (16
bolts, two nuts).
48. Using the special tools, remove the oil pan.
49. Remove the oil pump connecting pipe.

50. Remove the oil pump pick-up tube.


51. Remove the air conditioning (A/C) compressor
retaining bracket.

All vehicles
52. Remove the ladder frame (14 bolts).
Discard the gasket.
53. Remove the timing chain rear housing.

Discard the gasket.
54. CAUTIONS:
Keep the connecting rod bearing caps in

order for installation.
Keep the connecting rod bearing shells

and connecting rod bearing cap shells in
order for installation.
Remove the pistons.
55. CAUTION: Keep the main bearing lower

and upper shells in order for installation.
Remove the crankshaft.

Cylinder Head—75 PS/90 PS/110 PS, Transit/Tourneo Connect 2002.5 (06/2002-)
Vehicles Built From: 08/2006, Vehicles
Print
Disassembly and Assembly of Subassemblies

Special Tool(s)
Mounting Bracket, Engine/Differential
205-329 (15-105A)

303-037 (21-007A)

303-060 (21-024)
Adapter for 303-060 (21-024)

303-060-05 (21-024-05)

303-199A (21-110A)

303-362 (21-156)

303-390 (21-165)

303-397 (24-003)
Mounting Stand
303-435 (21-187)

303-435-06 (21-031B)
Socket, Cylinder Head Temperature Sensor

303-680 (21-239)
Materials

Name Specification
Hypoid oil SQM-2C-9002-AA
Disassembly
All vehicles
WARNINGS:
near any fuel related components. Highly flammable mixtures are always present and
may ignite. Failure to follow these instructions. Failure to follow these instructions may
This procedure involves fuel handling. Be prepared for fuel spillage at all times and
always observe fuel handling precautions. Failure to follow these instructions may result
in personal injury.
CAUTIONS:
Do not disassemble fuel injectors or clean the nozzles, even with an ultrasonic
cleaner.
1. Using the special tools, attach the cylinder head
to the mounting stand.
Vehicles with fixed vane turbocharger

2. Remove the EGR cooler outlet pipe.

valve
3. Remove the EGR cooler outlet pipe flange bolts.

4. Remove the EGR cooler flange bolts.
Discard the gasket.
5. Remove the EGR cooler.
6. Remove the exhaust manifold (six bolts and two

self-locking nuts).
Discard the gasket, the bolts and the nuts.
7. Remove the intake manifold (six bolts and two

self-locking nuts).
Discard the gasket, the bolts and the nuts.

valve
Discard the EGR cooler gaskets.

9. Remove the exhaust manifold.
Discard the exhaust manifold gasket and
retaining nuts.
10. Remove the intake manifold.

Discard the intake manifold gaskets and
retaining nuts.
All vehicles
11. Remove the engine rear lifting eye.
12. Remove the coolant outlet connector.

Discard the connector.

14. Using the special tool, remove the cylinder head
temperature (CHT) sensor.
Discard the sensor.
15. Disconnect the fuel injector fuel return lines from

the fuel injectors.
1. Using a suitable screwdriver, remove the
fuel injector fuel return line clip.
2. Disconnect the fuel injector fuel return line
from the fuel injector.
Install a clean blanking cap to the fuel
injector return line port.
Discard the fuel injector fuel return line O-
ring seals and the fuel injector fuel return
line clips.
16. Remove the engine front lifting eye.
17. Remove the glow plug wiring harness.

19. NOTE: Make a note of the position of the fuel
injectors to make sure that they are installed
in the same position.
Remove the fuel injectors and retaining clamps.
Discard the fuel injector clamp retaining
bolts.
Discard the fuel injector to cylinder head
sealing washers.
20. CAUTION: Loosen the camshaft bearing

cap nuts and bolts by one turn each until the
camshaft is released.
bolts and camshaft caps to make sure they
are installed in the same position.
Discard the camshaft oil seal.

valve tappets and adjustment shims to make
sure they are installed in the same position.
Remove the valve tappets and valve adjustment
shims.

camshaft lower bearing shells to make sure
they are installed in the same position.
Remove the camshaft lower bearing shells.

camshaft bearing cap shells to make sure
they are installed in the same position.
Remove the camshaft bearing cap shells.

24. Remove the brake booster vacuum pump.
25. Remove the brake booster vacuum pump drive

tappet.
26. Using the special tools, remove the valve collets.

valve springs and valve retainers to make
sure they are installed in the same position.
Remove the valve springs with valve retainers.
28. Using the special tool, remove the valve stem
seals.
Discard the seals.

valves to make sure they are installed in the
same position.
Remove the valves.
Assembly
All vehicles
1. Coat the valves with clean hypoid oil.
2. Install the valve stem mounting sleeves over the
valve collet grooves (valve shown removed for
clarity).
3. NOTE: Install new valve stem seals.

Using the special tool, install the valve stem
seals.
4. Remove the valve stem mounting sleeves.

5. Install the valve springs and valve retainers.
6. Using the special tools, install the valve collets.

8. Coat the brake booster vacuum pump drive
tappet with clean engine oil.
9. Install the brake booster vacuum pump drive
tappet.
10. NOTE: Install a new brake booster vacuum

pump O-ring seal.
Install the brake booster vacuum pump.
11. Install the camshaft bearing cap shells.
12. Coat the camshaft bearing cap shells with clean

engine oil.
13. Install the camshaft lower bearing shells.
14. Coat the camshaft lower bearing shells with clean

engine oil.
15. Coat the valve tappets and adjustment shims
with clean engine oil.
16. NOTE: The lettering on the valve adjustment
shims faces downwards.
Install the valve tappets and valve adjustment
shims.
17. NOTE: The larger semi-circle points

upwards.
Position the camshaft on the cylinder head.

18. Apply sealer to bearing cap number one at the
positions shown.
19. NOTE: The arrows on the camshaft bearing

caps must point to the front of the engine.
NOTE: Do not tighten the camshaft bearing
caps at this stage.
Install the camshaft bearing caps.
20. NOTE: Tighten the camshaft bearing cap

retaining nuts and bolts evenly, a turn at a
time.
Tighten the camshaft bearing cap retaining nuts
and bolts.
21. NOTE: Install a new camshaft oil seal.

Using the special tool, install the camshaft oil
seal.
22. NOTE: Make sure that the fuel injectors are

installed in their original position.
NOTE: Install new fuel injector to cylinder

head sealing washers.
NOTE: Install new fuel injector retaining
clamps.
clamps retaining bolts.
Install the fuel injectors and retaining clamps.
5 Nm
90 degrees
24. Install the glow plug wiring harness.
25. Install the engine front lifting eye.
26. CAUTION: Push the fuel injector fuel

return lines gently into the fuel injectors.
Failure to follow this instruction my result in
damage to the fuel injector fuel return line O-
ring seals.
NOTE: Install new fuel injector fuel return
line O-ring seals and new fuel injector fuel
return line clips.
Attach the fuel return lines to the fuel injectors.
1. Connect the fuel injector fuel return line to
the fuel injector.
2. Install the fuel injector fuel return line clip.
27. NOTE: Install a new cylinder head
Using the special tool, install the CHT sensor.

Apply sealantto the oil pressure switch
thread.
29. NOTE: Install a new coolant outlet

connector.
Install the coolant outlet connector.
Apply sealantto the coolant outlet
connector thread.
30. Install the engine rear lifting eye.

valve
31. NOTE: Install a new intake manifold gasket
and new self-locking nuts and bolts.
32. NOTE: Install a new exhaust manifold gasket

and new self-locking nuts and bolts.
Install the exhaust manifold.

33. Install the EGR cooler.
34. NOTE: Install a new EGR cooler flange

gasket.
Install the EGR cooler flange bolts.
35. Install the EGR cooler outlet pipe flange bolts.

valve
36. NOTE: Install new intake manifold gaskets
and retaining nuts.
37. NOTE: Install a new exhaust manifold gasket

retaining nuts.
Install the exhaust manifold.

38. CAUTION: Failure to follow this sequence
may result in premature failure of the
exhaust gas recirculation (EGR) cooler.
NOTE: Install new EGR cooler gaskets.
Handstart all of the EGR cooler retaining bolts
and then tighten in the sequence shown.
39. Using the special tool, connect the EGR cooler to

cylinder head coolant hose to the EGR cooler.
40. Using the special tool, connect the EGR cooler to

cylinder head coolant hose to the cylinder head.
All vehicles
41. Detach the cylinder head from the mounting
stand.
Remove the special tools.

Cylinder Head—Vehicles Without:
Common Rail Fuel Injection
Print
Special Tool(s)
303-037 (21-007A)

303-060 (21-024)
Adapter for 303-060 (21-024)

303-060-05 (21-024-05)

303-199A (21-110 A)

303-362 (21-156)

303-390 (21-165)

303-680 (21-239)
Materials
Name Specification
Hypoid oil SQM-2C-9022-AA
Disassembly
1. Remove the engine front lifting eye.
2. Remove the injector nozzles and detach the glow

plug wiring.
4. Remove the brake vacuum pump.
5. Using the special tool, remove the cylinder head

temperature (CHT) sensor and the oil pressure
switch.
Discard the CHT sensor.
7. Detach the components on the right-hand side of

the cylinder head.
1. Engine lifting eye.
2. Coolant connection.
Coolant hose.

8. Remove the exhaust manifold upper retaining
bolts.
Remove the exhaust gas recirculation
(EGR) flange bolts (2 bolts).
9. Remove the exhaust manifold lower retaining

bolts.
10. CAUTION: Loosen the nuts on the

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

13. NOTE: Position the cylinder head on wooden
blocks.
Using the special tools, remove the valve
springs.
1. Using the special tools, compress the
valve springs.
2. Using the special tool, remove the valve
collets.
Remove the valves, valve collets and the
valve springs and position them in order
to one side.
14. Using the special tool, remove the valve seals.
Assembly
1. Grind in the valves.
2. CAUTION: Protect the grooves on the

valve stems with protective sleeves.
NOTE: Only remove the protective sleeves
after the valve stem oil seals have been
installed.
Coat the new valve seals with engine oil and
install them.
3. Coat the valves with hypoid oil and insert them.

4. Install the valve springs.
Install the valve springs with the valve
spring retainers.
1. Using the special tool, compress the valve
springs.
2. Install the valve collets into the grooves
on the valve stem.
5. NOTE: The lettering on the valve

adjustment shims faces downwards.
NOTE: Coat the valve tappets and the valve
adjustment shims with engine oil before
installation.
NOTE: Installation sequence.
Install the valve tappets.

6. Insert the camshaft lower half shells and coat
them with engine oil.
7. Align the camshaft.
Insert the camshaft and turn it until the
groove on the eccentric cam is parallel to
the upper edge of the cylinder head (the
larger semi-circle faces upwards).
8. Insert the camshaft upper half shells and coat

them with engine oil.
9. Apply sealant to the bearing caps at the
positions shown.
10. NOTE: The arrows on the camshaft bearing

caps must point to the front of the engine.
NOTE: Tighten the camshaft bearing caps
evenly a turn at a time.
Install the camshaft.
1. Install the brake vacuum pump plunger.
2. Position camshaft bearing caps "1", "3"
and "5" and tighten the nuts fingertight.
3. Position the other camshaft bearing caps
and tighten the nuts fingertight.
11. NOTE: Tighten the camshaft bearing caps

evenly a turn at a time.
Tighten the camshaft bearing cap retaining nuts.

12. NOTE: Coat the camshaft taper and oil seal
lip with engine oil.
Using the special tool, install the camshaft oil
seal.
13. Install the intake manifold.
14. Tighten the exhaust manifold lower retaining

bolts.
15. Tighten the exhaust manifold upper retaining

bolts.
Tighten the EGR flange bolts (2 bolts).
16. Install the components on the right-hand side of

the cylinder head.
1. Engine lifting eye.
2. Coolant connection.
Coolant hose.

17. CAUTION: Install a new cylinder head
Install the CHT sensor.
19. Install the brake vacuum pump.
21. NOTE: Make sure that the fuel injectors are

installed in their original position.
NOTE: Install new fuel injector to cylinder
head sealing washers.

clamps.
clamps retaining bolts.
Install the fuel injectors and retaining clamps.
5 Nm
90 degrees
22. Install the glow plug wiring harness.
23. Install the engine front lifting eye.

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel -
Cylinder Head
Print

Special Tool(s)
303-037
303-060
303-060-05
Adapter for 303-060
303-362
303-508
Materials
Name Specification
Engine Oil - 5W-30 WSS-M2C153-G
General Equipment
Wooden Block
Disassembly
1. CAUTIONS:
Note the position of the components before removal.
Vacuum any foreign material from the fuel pump and fuel rail unions before
sealing the unions with blanking caps.
Make sure that the fuel line remains in contact at both ends until both unions
nuts have been unscrewed and the area around the joints thoroughly cleaned.
Use an open-ended wrench to prevent the component from turning.

2.
3.
4.
5.
6.

7.
8.
9.
10.
11.
12.
13. CAUTION: Note the position of the components before removal.

15.
16.

Special Tool(s): 303-060, 303-060-05, 303-362
General Equipment: Wooden Block

Assembly
20.

21. CAUTION: Make sure that the components are installed to the position noted before removal.
22. CAUTION: Make sure that the components are installed to the position noted
before removal.
before removal.
Special Tool(s): 303-060, 303-060-05, 303-362
General Equipment: Wooden Block
24.
25. Material: Engine Oil - 5W-30 (WSS-M2C153-G)
26. CAUTION: Make sure that the components are installed to the position noted before removal.
before removal.
Torque: 20 Nm

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

35.
1. Torque: 15 Nm
2. Torque: 2 Nm
36. Torque: 23 Nm

NOTE: Install all the bolts finger tight before final tightening.
1. CAUTION: Make sure that new bolts are installed.

Torque: 37 Nm
3. CAUTION: Use an open-ended wrench to prevent the component from

turning.
Torque: 40 Nm
4. Torque: 40 Nm

Engine—Vehicles With: Common Rail Fuel
Injection
Print
Assembly
Special Tool(s)
205-072 (15-030A)
Gauge, Bolt Angle

303-174 (21-540)

303-193 (21-104)

303-199A (21-110A)

303-376 (21-162B)

303-393 (21-168)

303-397 (24-003)
Mounting Stand
303-435 (21-187)

303-435-06 (21-031B)
Aligner, Oil Pump

303-652 (21-230)
Timing Tool, Crankshaft

303-710 (21-257)
Aligner, Clutch Disc

308-204 (16-067)
General Equipment
Micrometer
Feeler gauges
Internal micrometer
Piston ring compressor
Dial indicator gauge holding fixture
Dial indicator gauge
Plastigage
Materials
Name Specification
Silicone gasket and WSE-M4G323-A4
sealant
Engine oil SAE 5W 30 WSS-M2C912-A1
All vehicles
CAUTIONS:
ultrasonic cleaner.
Always carry out the cleaning process before carrying out any repairs to fuel system
components to prevent foreign material entering the components.
1. Coat the main bearing journals, bearing shells
and thrust half washers with clean engine oil.
2. Install the main bearing shells to the cylinder
block and to the main bearing caps.
3. Position the crankshaft in the cylinder block.
4. NOTE: The grooves in the thrust half washers
must face outwards.
Install the crankshaft thrust half washers into the
third main bearing with oil grooves facing
outwards.
5. NOTE: Install the main bearing caps with
arrows pointing forward. Caps are identified
1, 2, 3, 4, 5 from the front to the rear.
Install the crankshaft.
Tighten the bolts in three stages in the
sequence shown.
Stage 1: Tighten the bolts 1 through 10 to
45 Nm.
70 Nm.
60 degrees.

6. Coat the cylinder bores with clean engine oil.
7. NOTE: Install the pistons with the arrows
pointing to the front of the engine.
NOTE: The piston ring gaps and oil supply
ring elements must be distributed evenly
around the circumference.
Using a suitable piston ring compressor, install
the pistons.
Install clean and dry connecting rod
bearing shells in the connecting rods.
8. CAUTION: Connecting rod bearing cap

bolts must only be used two times.
NOTE: Stamp the bolt heads with a center
punch to indicate usage.
NOTE: The big-end bearing caps
identification marks must point to the front
of the engine.
Install the connecting rod bearing caps.
Tighten the bolts in four stages.
Stage 1: Tighten the bolts finger tight.
Stage 2: 27 Nm.
After installation lubricate the journals
with engine oil.
9. NOTE: Install a new timing chain rear
housing gasket.
Install the timing chain rear housing.
10. NOTE: Install a new ladder frame gasket.

Install the ladder frame (14 bolts).
Align the ladder frame flush with the
cylinder block.
Tighten the bolts in the sequence shown.

11. Install the air conditioning (A/C) compressor
retaining bracket.
12. NOTE: Install a new oil pump pickup tube O-

ring seal.
Install the oil pump pickup tube.
13. NOTE: Install new O-ring seals.

Install the oil pump connecting pipe.
14. NOTE: A new crankshaft rear oil seal carrier

is supplied with an alignment sleeve that
must be removed following installation.
rear oil seal carrier retaining bolts at this
stage.
Install the crankshaft rear oil seal carrier.
15. Tighten the crankshaft rear oil seal carrier
retaining bolts.
16. Remove the crankshaft rear oil seal carrier

alignment sleeve.

17. Using the special tool, install the crankshaft
position (CKP) sensor retaining bracket.
19. CAUTION: Make sure that the sealer

NOTE: Do not damage the mating faces.
frame.
20. NOTE: Install the oil pan within ten minutes
NOTE: Once the oil pan has contact with the
Apply a 2,5 mm diameter bead of silicone
gasket and sealant to the ladder frame
(dotted line).
Tighten bolts and nuts in the sequence
shown.

damage. Install a new drain plug and seal if
required.
Install the drain plug.

at this stage.
Install the dual mass flywheel.
23. Using the special tool, lock the dual mass

flywheel in position.

at this stage.
Using the special tool, install the dual mass
flywheel.
Tighten the bolts in two stages in the
sequence shown.
Stage 1: 35 Nm
Stage 2: 45 degrees

26. Inspect the dual mass flywheel.
For additional information, refer to: Flywheel
Inspection (303-00 Engine System - General
27. Using the special tool, centralize the clutch disc
on the pressure plate.

28. CAUTIONS:
Install new bolts.
Tighten the clutch pressure plate

retaining bolts finger tight and then by two
turns at a time in the sequence shown to the
specified torque.
Using the special tool, install the clutch disc and
pressure plate.
29. NOTE: Install a new crankshaft position
(CKP) sensor.
NOTE: The CKP sensor must make contact
with the flywheel.
Install the CKP sensor.
30. Install the fuel pump bracket.
31. Install the coolant distribution pipe.

hose to the coolant distribution pipe.

33.
1. 26 Nm
2. 50 Nm

34.
35.
All vehicles
36. NOTE: Install a new fuel pump gasket.
Install the fuel pump.
37. Install the fuel pump bracket.
38. Install the timing chain, sprockets and guides.

39. Install the fuel pump sprocket.
40. Install the timing chain tensioner.
41. NOTE: Install a new timing chain housing

cover gasket.
Using the special tool, install the timing chain
housing cover.
three stages.
Bolts 1 to 5: 10 Nm
Bolt 6:23 Nm
Bolts 7 to 19: 10 Nm
42. Install the accessory drive belt idler.

seal.
44. NOTE: Install a new crankshaft pulley bolt.

pulley.
Tighten the bolt in two stages.
Stage 1: 100 Nm
Stage 2: 180 degrees
45. NOTE: Install a new water pump gasket.

Install the water pump.
46. Using the special tool, install the water pump

pulley.
47. Install the engine front mount bracket.

NOTE: "TOP (OBEN)" mark.
NOTE: Install a new cylinder head gasket.
Install the cylinder head gasket.
49. CAUTION: Install new cylinder head

bolts.
four stages in the sequence shown.
20 Nm.
54 Nm.
90 degrees.
Stage 4: short bolts: 70 degrees, long
bolts: 90 degrees.

52. NOTE: Install a new fuel pump oil seal
retainer.
Install the fuel pump oil seal retainer.
53. Using sealant, seal the injection pump pulley to

the fuel pump sprocket.
Apply sealant to the outer edge of the fuel
pump pulley bolt holes.
54. Install the fuel pump pulley.
55. Using the special tool, install the camshaft oil

seal.

Install the camshaft pulley retaining bolt.


Remove the cylinder block blanking plug.

Turn the crankshaft to top dead center (TDC).
crankshaft stops.
60. CAUTIONS:
Make sure that the engine does not

Make sure engine is at the TDC position

before locking the special tool.

correctly.
Using the special tool, lock the engine in
position.
61. NOTE: Use only latest level timing belts.
logo.
Check the timing belt.

62. Check the timing belt tensioner.
2. Arrow denotes counterclockwise rotation of
tensioner.
63. Rotate the timing belt tensioner adjustment arm

clockwise to the 3 o'clock position.
64. NOTE: Do not fully tighten the timing belt
tensioner retaining bolt at this stage.
65. CAUTIONS:

then loosen by one-half turn.
67. NOTE: Using an Allen key, maintain the

tension on the timing belt until the timing
belt tensioner bolt is tightened.

arm counterclockwise to tension the timing
belt slightly.
bolt.

2. Tighten the bolt.

Operation).
73. NOTE: Only turn the engine in the normal

NOTE: Using a suitable marker, mark the
crankshaft pulley to show TDC.
Turn the engine six revolutions.

Turn the engine to TDC.
Turn the engine slowly until the crankshaft
stops.
76. CAUTIONS:
Make sure that the engine does not

Make sure the engine is TDC position

before locking the special tool.

correctly.
Using the special tool, lock the engine in
position.
78. CAUTION: If the pointer is not visible in

the timing belt tensioner window, the timing
belt tensioning steps must be repeated.
Check that the timing belt tensioner pointer is
positioned in the window.
79. CAUTION: If the special tool cannot be

installed, the timing belt tensioning steps
must be repeated.
repeat procedure from previous steps.

necessary.
82.
83. Install the fuel injectors.

Stage 1: 5 Nm
Stage 2: 90 degrees
84. Install the fuel injection supply manifold

retaining bracket.

85. NOTE: Do not tighten the fuel injection
supply manifold retaining bolts at this stage.
Install the fuel injection supply manifold.
86. NOTE: Install new high-pressure fuel supply

lines.
Lubricate the high-pressure fuel supply line
union threads with clean ISO 4113 lubricant
from the high-pressure fuel supply line parts kit.
87. CAUTIONS:

Do not allow the unions to hit the olive

ends of the high-pressure fuel supply line as
this may damage the ends of the line and
allow foreign material to enter the fuel
injection system.
Remove the blanking plugs from the

high-pressure fuel supply line, the fuel
injector and the fuel injection supply
manifold at the last possible moment. Failure
foreign matter ingress to the fuel injection
system.
NOTE: To aid identification of the high-
pressure fuel supply lines, the unions at the
fuel injector end are etched with the cylinder
number.
NOTE: Do not tighten the high-pressure fuel
pressure fuel supply line to keep the lines in

contact with the fuel injector cones while
hand installing the union.
Install the high-pressure fuel supply lines to the
fuel injectors.
Discard the blanking plugs.
88. CAUTIONS:

injection system.

to follow this instruction may result in foreign
contact with the fuel injection supply
manifold cones while installing the union.
Install the high-pressure fuel supply lines of
89. NOTE: Make sure the clamp is installed in
Install the high-pressure fuel supply line clamp
to the high-pressure fuel supply line.
90. NOTE: Install a new high-pressure fuel

supply line union.
Lubricate the high-pressure fuel supply line
union threads with clean ISO 4113 lubricant
from the high-pressure fuel supply line parts kit.
91. CAUTIONS:

injection system.

to follow this instruction may result in foreign
supply line union at this stage.
pressure fuel supply line to keep the line in
contact with the fuel pump and fuel injection
supply manifold cones while installing the
unions.
Install the high-pressure fuel supply line.
1. Install the high-pressure fuel supply line
union to the fuel injection supply manifold.
2. Install the high-pressure fuel supply line
union to the fuel pump.
92. CAUTIONS:


injection system.

system.
NOTE: To aid identification of the high-
pressure fuel supply lines, the unions at the
fuel injector end are etched with the cylinder
number.
contact with the fuel injector cones while
hand installing the union.
Install the high-pressure fuel supply lines to the
fuel injectors.
93. CAUTIONS:

injection system.

system.
contact with the fuel injection supply
manifold cones while installing the union.
Install the high-pressure fuel supply lines of
manifold.
94. Connect the fuel injector return line to the fuel
injectors.
95. NOTE: Do not tighten the high-pressure fuel

supply line clamps at this stage.
NOTE: Make sure the clamps are installed in
Install the high-pressure fuel supply line clamps.
96. NOTE: Do not fully tighten the high-pressure

fuel supply line clamp retaining nut at this
stage.
Install the high-pressure fuel supply line clamp
retaining nut.
97. Tighten the fuel injection supply manifold

retaining bolts.

98. CAUTIONS:

Make sure the tool used to tighten the

high-pressure fuel supply line unions is used
at the top of the union as this is where there
is most material. Failure to follow this
instruction may result in damage to the
union.
Tighten the high-pressure fuel supply line unions
of cylinder one and four to the fuel injectors.

tighten the high-pressure fuel supply line
to the union.
of cylinder one and four to the fuel injection
supply manifold.

to the union.
Tighten the high-pressure fuel supply line
unions.
101. CAUTIONS:

Make sure the tool used to tighten the

high-pressure fuel supply line unions is used
at the top of the union as this is where there
is most material. Failure to follow this
instruction may result in damage to the
union.
of cylinder two and three to the fuel injectors.

to the union.
of cylinder two and three to the fuel supply
manifold.
103. NOTE: Make sure the clamps are installed in

Tighten the high-pressure fuel supply line
clamps.
104. CAUTION: Cover the high-pressure fuel

pump opening to prevent dirt ingress.
Tighten the high-pressure fuel supply line clamp
retaining nut.
105. Connect the high-pressure fuel pump electrical

connectors.
106. Connect the high-pressure fuel sensor electrical

connector.
107. Connect the knock sensor (KS) electrical

connector.

108. Attach the glow plug wiring harness bracket to
the oil level indicator tube bracket.
109. Attach the oil level indicator tube bracket to the

thermostat housing.

connector.

112. Connect the high-pressure fuel injector electrical

connectors.

113. Connect the fuel injector return line to the fuel
pump.
114. NOTE: Install a new brake booster vacuum

pump O-ring seal.
Install the brake booster vacuum pump.
115. Using the special tool, attach the positive

crankcase ventilation (PCV) hose to the brake
booster vacuum pump.
116. Install the PCV housing.

1. Connect the electrical connector.
2. Attach the electrical connector to the PCV
housing.

118. Using the special tool, attach the PCV hoses to
the valve cover.
119. Using the special tool, attach the PCV hoses to

the lower PCV pipe.
120. NOTE: Install a new oil cooler gasket.

Install the oil cooler.

122. NOTE: Install a new turbocharger oil return

tube O-ring seal.
Attach the turbocharger oil return tube.

123. NOTE: Install new turbocharger oil supply
line sealing washers.
Install the turbocharger oil supply line.

line sealing washers.
Attach the turbocharger oil supply tube to the
turbocharger.


Engine—Vehicles Without: Common Rail
Fuel Injection
Print
Assembly
Special Tool(s)
205-072 (15-030A)
Gauge, Bolt Angle

303-174 (21-540)

303-193 (21-104)

303-199A (21-110A)

303-376 (21-162B)

303-393 (21-168)

303-397 (24-003)
Mounting Stand
303-435 (21-187)

303-435-06 (21-031B)
Aligner, Oil Pump

303-652 (21-230)

308-204 (16-067)
Alignment Peg, Crankshaft Position Sensor bracket

310-057 (23-049)
General Equipment
Micrometer
Feeler gauges
Internal micrometer
Piston ring compressor
Dial indicator gauge holding fixture
Plastigage
Materials
Name Specification
Sealant WSE-M4G323-A4
Engine oil SAE 5W 30 WSS-M2C912-A1
Assembly
All vehicles

1. Coat the main bearing journals, bearing shells
and thrust half washers with clean engine oil.
2. CAUTION: Install the main bearing upper

and lower shells in the correct order
Install the main bearing shells to the cylinder
block and to the main bearing caps.
3. Position the crankshaft in the cylinder block.
4. NOTE: The grooves in the thrust half washers
must face outwards.
Install the crankshaft thrust half washers into the
third main bearing with oil grooves facing
outwards.
5. NOTE: Install the main bearing caps with
arrows pointing forward. Caps are identified
1, 2, 3, 4, 5 from the front to the rear.
Install the crankshaft.
sequence shown.
45 Nm.
70 Nm.
60 degrees.
6. Coat the cylinder bores with clean engine oil.
7. NOTE: Install the pistons with the arrows
pointing to the front of the engine.
NOTE: The piston ring gaps and oil supply

ring elements must be distributed evenly
around the circumference.
Using a suitable piston ring compressor, install
the pistons.
Install clean and dry connecting rod
bearing shells in the connecting rods.
8. CAUTION: Connecting rod bearing cap

bolts must only be used two times.
NOTE: Stamp the bolt heads with a center
punch to indicate usage.
NOTE: The big-end bearing caps
identification marks must point to the front
of the engine.
Install the connecting rod bearing caps.
Tighten the bolts in four stages.
Stage 1: Tighten the bolts finger tight.
Stage 2: 27 Nm.
After installation lubricate the journals
with engine oil.
9. NOTE: Install a new timing chain rear
housing gasket.
Install the timing chain rear housing.
10. NOTE: Install a new ladder frame gasket.

Install the ladder frame (14 bolts).
Align the ladder frame flush with the
cylinder block.
Tighten the bolts in the sequence shown.

11. Install the air conditioning (A/C) compressor
retaining bracket.
All vehicles
12. NOTE: Install a new oil pump pickup tube O-
ring seal.
Install the oil pump pick-up tube.
13. NOTE: Install new O-ring seals.

Install the oil pump connecting pipe.

frame.
15. CAUTION: Make sure that the sealer

NOTE: Install the oil pan within ten minutes
NOTE: Once the oil pan has contact with the
Apply a 2.5 mm diameter bead of sealant
to the ladder frame (dotted line).
Tighten bolts and nuts in the sequence
shown.

damage. Install a new drain plug and seal if
required.
Install the drain plug.
17. NOTE: A new crankshaft rear oil seal carrier

is supplied with an alignment sleeve that
must be removed following installation.
rear oil seal carrier retaining bolts at this
stage.
Install the crankshaft rear oil seal carrier.
18. Tighten the crankshaft rear oil seal carrier
retaining bolts.
19. Remove the crankshaft rear oil seal carrier

alignment sleeve.
20. NOTE: Do not fully tighten the crankshaft

position (CKP) sensor retaining bracket bolts
at this stage.
Install the CKP sensor retaining bracket.

Using the special tool, install the flywheel.
sequence shown.
Stage 1: 18 Nm.

23. Using the special tool, centralize the clutch disc
on the pressure plate.
24. CAUTION: Tighten the clutch pressure

plate retaining bolts finger tight and then by
two turns at a time in the sequence shown to
the specified torque.
Using the special tool, install the clutch disc and
pressure plate.
25. Using the special tool, install the CKP sensor

retaining bracket.
26. Install the coolant distribution pipe.

hose to the coolant distribution pipe.
28. NOTE: Install a new fuel injection pump

gasket.
Install the fuel injection pump.
29. Install the fuel injection pump bracket.
30. Install the timing chain, sprockets and guides.
31. NOTE: Do not tighten the fuel injection pump

sprocket bolts at this stage.
Install the fuel injection pump sprocket.

32. Install the timing chain tensioner.
33. Using the special tool, install the timing chain

housing cover.
three stages.
Bolts 1 to 5: 10 Nm
Bolt 6:23 Nm
Bolts 7 to 19: 10 Nm
34. Install the accessory drive belt idler.
35. Using the special tool, install the crankshaft

pulley.
Tighten the bolt in two stages.
Stage 1: 100 Nm.

Remove the cylinder block blanking plug.

crankshaft stops.
38. NOTE: Using a 6 mm drill bit, set the fuel
injection pump to crankshaft TDC.
Install the fuel injection pump sprocket.

NOTE: Using a suitable marker, mark the
crankshaft pulley to show TDC.
Turn the crankshaft 90 degrees.
41. NOTE: Install a new water pump gasket.

Install the water pump.
42. Using the special tool, install the water pump

pulley.

NOTE: "TOP (OBEN)" mark.
44. NOTE: The turbocharger oil return hose must

be attached when the cylinder head is
installed.
Install the cylinder head.
45. CAUTION: Install new cylinder head

bolts.
four stages in the sequence shown.
20 Nm.
54 Nm.
90 degrees.
Stage 4: short bolts: 70 degrees, long
bolts: 90 degrees.

46. NOTE: Make sure that new bolts are
installed.
Install the fuel injectors.
Stage 1: 5 Nm
Stage 2: 90 degrees
49. NOTE: Install a new fuel injection pump oil

seal retainer.
Install the fuel injection pump oil seal retainer.

50. Using sealant, seal the fuel injection pump pulley
to the fuel injection pump sprocket.
Apply sealant to the outer edge of the fuel
injection pump pulley bolt holes.
51. Install the fuel injection pump pulley.
52. Using the special tool, install the camshaft oil

seal.

Install the camshaft pulley retaining bolt.


crankshaft stops.
57. CAUTIONS:

Make sure the crankshaft is at the TDC


correctly.
Using the special tool, lock the crankshaft in
position.
58. NOTE: Use only latest level timing belts.
logo.
Check the timing belt.

All vehicles
60. Check the timing belt tensioner.
2. Arrow denotes counterclockwise rotation of

tensioner.
61. Rotate the timing belt tensioner adjustment arm

clockwise to the 3 o'clock position.
62. NOTE: Do not fully tighten the timing belt
tensioner retaining bolt at this stage.
63. CAUTIONS:

arrows in the direction of crankshaft rotation.
then loosen by one-half turn.
65. NOTE: Using an Allen key, maintain the

tension on the timing belt until the timing
belt tensioner bolt is tightened.
arm counterclockwise to tension the timing
belt slightly.
bolt.



crankshaft stops.
73. CAUTIONS:

Make sure the crankshaft is in TDC


correctly.
Using the special tool, lock the crankshaft in
position.
74. CAUTION: If the pointer is not visible in

the timing belt tensioner window, the timing
belt tensioning steps must be repeated.
Check that the timing belt tensioner pointer is
positioned in the window.
75. CAUTION: If the special tool cannot be

installed, the timing belt tensioning steps
must be repeated.
repeat procedure in previous steps.


Vehicles without charge air cooler

79. Install the timing belt lower cover.
All vehicles
necessary.
1. Lubricate the valve cover gasket with
engine oil before installation.
81. Install the generator bracket.

82. NOTE: Install a new oil cooler gasket.
Install the oil cooler.


line O-ring seals.
Install the turbocharger oil supply line.
85. NOTE: Install a new turbocharger oil supply

line O-ring seal.
Attach the turbocharger oil supply line to the
turbocharger.
86. Install the generator and drive shaft.

87. NOTE: Install new high pressure fuel supply
lines.
Install the high pressure fuel supply lines.
88. NOTE: Secure the oil separator to the engine

lifting eye. Tighten the engine lifting eye and
then tighten the oil separator.
NOTE: Install the clip at a 45 degree angle to
the horizontal.
Attach the crankcase ventilation oil separator.


Engine
Print
Installation
Special Tool(s)
205-316 (15-097A)
Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
Aligner, Gear Shift Lever

308-273 (16-088)
General Equipment
Workshop table
Retaining straps
Materials
Name Specification
Anti seize grease SAM-1C9107-A
Installation
All vehicles

personal injury.
Install the transaxle to the engine.

Operation) /
and Operation).

transaxle assembly on wooden blocks.
Failure to follow these instruction may result
in personal injury.
CAUTION: Support the engine on the oil

pan flange.

Using suitable retaining straps, secure the
engine and transaxle assembly on the workshop
table and position it under the vehicle.
4. Install the engine rear mount.
6. Check the lower arm ball joint heat shield.

For additional information, refer to: Lower Arm
Ball Joint (204-01 Front Suspension, Removal
and Installation).
7. Using a suitable transmission jack, position and
raise the crossmember until the crossmember is
approximately 100 mm from the body.
8. Install new power steering line O-ring seals.
Steering System Flushing - 1.8L Duratorq-TDCi
(Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel
(211-00 Steering System - General Information,
9. Attach the power steering line to the steering

gear (crossmember shown removed for clarity).
1. Rotate the clamp clockwise.

10. Install the power steering line retaining bracket
(crossmember shown removed for clarity).
11. Install the steering gear heat shield (two bolts).
12. CAUTION: Make sure that the

crossmember ball bearing washers are
installed correctly.
Using a suitable transmission jack and the
special tool, position and align the crossmember.
washers.
washers and into the groove of the special
tool and tighten the alignment pin sleeve.
alignment pins into the chassis alignment
holes.

crossmember does not move while
tightening the crossmember retaining bolts.
Install the crossmember retaining bolts
(transmission jack shown removed for clarity).
14. Remove the retaining strap and the transmission

jack.
15. Attach the starter motor wiring harness bracket
and engine ground cable to the transaxle
housing.
16. Attach the high pressure line to the clutch slave

cylinder.
1. Install the retaining clip.
2. Attach the bracket together with the
rubber grommets.
17. CAUTIONS:

degrees.

18. CAUTIONS:

45 degrees.

NOTE: Install new lock nuts and a new
centre bearing caps.
Attach the right-hand halfshaft to the transaxle
and install the bearing cap.
19. Install the engine support insulator.
20. NOTE: Install new nuts.

Attach the exhaust flexible pipe to the exhaust

system.
Coat the studs with anti seize grease .
21. Remove the support wrap from the exhaust

flexible pipe.
22. Attach the gear shift cables to the transaxle.

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

and the power supply.
25. Install the fender splash shield.

26. Tighten the bolts with 10 Nm.

ball joint seal.
Attach the lower arm to the wheel knuckle on
both sides (left-hand side shown).
28. NOTE: Install a new nut.

Attach the left-hand tie-rod end.
29. Attach the stabiliser bar connecting link on both

sides.
30. Install the left front wheel and tire.

For additional information, refer to: Wheel and
Tire (204-04 Wheels and Tires, Removal and
Installation).
31. Using the special tool, attach the coolant hose to
the oil cooler.

32. Attach the air conditioning compressor (four
bolts).
33. Connect the air conditioning compressor clutch

electrical connector and attach the wiring
harness to the air conditioning compressor.
All vehicles
34. Connect the horn electrical connector and the
horn wiring harness.


37. Remove the cable ties.

All vehicles
38. Connect the cooling fan motor electrical
connector and attach the cooling fan wiring
harness to the cooling fan shroud.
40. Using the special tool, connect the lower coolant

hose to the coolant expansion tank.
41. Connect the fuel supply and return line quick

release coupling.
42. Attach the fuel supply and return line to the fuel
line bracket.


the bracket.




48. Connect the fuel injection pump electrical
connector.
49. Attach the vacuum hoses and the electrical

connector to the emission gas recirculation
(EGR) valve.
All vehicles
50. Attach the upper coolant hose to the EGR cooler.

51. Attach the electronic vacuum regulating valves
support bracket to the intake manifold.

54. Connect the injector driver module electrical

connector.
All vehicles
55. Connect the engine wiring harness.
56. Attach the vacuum hose to the vacuum

diaphragm unit.
57. Install the generator electrical connector cover.

58. Connect the generator battery positive cable.
59. Using the special tool, attach the cooling hoses

to the thermostat housing and to the coolant
distribution pipe.

60. Connect the fuel pressure sensor electrical
connector.
All vehicles
61. NOTE: Install a new gasket.


vacuum pump.
64. Install the oil level indicator and oil level

indicator tube.
65. Connect the glow plug wiring harness to the

terminal block.
66. Connect the glow plug wire to the terminal block.

67. Install the air cleaner intake pipe.

71. Install the charge air cooler air guide.

72. CAUTION: Install a new turbocharger
outlet hose and clamps in the same position
as removed. Faliure to follow this instruction
may cause premature failure of adjacent
components.
Install the turbocharger outlet hose to the charge
air cooler intake pipe.

air cooler.
NOTE: Install a new charge air cooler intake
intake hose.
when removed.
74. CAUTION: The charge air cooler to

intake manifold hose retaining clamp must be
installed in the same position as removed.
Failure to follow this instruction may cause
premature failure of adjacent components.
Install the charge air cooler to intake manifold
hose and retaining clamp.
Install the hose retaining clamp in the
same position as when removed.


cooler.
NOTE: Install a new charge air cooler outlet
outlet hose.
Install the charge air cooler outlet hose
when removed.
76. Install the engine upper cover.

nuts on both sides.

column shaft to the steering gear pinion
extension retaining bolt. Failure to follow this
NOTE: Make sure that the road wheels are in
Connect the steering column shaft to the

80. Fill and bleed the cooling system.

Procedures).
82. Adjust the gearshift cable.
For additional information, refer to: Gearshift
Cable Adjustment (308-00 Manual
83. Install the battery tray.
and Installation).

Engine Cooling - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Item Specification
Motorcraft Super Plus 2000 WSS-M97B44-D
Antifreeze Specification
Specific Gravity (providing no Approximate percentage of Remains

other additive is in the coolant) antifreeze (by volume) fluid to Solidifies at
1.061 at +15° C 50% -25° C (-13° -30° C (-
F) 22° F)
Operating Specifications
Pressure kpa Temperature °C (°

Description (psi) F)
Coolant expansion tank release pressure 120-150 (17- -
21)
Thermostat opening temperature (all except vehicles with - 92 (197)
diesel engine)
Thermostat opening temperature (vehicles with diesel - 88 (190)
engine)
Torque Specifications - all except vehicles with diesel engines

Radiator support bracket retaining bolts 25 18 -
Water pump retaining bolts 18 13 -
Thermostat cover retaining bolts 5 - 44
Cooling fan motor retaining bolts 5 - 44
Roll restrictor retaining bolts 48 35 -
Engine front mounting to body retaining bolts 48 35 -
Torque Specifications - vehicles with diesel engines

Radiator support bracket retaining bolts 25 18 -
Water pump retaining bolts (M6) 10 - 89
Water pump retaining bolt (M10) 23 17 -
Thermostat cover retaining bolts 9 - 80
Cooling fan motor retaining bolts 5 - 44
Charge air cooler outlet pipe retaining nuts 9 - 80
Engine front mounting bracket retaining bolts 33 24 -

Engine Cooling - Engine Cooling Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Pressure Tester, Cooling System
303-396 (24-001 A)
Adaptor for 24-001 A

303-396-01 (24-001-01 A)
General Equipment
Coolant leaks Fuse(s)
Gaskets/seals Wiring harness
Core plug(s) Electrical connector(s)
Hose(s)/hose joints Cylinder head temperature (CHT) sensor
Coolant expansion tank cap and seal Engine coolant temperature (ECT) sensor
Coolant expansion tank Cooling fan
Radiator Auxiliary Heater - vehicles with diesel
Water pump engine
Thermostat housing Powertrain control module (PCM)
Heater core
Heater control valve
Exhaust gas recirculation (EGR)
cooler
Accessory drive belt
Chart.
Symptom Chart
Symptom Chart

Loss of coolant * Coolant expansion * CHECK the coolant expansion tank cap for
tank cap or seal. tightness. If OK, CARRY OUT the Coolant
Expansion Tank Cap Pressure Test Component
Test in this section.
* Cooling system. * INSPECT the cooling system for leaks. CARRY
OUT the Pressure Test Component Test in this
section. INSTALL new component(s) as

necessary.
* Engine. * INSPECT the engine, cylinder head, cylinder
block and cylinder head gasket.
REFER to: Cylinder Head (303-01A Engine -
1.8L Duratec-DOHC (85kW/115PS) - Zetec, In-
vehicle Repair) /
Cylinder Head - 1.8L Duratorq-TDDi (Lynx)
Diesel (75 PS), Vehicles Without: Common Rail
Fuel Injection (303-01B Engine - 1.8L Duratorq-
Diesel, In-vehicle Repair) /
Cylinder Head - 1.8L Duratorq-TDCi (Lynx)
Diesel (90 PS), Vehicles With: Common Rail
Diesel, In-vehicle Repair).
The engine * Air in cooling system. * BLEED the cooling system.
overheats (signs of REFER to: Cooling System Draining, Filling and
coolant boiling) Bleeding (303-03 Engine Cooling, General
Procedures).
* Cooling system does * CARRY OUT the Coolant Expansion Tank Cap
not hold pressure. Pressure Test Component Test in this section.
* INSPECT the engine, cylinder head, cylinder
vehicle Repair) /
* Coolant * CHECK the coolant level. REFILL the cooling
level/condition. system as necessary.
REFER to: Cooling System Draining, Filling and
Bleeding (303-03 Engine Cooling, General
Procedures).
* CHECK the coolant condition and concentration.
If the coolant is contaminated or the
concentration is below specifications, drain and
refill with new coolant.
REFER to: Cooling System Draining, Filling and
Procedures).
* Radiator grille. * INSPECT the radiator grille for air
restrictions/damage. REPAIR or INSTALL new
parts as necessary.
* Cooling fan. * CHECK the operation of the cooling fan. REFER
to WDS.
* Thermostat. * CARRY OUT the Thermostat Test Component
Test in this section. INSTALL a new thermostat
as necessary.
* Water pump. * REMOVE AND INSPECT the water
pump/impeller. INSTALL a new water
pump/water pump gasket as necessary.

REFER to: Water Pump - 1.8L Duratec-DOHC
(85kW/115PS) - Zetec (303-03 Engine Cooling,
Water Pump - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (303-
03 Engine Cooling, Removal and Installation).
* Cooling system * REFER to: Cooling System Backflushing (303-
restriction/blockage. 03 Engine Cooling, General Procedures). If the
concern persists, INSTALL new components as
necessary.
* Engine. * INSPECT the engine, cylinder head, cylinder
vehicle Repair) /
The engine does * Thermostat. * CARRY OUT the Thermostat Test Component
not reach normal Test in this section. INSTALL a new thermostat
operating as necessary.
temperature.
Component Tests
Pressure Test
WARNING: When releasing the system pressure, cover the expansion tank cap with a
thick cloth to prevent the possibility of coolant scalding, Failure to follow this instruction
1. 1. Remove the coolant expansion tank cap.
2. 2. Install the special tools to the coolant expansion tank.
3. 3. Pressurize the system to the coolant expansion tank cap release pressure.
REFER to: Specifications (303-03 Engine Cooling, Specifications).
4. 4. Observe the cooling system pressure tester gauge reading for approximately two
minutes. The pressure should not drop during this time. If the system holds
pressure, proceed to step 7. If the system does not hold pressure, check it
thoroughly for coolant leaks.
5. 5. On vehicles with 1.8L diesel engine - if a coolant leak cannot be found, check the
EGR cooler (this may leak internally), engine oil cooler (this may produce oil in the
coolant expansion tank and the engine for cylinder leakage. Drain the cooling
system, repair any coolant leaks found and fill and bleed the cooling system as
necessary.
REFER to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling,
6. 6. All vehicles except with diesel engine - check the engine for coolant leaks. Drain

the cooling system, repair any coolant leaks found and fill and bleed the cooling
system as necessary.
REFER to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling,
7. 7. Recheck the system by repeating steps 3 and 4 at least twice.
Radiator Leak Test, Removed From Vehicle
CAUTION: Radiator internal pressure must not exceed 130 kpa (20 psi) or damage
may result.
Clean the radiator thoroughly before leak testing it, to prevent contamination of the water
in the test tank. Leak test the radiator in clean water with 138 kpa (20 psi) air pressure.
Check it thoroughly for air leaks. INSTALL a new radiator if necessary.
REFER to: Radiator (303-03 Engine Cooling, Removal and Installation).
Coolant Expansion Tank Cap Pressure Test
thick cloth to prevent the possibility of coolant scalding, Failure to follow this instruction
1. 1. Remove the coolant expansion tank cap.
2. 2. Use water to clean the area of the rubber seal and pressure relief valve. Install the
pressure tester and adapter and immerse the coolant expansion tank cap in water.
NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure
reading will result.
3. 3. Slowly depress the plunger of the pressure test pump until the pressure gauge
reading stops increasing, and note the highest pressure reading obtained.
4. 4. Release pressure by turning the pressure relief screw counterclockwise. Tighten

the pressure relief screw and repeat step 3 at least twice to make sure the pressure
test reading is repeatable and within acceptable gauge reading limits of the coolant
expansion tank cap.
5. 5. If the pressure test gauge readings are not within the acceptable gauge reading
limits, INSTALL a new coolant expansion tank cap.
Thermostat Test
1. 1. Connect the WDS to the data link connector (DLC).
2. 2. Using the WDS datalogger function, SELECT the following sensors (as applicable to
the application):
IAT - intake air temperature (IAT) sensor

ECT - engine coolant temperature (ECT) sensor
CHT - cylinder head temperature (CHT) sensor
LOAD - engine load
VSS - vehicle speed sensor (VSS)
RPM - engine speed
DSRPM - desired engine speed

The IAT sensor output is useful if the engine being tested is cold or after an over-night cold
soak. The ECT sensor or CHT sensor and the IAT sensor should either indicate the same
value or be within 1 to 2 degrees Celsius of each other.
The ECT sensor output is important to display as it indicates the engine warm-up and
opening temperature for the thermostat. It will initially indicate a slightly higher reading
just before the thermostat opens and then drops back before settling to a near flat line
output (see graphic below).

A - Thermostat opens
B - Thermostat settles into a cyclic open and closure pattern
CAUTION: If the ECT sensor output reaches the 120ºC default line under normal
cooling system pressure, internal damage may be caused to the engine and a diagnostic
trouble code (DTC) will be set in the PCM. The test should be stopped and the cause
located and corrected. If the cooling system does not pressurize, the coolant will boil at
100ºC which may also damage the engine. CARRY OUT the Coolant Expansion Tank Cap
Pressure Test Component Test in this section.
If the WDS only allows the ECT sensor to be displayed in volts, refer to the following table
for corresponding Celsius values:
Volts ºCelsius
1.33 60
1.02 70
0.78 80
0.60 90
0.46 100
0.35 110
0.27 120
The CHT sensor output is useful to examine the cylinder head temperature rise during the
warm-up cycle and later during the normal light throttle cruise test. This sensor output may
vary between vehicles with manual transmission and vehicles with automatic transmission
and should be used for reference only.
The LOAD display is used for reference as it is necessary to maintain a stable load line
during the test. It is necessary to carry out the test under normal light throttle cruise
driving conditions and average loads, typically 40% to 70% of the load value.
The VSS output is used for reference but can help to identify misfires and sensors which fail
during the warm-up cycle.
The RPM display indicates the engine speed and can be compared with the DSRPM.
The DSRPM is the desired or calculated idle speed which the PCM commands the engine to
reach. If the thermostat opens too early (before the correct opening temperature has been
reached), the engine will not reach this value.
When using the WDS in data logger mode, the signals recorded should remain within the

DEFAULT values set by the WDS.
3. WARNING: Make sure that the WDS is placed in the vehicle so that it does not
interfere with the safe operation of the vehicle. Do not place the WDS in the
deployment path of any air bag. Failure to follow these instructions may result in
personal injury.
NOTE: The road test is best carried out with the aid of another technician in the
vehicle to enable the vehicle to be driven safely while the sensor outputs are
monitored within datalogger. If there is only one technician available, the WDS can
be set up (using the record/capture mode camera icon) before leaving the
workshop to record a 16 km (10 mile) test.
NOTE: The results from the test are more conclusive if the engine is cold when the
test is started.
3. Carry out a road test.
REFER to: Road/Roller Testing (100-00 General Information, Description and
Operation).
4. 4. Drive the vehicle at a constant throttle opening and set speed until the ECT value
settles into a shallow rise and fall signal, close to a straight line. This indicates that
the thermostat is functioning correctly.
NOTE: Some thermostats indicate the temperature(s) in Celsius and Fahrenheit.

The graphic below shows the location and an example of the opening temperature (88ºC)
and fully open temperature (102ºC) of a thermostat.
The graphic below shows an alternative method used to show the opening temperature
(88ºC) and fully open temperature (112ºC) of a thermostat.

A - Opening temperature
B - Fully open temperature
NOTE: Generally, most thermostats maintain a coolant temperature between 88ºC
(190ºF) and 92ºC (198ºF) although dual stage electric thermostats may increase the
coolant temperature up to 100ºC (212ºF) under light engine load conditions.
The engine should start cleanly and the ECT value will rise quite quickly with smooth
progression. If the ECT signal appears unstable or erratic, the ECT sensor, electrical

connector and wiring harness to the PCM need to be visually inspected for damage, chafing
or water ingress.
The temperature should rise to approximately 90ºC for a thermostat that has an 88ºC
value. The signal value will then fall as cooler coolant enters the engine.
If the ECT value fails to maintain a constant value and falls back to lower figures, typically
between 60ºC (140ºF) and 70ºC (150ºF), the thermostat and its sealing function within the
thermostat housing must be checked.
5. 5. INSTALL a new thermostat.

REFER to: Thermostat - 1.8L Duratec-DOHC (85kW/115PS) - Zetec (303-03 Engine
Cooling, Removal and Installation) /
Thermostat - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel
(303-03 Engine Cooling, Removal and Installation).
6. 6. Carry out another road test from step 1 using the same criteria to confirm that the
concern has been rectified.
7. 7. Using the WDS, clear the PCM keep alive memory (KAM) or electrically erasable
programmable read only memory (EEPROM) so that new drive values can be learnt.

Engine Cooling - Cooling System Flushing Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Procedures
1. To remove rust, sludge and other foreign

material from the cooling system, use Premium
Cooling System Flush, that is safe for use with
aluminum radiators, for additional information -
Refer to Specifications in this section. Remove
the thermostat prior to pressure flushing. This
cleaning restores cooling system efficiency and
helps prevent overheating. A pulsating or
reversed direction of flushing water will loosen
sediment more quickly than a steady flow in the
normal coolant flow direction. In severe cases
where cleaning solvents will not properly clean
the cooling system for efficient operation, it will
be necessary to use the pressure flushing
method using Cooling System Flusher. Dispose of
old coolant and flushing water contaminated with
antifreeze and cleaning chemicals in accordance
with local, state or federal laws.
2. Remove the radiator.
3. CAUTION: Radiator internal pressure

must not exceed 138 KPa (20 psi). Damage
may result.
With the radiator in an upside down position,
flush the radiator with a high-pressure water
hose in the lower hose location.
4. Remove the thermostat.
5. Position the high-pressure water hose into the
engine through the engine coolant return and
flush the engine.

Engine Cooling - Cooling System
Backflushing
Print
General Procedures
CAUTION: The heater core must be backflushed separately from the engine cooling
system to make sure correct backflush water flow direction through the heater core. All
engine cooling system flushing and backflushing procedures must include a separate
backflushing of the heater core or A/C system heater core after the flushing or
backflushing of the engine cooling system to prevent the engine cooling system particles
from clogging the heater core tubes and reducing (or preventing) coolant flow through
the heater core.
1. Disconnect the heater outlet hose from the
engine intake connector and install a garden
hose (from a tap), with a male adapter into the
end of the heater outlet hose. Secure with a hose
clamp.
2. Connect a garden hose to the engine intake
connector and secure with a hose clamp. Allow
the open end to drain into a suitable container or
drain.
3. Turn the water supply tap ON and OFF several
times, so that the surge action will help to
dislodge larger, stubborn particles from the
heater core tubes. Allow water pressure to flow
for approximately five minutes.
4. Remove the garden hose with the male adapter
from the heater outlet hose. Remove the garden
hose from the engine intake connector and
reconnect the heater outlet hose onto the engine
intake connector.
5. Fill the cooling system as described, using a
50/50 mixture of Ford cooling system fluid and
water.
For additional information, refer to Specifications
in this section.
6. Test the system for correct heater operation
within the engine cooling system conditions.

Engine Cooling - Cooling System Draining,
Filling and Bleeding
Print
General Procedures
General Equipment
Funnel
Draining
thick cloth to prevent the possibility of coolant scalding. Failure to follow this instruction
CAUTION: When draining the engine coolant or changing any cooling system
components, it is imperative that no coolant comes into contact with the timing belt or
accessory drive belt. If necessary, protect the belt and accessory drive belt from
contamination by the coolant. Contamination may result in timing belt or accessory drive
belt failure.
1. Release the cooling system pressure by slowly
turning the expansion tank cap a quarter of a
turn
2. Remove the cap when all the pressure has been
released.
Lifting.
4. NOTE: Drain the coolant into a suitable
container.
Open the radiator drain valve to drain the
coolant.
5. Close the drain valve when all the coolant has

been drained from the system.
Refill
1. Disconnect the heater supply hose from the
engine.
2. Using a funnel, fill the cooling system through
the supply hose until coolant starts to trickle
from the engine.
3. Reconnect the heater supply hose.
4. NOTE: Make sure that the in-car heater
temperature control is in the HOT position
and the heater blower switch is in the OFF
position. Make sure the air conditioning is
switched OFF.
Refill the coolant expansion tank up to the MAX
mark (with the engine switched off).

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

Engine Cooling - Thermostat—1.8L
Print

For additional information, refer to Cooling
System Draining, Filling and bleeding in this
section.
3. Remove the components in the order indicated in the following illustration(s) and table
(s).

1 - Thermostat cover retaining bolts
2 - Thermostat cover heat shield
3 - Thermostat cover
See Removal Detail
4 - Thermostat
5 - Thermostat O-ring seal
See Removal Detail
See Installation Detail

Removal Details
Item 3 : Thermostat cover
1. Detach the thermostat housing cover and

Item 5 : Thermostat O-ring seal
NOTE: Discard the O-ring seal.
Installation Details
NOTE: Install a new O-ring seal.

Engine Cooling - Thermostat—1.8L
Duratorq-TDCi (Lynx) Diesel/1.8L Transit/Tourneo Connect 2002.5 (06/2002-)
Print
1. Remove the charge air cooler. For additional

System Draining, Filling and Bleeding in this
section.
(s).

3 - Thermostat
4 - Thermostat seal
See Removal Detail
Removal Details
Item 4 : Thermostat seal
Item 4 : Thermostat seal

Engine Cooling - Thermostat Housing—
Zetec
Print
Special Tool(s)
303-397 (24-003)

System Draining , Filling and Bleeding in this
section.
(s).

1 - Radiator to thermostat housing coolant hose retaining clamp
See Removal Detail
2 - Radiator to thermostat housing coolant hose
-

-
3 Radiator bypass to thermostat housing coolant hose retaining clamp
4 - Radiator bypass to thermostat housing coolant hose
5 - Coolant expansion tank to thermostat housing coolant hose retaining
clamp
6 - Coolant expansion tank to thermostat housing coolant hose
7 - Thermostat housing retaining bolts
8 - Thermostat housing seal
See Removal Detail
9 - Heater core to thermostat housing coolant hose retaining clamp
10 - Heater core to thermostat housing coolant hose
11 - Thermostat housing and thermostat

13 - Thermostat cover heat shield
15 - Thermostat
See Removal Detail
17 - Thermostat housing
Removal Details
Item 1 : Radiator to thermostat housing coolant hose retaining clamp
1. Using the special tool, detach the radiator to

thermostat housing coolant hose retaining clamp.

Item 8 : Thermostat housing seal
NOTE: Remove and discard the thermostat housing seal.
NOTE: Install a new thermostat housing seal.

1.8L Duratorq-TDDi (Lynx) Diesel
Print
Special Tool(s)
303-397 (24-003)

section.
(s).
Item Description

-
1 Oil level indicator tube retaining bolt
2 - Oil level indicator tube
See Removal Detail
clamp
See Removal Detail
7 - Water pump to thermostat housing coolant hose retaining clamp
8 - Water pump to thermostat housing coolant hose
10 - Thermostat housing assembly
See Removal Detail

-

-
14 Thermostat
See Removal Detail
Removal Details
Item 2 : Oil level indicator tube
1. Detach the oil level indicator tube and position it

to one side.
Item 3 : Coolant expansion tank to thermostat housing coolant hose retaining clamp
1. Using the special tool, detach the coolant

expansion tank to thermostat housing coolant

NOTE: Discard the thermostat housing seal.

1.8L Duratorq-TDCi (Lynx) Diesel
Print
Special Tool(s)
303-397 (24-003)

section.
(s).

-

-
1 Fuel pressure sensor electrical connector

See Removal Detail
2 - Glow plug wire terminal block retaining bolt
3 - Glow plug wire terminal block
4 - Oil level indicator tube retaining bolt
See Removal Detail
clamp
See Removal Detail
11 - Water pump to thermostat housing coolant hose retaining clamp
12 - Water pump to thermostat housing coolant hose
13 - Thermostat housing assembly
See Removal Detail
Part Number

Item Description
17 - Thermostat
See Removal Detail
Removal Details

to one side.
Item 6 : Coolant expansion tank to thermostat housing coolant hose retaining clamp
1. Using the special tool, detach the coolant

expansion tank to thermostat housing coolant


Engine Cooling - Water Pump—1.8L
Print

Special Tool(s)
303-397 (24-003)

section.
3. Remove the splash shield.
4. Loosen the water pump pulley retaining bolts.

1. Rotate the accessory drive belt tensioner
clockwise.
6. Remove the roll restrictor to crossmember

retaining bolt.

to one side.
9. Detach the engine ground cable.
10. Remove the engine front mounting to body

retaining bolts.
11. Reposition the engine.

Slide the engine forward.
Secure in position using an engine
mounting to body retaining bolt.
(s).

1 - Water pump pulley retaining bolts
2 - Water pump pulley
3 - Water pump retaining bolts
4 - Water pump
5 - Water pump O-ring seal
See Removal Detail
Removal Details
Item 5 : Water pump O-ring seal
1. Discard the O-ring seal.
Item 5 : Water pump O-ring seal
1. Install a new O-ring seal.

Item 1 : Water pump pulley retaining bolts
1. Do not fully tighten the water pump pulley


Engine Cooling - Water Pump—1.8L
Print
Special Tool(s)
Support Bar, Engine
303-290A (21-140A)

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)
General Equipment
Laminated card
All vehicles
For additional information, refer to: Charge Air
Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L
Duratorq-TDDi (Lynx) Diesel (75 PS/90 PS)
Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx)
From: 08/2006 (303-12 Intake Air Distribution
and Filtering, Removal and Installation).
it to one side.


All vehicles
7. Loosen the water pump pulley retaining bolts.

10. Remove the engine support insulator retaining
bolt.

(s).

1 - Engine front mounting bracket
2 - Power steering pipe retaining bracket
See Removal Detail
3 - Timing belt cover

4 - Coolant pump pulley retaining bolts
5 - Coolant pump pulley
6 - Coolant pump upper retaining bolt
See Removal Detail
7 - Coolant pump retaining bolts
8 - Coolant pump
See Removal Detail
9 - Coolant pump gasket
Removal Details
Item 2 : Power steering pipe retaining bracket
1. Detach the power steering pipe retaining clip

Item 6 : Coolant pump upper retaining bolt
1. Install the fabricated piece of laminated card

between the timing belt and the coolant pump
upper retaining bolt.
Using the fabricated piece of laminated
card to protect the timing belt, remove the

coolant pump upper retaining bolt.
Item 8 : Coolant pump

NOTE: The engine will need to be raised using the special tool to allow removal of the
water pump.
1. Using the special tool, raise the front of the
engine by 60 mm.
Item 8 : Coolant pump
NOTE: Install the water pump onto the dowels before installing the coolant pump
retaining bolt.
Item 6 : Coolant pump upper retaining bolt
CAUTION: Make sure the fabricated piece of laminated card is correctly positioned
between the timing belt and coolant pump before installing the coolant pump upper
retaining bolt.
Item 4 : Coolant pump pulley retaining bolts
1. Install the coolant pump pulley retaining bolts

hand tight.
2. Using the special tool, lower the front of the
engine to its original position.

Engine Cooling - Radiator Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
303-397 (24-003)
1. Remove the cooling fan motor and shroud.

For additional information, refer to Cooling fan
motor and shroud in this section.
section.
(s).

1 - Left-hand front fender splash shield extension retaining bolts
2 - Left-hand front fender splash shield extension
3 - Right-hand front fender splash shield extension retaining bolts
4 - Right-hand front fender splash shield extension
5 - Radiator splash shield retaining clips
6 - Radiator splash shield

7 - Horn electrical connector
8 - Radiator upper hose retaining clamp
See Removal Detail
9 - Radiator upper hose
10 - Radiator lower hose retaining clamp
11 - Radiator lower hose
12 - Coolant expansion tank outlet hose retaining clamp
13 - Coolant expansion tank outlet hose
14 - Coolant expansion tank inlet hose retaining clamp
15 - Coolant expansion tank inlet hose
16 - Radiator support bracket retaining bolts
17 - Radiator support bracket retaining bolts
See Removal Detail
18 - Radiator support bracket
19 - Radiator rubber insulators
20 - Radiator
See Removal Detail
-

21 Radiator rubber insulators
Removal Details
Item 8 : Radiator upper hose retaining clamp
1. Using the special tool, detach the radiator upper

Item 17 : Radiator support bracket retaining bolts
1. With the aid of another technician, support the

radiator and air conditioning (A/C) condenser.
Item 20 : Radiator
1. Detach the A/C condenser from the radiator.

Engine Cooling - Cooling Fan Motor Transit/Tourneo Connect 2002.5 (06/2002-)
Print
1. Remove the cooling fan motor and shroud.

For additional information, refer to Cooling Fan
Motor and Shroud in this section.
(s).

1 - Cooling fan motor retaining bolts
2 - Cooling fan and motor

Engine Cooling - Cooling Fan Motor and
Shroud
Print

(s).

1 - Cooling fan speed resistor electrical connector
2 - Air conditioning (A/C) fan motor electrical connector
3 - Heated oxygen sensor (HO2S) electrical connector
4 - Power steering switch wiring harness retaining clips
5 - Power steering switch wiring harness retaining clip
See Removal Detail
6 - Cooling fan motor electrical connector
7 - Cooling fan shroud retaining nuts

See Removal Detail
8 - Cooling fan motor and shroud
See Removal Detail
Removal Details
Item 5 : Power steering switch wiring harness retaining clip

Lifting.
Item 7 : Cooling fan shroud retaining nuts
1. Loosen the cooling fan shroud retaining nuts.

Item 8 : Cooling fan motor and shroud
1. Raise the cooling fan shroud to disengage from

the radiator retaining clips.
Item 5 : Power steering switch wiring harness retaining clip

Fuel Charging and Controls - 1.8L
Duratec-DOHC (85kW/115PS) - Zetec - Transit/Tourneo Connect 2002.5 (06/2002-)
Specifications
Print

Throttle body retaining bolts a - -
Fuel pressure regulator retaining bolts 6 - 53
Fuel injection supply manifold retaining bolts 10 - 89
a Refer to the procedure in this section.

Fuel Charging and Controls
Print
Fuel line(s) Wiring harness
Vacuum line(s) Electrical connector(s)
Gasket(s)/seal(s) Fuel injector(s)
Fuel pressure regulator
Throttle body
Fuel injection supply manifold
4. 4. If the concern is not visually evident, verify the symptom and refer to WDS to
diagnose the system.

Throttle Body
Print
CAUTION: Do not attempt to clean the throttle body. The bore and the throttle plate
have a special coating applied during manufacture which should not be removed.
(s).

1 - Air cleaner outlet pipe to air cleaner retaining clamp
2 - Air cleaner outlet pipe to throttle body retaining clamp
3 - Air cleaner outlet pipe
4 - Accelerator cable, inner cable to throttle body
5 - Accelerator cable, outer cable to throttle body
See Removal Detail
6 - Throttle position (TP) sensor electrical connector
7 - Throttle body retaining bolts
-

-
8 Throttle body
9 - Throttle body seal
See Removal Detail
Removal Details
Item 5 : Accelerator cable, outer cable to throttle body
1. Rotate and detach the accelerator cable from the

throttle body accelerator cable retaining bracket.
Item 9 : Throttle body seal

NOTE: Discard the throttle body seal.
Item 9 : Throttle body seal
NOTE: Install a new throttle body seal.
Item 8 : Throttle body
NOTE: Inspect the intake manifold to throttle body interface for loose plastic material
produced by the throttle body retaining bolts during initial assembly.
Item 7 : Throttle body retaining bolts
1. NOTE: Hand start each throttle body

retaining bolt by three full turn's.
Tighten the throttle body retaining bolts in the
order indicated.

Fuel Charging Wiring Harness
Print

(s).

4 - Throttle position (TP) sensor electrical connector
5 - Camshaft position (CMP) electrical connector
6 - Idle air control (IAC) valve electrical connector
7 - Cylinder head temperature (CHT) sensor electrical connector
8 - Oil pressure switch electrical connector

See Removal Detail
9 - Fuel charging wiring harness electrical connector
See Removal Detail
10 - Fuel injector electrical connectors
11 - Fuel charging wiring harness
Removal Details
Item 8 : Oil pressure switch electrical connector

Lifting.
Item 9 : Fuel charging wiring harness electrical connector
Item 8 : Oil pressure switch electrical connector
1. Raise the vehicle.

Item 7 : Cylinder head temperature (CHT) sensor electrical connector

Fuel Injection Supply Manifold
Print

Special Tool(s)
Disconnect Tool, Fuel Line (5/16")
310-040
Materials
Name Specification
Formula E Engine Oil WSS-M2C911-A1
SAE 5W-30
1. WARNINGS:

flammable vapors are always present and
This procedure involves fuel handling. Be

prepared for fuel spillage at all times and
always observe fuel handling precautions.
Failure to follow these instructions may result
in personal injury.
The fuel system remains pressurized for

a long time after the ignition is switched off.
The fuel pressure must be relieved before
attempting any repairs. failure to follow this
Release the fuel system pressure. For additional
(s).

4 - Accelerator cable to throttle body
5 - Accelerator cable to throttle body accelerator cable retaining bracket
See Removal Detail

7 - Fuel pressure regulator vacuum line
8 - Fuel supply line to fuel injection supply manifold fuel supply pipe quick
release coupling
See Removal Detail
9 - Fuel return line to fuel pressure regulator spring release coupling
See Removal Detail
10 - Fuel injection supply manifold retaining bolts
11 - Fuel injector retaining clips
12 - Fuel injectors
13 - O-ring seals
14 - Fuel pressure regulator retaining bolts
15 - Fuel pressure regulator
16 - O-ring seal
17 - Fuel injection supply manifold fuel supply pipe retaining bolts
18 - Fuel injection supply manifold fuel supply pipe retaining clip
19 - Fuel injection supply manifold fuel supply pipe
-

20 O-ring seal
21 - Fuel injection supply manifold
Removal Details
Item 5 : Accelerator cable to throttle body accelerator cable retaining bracket

Item 8 : Fuel supply line to fuel injection supply manifold fuel supply pipe quick release
coupling
CAUTION: The generator must be protected from contamination. Failure to follow this
instruction may cause premature failure of the generator.
prevent contamination.
2. Disconnect the fuel supply line from the fuel
injection supply manifold fuel supply pipe. For
Fuel System - General Information / 310-00B
Fuel System - General Information.
Item 9 : Fuel return line to fuel pressure regulator spring release coupling
1. Disconnect the fuel return line from the fuel

pressure regulator. For additional information,
Information.
Item 20 : O-ring seal
Item 16 : O-ring seal
Item 13 : O-ring seals
CAUTION: Do not use silicone grease to lubricate O-ring seals as it will block the fuel
injectors.
1. Lubricate the seals with clean engine oil to assist
with installation.

Fuel Pressure Regulator
Print

Special Tool(s)
310-040
Materials
Name Specification
Formula E Engine Oil WSS-M2C912-A1
SAE 5W-30
1. WARNINGS:


in personal injury.

attempting any repairs. failure to follow this
Release the fuel system pressure. For additional
(s).

See Removal Detail
2 - Fuel injection supply manifold fuel supply pipe retaining clip
3 - Fuel pressure regulator vacuum line
4 - Fuel pressure regulator retaining bolts
6 - Fuel pressure regulator O-ring seal
See Removal Detail
Removal Details

Information.
Item 6 : Fuel pressure regulator O-ring seal
NOTE: Discard the fuel pressure regulator O-ring seal.
Item 6 : Fuel pressure regulator O-ring seal
CAUTION: Do not use silicone grease to lubricate O-ring seals as it will block the fuel
injectors.
NOTE: Install a new fuel pressure regulator O-ring seal.
1. Lubricate the fuel pressure regulator O-ring seal
with clean engine oil to aid installation.

Fuel Injectors
Print
1. Remove the fuel injection supply manifold.

For additional information, refer to Fuel Injection
Supply Manifold in this section.

Description Specifications
Silicone Sealant WSE-M4G323-A4
Gasket Eliminator Sealant WSK-M2G348-A5
Torque Specifications - vehicles with 75 PS/90 PS diesel engine

Fuel return line venturi 6 - 53
Charge air cooler intake pipe retaining nuts 9 - 80
Generator electrical connector retaining nut 9 - 80
Fuel injection pump seal retaining nuts 10 - 89
Fuel injection pump locking bolt 12 9 -
Fuel injection pump retaining bolts 20 15 -
Fuel injection pump bracket retaining bolts 23 18 -
Generator bracket retaining bolts 25 18 -
Air conditioning compressor retaining bolts 25 18 -
Fuel injection supply manifold retaining bolts 28 21 -
High-pressure fuel supply line clamp 33 24 -
Fuel injection pump sprocket retaining bolts 24 18 -
Fuel injector clamp retaining bolts a - -
High pressure fuel injection pipe unions 40 29 -
Fuel injection pump pulley retaining bolts 42 31 -
Fuel metering valve retaining bolts a - -
a) Refer to the relevant procedure in this section.
For additional information, refer to: Fuel Metering Valve - 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS/90 PS) (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Removal and Installation).
Torque Specifications - vehicles with 110 PS diesel engine

Fuel pump sprocket seal nuts 10 - 89
Fuel pump bolts 20 15 -
Fuel pump bracket bolts 23 18 -
Fuel rail bolts 24 18 -
Fuel pump high-pressure fuel supply line union 25 18 -
High-pressure fuel supply line to fuel injector union 25 18 -
Fuel metering valve 28 21 -
Fuel pump sprocket bolts 24 18 -
Fuel injector clamp a - -
Fuel rail high-pressure fuel supply line union 38 28 -
Fuel pump pulley bolts 42 31 -
Fuel pump sprocket nut 45 33 -

Duratorq-TDDi (Lynx) Diesel - Fuel Transit/Tourneo Connect 2002.5 (06/2002-)
Charging and Controls—75 PS/90 PS/110
PS, Vehicles Built From: 08/2006
Print
Overview

1 - Fuel injector(s)
2 - Fuel rail pressure (FRP) sensor
4 - Fuel pump
5 - Fuel metering valve
6 - Fuel rail
General
A Siemens common rail fuel injection system is used on the Stage IV 1.8L Duratorq-TDCi
(Kent) 75PS, 90PS and 110PS diesel engines.
Within the fuel pump there is an integral fuel transfer pump which draws the fuel from the
fuel tank to the fuel pump.
A fuel metering valve is located in the supply port to the high-pressure chamber of the fuel
pump. The fuel metering valve varies the quantity of fuel supplied to the fuel rail and fuel
injector(s), in relation to the driving conditions.
The fuel is supplied at high-pressure to the fuel rail and to the fuel injectors ready for
injection. Depending on engine operating conditions, the fuel injection pressure varies
between 200 bar and 1600 bar.
Fuel system pressure is measured using an FRP sensor located in the fuel rail. The FRP
sensor converts the fuel system pressure into a voltage signal. This voltage signal acts as
an input signal to the powertrain control module (PCM) for calculation of the fuel injection
quantity.

The PCM calculates the time of fuel injection and the fuel injection quantity depending on
various input variables.
The specified quantity of fuel is injected into the respective combustion chamber through
the piezo-electrically actuated fuel injector(s).
The excess fuel is returned to the fuel tank through the fuel return line.
The fuel pressure regulator on the high-pressure outlet of the fuel pump regulates the fuel
pressure in the fuel rail.
Fuel pump

1 - Fuel pump fuel return port
3 - High-pressure fuel supply line port
4 - Fuel pump fuel supply port
The fuel pump is driven clockwise at half the engine speed by the timing belt.
The fuel pump has three pump elements, each offset from each other by 120 degrees.
The fuel transfer pump is incorporated into the fuel pump and is located on the drive
flange. The fuel transfer pump is a vane type pump.
The fuel metering valve is actuated by the PCM using pulse width modulation.
The fuel pressure regulator is located on the fuel pump. The fuel pressure regulator
operates electromagnetically and is actuated by the PCM.
Fuel rail

1 - FRP sensor
CAUTION: The FRP sensor must not be detached or removed from the fuel rail.
Failure to follow this instruction may result in foreign material ingress to the fuel injection
system.
The fuel rail is made from forged steel and is retained by a support bracket located on the
cylinder block.
The fuel is delivered to the fuel rail by one high-pressure fuel supply line from the fuel
pump.
From the fuel rail, the fuel travels through high-pressure fuel supply line(s) to the fuel
injector(s).
Fuel injectors

1 - Fuel injector electrical connector
2 - Fuel injector
3 - High-pressure fuel supply port
4 - Sealing washer
5 - Fuel injector retaining clamp
6 - Fuel injector fuel return line retaining clip
NOTE: New fuel injector fuel return line retaining clips must be installed, when the fuel
injector fuel return line has been removed from the fuel injectors.
The fuel injector(s) are offset by 20 degrees from vertical in the cylinder head upper section
and are attached by means of retaining clamps.
The fuel injector(s) are sealed from the combustion chamber by means of a copper sealing
washer located between the fuel injector and the cylinder head. A new sealing washer must
always be installed when carrying out installation work.
The fuel injectors are controlled directly by the PCM.
The fuel return line(s) are attached to the fuel injectors by using the fuel injector fuel return
line retaining clips and are connected in parallel.

Duratorq-TDDi (Lynx) Diesel - Fuel
Charging and Controls
Print
1.8L Duratorq DI (55 kW)

System overview

1 - Injector nozzle
2 - High pressure lines
3 - Pump control unit
4 - Bosch distributor injection pump VP 30
5 - Low pressure lines

2 - Distributor pump VP 30
3 - Fuel injector line
4 - Fuel return line
5 - Injector
6 - Powertrain Control Module (PCM)
7 - Fuel tank
8 - Fuel filter
9 - Fuel supply line
Low pressure system/high pressure system
Electrical control is performed by the pump control unit

The low pressure system consists of the following components:
Fuel reservoir
Fuel filter
Low pressure fuel lines
Fuel tank

The high pressure system consists of the following components:
Distributor pump VP 30
Injector
High pressure fuel lines
Fuel filter

1 - Retaining clip
2 - Control valve
3 - Return
4 - Feed
5 - Fuel filter
A fuel filter specially matched to the requirements of the fuel injection system is installed in
order to guarantee problem free operation of the fuel injection system.
A control valve used to pre-warm the fuel is mounted on the top of the fuel filter. It is held
in the filter housing with a securing clip.
The control valve is made of bi-metal. It closes the return to the fuel tank at low
temperatures. This causes the warmed fuel to flow from the injection pump back into the
fuel filter, thus warming it, after which the fuel flows on to the distributor pump.
The fuel lines have a push-fit connection, and can be separated after the retainers have
been disengaged.
The feed and return fuel lines are colour coded: feed white, return black.
The correct installation orientation (arrow) must be observed when installing the fuel filter.
The fuel filter is provided with a water collection chamber in order to prevent the fuel
injection system being damaged by condensed water.

1 - Water indication sensor
2 - Connection
3 - Water drain valve
On vehicles for Turkey, a water indication sensor is installed on the base of the fuel filter,
which measures the water content in the fuel filter.
A warning lamp (near the instrument cluster) comes on if the accumulated amount of water
exceeds a certain value.
Please refer to the current service literature for details of how to drain the water from the
fuel filter.
Injector nozzle

1 - Copper sealing ring
2 - Injector
3 - Retaining bolt
4 - Retainer
NOTE: The securing bolts of the retainers must be tightened to the specified torque. The
bolts and the copper sealing rings must not be re-used, refer to the current service
literature.
The 5-hole fuel injectors are a push-fit in the cylinder head. A copper sealing ring is used as
a seal.
The installation position of the fuel injector is defined by a slotted mounting. The retainer

engages in the slotted mounting and centralises the fuel injector.
The retainer is guided by a ball-head and is bolted to the cylinder head.
In order to achieve soft combustion, two springs with different spring rates are located on
the nozzle holder.
The first spring is tuned in such a way that a small amount of fuel is pre-injected at low
pressure at the beginning of the injection process.
This pre-injection ensures a gentle increase in the combustion pressure and achieves the
ignition conditions for the main fuel quantity which will be injected at high pressure by the
second spring.
Because of the gentle rise in pressure in the combustion chamber, the mechanical load on
the crank assembly is less and the combustion noise is lower.

A - Injector nozzle closed
B - Pre-injection
C - Main injection
1 - Spring 1
2 - Spring 2
3 - Stroke 1
4 - Stroke 1 + stroke 2
5 - Stroke 2
Injection pipes

The length and the bend radii are exactly matched to the system and must not be changed
during installation. The injection lines must be installed without strain.
Distributor injection pump VP 30

1 - Vane cell pump
2 - Rotational angle sensor
3 - Roller ring
5 - Plug connection
6 - Axial piston
7 - High pressure solenoid valve
8 - Pressure valve
9 - Solenoid valve, adjustment of start of injection
10 - Injection regulator
-

-
11 Eccentric disc
12 - Pickup for rotational angle sensor
The VP 30 is modularly constructed. The fuel supply system is completely electronically
controlled.
The following requirements are optimally satisfied by the use of the VP 30

low emissions of pollutants
high economicalness
high driving comfort
The VP 30 is an axial piston distribution injection pump which is controlled by a high-

pressure solenoid valve. It has fully electronic control of the fuel quantity and the injection
timing.
A pump high pressure of up to 900 bar is created in the VP 30, which produces high
atomisation energy at the nozzle and a fast response to the fuel quantity regulation by fast
switching of the high pressure solenoid valve.
The pump control unit is mounted on the top of the injection pump. It uses information from
the rotational angle sensor and from the PCM to calculate the control signals for the high
pressure solenoid valve and the start of injection timing.
NOTE: Before the electrical plug connection of the pump control unit is disturbed, make
absolutely certain that no electrostatic charge is present. An electric discharge may lead
to a fault in the control unit.
The fuel system cannot be driven dry while the vehicle is driving. When there is only a
certain amount of fuel remaining, a signal from the sender in the tank causes the PCM to
make the engine judder.
Fuel supply metering by the high pressure solenoid valve

A - Filling
B - Supply
C - End of supply
1 - Axial piston
2 - High pressure chamber
3 - Ring channel
4 - Coil
5 - Needle valve
6 - Supply channel
7 - Stroke direction of the axial piston
8 - Channel of the injector nozzle
9 - Control slot
10 - Oil return channel
Controlled by the pump control unit, the high pressure solenoid valve determines the
injection quantity and the injection time for each individual injection.
At the bottom dead centre position of the eccentric disc of the axial piston high pressure
pump, the high pressure solenoid valve is closed through the needle valve by a control
impulse from the PCM. The closing timing of the valve determines the start of fuel delivery
from the injection pump.

Through electronic recognition of the time of closing, the pump control unit receives exact
information about the start of supply.
The fuel supply measurement occurs between start of supply and end of control of the high
pressure valve and is described as supply period and supply quantity.
Filling
The axial piston is moving backwards. The high pressure solenoid valve and therefore the
supply channel are open.
Because of the pump pressure and the suction effect of the axial piston, the fuel passes
into the high pressure chamber.
Supply
The axial piston is moving forwards, the control slot is opened.
At this moment no fuel is supplied, because the high-pressure solenoid valve is still not
activated by the pump control unit (situation as in illustration "C", only that the axial
piston is not so far advanced).
At a moment determined by the pump control unit, the high pressure solenoid valve is
closed and the needle valve closes the supply channel.
The moment at which the needle valve closes defines the instant which is described as
start of supply. From this time the pressure begins to rise within the high pressure
system.
End of supply
The axial piston is still moving forwards, the control slot is opened more.
At a moment determined by the pump control unit, the high pressure solenoid valve is
opened again and the needle valve opens the supply channel.
The fuel which is still being supplied by the axial piston can return into the pump housing
through the return channel.
To stop the engine, creation of high pressure is completely interrupted (injection quantity
= 0), so that an additional cut-off valve is not provided.
Rotational angle sensor in the distribution injection pump VP 30

The rotational angle sensor rotates on a bearing ring which is rigidly linked to the roller ring
and the injection regulator.
The rotational angle sensor is located on a rotating mounting because it needs to generate
its signal relative to the angular position of the roller ring.

1 - Flexible conducting film
3 - Rotating bearing ring
4 - Pickup wheel (fixed onto the input shaft)
5 - Input shaft
6 - Connection between roller ring and injection regulator
7 - Gap in the teeth
The pulse for the rotational angle sensor is generated by a pickup wheel which is rigidly
mounted onto the input shaft. It has four gaps in the teeth evenly distributed around its
circumference (the four gaps correspond to the number of cylinders).
A rotational angle sensor scans the sequence of teeth and gaps.
The rotational angle sensor generates its signal relative to the angular position of the roller
ring. For this reason it is attached to a rotating mounting and is turned together with the
roller ring when the injection regulator is moved.
When the injection is adjusted by the injection regulator, the roller ring and therefore the
rotational angle sensor is rotated in the direction of advancing or retarding the injection
timing.
The signal from the rotational angle sensor is transmitted via a flexible conductor film
to the pump control unit and then used for the following tasks:
Measurement of the current rotational speed of the distribution injection pump,
Determination of the current angular position,
Determination of the current position of the injection regulator.
The current rotational speed of the distribution injection pump is an input variable for the
pump control unit of the distribution injection pump. The pump control unit uses it to obtain
the actuation time of the high-pressure solenoid valve and the injection regulator solenoid
valve.
The designated injection quantity determines the actuation time of the high-pressure
solenoid valve. The current angular position determines the actuation timing points for the

high-pressure solenoid valve.
Angular precision is required for the actuation to ensure that both the opening and the
closing of the high-pressure solenoid valve occur during the correct cam lift. The precise
actuation ensures that the start of delivery and the injected fuel quantity are correct.
The precise angular position is determined by comparison of the signals from the
Crankshaft Position (CKP) sensors and the rotational angle sensor.
The current position of the injection regulator, which is required for adjustment of the
injection timing, is also determined by comparing the signals from the CKP sensor and the
rotational angle sensor.
1.8L Duratorq TDCi (66 kW)
The 1.8L Duratorq TDCi engine with common rail injection system is based on the 1.8L
Endura DI diesel engine with the distributor injection pump.
System overview

1 - Fuel filter
2 - Injector
3 - Common rail with fuel pressure sensor
4 - High-pressure line to the fuel distribution pipe
5 - High-pressure pump
6 - Low pressure line, fuel filter to high pressure pump
7 - PCM
8 - High-pressure lines from the fuel distribution pipe to the injectors

Low pressure system/high pressure system
Electrical control is performed by the PCM

The low pressure system consists of the following components:
Fuel reservoir
Fuel filter
Low pressure fuel lines
Fuel tank
The high pressure system consists of the following components:
High pressure pump with fuel temperature sensor and fuel metering valve
Common rail with fuel pressure sensor
Solenoid valve controlled injector valve
High pressure fuel lines

1 - High-pressure pump
2 - Fuel temperature sensor
4 - Fuel pressure sensor
5 - Common rail
6 - Fuel injectors
7 - PCM
-

8 Fuel tank
9 - Fuel filter
A - Cables
B - High pressure lines
C - Low pressure lines
Fuel filter

1 - Feed, high pressure pump
2 - Feed, fuel tank
3 - Return, high pressure pump
4 - Bracket
5 - Water drain screw
A fuel filter specially matched to the requirements of the fuel injection system is installed in
order to guarantee problem free operation of the fuel injection system.
The fuel filter is provided with a water collection chamber in order to prevent the fuel
injection system being damaged by condensed water.

1 - Water indication sensor
2 - Connection
3 - Water drain valve
On vehicles for Turkey, a water indication sensor is installed on the base of the fuel filter,

which measures the water content in the fuel filter.
A warning lamp (near the instrument cluster) comes on if the accumulated amount of water
exceeds a certain value.
Please refer to the current service literature for details of how to drain the water from the
fuel filter.
A temperature-dependent control valve is integrated in the return part of the fuel filter.
The control valve is a ball valve controlled by a bi-metal strip. When the fuel heats up, the
bi-metal closes the return to the filter progressively, so that at temperatures above 50 °C
only a very small amount of fuel can get to the fuel filter.
The feed and return fuel lines are colour coded: feed white, return red.
High-pressure pump

1 - Position of pressure control valve
2 - Transfer pump
3 - Eccentric ring
4 - Bore between transfer pump and high-pressure chamber
6 - Venturi nozzle in fuel return
8 - High pressure connection to common rail
9 - High pressure channel
-

10 High pressure chamber
11 - Input shaft
The fuel sucked in by the transfer pump passes from the transfer pump through a bore into
the high pressure chamber.
The fuel metering valve is located in the bore between the transfer pump and the high
pressure chamber.
Depending on operating conditions, and under the control of the PCM the electronically
controlled fuel metering valve changes the cross section of the bore and thus the quantity of
fuel which passes into the high pressure chamber.
Transfer pump

1 - High-pressure side
2 - Suction side
The transfer pump (a vane cell pump) is mechanically driven by the pump driveshaft.
The transfer pump sucks fuel from the fuel tank under vacuum which depends on the engine
speed and supplies it to the high pressure chamber.
There is a pressure control valve located in the low pressure circuit between the transfer
pump and the high pressure chamber, and this limits the transfer pressure.
Low pressure fuel return
The low pressure fuel return has the following functions:
Cooling and lubrication of the high pressure pump by internal return of the low pressure
fuel to the fuel tank.
Return of the leak-off fuel from the injector valves to the fuel tank.
Fuel is continually supplied to the high pressure chamber during an acceleration phase.
At the same time, some of the fuel is used to lubricate the pump and runs through the
venturi nozzle and the fuel return line back into the tank.
The venturi nozzle in the fuel return line operates according to the venturi pump principle.
The nozzle creates a slight vacuum in the leak-off line, the leak-off fuel is sucked in and is
therefore removed more easily.

-- Fuel 1 Position of pressure control valve
- return 2 Return bore
during
- acceleration 3 Feed bore, high pressure chamber
- 4 Leak-off fuel from the injectors
5 - Fuel return to tank
6 - High pressure channel to common rail
7 - Transfer pump
8 - Fuel feed
The fuel metering valve closes the feed to the high pressure chamber during overrun.
This causes an increase in pressure in the feed and return bores. If this pressure reaches a
value of approx. 6 bar at approx. 2500 rev/min, the pressure control valve opens. The
pressure control valve is connected to the transfer pump by a bore.
The excess fuel partly flows back to the suction side of the transfer pump, and back into
the fuel tank through the venturi nozzle in the fuel return.

1 - Position of pressure control valve
2 - Return bore
3 - Feed bore, high pressure chamber
4 - Leak-off fuel from the injectors
5 - Fuel return to tank
7 - Transfer pump
8 - Fuel feed
9 - Fuel to suction side, transfer pump
High-pressure pump
-- High 1 Intake valve

- pressure 2 Cam ring
chamber
-

(outlet 3 Roller and roller shoe
- valve 4 High pressure chamber
closed)
- 5 Exhaust valve
6 - Pump piston
The storage pressure required for the common rail is created in the high pressure chamber
of the high pressure pump.
The system operates according to the radial piston principle and consists of an inlet and
outlet valve, both equipped with a return valve, two pump pistons with rollers and roller
shoes and a cam ring. The cam ring is part of the drive shaft.
Filling the high pressure chamber
If the transfer pressure exceeds the internal pressure of the high pressure chamber, the
inlet valve opens. Fuel flows into the high pressure chamber and presses the pump piston
and the roller shoe outwards against the cam track of the cam ring (cams run down from
the roller of the pump piston.)
The outlet valve remains closed because of the higher pressure in the high pressure
channel which is behind it

1 - Intake valve
2 - Cam ring
3 - Roller and roller shoe
5 - Exhaust valve
6 - To high pressure channel/high pressure connection
7 - Pump piston
Creation of high pressure in the high pressure chamber

When a cam begins to run onto the roller shoe of the pump piston, the piston moves
towards the centre of the high pressure chamber. As this occurs, the supply pressure of
the pump piston exceeds the transfer pressure and the inlet valve is closed.
As soon as the pressure in the high pressure chamber exceeds the pressure in the high
pressure channel, the outlet valve opens and fuel is supplied to the common rail through
the high pressure connection.
The supply phase continues until the roller of the roller shoe reaches the peak of the
curve of the cam and the pump pistons have moved the maximum supply travel.
At this moment the pressure in the high pressure chamber drops below that in the high
pressure channel. Because of the higher pressure in the high pressure channel, the outlet
valve is closed again and the supply of fuel is therefore stopped.
The amount of fuel supplied depends on the cross-section of the opening of the fuel
metering valve.

Common rail

1 - Common rail
3 - Line connections to the high pressure pump
4 - Line connections to the fuel injectors
The common rail is made of forged steel.
The common rail performs the following functions:

stores fuel under high pressure and
prevents pressure fluctuations.
Because of the operating movement in the high pressure chamber of the high pressure
pump and the opening and closing of the solenoid valves at the fuel injectors, pressure
fluctuations occur in the high pressure fuel system.
The common rail is constructed in such a way that it has a volume large enough to keep the
pressure fluctuations to a minimum.
For fast starting, the volume in the common rail is small enough to allow build up of the
required fuel pressure in the shortest possible time.
The fuel supplied by the high pressure pump passes through a high pressure line to the
high pressure reservoir. The fuel is supplied to each fuel injector by the four fuel injection
lines, all of which are the same length.
If fuel for one injection is taken from the common rail, the pressure in the common rail
remains almost constant.
The pressure sensor in the common rail informs the PCM of the current fuel pressure in the
common rail.
High pressure fuel pipes

1 - High-pressure fuel lines between the fuel distribution pipe (common
rail) and the injectors

NOTE: After releasing the injector lines it is necessary to renew the fuel lines to ensure
complete tightness.
NOTE: The lengths and radii of the bends are matched to the system exactly, and must
not be changed.
NOTE: The fuel injection system does not need bleeding.
The high pressure fuel pipes connect the high pressure pump to the common rail and the
common rail to the individual fuel injectors.
The fuel pipes conveying fuel at high pressure must withstand the maximum system
pressure and the pressure fluctuations.
The four high-pressure fuel lines between the fuel distribution pipe and the injectors all
have the same length.
Fuel injectors

1 - Upper inlet choke (control chamber)
2 - Solenoid valve
3 - Solenoid valve spring
4 - Needle valve
5 - Drain bore
6 - Control chamber drain choke
7 - Control chamber
8 - Nozzle openings
9 - Nozzle needle
10 - Nozzle chamber
11 - Nozzle chamber inlet choke
12 - Control chamber lower inlet choke
NOTE: When a fuel injector is changed, the fuel injector number found on the injector and
the appropriate cylinder assignment must be entered in the PCM using WDS.
The function of the solenoid valve controlled fuel injectors is to regulate the start of fuel
injection and the quantity of fuel injected according to the instructions received from the
PCM.

Six-hole fuel injectors are used.
The very small moving masses of the control valves have made it possible to achieve rapid
switching time of 0.3 ms. This is the response time which the fuel injection system needs to
be able to react rapidly to changes in the operating states.
The fuel injectors have four operating states:
Fuel injector closed

Fuel injector beginning to open
Fuel injector completely opened (fuel injection)
Fuel injector closing
For manufacturing reasons, the fuel injectors have different production tolerances which
can be identified by a number on the injector.
In order to be able to calculate the correct fuel quantity, the PCM must be notified of a
change in the system, in this case the changing of the injectors.
Fuel injector closed

1 - Solenoid valve
2 - Fuel return
3 - Needle valve
4 - Control chamber
5 - Nozzle spring
6 - Nozzle needle
7 - Nozzle chamber
8 - Fuel feed
Fuel under pressure is passed from the common rail through the fuel inlet channel, into the
nozzle chamber and then into the control chamber.
The solenoid valve is de-energised, the control valve is closed, and therefore the fuel return
is closed.
In this state the same pressure is present in the nozzle chamber and the control chamber.

Because the nozzle spring also operates on the nozzle needle in the control chamber, the
nozzle opening remains closed.
Fuel injector beginning to open

1 - Solenoid valve
2 - Fuel return
3 - Needle valve
4 - Drain choke
5 - Control chamber
The solenoid valve is actuated by the PCM and the needle valve opens the fuel return.
Because of the opening of the needle valve, the pressure in the control chamber can
dissipate through the control chamber drain choke.
The pressure drop is suitably delayed by the control chamber drain choke, so that the
injector still remains closed.
Fuel injector completely opened (fuel injection)

1 - Fuel return
2 - Control chamber
3 - Nozzle needle
4 - Nozzle chamber
The high pull-up current of 12 A is reduced to a low holding current of 6 A. The fuel return
is still open.
As soon as the pressure in the nozzle chamber is higher than that in the control chamber
(hydraulic pressure plus spring pressure is less than the pressure in the nozzle chamber)
the nozzle needle begins to open (start of injection).
Fuel injection is stopped

1 - Solenoid valve
-

2 Fuel return
3 - Needle valve
4 - Control chamber
5 - Nozzle needle
6 - Nozzle chamber
7 - Nozzle chamber inlet choke
8 - Control chamber lower inlet choke
9 - Control chamber upper inlet choke
After a time determined by the PCM the current supply to the solenoid valve is interrupted,
and the needle valve closes the fuel return as a result of the solenoid valve spring force .
The pressure in the control chamber is built up again through the control chamber upper
and lower inlet chokes.
At the same time the inlet chokes of the nozzle chamber prevent a sudden back pressure of
fuel in the nozzle chamber. This causes a high pressure level in the control chamber and the
nozzle needle closes the fuel injector nozzles.
Control of system pressure
The engine management system is able to make the optimum injection pressure available
for every operating state.
Maximum fuel pressure is controlled so that it is only available above a certain engine speed
(about 3000 rev/min). Below this engine speed the fuel pressure must be reduced.
In this way the noise emissions during fuel combustion are lowered and the engine
management system can perform fuel metering more easily and more precisely. This has a
positive effect on the exhaust emissions and on fuel consumption.
For this reason, controlled pressure reduction in the common rail is necessary.
The pressure drop occurs when the solenoid valve applies current to the injector valves at
short intervals.
Each time the pull-in current is enough to open the control valve, but remains small enough
so that the needle valve does not lift and therefore does not permit an undesired fuel
injection.
Pressure drop when the engine is switched off
Pressure drop also occurs after the engine is switched off, in the same way as when the
system pressure is controlled.
As soon as the solenoid valves are actuated the pressure is fully depleted within the space
of a few seconds.
Afterwards current is no longer applied to the solenoid valves of the injectors. This results in
zero pressure difference between the control chamber and the nozzle chamber. No more
fuel injection can occur.
Before opening the high-pressure system, use WDS to make sure that the fuel
pressure has been completely depleted and that the fuel temperature is below 30
°C.

Charging and Controls—75 PS
Print

WARNINGS:
Do not smoke or carry lighted tobacco of any type when working on or near any fuel
related components. Highly flammable mixtures are always present and may ignite.
Failure to follow these instructions may result in personal injury.
This procedure involves fuel handling. Be prepared for fuel spillage at all times.

and fine clearances. The fuel injection pump is fully electronic and has no linkages or
cables. Do not grease any of the fuel injection pump terminals or connectors. It is
therefore essential that absolute cleanliness is observed when working with these
components. Always fit blanking plugs to any open orifices or lines.
NOTE: As well as carrying out its normal function the glow plug lamp also acts as an
engine check lamp which will flash continuously when a hard diagnostic trouble code
(DTC) is detected by the powertrain control module (PCM). Soft DTCs are also stored by
the PCM but will only be known if the system is checked for DTCs using WDS.
NOTE: If a DTC is detected, all DTCs must be cleared after the cause is repaired. Failure
to clear all DTCs may cause driveability concerns.
NOTE: If the fuel level in the fuel tank drops below approximately 4 liters, rough running
will occur. This is to signal to the driver that the vehicle requires refuelling in order to
prevent the fuel system from running dry.
Fuel level Fuse(s)
Fuel leak(s) Relay(s)
Air leak(s) Wiring harness
Fuel filter Electrical connector(s)
Air cleaner element Passive anti-theft system (PATS) LED operation
Fuel supply lines Sensor(s)
Hose(s)/hose connections Glow plug lamp operation
Pipe(s)/pipe connections Battery
Contaminated fuel PCM
High-pressure fuel supply line(s)
Fuel injector(s)
Fuel injection pump
4. 4. If the cause is not visually evident, verify the symptom and refer to Symptom
Chart.

Symptom Chart
Symptom Chart

Engine does not * DTC detected. * REFER to WDS.
crank and glow plug
indicator is flashing
Engine does not * Starting system. * REFER to Section 303-06 Starting System.
crank
Engine cranks but * DTC detected. * REFER to WDS.
does not start and
glow plug indicator
is flashing
Engine cranks but * The fuel injection * REFER to WDS.
does not start pump control unit
and the PCM are not
matched.
* Fuel injection pump * MAKE SURE the fuel injection pump control unit
control unit electrical electrical connector and locking tang are
connector. correctly installed.
* Fuel injection pump * CARRY out the relay component test. REFER to
relay. Wiring Diagrams.
* Glow plug relay. * CARRY out the relay component test. REFER to
Wiring Diagrams.
* Fuel filter blocked. * REFER to Section 310-00A Fuel System -
* Fuel lines damaged General Information / 310-00B Fuel System -
or blocked. General Information.
* Air ingress into the
fuel lines.
* Sensor(s). * REFER to WDS.
* Fuel injection pump.
* Glow plugs.
* PCM.
* Incorrect valve * REFER to Section 303-01A Engine / 303-01B
timing. Engine.
* Fuel injection pump * CHECK the fuel injection pump timing.
timing. REFER to Fuel Injection Pump - 1.8L Diesel
(75PS) in this section.
Poor starting and * DTC detected. * REFER to WDS.
glow plug indicator
is flashing
Poor starting * Fuel filter blocked. * REFER to Section 310-00A Fuel System -
* Fuel system leak. General Information / 310-00B Fuel System -
* Fuel system General Information.
restriction.
* Air ingress into the
fuel lines.
* Glow plug relay. * CARRY OUT the Relay Component Test. REFER
to Wiring Diagrams.
* Glow plugs. * REFER to WDS.
* Incorrect engine oil. * INSTALL a new engine oil filter and engine oil.
* Fuel injector(s). * Have the fuel injectors checked by an
appropriate fuel injection specialist agent.
CLEAN the fuel injectors or INSTALL a new set

of injectors as required only after the specialist
agent checks have been carried out.
* Low cylinder * REFER to Section 303-00 Engine System -
compression. General Information.
Engine starts but * DTC detected. * REFER to WDS.
immediately stops
and glow plug
Engine starts but * Air ingress into the * REFER to Section 310-00A Fuel System -
immediately stops fuel lines. General Information / 310-00B Fuel System -
* Blocked or damaged * INSTALL a new fuel filter.
fuel filter.
* Fuel injection pump
control unit.
* PCM.
Poor idling and glow * DTC detected. * REFER to WDS.
plug indicator is
flashing
Poor idling * Fuel filter blocked. * REFER to Section 310-00A Fuel System -
* Contaminated fuel. General Information / 310-00B Fuel System -
* Air ingress into the General Information.
fuel lines.
* Fuel injection pump. * REFER to WDS.
Engine stumbling * DTC detected. * REFER to WDS.
and glow plug
Engine stumbling * Air ingress into the * REFER to Section 310-00A Fuel System -
fuel lines. General Information / 310-00B Fuel System -
Engine lacks power * DTC detected. * REFER to WDS.
and glow plug
Engine lacks power * Brakes binding. * CHECK the braking system. REFER to Section
206-00 Brake System - General Information.
* Vehicle overloaded, * ADVISE the customer about the effects of
or excessive wind overloading the vehicle and wind resistance on
resistance (roof the fuel consumption.
racks, towing etc).
* Charge air cooler * INSPECT for visible signs of damage or
blocked or cracked. blockage. CLEAN, REPAIR or INSTALL new parts

* Charge air cooler as necessary.
pipes split or
cracked.
* Charge air cooler
retaining clips
missing or loose.
* Fuel filter blocked. * REFER to Section 310-00A Fuel System -
* Contaminated fuel. General Information / 310-00B Fuel System -
* Air ingress into the General Information.
fuel lines.
* Exhaust gas * REFER to Section 303-08A Engine Emission
recirculation (EGR) Control / 303-08B Engine Emission Control.
valve.
* Catalytic converter
* CHECK if the catalytic converter rattles if gently
blocked. tapped. If noise is present, REMOVE and
visually INSPECT the catalytic convertor for
damage. INSTALL a new catalytic converter as
necessary. REFER to Section 309-00 Exhaust
System.
* ROADTEST at full throttle.
- With EGR disconnected, 1st gear to 35mph
(55kph)
- 2nd gear to 50mph (80kph)
- 3rd gear to 70mph (110kph)
* Turbocharger * REFER to Section 303-04A Fuel Charging and
wastegate actuator. Controls / 303-04B Fuel Charging and
* Turbocharger. Controls / 303-04C Fuel Charging and Controls
- Turbocharger / 303-04D Fuel Charging and
Controls.
* Incorrect valve * CHECK the valve timing. REFER to Section
timing. 303-01A Engine / 303-01B Engine.
* Fuel injection pump. * Have the fuel injection pump checked by an
INSTALL a new fuel injection pump as required
only after the specialist agent checks have been
carried out.
Black smoke at idle * DTC detected. * REFER to WDS.
and glow plug
Black smoke at idle * Sensor(s). * REFER to WDS.
* PCM.
* EGR system. * REFER to Section 303-08A Engine Emission
Control / 303-08B Engine Emission Control.

Excessive black * DTC detected. * REFER to WDS.
smoke during
acceleration and
glow plug indicator
is flashing
Excessive black * Sensor(s). * REFER to WDS.
smoke during * Blocked air intake * CHECK the air intake system for blockages,
acceleration system. REPAIR and INSTALL new components as
necessary.
* Turbocharger. * REFER to Section 303-04A Fuel Charging and
Controls / 303-04B Fuel Charging and
Controls / 303-04C Fuel Charging and Controls
Controls.
Black smoke at * DTC detected. * REFER to WDS.
cruising speeds and
glow plug indicator
is flashing
Black smoke at * Sensor(s). * REFER to WDS.
cruising speeds * Blocked air intake * CHECK the air intake system for blockages,
system. REPAIR and INSTALL new components as
necessary.
Controls / 303-04B Fuel Charging and
Controls.
Blue smoke and * DTC detected. * REFER to WDS.
glow plug indicator
is flashing
Blue smoke * Engine breather * REFER to Section 303-08A Engine Emission
system. Control / 303-08B Engine Emission Control.
* Contaminated fuel. * REFER to Section 310-00A Fuel System -
General Information / 310-00B Fuel System -
* Turbocharger oil * REFER to Section 303-04A Fuel Charging and
seals leaking. Controls / 303-04B Fuel Charging and
* Turbocharger oil Controls / 303-04C Fuel Charging and Controls
return tube blocked - Turbocharger / 303-04D Fuel Charging and
or damaged. Controls.
* Engine burning oil. * CARRY OUT a controlled oil consumption test

over 1000 km (600 miles). CONFIRM that the
oil consumption is less than 0.1 of a liter per
1000 km (600 miles). REFER to Section 303-00
White smoke and * DTC detected. * REFER to WDS.
glow plug indicator
is flashing
White smoke * Water in fuel. * REFER to Section 310-00A Fuel System -
* Coolant in the * REFER to Section 303-03 Engine Cooling.
combustion
chamber.
Engine misfire and * DTC detected. * REFER to WDS.
glow plug indicator
is flashing
Engine misfire * Sensor(s). * REFER to WDS.
* Air ingress into the General Information / 310-00B Fuel System -
fuel lines. General Information.
* Engine operating * REFER to Section 303-03 Engine Cooling.
temperature too
high.
* Worn or damaged * REFER to Section 303-01A Engine / 303-01B
engine components. Engine.
Engine knock at idle * DTC detected. * REFER to WDS.
and glow plug
Engine knock at idle * Low engine oil level. * CHECK the engine oil level. REFILL as
necessary.
Engine knock during * DTC detected. * REFER to WDS.
acceleration and
glow plug indicator
is flashing

Engine knock during * Sensor(s). * REFER to WDS.
acceleration * Worn or damaged * REFER to Section 303-01A Engine / 303-01B
Excessive fuel * DTC detected. * REFER to WDS.
consumption and
glow plug indicator
is flashing
Excessive fuel * Brakes binding. * CHECK the braking system. REFER to Section
consumption 206-00 Brake System - General Information.
or excessive wind overloading the vehicle and wind resistance on
resistance (roof the fuel consumption.
racks, towing etc).
* Fuel leak(s). * REFER to Section 310-00A Fuel System -
* Air ingress into the General Information / 310-00B Fuel System -
fuel lines. General Information.
* Incorrect engine oil. * INSTALL a new oil filter and engine oil.
* Clutch worn or * REFER to Section 308-00 Manual
slipping. Transmission/Transaxle and Clutch - General
Information.
* Turbocharger Controls / 303-04B Fuel Charging and
wastegate actutator. Controls / 303-04C Fuel Charging and Controls
Controls.

Charging and Controls—90 PS
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Special Tool(s)
Diagnostic Tool, Common Rail Fuel Injection
310-129
Hand Pressure Pump with Adapter Kit

310-110
Test Hose for 310-025

310-025-18
Test Hose for 310-025

310-025-19A
General Equipment
Brake hose clamp
Magnet
Transparent container
System overview

A - High-pressure fuel injector fuel supply line
B - High-pressure fuel supply line
C - Fuel pump fuel return line
D - Fuel pump fuel supply line
E - Fuel injector fuel return line
F - Fuel filter to fuel tank fuel return line
1 - Fuel injector
2 - Fuel rail
3 - Fuel pump
4 - Fuel filter
5 - Fuel tank
6 - PCM
To meet the increasing demands for lower exhaust emissions, greater economy, improved
driving characteristic's, lower noise output and increased power output from modern diesel
engines, the vehicle requires a fuel supply system which can deliver small fuel droplets at
high speed with refined control. The common rail fuel injection system has been introduced
to the diesel engine to meet these demands.
The Delphi system fitted to the 1.8L diesel engine fulfills this role by using controlled high-
pressure fuel delivery to individually electronically controlled injectors.

Fuel pump fuel supply

1 - Fuel pump fuel return line connection
2 - Fuel tank fuel supply line connection
3 - Fuel pump fuel supply line connection
4 - Filter element
5 - Filter drain screw
6 - Bimetallic fuel return sensor
7 - Fuel return bypass valve
CAUTION: The fuel system on this vehicle is designed to prevent the fuel tank being
run dry. When the fuel tank reaches a preset limit after the low fuel warning indicator has
been illuminated, the engine will be made to run rough to indicate very low fuel level.
Failure to refill the fuel system at this time, will result in damage to the fuel injection
components if the fuel system is allowed to run dry.
The fuel filter element in the common rail fuel system is designed to extract far smaller
particles from the fuel supply than conventional fuel filters.
To aid with the rapid warm up of the fuel supply to the fuel pump, the fuel filter is fitted
with a temperature conscious fuel return bypass valve.
At temperatures below 50°C, the bypass valve is fully open and the majority of the
returned fuel is circulated through the fuel filter and back to the fuel pump.
When the fuel temperature in the fuel filter has reached a temperature above 50°C, the fuel
return bypass valve closes and the returned fuel is delivered back to the fuel tank.
The return fuel cannot be allowed to continue to circulate through the fuel filter after 50°C
as the temperatures produced by compressing the fuel to such high pressures would cause
the fuel to overheat. When the fuel is returned to the fuel tank, the fuel line which transfers
the fuel along the underbody, cools the fuel sufficiently to prevent overheat concerns.
High-pressure fuel pump

1 - Input shaft
2 - Transfer pump
3 - High-pressure fuel pump cam ring
4 - High-pressure pump low pressure fuel inlet channel
6 - Fuel return line venturi
8 - High-pressure fuel outlet union
9 - High-pressure fuel pump fuel outlet channel
10 - High-pressure fuel pump chamber
Fuel is drawn from the fuel tank through the fuel filter by means of a transfer pump. The
transfer pump is built into the high-pressure pump and driven by the high-pressure pump
input shaft.
Fuel from the transfer pump is passed through the high-pressure pump low pressure fuel
inlet channel into the high-pressure fuel pump chamber.
In the high-pressure pump low pressure fuel inlet channel is situated a fuel metering valve.
The fuel metering valve is controlled by the PCM. A fuel pressure sensor input signal is used
by the PCM to calculate the position required by the fuel metering valve to achieve the
desired fuel rail pressure. The fuel metering valve reduces the cross sectional area of the
high-pressure pump low pressure fuel inlet channel and so decreases the quantity of fuel
allowed to reach the high-pressure fuel pump chamber.
Located in the rear of the fuel pump is a fuel temperature sensor which monitors the fuel
transfer pump fuel delivery temperature. The sensor information is used by the PCM to
adjust the fuel metering valve to compensate for cold fuel charge values.
If the fuel temperature sensor or its related circuits become shorted to ground, the engine
will shut down and not restart.
If the fuel temperature sensor or its related circuits become open circuit, the engine
management system will default to a value of 39°C and cold start characteristics will be
impaired.

Fuel pump high pressure fuel development

1 - Fuel inlet valve
2 - High-pressure fuel pump cam ring
3 - Fuel pump piston roller and shoe
5 - Fuel outlet valve
6 - Fuel pump piston
CAUTION: The high pressure fuel pump relies on the fuel in the pump for lubrication.
The fuel pump input shaft should not be allowed to rotate above hand cranking speed
unless the air has been bled from the fuel pump fuel supply lines and fuel is present in
the fuel transfer pump. Failure to follow this instruction may result in damage to the
components of the high-pressure fuel pump.
Fuel enters the high-pressure fuel pump chamber through a fuel inlet valve. The inlet valve
will only allow fuel to enter the fuel pump chamber, if the fuel pressure in the chamber is
lower than the pressure in the high-pressure pump low pressure fuel inlet channel.
Fuel entering the high-pressure fuel pump chamber, forces the fuel pump piston's outwards
and holds the fuel pump piston roller and shoe against the high-pressure fuel pump cam
ring.
The high-pressure fuel pump fuel outlet valve will remain closed until the fuel pressure
inside the high-pressure fuel pump chamber exceeds the pressure in the fuel rail.

1 - Fuel inlet valve
-

2 High-pressure fuel pump cam ring
3 - Fuel pump piston roller and shoe
5 - Fuel outlet valve
6 - High-pressure fuel to high-pressure fuel outlet union
7 - Fuel pump piston
As the high-pressure fuel pump cam ring rotates, the fuel pump roller, shoe and piston is
forced by the cam lobe inwards compressing the fuel held in the high-pressure fuel pump
chamber.
The fuel pressure in the high-pressure fuel pump chamber rises above the fuel pressure
developed by the transfer pump and the fuel inlet valve is closed.
As the fuel in the high-pressure fuel pump chamber exceeds the pressure of the fuel in the
fuel rail, the fuel outlet valve opens and high-pressure fuel is delivered to the fuel rail.
Fuel from the high-pressure fuel pump chamber will enter the fuel rail until the fuel pump
pistons have reached the maximum delivery movement. At this point the fuel pressure in
the high-pressure fuel pump chamber drops to below the pressure of the fuel in the fuel rail
and the fuel outlet valve is closed.
For each full rotation of the fuel pump cam ring, the fuel pump pistons go through four
compression cycles.

1 - High-pressure fuel outlet union
3 - Pressure release ball valve
4 - Calibrated pressure release spring
As a safety precaution, built into the fuel pump body is a high-pressure fuel relief valve. If
the fuel pump fuel pressure exceeds the maximum permissible value, the fuel relief valve
will open and vent the excess fuel pressure into the fuel pump inner chamber.
Fuel pump fuel flow and control

1 - Low pressure fuel control valve
2 - Calibrated fuel pump fuel return bore
4 - Fuel injector fuel return
5 - Fuel pump to fuel filter fuel return
7 - Fuel feed to fuel transfer pump
Under normal demand conditions, fuel is delivered to the high-pressure fuel pump chamber
unrestricted where it is compressed and delivered to the fuel rail.
A small proportion of fuel is diverted through the calibrated fuel pump fuel return bore. This
returned fuel is used to lubricate and cool the high-pressure pump. As the fuel exits
through the fuel return line venturi, the accelerated flow across the injector return line
orifice creates a partial vacuum in the fuel injector return line. This partial vacuum assists
with the scavenging of fuel injector fuel return fuel.

1 - Low pressure fuel control valve
2 - Calibrated fuel pump fuel return bore
4 - Fuel injector fuel return
5 - Fuel pump to fuel filter fuel return
7 - Fuel feed to fuel transfer pump
When the engine is off demand (decelerating), the fuel shut-off valve restricts the high-
pressure pump fuel supply. As the pressure in the high-pressure pump low pressure fuel
inlet channel increases, the low pressure fuel control valve opens and recirculates low
pressure fuel through the fuel transfer pump.
Fuel rail

1 - Fuel rail
3 - Fuel pump high-pressure fuel line connection
4 - Fuel injector high-pressure fuel line connections
The fuel rail function, is to supply a reservoir of fuel at a constant controlled pressure to all
four fuel injectors.

The action of the fuel injectors opening and closing causes changes in pressure to the fuel
behind the fuel injector. The fuel rail acts as an accumulator, minimizing this affect.
The volume of fuel held by the fuel rail cannot be to large as this will cause a increase in
pressurization time and a corresponding increase in engine start time.
The four fuel injector high-pressure fuel lines attached to the fuel rail are of equal length.
This is to eliminate any variation in delivery pressure at the fuel injectors.
Fitted into the fuel rail is the fuel pressure sensor. The fuel pressure sensor monitors the
current fuel pressure available at the fuel injectors. The fuel pressure sensor is a non
serviceable component. Due to the tapered thread construction of the fuel rail union, a fuel
tight seal capable of withstanding the high fuel pressures cannot be guaranteed. So the fuel
rail and fuel pressure sensor must be renewed as one component
If the fuel pressure sensor does not see a minimum preset value during cranking, the PCM
will not allow the fuel injectors to inject and the engine will not start.
If the fuel pressure sensor signal to the PCM is lost or the value indicated does not match
the expected value for the given engine condition, the fuel metering valve will default to the
closed position and will not allow the development of the high-pressure fuel supply.
Fuel injector

1 - Control chamber fuel inlet choke
2 - Solenoid valve
3 - Injection control valve spring
4 - Injection control valve
5 - Injection control valve fuel return bore
6 - Injector needle upper control chamber fuel outlet choke
7 - Injector needle upper chamber
8 - Injector needle high-pressure fuel outlet
9 - Injector needle
10 - Injector needle lower chamber
-

11 Injector needle lower chamber fuel inlet choke
12 - Injector needle upper chamber fuel inlet choke
The fuel injector consists of two main sections.
Electrically operated solenoid control valve.

Mechanically operated fuel injection valve.
The solenoid control valve has a switching time of approximately 0.3 milliseconds. This
short switching time is achieved by keeping the moving components and the distances
required to function to a minimum. The design of the fuel injector chambers means that at
no time does the solenoid control valve work against any major forces other than that of the
solenoid valve spring.
The fuel injector needle works on a combination of hydraulic and spring control.
All injectors are calibrated to take into account manufacturing tolerances. These calibrations
are indicated on the exterior of the injector by a code. The code is used by the PCM to
adjust the duration of the injection cycle.
If the codes for the individual injector's are incorrectly matched to the codes stored in the
PCM, the engine may exhibit rough idle, increased combustion noise and black smoke
emissions.
Fuel injector working state closed

1 - Solenoid valve
4 - Injector needle control spring
5 - Injector needle
7 - High-pressure fuel feed
With the solenoid valve de-energised, the injection control valve is held in the closed
position by the injection control valve spring. Fuel pressure above and below the injection

control valve is slightly above atmospheric pressure during engine run conditions.
Fuel pressure in the injector needle upper chamber and injector needle lower chamber is
equal to the high-pressure fuel feed pressure. The injector needle is held in the closed
position by the injector needle control spring.
Fuel injector working state opening

1 - Solenoid valve
2 - Fuel injector fuel return bore
4 - Injector needle upper control chamber fuel outlet choke
The fuel injection process starts with a voltage being applied to the solenoid valve with a
pull-in current of 12 amperes.
The solenoid valve moves the injection control valve against the pressure of the injection
control valve spring.
The injection control valve releases the high fuel pressure from the injector needle upper
chamber and vents the excess pressure out through the fuel injector fuel return bore. The
fuel pressure does not drop instantly but is slowed down by the injector needle upper
control chamber fuel outlet choke.
High-pressure fuel entering the injector needle upper chamber and the injection control
valve chambers is restricted by the very small diameters of the injector needle upper
chamber fuel inlet choke and the control chamber inlet choke.
Fuel injector working state injecting

1 - Solenoid valve
2 - Fuel injector fuel return bore
4 - Injector needle
During the injection state of the process, the current applied to the solenoid valve is
reduced to 6 amperes. This value is sufficient to maintain the injection control valve in the
open position.
As the fuel pressure in the injector needle upper chamber decays, the fuel pressure in the
injector needle lower chamber forces the injector needle open against the injector needle
control spring. Fuel is injected into the engine combustion chamber.
Fuel will continue to be injected as long as the fuel pressure in the injector needle lower
chamber is higher than the combined force of the fuel pressure in the injector needle upper
chamber and the injector needle control spring.
Fuel injector working state closing

1 - Solenoid valve
4 - Injector needle control spring
5 - Injector needle
7 - High-pressure fuel feed
When the fuel injection process has reached the desired injection duration, the solenoid
valve is de-energised.
The injection control valve spring closes the injection control valve and the fuel pressure in
the injector needle upper chamber rises to equal the pressure of the injector needle lower
chamber. As the pressures equalize, the injector needle spring closes the injector needle so
preventing fuel injection.
To prevent a sudden increase in the pressure in the injector needle lower chamber as the
injector needle closes, the fuel entering the chamber is restricted by the injector needle
lower chamber fuel inlet choke.
Fuel injector fuel return
The fuel injector fuel return is required to make the fuel injectors function.
The amount of return fuel developed during the normal functioning of a fuel injector
indicates the condition of that injector. By measurement and comparison of fuel injector
fuel return quantities, diagnosis of the fuel injectors is possible.
WARNINGS:


NOTE: As well as carrying out its normal function the glow plug indicator also acts as an
the PCM but will only be known if the system is checked for DTCs using WDS.
NOTE: If a DTC is detected, all DTCs must be cleared after the concern is repaired. Failure
NOTE: If the fuel level in the fuel tank drops below approximately four litres, rough
running will occur. This is to signal to the driver that the vehicle requires refuelling in
order to prevent the fuel system from running dry.
Fuel leak(s) Fuse(s)
Fuel filter Relay(s)
Air cleaner element Wiring harness
Vacuum line(s)/vacuum connections Electrical connector(s)
Hose(s)/hose connections Passive anti-theft system (PATS) LED operation
Tube(s)/tube connections Sensor(s)
Contaminated fuel Glow plug indicator
Fuel supply line(s) Powertrain control module (PCM)
Fuel return line(s)
Fuel injectors
Fuel injection supply manifold
Fuel pump
4. NOTE: A PCM calibration update should only be carried out if it is applicable to the
symptoms exhibited by the vehicle.
4. If the cause is not visually evident, verify the symptom and refer to WDS. Check
for the availability of an applicable PCM calibration update. Continue with WDS and
retrieve the DTCs.
5. 5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart
below to continue diagnostics.
Symptom Chart
Symptom Chart

Engine does not crank and * DTC detected. * REFER to WDS.
glow plug indicator is flashing
Engine does not crank * Starting system. * REFER to: Starting System - Vehicles
Built From: 08/2006 (303-06 Starting

System, Diagnosis and Testing).
Engine cranks but does not * DTC detected. * RETRIEVE the DTCs using WDS.
start and glow plug indicator INVESTIGATE and RESOLVE all stored
is flashing DTCs. If the concern persists, GO to
Pinpoint Test C.
Engine cranks but does not * Low fuel tank fuel * CHECK the fuel tank fuel level is
start level. greater than four litres. If the fuel tank
fuel level is less then four litres, FILL
with fuel.
* Fuel pump. * GO to Pinpoint Test C.
* Fuel injectors. * GO to Pinpoint Test C.
* Fuel filter blocked. * GO to Pinpoint Test B.
* Fuel lines damaged * GO to Pinpoint Test B.
or blocked.
* Air ingress into the * REFER to: Fuel System - 75 PS/90 PS
fuel lines. (310-00A Fuel System - General
* Incorrect or * CHECK for signs of contamination
contaminated fuel. such as strange odors from the fuel
tank.
* CHECK for signs of water or petrol in
the diesel.
* If contaminated fuel is found, GO to
Pinpoint Test C.
* Crankshaft position * REFER to WDS.
(CKP) sensor.
* Camshaft position * REFER to WDS.
(CMP) sensor.
* Cylinder head * REFER to WDS.
temperature (CHT)
sensor.
* PCM. * REFER to WDS.
* Fuel injection * REFER to WDS.
supply manifold fuel
pressure sensor.
* Fuel inlet metering * REFER to WDS.
valve.
* Incorrect valve * CHECK the valve timing.
timing.
* Low cylinder * CHECK the cylinder compression.
compression.
Poor starting and glow plug * DTC detected. * RETRIEVE the DTCs using WDS.
indicator is flashing INVESTIGATE and RESOLVE all stored
DTCs. If the concern persists, GO to
Pinpoint Test C.
Poor starting * Low fuel tank fuel * CHECK the fuel tank fuel level is
level. greater than four litres. If the fuel tank
with fuel.
* Fuel system * GO to Pinpoint Test B.
restriction.
* Fuel pump. * GO to Pinpoint Test B.
* Fuel injector(s). * GO to Pinpoint Test A.

* Air cleaner element * INSTALL a new air cleaner element.
blocked.
* Fuel system leak. * CHECK the system for fuel leak(s).
REPAIR the system as necessary.
* Incorrect engine oil. * INSTALL a new engine oil filter and
engine oil.
* Incorrect power * DRAIN and REFILL the power steering
steering fluid. system with the correct fluid.
REFER to: Power Steering System
Flushing - 1.8L Duratorq-TDCi (Lynx)
Procedures).
* CKP sensor. * REFER to WDS.
* CHT sensor. * REFER to WDS.
* Fuel temperature * REFER to WDS.
sensor.
* Intake air * REFER to WDS.
temperature (IAT)
sensor.
* Manifold absolute * REFER to WDS.
pressure (MAP)
sensor.
pressure sensor.
valve.
* Catalytic converter * REMOVE and visually INSPECT the
blocked. catalytic converter for damage.
INSTALL a new catalytic converter as
necessary.
REFER to: Catalytic Converter - 1.8L
Duratorq-TDDi (Lynx) Diesel (309-00
Exhaust System, Removal and
Installation).
* Low cylinder * TEST the engine cylinder compression.
compression.
Engine starts but immediately * DTC detected. * REFER to WDS.
stops and glow plug indicator
is flashing
Engine starts but immediately * Air cleaner element * INSTALL a new air cleaner element.
stops blocked.
* PCM relay. * CARRY OUT the relay component test.
REFER to Wiring Diagrams.
* CMP sensor. * REFER to WDS.
* PCM. * REFER to WDS.
valve.
* Dual mass flywheel. * INSPECT the dual mass flywheel for

damage. INSTALL a new dual mass
flywheel as necessary.
Poor idling and glow plug * DTC detected. * REFER to WDS. RETRIEVE the DTCs
indicator is flashing using WDS. INVESTIGATE and
RESOLVE all stored DTCs. If the
concern persists, GO to Pinpoint Test
C.
Poor idling * Low fuel tank fuel * CHECK the fuel tank fuel level is
level. greater than four litres. If the fuel tank
with fuel.
blocked.
tank.
the diesel.
Pinpoint Test C.
* EGR valve sticking * REFER to: Engine Emission Control -
open. 75 PS/90 PS (303-08B Engine
* EGR vacuum Emission Control - 1.8L Duratorq-TDCi
regulator valve. (Lynx) Diesel/1.8L Duratorq-TDDi
(Lynx) Diesel, Diagnosis and Testing).
* IAT sensor. * REFER to WDS.
* MAP sensor. * REFER to WDS.
* Knock sensor (KS). * REFER to WDS.
pressure sensor.
valve.
Engine stumbling and glow * DTC detected. * REFER to WDS.
plug indicator is flashing
Engine stumbling * Low fuel level. * CHECK the fuel tank level is greater
than four litres. If the fuel tank level is
less than four litres, FILL with fuel.
* Acceleration pedal * REFER to WDS.
position (APP)
sensor.
pressure sensor.

Engine lacks power and glow * DTC detected. * REFER to WDS.
Engine lacks power * Brakes binding. * CHECK the braking system.
REFER to: Brake System (206-00
Brake System - General Information,
* Vehicle overloaded, * ADVISE the customer about the
or excessive wind effects of overloading the vehicle and
resistance (roof wind resistance on the fuel
racks, towing etc). consumption.
* Air cleaner element * INSTALL a new air cleaner element as
blocked. necessary.
* Kinked or restricted * GO to Pinpoint Test B.
fuel lines.
* Turbocharger. * INSPECT the vacuum line(s) for visible
* Turbocharger signs of damage or blockage. CLEAN,
vacuum diaphragm REPAIR or INSTALL new parts as
unit. necessary.
* Vane adjustment REFER to: Turbocharger - 75 PS/90
solenoid valve. PS/110 PS, Vehicles Built From:
08/2006 (303-04C Fuel Charging and
Controls - Turbocharger, Description
and Operation).
* Charge air cooler * INSPECT for visible signs of damage
blocked or cracked. or blockage. CLEAN, REPAIR or
* Charge air cooler INSTALL new parts as necessary.
pipes split or
cracked.
* Charge air cooler
retaining clips
missing or loose.
tank.
the diesel.
Pinpoint Test C.
* Vehicle speed * REFER to WDS.
sensor (VSS).
* APP sensor. * REFER to WDS.
* Fuel temperature * REFER to WDS.
sensor.

pressure sensor.
valve.
timing.
* Low cylinder * TEST the engine cylinder compression.
compression.
necessary.
Installation).
Black smoke at idle and glow * DTC detected. * REFER to WDS.
Black smoke at idle * Air cleaner element * INSTALL a new air cleaner element as
blocked. necessary.
* Glow plug system. * REFER to WDS.
* Turbocharger * INSPECT the vacuum line(s) for visible
vacuum control. signs of damage or blockage. CLEAN,
* Vane adjustment REPAIR or INSTALL new parts as
solenoid valve. necessary.
REFER to: Turbocharger - 75 PS/90
PS, Vehicles Built Up To: 08/2006
(303-04C Fuel Charging and Controls -
Turbocharger, Diagnosis and Testing).
*
CHT sensor. * REFER to WDS.
*
IAT sensor. * REFER to WDS.
*
MAP sensor. * REFER to WDS.
Fuel injection
* * REFER to WDS.
pressure sensor.
timing.
necessary.
Installation).
Excessive black smoke during * DTC detected. * REFER to WDS.
acceleration and glow plug
Excessive black smoke during * Air cleaner element * INSTALL a new air cleaner element as
acceleration blocked. necessary.
tank.
the diesel.

Pinpoint Test C.
* APP sensor. * REFER to WDS.
* Knock sensor. * REFER to WDS.
* Fuel injector(s). * REFER to WDS.
pressure sensor.
necessary.
Installation).
Black smoke at cruising * DTC detected. * REFER to WDS.
speeds and glow plug
Black smoke at cruising * Air cleaner element * INSTALL a new air cleaner element.
speeds blocked.
* Turbocharger * REFER to: Turbocharger - 75 PS/90
vacuum diaphragm PS, Vehicles Built Up To: 08/2006
unit. (303-04C Fuel Charging and Controls -
pressure sensor.
necessary.
Installation).
Blue smoke and glow plug * DTC detected. * REFER to WDS.
Blue smoke * Engine burning oil. * CARRY OUT a controlled oil
consumption test over 1000 km (600
miles). CONFIRM that the oil

consumption is less than 0.1 of a litre
per 1000 km (600 miles).
tank.
the diesel.
Pinpoint Test C.
* Worn or damaged * REMOVE the cylinder head. INSPECT
valve guide(s), the cylinder head, pistons and cylinder
piston ring(s), bores for signs of wear or damage.
cylinder bore(s), REFER to: Cylinder Head - 1.8L
cylinder head or Duratorq-TDCi (Lynx) Diesel (90 PS),
gasket. Vehicles With: Common Rail Fuel
Injection (303-01B Engine - 1.8L
Duratorq-TDDi (Lynx) Diesel, In-
vehicle Repair).
* Positive crankcase * INSPECT for visible signs of damage
ventilation (PCV) or blockage. CLEAN, REPAIR or
system. INSTALL new parts as necessary.
* Turbocharger oil * REFER to: Turbocharger - 75 PS/90
return tube blocked PS, Vehicles Built Up To: 08/2006
or damaged. (303-04C Fuel Charging and Controls -
White smoke and glow plug * DTC detected. * REFER to WDS.
White smoke * Water in fuel. * CHECK for signs of water in the diesel.
Pinpoint Test C.
timing.
* Coolant in the * CARRY OUT a cooling system pressure
combustion test.
chamber. REFER to: Engine Cooling (303-03
Engine Cooling, Diagnosis and
Testing).
REMOVE the cylinder head. INSPECT
the cylinder head, cylinder head
gasket and cylinder bores for wear or
damage.
REFER to: Cylinder Head - 1.8L
Duratorq-TDCi (Lynx) Diesel (90 PS),
Vehicles With: Common Rail Fuel
vehicle Repair).
Engine misfire and glow plug * DTC detected. * REFER to WDS.
Engine misfire * Low fuel tank level. * CHECK the fuel tank level is greater

than four litres. If the fuel tank level is
less than four litres, FILL with fuel.
tank.
the diesel.
Pinpoint Test C.
* Engine overheats. * REFER to: Engine Cooling (303-03
Engine Cooling, Diagnosis and
Testing).
* CMP sensor. * REFER to WDS.
pressure sensor.
* Low cylinder * CHECK the cylinder compression.
compression.
* Worn or damaged * REMOVE the cylinder head. INSPECT
valve(s), tappet(s) the cylinder head, valves, tappets and
or camshaft(s). camshafts for signs of wear or
damage.
vehicle Repair).
* Damaged cylinder * REMOVE the cylinder head. INSPECT
head gasket. the cylinder head gasket and cylinder
bores for wear or damage.
vehicle Repair).
Engine knock at idle and glow * DTC detected. * REFER to WDS.
Engine knock at idle * Low engine oil * CHECK the engine oil level. REFILL as
level. necessary.

tank.
the diesel.
Pinpoint Test C.
timing.
* Excessive carbon * REMOVE the cylinder head. INSPECT
build up. the cylinder head and pistons for signs
carbon build up.
vehicle Repair).
* Worn or damaged * INSPECT the engine components.
oil pump.
* Worn or damaged
timing chain or
sprocket.
* Major mechanical
engine failure.
Engine knock during * DTC detected. * REFER to WDS.
acceleration and glow plug
Engine knock during * Knock sensor. * REFER to WDS.
acceleration * Fuel injector(s). * GO to Pinpoint Test A.
valve.
* Major mechanical * INSPECT the engine components.
engine failure.
Excessive fuel consumption * DTC detected. * REFER to WDS.
and glow plug indicator is
flashing
NOTE: Before proceeding * Brakes binding. * CHECK the braking system.
with any of the actions in REFER to: Brake System (206-00
relation to the possible Brake System - General Information,
sources for excessive fuel Diagnosis and Testing).
consumption, a fuel * Vehicle overloaded, * ADVISE the customer about the
consumption test must be or excessive wind effects of overloading the vehicle and
carried out using WDS. resistance (roof wind resistance on the fuel
Excessive fuel consumption racks, towing etc). consumption.
blocked.
* Fuel system leak(s). * CHECK the system for fuel leak(s).
REPAIR or INSTALL new parts as

necessary.
* Generator. * REFER to WDS.
* Turbocharger * REFER to: Turbocharger - 75 PS/90
vacuum diaphragm PS, Vehicles Built Up To: 08/2006
unit. (303-04C Fuel Charging and Controls -
* Turbocharger. Turbocharger, Diagnosis and Testing).
timing.
* Slipping clutch. * REFER to: Manual Transaxle and
Clutch (308-00 Manual
Transmission/Transaxle and Clutch -
General Information, Diagnosis and
Testing).
* Low cylinder * CHECK cylinder compression.
compression.
Engine cuts out during hard * CMP sensor. * REFER to WDS.
acceleration * CKP sensor. * REFER to WDS.
pressure sensor.
valve.
* Fuel pump. * REFER to WDS.
PINPOINT TEST A : FUEL INJECTOR BACK LEAK TEST
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: FUEL SYSTEM HIGH-PRESSURE TEST
CAUTIONS:
Do not run the fuel system high-pressure test more than twice. Failure to follow this
instruction may result in damage to the fuel pump.
Do not crank the engine for more than 5 seconds during the fuel system high-
pressure test. Failure to follow this instruction may result in damage to the fuel pump.
1 Disconnect the fuel injector fuel return lines.

NOTE: The fuel injector fuel return line must be
clamped, to prevent air entering the fuel system.
2 Using a suitable brake hose clamp, clamp the fuel
injector fuel return line.
NOTE: Make sure that the clear plastic hoses of the

special tool are equal in length. If a hose is
damaged, a hose of equal internal diameter and
original length (500 mm) should be installed.
3 Install the special tool to the fuel injectors.
Using WDS, guided diagnostic, run the fuel system

4
pressure test.
Is the fuel system pressure greater than 1050 bar?
Yes
GO to A2.
No
GO to A4.
A2: CHECK THE FUEL INJECTOR BACK LEAK AFTER 1 MINUTE ENGINE RUN TIME
1 Remove the special tool.
2 Empty the special tool of fuel.
3 Remove the brake hose clamp from the fuel
4 Connect the fuel injector fuel return lines to the
fuel injectors.
5 Connect the fuel metering valve electrical
connector.
6 Connect the fuel injector electrical connectors.
7 Start the engine.
8 Using WDS datalogger, PCM function, select the
signal for CHT. Allow the engine to reach 70°C.
9 Stop the engine.

11 Clamp the fuel injector fuel return line.
12 Start the engine.
13 Allow the engine to idle for 1 minute.
14 Stop the engine.
15 Invert the containers of the special tool, raise the
containers above the engine and allow the collected
fuel to drain into the clear plastic hoses connecting
the containers to the fuel injectors.
16 Observe the quantities of fuel collected within the

lengths of clear plastic hose.
Are the quantities of fuel contained within the lengths
of clear plastic hose approximately equal?
Yes
GO to A3.
No
If one or more fuel volumes is significantly higher
within the special tool clear plastic hose, INSTALL a
new fuel injector(s) as required.
REFER to: Fuel Injectors - 1.8L Duratorq-TDCi
(Lynx) Diesel (303-04B Fuel Charging and Controls
- 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-
TDDi (Lynx) Diesel, Removal and Installation).
TEST the system for normal operation.If the fuel
volumes for all four fuel injectors exceed the length
of clear plastic hose, using WDS Program Module
Routine, INPUT the fuel injector correction values.
A3: CHECK THE FUEL INJECTOR BACK LEAK AFTER 4 MINUTES ENGINE RUN TIME
1 Position the containers of the special tool below the
height of the fuel injector fuel return line
connection.
2 Start the engine.
3 Allow the engine to idle for 4 minutes.
4 Stop the engine.
5 Disconnect the special tool from the fuel injectors
and allow the fuel in the clear plastic hoses to flow
into the special tool containers.
6 Record the volumes of fuel collected in the special
tool containers.

7 Multiply the lowest recorded value by 1.4 to
calculate the maximum permissible value
(maximum permissible value = minimum
recorded value + 40%).
Example:
Quantity of lowest volume container = 10 ml
1.4 X 10 ml = 14 ml
Maximum permissible value = 14 ml
Are the volumes of fuel in each of the special tool
containers lower than the calculated maximum
permissible variation value?
Yes
NO fault is indicated with the fuel injectors. To
continue diagnostics, RETURN to the Symptom
Chart.
No
If one or more fuel volumes in the special tool
containers has a volume above the maximum
permissible variation value, using WDS Program
Module Routine, INPUT the fuel injector correction
values. TEST the system for normal operation.
A4: CHECK THE FUEL INJECTOR BACK LEAK AFTER FUEL SYSTEM PRESSURE TEST
Measure and record the length of clear plastic hose

2
containing fuel for each fuel injector.
Do one or more clear plastic hoses contain no fuel and
one or more have a recorded value greater than 21 cm
in length?
Yes
GO to A5.
No
GO to A6.
A5: FUEL INJECTOR BACK LEAK TEST FAILURE MODE 1
1 Install new fuel injectors for those injectors with
recorded values of greater than 21 cm.

2 Empty the special tool of fuel.
CAUTION: Do not run the fuel system high-

pressure test more than twice.
3 Using WDS repeat the fuel system pressure test.
4 Measure and record the length of clear plastic hose
Do all of the clear plastic hoses contain fuel?
Yes
ASSEMBLE the vehicle. TEST the system for normal
operation.
No
INSTALL new fuel injectors for those injectors
where no fuel is present within the clear plastic
hose.
1 Compare the recorded values for the clear plastic
hoses containing fuel.
Do all of the clear plastic hoses contain fuel and one or
more have a recorded value greater than 21 cm in
length?
Yes
INSTALL new fuel injectors for recorded values
greater than 21 cm.
No
GO to A7.
Are all of the recorded values less than 21 cm and one

or more clear plastic hoses contain no fuel?
Yes
hose.
No
INSTALL a new fuel pump.
REFER to: Fuel Injection Pump - 1.8L Duratorq-
TDCi FGT (55kW/75PS) - Lynx/1.8L Duratorq-TDCi
(66kW/90PS) - Lynx/1.8L Duratorq-TDCi FGT
(66kW/90PS) - Lynx/1.8L Duratorq-TDCi VNT
(81kW/110PS) - Lynx, Vehicles Built Up To:

03/2008 (303-04B Fuel Charging and Controls -
1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-
Test the system for normal operation.
PINPOINT TEST B : FUEL PUMP FUEL SUPPLY TEST

B1: CHECK THE FUEL PUMP FUEL SUPPLY PRESSURE
1 Clean the area around the fuel filter quick release
couplings.
REFER to: Fuel Injection Component Cleaning -
Vehicles With: Common Rail Fuel Injection (303-
04B Fuel Charging and Controls - 1.8L Duratorq-
Diesel, General Procedures).
2 Disconnect the fuel tank to fuel filter fuel supply
REFER to: Quick Release Coupling (310-00A Fuel
Procedures).
3 Install the special tool adapter to the fuel tank to

fuel filter fuel supply line.
4 Install the special tool adapter to the fuel filter.
NOTE: Make sure that the hand pressure pump

arrow indicating the fuel flow is pointing towards
the fuel filter.
5 Install the special tool between the special tool
adapters.
6 Connect the WDS pressure transducer to the

special tool.

7 Using WDS, select the digital multimeter (DMM)
function from the toolbox menu. Select the
pressure vacuum transducer (PVT) function and
configure the DMM to display pressure/vacuum.
8 Start the engine.
9 Allow the engine to idle for at least one minute.
10 Make a note of the value displayed by WDS.
Is the value displayed between -65 mB and -85 mB?
Yes
GO to B3.
No
If the displayed value is between 0 mB and -65 mB,
GO to B2. If the displayed value is -85 mB or a
greater negative value, GO to B4.
B2: CHECK THE FUEL SYSTEM FOR AIR INGRESS
NOTE: A small amount of air bubbles in the fuel
supply line is acceptable.
1 Observe the flow of fuel through the clear plastic
pipe of the hand pressure pump.
Is the hand pressure pump clear plastic pipe free from
an excessive volume of air bubbles?
Yes
pressure test, CHECK the fuel pump high-pressure
fuel supply pressure.
No
CHECK for air ingress into the fuel lines.
REFER to: Fuel System - 75 PS/90 PS (310-00A
Fuel System - General Information, Diagnosis and
Testing).
B3: CHECK THE FUEL PUMP FUEL RETURN PRESSURE
NOTE: Before this test can be carried out, the latest calibration must be programed into
the PCM and IDM if applicable.
1 Remove the charge air cooler.
REFER to: Charge Air Cooler - 1.8L Duratorq-TDCi
(Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (75
PS/90 PS) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
2 Clean the area around the fuel filter to fuel pump
fuel return line quick release coupling.
3 Connect special tools 310-025-18 and 310-025-19A
to the WDS pressure transducer adaptor GV2323.

4 Disconnect the fuel pump fuel return line quick
release coupling.
Procedures).
5 Connect the special tools between the fuel pump

fuel return line quick release coupling and the fuel
pump.
6 Install the charge air cooler.

7 Start the engine.
8 Using WDS data logger function, monitor the fuel
system temperature until a temperature of
between 35°C and 40°C is obtained.
9 Stop the engine.
10 Disconnect the WDS pressure transducer from the
special tool 310-110.
11 Connect the WDS pressure transducer to the WDS
pressure transducer adaptor GV2323.
12 Using WDS, select the digital multimeter (DMM)

function from the toolbox menu. Select the
pressure vacuum transducer (PVT) function and
configure the DMM to display pressure/vacuum.
13 Start the engine.
14 Make a note of the value displayed by WDS with
the engine at idle and at 2000 RPM.
Is the value displayed between -175 mB to -220 mB at

idle and -180 mB to -230 mB at 2000 RPM?
Yes
pressure test, CHECK the fuel pump high-pressure

fuel supply pressure. If no fault is indicated with the
high-pressure fuel supply pressure, RETURN to the
Symptom Chart.
No
CHECK the fuel return system for damage or
restriction. REPAIR or INSTALL new components as
required. TEST the system for normal operation.
B4: CHECK THE FUEL PUMP FUEL SUPPLY SYSTEM FOR RESTRICTION
1 Remove the charge air cooler.
REFER to: Charge Air Cooler - 1.8L Duratorq-TDCi
(Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (75
PS/90 PS) (303-12 Intake Air Distribution and
2 Clean the area around the fuel filter to fuel pump
fuel return line quick release coupling.
3 Disconnect the fuel pump fuel supply line.
Procedures).
Install a blanking plug to the open end of the fuel

pump union.
4 Place the open end of the fuel pump fuel supply

line into a clean container.
5 Operate the hand pressure pump at least three
times in rapid succession and observe the value
displayed by WDS.
Does the fuel pressure indicated by WDS when
operating the hand pressure pump instantly fall to zero
when the hand pressure pump is released?
Yes
CHECK the fuel level sensor and fuel tank fuel
supply line for restriction. REPAIR or INSTALL new
components as required.
No
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx)
Diesel (310-01A Fuel Tank and Lines, Removal and
Installation).
PINPOINT TEST C : FUEL INJECTOR BACK LEAK TEST

C1: FUEL SYSTEM HIGH-PRESSURE TEST
CAUTIONS:
Do not run the fuel system high-pressure test more than twice. Failure to follow this
instruction may result in damage to the fuel pump.
Do not crank the engine for more than 5 seconds during the fuel system high-

pressure test. Failure to follow this instruction may result in damage to the fuel pump.
1 Disconnect the fuel injector fuel return lines.
NOTE: The fuel injector fuel return line must be

clamped, to prevent air entering the fuel system.
2 Using a suitable brake hose clamp, clamp the fuel
NOTE: Make sure that the clear plastic hoses of the

special tool are equal in length. If a hose is
damaged, a hose of equal internal diameter and
original length (500 mm) should be installed.

4
pressure test.
Is the fuel system pressure greater than 1050 bar?
Yes
No fault is indicated with the high pressure fuel
supply system components. To continue with the
diagnostics, return to the symptom chart.
No
GO to C2.
C2: CHECK THE FUEL INJECTOR BACK LEAK AFTER FUEL SYSTEM PRESSURE TEST
Measure and record the length of clear plastic pipe

2
Do all of the clear plastic hoses contain no fuel?
Yes
GO to C7.
No
GO to C3.
C3: FUEL INJECTOR LEAK-OFF TEST CONFIRMATION

Compare the recorded values for the clear plastic
1
Do one or more clear plastic hoses contain no fuel and
one or more have a recorded value greater than 21 cm
in length?
Yes
GO to C4.
No
GO to C5.
C4: FUEL INJECTOR BACK LEAK TEST FAILURE MODE 1
1 Install new fuel injectors for those injectors with
recorded values of greater than 21 cm.
2 Empty the special tool of fuel .

4 Measure and record the length of clear plastic pipe
Do all of the clear plastic hoses contain fuel?
Yes
ASSEMBLE the vehicle. TEST the system for normal
operation.
No
hose.
Do all of the clear plastic hoses contain fuel and one or
more have a recorded value greater than 21 cm in
length?
Yes
INSTALL new fuel injectors for recorded values
greater than 21 cm.
No
GO to C6.
Are all of the recorded values less than 21 cm and one
or more clear plastic hoses contain no fuel?
Yes

hose.
No
INSTALL a new fuel pump.
C7: FUEL PUMP MECHANICAL FAILURE TEST
1 Disconnect the fuel filter fuel return line.
Install a blanking cap to the open port of the fuel

filter.
2 Position a clean transparent container under the

open union of the fuel filter fuel return line.

4 Using a magnet, draw all possible metal particles
contained in the collected fuel, to the base of the
transparent container.
5 Measure the diameter of the collected magnetic

deposit at the base of the transparent container.

Is the collected magnetic deposit of a diameter equal to
or greater than 5 mm and mainly black in appearance?
Yes
REMOVE and DISCARD the fuel filter, fuel pump fuel
supply line, fuel injector and fuel pump to fuel filter
fuel return line. REMOVE the fuel tank.
REFER to: Fuel Tank - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (310-01A
Fuel Tank and Lines, Removal and Installation).
Using clean fuel, FLUSH the fuel tank until all
foreign particles are removed. Using a workshop
compressed air line, PURGE the fuel tank fuel lines
from the engine bay end. Take care not to
damage the quick release couplings of the fuel
lines.INSTALL the fuel tank,
REFER to: Fuel Tank - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (310-01A
Fuel Tank and Lines, Removal and Installation).
INSTALL new fuel injectors, fuel pump and fuel rail.
TDDi (Lynx) Diesel, Removal and Installation) /
Fuel Injection Supply Manifold - 1.8L Duratorq-TDCi
Fuel Injection Pump - 1.8L Duratorq-TDCi FGT
INSTALL a new fuel pump fuel supply line. INSTALL
a new fuel injector and fuel pump to fuel filter fuel
return line. INSTALL a new fuel filter.
Installation).
PRIME the fuel pump.

The engine must not be cranked until the fuel
pump has been primed. Test the system for
normal operation.
No
If contaminated fuel was present in the fuel system,
DRAIN and FLUSH with clean fuel the fuel tank, fuel
pump, fuel supply lines and fuel return lines.
INSTALL a new fuel filter,
Installation).
PRIME the fuel pump.
The engine must not be cranked until the fuel
pump has been primed. Using WDS REPEAT the
fuel system high-pressure test. If the fuel system
pressure test result is not above 1050 bar, INSTALL
a new fuel pump.
If no contaminated fuel is present in the fuel
system and the vehicle has failed the fuel system
high-pressure test, INSTALL a new fuel pump.

Charging and Controls—75 PS/90 PS/110
PS, Vehicles Built From: 08/2006
Print
General Equipment
The 1.8L Duratorq-TDCi (Kent) diesel engine uses the Siemens common rail fuel injection
system. The systems main components consist of a fuel pump, fuel rail, electrically
operated fuel injectors, fuel metering valve, fuel pressure regulator and a fuel temperature
sensor.
Fuel pump

1 - Fuel pump fuel supply port
3 - Fuel pump fuel supply union
5 - High-pressure fuel supply line port
The fuel pump consists of a transfer pump and a high-pressure fuel delivery pump. The
transfer pump draws fuel from the fuel tank through the fuel filter and delivers the fuel to
the three high-pressure fuel pump chambers through a fuel metering valve.
Fuel is also delivered to the high-pressure fuel pump chambers through an internal
scavenging valve to lubricate and maintain fuel in the fuel pump.
The fuel metering valve controls the quantity of fuel that is allowed to enter the high-
pressure fuel pump chambers. Excess fuel volume developed in the high-pressure fuel
pump chamber is returned to the fuel tank. The fuel metering valve is controlled by the

powertrain control module (PCM) using a pulse-width modulated signal.
The high-pressure fuel pump supply pressure is controlled by an electronic fuel metering
valve which is also controlled by the PCM.

1 - Transfer pump
3 - High-pressure fuel pump chambers
5 - Fuel pump internal pressure regulator
6 - Scavenging valve
a - Fuel pump fuel supply port
b - High-pressure fuel supply port
c - Fuel pump fuel return port
Fuel rail

1 - Fuel rail
2 - Fuel rail pressure (FRP) sensor
The fuel rail provides a reservoir of high-pressure fuel which is available for all four fuel
injectors. The fuel rail also provides pulse damping of the pressure surges in high-pressure
fuel system. Attached to the fuel rail is a FRP sensor. The FRP sensor monitors the fuel
pressure in the fuel rail. The FRP sensor provides a controlled variable voltage signal to the
PCM, which is converted into a pressure signal.
Fuel injectors

2 - Fuel injector
-

3 High-pressure fuel supply port
4 - Sealing washer
5 - Fuel injector retaining clamp
6 - Fuel injector fuel return line retaining clip

1 - High-pressure fuel supply port
2 - Fuel injector fuel return port
4 - Piezoelectric actuator
5 - Piezoelectric actuated valve
6 - needle valve
8 - Fuel injection valve
9 - High-pressure fuel chamber
10 - Fuel injector fuel delivery holes
The fuel injectors have a Piezoelectric actuator. The advantages of using Piezoelectric
instead of traditional solenoid actuators are the reduction in reaction switching times and
the lower switching currents. Both of which improve the control and therefore the efficiency
of the fuel injector.
Fuel temperature sensor

1 - Fuel injector fuel return line
3 - Fuel pump fuel return line
4 - Fuel tank fuel return line union
The fuel temperature sensor is installed into the fuel injector to fuel tank fuel return line.
The fuel temperature sensor monitors the temperature of the fuel returning to the fuel tank
from the fuel injectors and sends a signal to the PCM.
WARNINGS:

NOTE: As well as carrying out its normal function the glow plug indicator also acts as an
the PCM but will only be known if the system is checked for DTCs using the WDS.
NOTE: If a DTC is detected, all DTCs must be cleared after the concern is rectified. Failure
NOTE: If the fuel level in the fuel tank drops below approximately four liters, rough
running will occur. This is to signal to the driver that the vehicle requires refuelling in
order to prevent the fuel system from running dry.

Fuel leak(s) Fuse(s)
Fuel filter Relay(s)
Air cleaner element Wiring harness
Vacuum line(s)/vacuum connections Electrical connector(s)
Hose(s)/hose connections Sensor(s)
Tube(s)/tube connections
Contaminated fuel
Fuel supply line(s)
Fuel return line(s)
Fuel injectors
Fuel rail
Fuel pump
4. 4. If the cause is not visually evident, verify the symptom and refer to WDS to
retrieve the diagnostic trouble codes (DTCs).
5. 5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart
below to continue diagnostics.
Symptom Chart

Engine does not * PATS system fault * REFER to: Anti-Theft - Passive (419-01B Anti-Theft
crank and passive detected. - Passive, Diagnosis and Testing).
anti-theft system
(PATS) LED is
flashing
Engine does not * DTC detected. * REFER to the WDS.
crank and glow
plug indicator is
flashing
Engine does not * Starting system. * REFER to: Starting System - Vehicles Built From:
crank 08/2006 (303-06 Starting System, Diagnosis and
Testing).
Engine cranks but * DTC detected. * REFER to the WDS.
does not start
and glow plug
indicator is
flashing
Engine cranks but * Low fuel tank fuel * CHECK the fuel tank fuel level is greater than four
does not start level. liters. If the fuel tank fuel level is less then four
liters, FILL with fuel.
* Fuel filter blocked. * INSTALL a new fuel filter.
Installation).
* Fuel lines damaged * REFER to: Fuel System - 1.8L Duratorq-TDCi
or blocked. (Lynx) Diesel (75 PS/90 PS/110 PS), Vehicles Built
From: 08/2006 (310-00A Fuel System - General

* Air ingress into the * REFER to: Fuel System - 1.8L Duratorq-TDCi
fuel lines. (Lynx) Diesel (75 PS/90 PS/110 PS), Vehicles Built
* Glow plugs. * REFER to the WDS.
timing. REFER to: Timing Belt - 1.8L Duratorq-TDCi (Lynx)
Diesel (75 PS/90 PS/110 PS), Vehicles Built From:
08/2006 (303-01B Engine - 1.8L Duratorq-TDCi
In-vehicle Repair).
* Low cylinder * REFER to: Engine (303-01B Engine - 1.8L
compression. Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi
* Crankshaft position * REFER to the WDS.
(CKP) sensor.
* Camshaft position * REFER to the WDS.
(CMP) sensor.
* Cylinder head * REFER to the WDS.
temperature (CHT)
sensor.
* PCM. * REFER to the WDS.
* Fuel rail fuel * REFER to the WDS.
pressure sensor.
* Fuel pump fuel * REFER to the WDS.
pressure regulator.
* Fuel pump. * REFER to the WDS.
* Fuel injector(s). * REFER to the WDS.
Poor starting and * DTC detected. * REFER to the WDS.
glow plug
indicator is
flashing
Poor starting * Low fuel tank fuel * CHECK the fuel tank fuel level is greater than four
level. liters. If the fuel tank fuel level is less then four
* Fuel filter blocked. * INSTALL a new fuel filter element.
Installation).
blocked.
* Glow plugs. * REFER to the WDS.
* Fuel system leak. * CHECK the system for fuel leak(s). REPAIR the
system as necessary.
* Fuel system * REFER to: Fuel System - 1.8L Duratorq-TDCi
restriction. (Lynx) Diesel (75 PS/90 PS/110 PS), Vehicles Built
* Incorrect engine oil. * INSTALL a new engine oil filter and engine oil.
* Catalytic converter * REMOVE and visually INSPECT the catalytic
blocked. converter for damage. INSTALL a new catalytic
converter as necessary.

* CKP sensor. * REFER to the WDS.
* CHT sensor. * REFER to the WDS.
* Fuel temperature * REFER to the WDS.
sensor.
* Mass air flow (MAF) * REFER to the WDS.
sensor.
* Manifold absolute * REFER to the WDS.
pressure (MAP)
sensor.
* FRP sensor. * REFER to the WDS.
* Fuel pressure * REFER to the WDS.
regulator.
* Intake manifold * CHECK the intake manifold EGR throttle butterfly
Exhaust gas for obstructions and correct operation.
recirculation (EGR) * REFER to the WDS.
throttle.
* Intake manifold * CHECK the intake manifold EGR throttle vacuum
EGR throttle control solenoid vacuum lines for kinks or
vacuum control restrictions.
solenoid. * REFER to the WDS.
Engine starts but * DTC detected. * REFER to the WDS.
immediately
stops and glow
plug indicator is
flashing
Engine starts but * Air cleaner element * INSTALL a new air cleaner element.
immediately blocked.
stops * Air ingress into the * REFER to: Fuel System - 1.8L Duratorq-TDCi
* PCM relay. * CARRY OUT the relay component test. REFER to
Wiring Diagrams.
* CMP sensor. * REFER to the WDS.
* PCM. * REFER to the WDS.
regulator.
EGR throttle. for obstructions and correct operation.
* REFER to the WDS.
Poor idling and * DTC detected. * REFER to the WDS.
glow plug
indicator is
flashing
Poor idling * Low fuel tank fuel * CHECK the fuel tank fuel level is greater than four
level. liters. If the fuel tank fuel level is less then four

blocked.
Installation).
* Incorrect or * CHECK for signs of contamination such as strange
contaminated fuel. odors from the fuel tank.
* CHECK for signs of water or petrol in the diesel.
* If contaminated fuel is found, DRAIN the complete
fuel system. FLUSH the fuel system through with
clean diesel.
REFER to: Fuel Tank Draining (310-00A Fuel
Procedures).
INSTALL a new fuel filter element.
Installation).
INSTALL a new fuel pump, fuel injectors, fuel rail,
and high-pressure fuel supply lines.
Fuel Injection Supply Manifold - 1.8L Duratorq-
TDCi (Lynx) Diesel (303-04B Fuel Charging and
Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L
Duratorq-TDDi (Lynx) Diesel, Removal and
Installation) /
Fuel Injectors - 1.8L Duratorq-TDCi (Lynx) Diesel
(303-04B Fuel Charging and Controls - 1.8L
* EGR valve incorrect * REFER to: Engine Emission Control - 75 PS/90 PS,
operation. Vehicles Built From: 08/2006 (303-08B Engine
Emission Control - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis
and Testing).
* MAF sensor. * REFER to the WDS.
* MAP sensor. * REFER to the WDS.
regulator.
* REFER to the WDS.

Engine stumbling * DTC detected. * REFER to the WDS.
and glow plug
indicator is
flashing
Engine stumbling * Low fuel level. * CHECK the fuel tank level is greater than four
liters. If the fuel tank level is less than four liters,
FILL with fuel.
* Accelerator pedal * REFER to the WDS.
position (APP)
sensor.
Engine lacks * DTC detected. * REFER to the WDS.
power and glow
plug indicator is
flashing
Engine lacks * Brakes binding. * CHECK the braking system.
power REFER to: Brake System (206-00 Brake System -
General Information, Diagnosis and Testing).
or excessive wind overloading the vehicle and wind resistance on the
resistance (roof fuel consumption.
racks, towing etc).
* Air cleaner element * INSTALL a new air cleaner element as necessary.
blocked.
Installation).
* Kinked or restricted * REFER to: Fuel System - 1.8L Duratorq-TDCi
* Turbocharger. * INSPECT the vacuum line(s) for visible signs of
* Turbocharger damage or blockage. CLEAN, REPAIR or INSTALL
vacuum diaphragm new parts as necessary.
unit. REFER to: Turbocharger - 75 PS/90 PS/110 PS,
Vehicles Built From: 08/2006, Vehicles With: Fixed
Vane Turbocharger (303-04C Fuel Charging and
Controls - Turbocharger, Diagnosis and Testing).
In-vehicle Repair).

and Testing).
* Charge air cooler * INSPECT for visible signs of damage or blockage.
blocked or cracked. CLEAN, REPAIR or INSTALL new parts as
* Charge air cooler necessary.
pipes split or
cracked.
* Charge air cooler
pipe retaining clips
missing or loose.
clean diesel.
Procedures).
Installation).
Installation) /
* Vehicle speed * REFER to the WDS.
sensor (VSS).
* APP sensor. * REFER to the WDS.
* Fuel temperature * REFER to the WDS.
sensor.

regulator.
* REFER to the WDS.
Black smoke at * DTC detected. * REFER to the WDS.
idle and glow plug
indicator is
flashing
Black smoke at * Air cleaner element * INSTALL a new air cleaner element as necessary.
idle blocked.
* Glow plug system. * REFER to the WDS.
In-vehicle Repair).
* REFER to the WDS.
Excessive black * DTC detected. * REFER to the WDS.
smoke during
acceleration and
glow plug
indicator is
flashing
Excessive black * Air cleaner element * INSTALL a new air cleaner element as necessary.
smoke during blocked.
acceleration * Incorrect or * CHECK for signs of contamination such as strange
clean diesel.
Procedures).

Installation).
Installation) /
and Testing).
* APP sensor. * REFER to the WDS.
* REFER to the WDS.
Black smoke at * DTC detected. * REFER to the WDS.
cruising speeds
and glow plug
indicator is
flashing
Black smoke at * Air cleaner element * INSTALL a new air cleaner element.
cruising speeds blocked.
and Testing).
* Turbocharger. * REFER to: Turbocharger - 75 PS/90 PS/110 PS,
Controls - Turbocharger, Diagnosis and Testing) /
Turbocharger - 75 PS/90 PS/110 PS, Vehicles Built

From: 08/2006, Vehicles With: Variable Vane
Turbocharger (303-04C Fuel Charging and Controls
- Turbocharger, Diagnosis and Testing).
* REFER to the WDS.
Blue smoke and * DTC detected. * REFER to the WDS.
glow plug
indicator is
flashing
Blue smoke * Engine burning oil. * CARRY OUT a controlled oil consumption test over
1000 km (600 miles). CONFIRM that the oil
consumption is less than 0.1 of a litre per 1000 km
(600 miles).
REFER to: Engine (303-01B Engine - 1.8L
clean diesel.
Procedures).
Installation).
Installation) /

* Worn or damaged * REMOVE the cylinder head. INSPECT the cylinder
valve guide(s), head, pistons and cylinder bores for signs of wear
piston ring(s), or damage.
cylinder bore(s), REFER to: Cylinder Head - 75 PS/90 PS/110 PS,
cylinder head or Vehicles Built From: 08/2006, Vehicles With:
gasket. Common Rail Fuel Injection (303-01B Engine -
* Positive crankcase * INSPECT for visible signs of damage or blockage.
ventilation (PCV) CLEAN, REPAIR or INSTALL new parts as
system. necessary.
* Turbocharger oil * REFER to: Turbocharger - 75 PS/90 PS/110 PS,
return tube blocked Vehicles Built From: 08/2006, Vehicles With: Fixed
or damaged. Vane Turbocharger (303-04C Fuel Charging and
White smoke and * DTC detected. * REFER to the WDS.
glow plug
indicator is
flashing
White smoke * Water in fuel. * CHECK for signs of water in the diesel.
clean diesel.
Procedures).
Installation).
Installation) /

and Testing).
In-vehicle Repair).
* Coolant in the * CARRY OUT a cooling system pressure test.
combustion REFER to: Engine Cooling (303-03 Engine Cooling,
chamber. Diagnosis and Testing).
REMOVE the cylinder head. INSPECT the cylinder
head, cylinder head gasket and cylinder bores for
wear or damage.
REFER to: Cylinder Head - 75 PS/90 PS/110 PS,
Vehicles Built From: 08/2006, Vehicles With:
Common Rail Fuel Injection (303-01B Engine -
Engine misfire * DTC detected. * REFER to the WDS.
and glow plug
indicator is
flashing
Engine misfire * Low fuel tank level. * CHECK the fuel tank level is greater than four
liters. If the fuel tank level is less than four liters,
FILL with fuel.
clean diesel.
Procedures).
Installation).
Installation) /

and Testing).
* Worn or damaged * REMOVE the cylinder head. INSPECT the cylinder
valve(s), tappet(s) head, valves, tappets and camshafts for signs of
or camshaft(s). wear or damage.
* Damaged cylinder * REMOVE the cylinder head. INSPECT the cylinder
head gasket. head gasket and cylinder bores for wear or
damage.
* Engine overheats. * REFER to: Engine Cooling (303-03 Engine Cooling,
* CMP sensor. * REFER to the WDS.
* REFER to the WDS.
Engine knock at * DTC detected. * REFER to the WDS.
idle and glow plug
indicator is
flashing
Engine knock at * Low engine oil * CHECK the engine oil level. REFILL as necessary.
idle level.

clean diesel.
Procedures).
Installation).
Installation) /
In-vehicle Repair).
* Excessive carbon * REMOVE the cylinder head. INSPECT the cylinder
build up. head and pistons for signs carbon build up.
* Worn or damaged * REFER to: Engine (303-01B Engine - 1.8L
oil pump. Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi
* Major mechanical (Lynx) Diesel, Diagnosis and Testing).
engine failure.
Engine knock * DTC detected. * REFER to the WDS.
during
acceleration and
glow plug
indicator is
flashing
Engine knock * Fuel injector(s). * REFER to the WDS.
during * Major mechanical * REFER to: Engine (303-01B Engine - 1.8L
acceleration engine failure. Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi

regulator.
Excessive fuel * DTC detected. * REFER to the WDS.
consumption and
glow plug
indicator is
flashing
Excessive fuel * Brakes binding. * CHECK the braking system.
consumption REFER to: Brake System (206-00 Brake System -
General Information, Diagnosis and Testing).
or excessive wind overloading the vehicle and wind resistance on the
resistance (roof fuel consumption.
racks, towing etc).
blocked.
Installation).
* Fuel system leak * CHECK the system for fuel leak(s). REPAIR or
(s). INSTALL new parts as necessary.
* Generator. * REFER to the WDS.
and Testing).
In-vehicle Repair).
* Turbocharger. * REFER to: Turbocharger - 75 PS/90 PS/110 PS,
* Slipping clutch. * REFER to: Clutch (308-01 Clutch, Diagnosis and
Testing).

* REFER to the WDS.
Engine cuts out * CMP sensor. * REFER to the WDS.
during hard * CKP sensor. * REFER to the WDS.
acceleration * FRP sensor. * REFER to the WDS.
regulator.

Injection Component Cleaning—Vehicles
Print
General Procedures
General Equipment
WARNINGS:
may ignite. Failure to follow these instructions may result in personal injury.
Do not carry out any repairs to the fuel injection system with the engine running. The
fuel pressure within the system can be as high as 1600 bar. Failure to follow this
Eye protection must be worn at all times when working on or near any fuel related
components. Failure to follow this instruction may result in personal injury.
CAUTIONS:
Make sure that the workshop area in which the vehicle is being worked on is as clean
and dust-free as possible. Areas in which work on clutches, brakes or where welding or
machining are carried out are not suitable in view of the risk of contamination to the fuel
system.
Make sure that clean non-plated tools are used. Clean tools using a new brush that
will not lose its bristles and fresh suitable evaporative cleaning agent, prior to starting
work on the vehicle.
Use a steel topped workbench and cover it with clean, lint-free non-flocking material.
Make sure that all parts removed from the vehicle are placed on the lint-free non-
flocking material.
Make sure that any protective clothing worn is clean and made from lint-free non-
flocking material.
Make sure that any protective gloves worn are new and are of the non-powdered
latex type.
Before using the suitable evaporative cleaning agent, protect all electrical
components and connectors with lint-free non-flocking material.
1. For additional information, refer to: Solvents,
Sealants and Adhesives (100-00 General
Information, Description and Operation) / Diesel
Fuel System Health and Safety Precautions (100-
00 General Information, Description and
Operation).
2.

CAUTION: Use lint free cloth.
3. Using Brake Cleaner: 3U7J-2C410-AA
4. Using a new brush that will not lose its bristles,

brush a suitable evaporative cleaning agent onto
the components being removed and onto the
surrounding area.
5. Using the pneumatic vacuum gun, remove all
traces of evaporative cleaning agent and foreign
material.
6. Dispose of any unused evaporative cleaning
agent and the brush after completing the repair.

Injectors—1.8L Duratorq-TDDi (Lynx)
Diesel
Print
present and can ignite. Failure to follow these instructions may result in personal injury.

(s).

1 - High-pressure fuel supply line to fuel injector unions
2 - High-pressure fuel supply line to fuel injection pump unions
3 - High-pressure fuel supply lines
See Removal Detail
4 - Fuel return lines
5 - Fuel injector clamp retaining bolts
See Removal Detail
6 - Fuel injector clamps
7 - Fuel injectors
See Removal Detail
8 - High-pressure fuel supply line to fuel injector unions
9 - High-pressure fuel supply line to fuel injection pump unions
10 - High-pressure fuel supply lines
See Removal Detail
11 - Fuel injector clamp retaining bolts

See Removal Detail
12 - Fuel injector clamps
13 - Fuel injectors
See Removal Detail
5. Using the special tool, prime the fuel injection

pump until clean fuel is seen entering the
vacuum pump reservoir.

7. Turn the ignition switch to position three (engine
cranking). Crank the engine until clean fuel
escapes from the high-pressure fuel supply line
unions.
8. Tighten the high-pressure fuel supply line unions.
Removal Details
Item 3 : High-pressure fuel supply lines
NOTE: Discard the high-pressure fuel supply lines.
Item 7 : Fuel injectors
1. NOTE: Rotate the injector to aid removal.

Discard the fuel injector copper heat shield
washer.

NOTE: Discard the high-pressure fuel supply lines.
Item 11 : Fuel injector clamp retaining bolts
NOTE: Discard the fuel injector clamp retaining bolts.
1. NOTE: Rotate the injector to aid removal.

Discard the fuel injector copper heat shield
washer.

NOTE: Install new fuel injector copper heat shield washer.
Item 11 : Fuel injector clamp retaining bolts
1. NOTE: Install new fuel injector clamp

retaining bolts.
Install the fuel injector bolts.
Stage 1: 5 Nm
Stage 2: 90 degrees

NOTE: Install new high-pressure fuel supply lines.
Item 8 : High-pressure fuel supply line to fuel injector unions
1. Do not tighten the high-pressure fuel supply line

unions at this stage.
NOTE: Install new fuel injector copper heat shield washer.
NOTE: Install new high-pressure fuel supply lines.
Item 1 : High-pressure fuel supply line to fuel injector unions
1. Do not tighten the high-pressure fuel supply line

unions at this stage.

Injectors—1.8L Duratorq-TDCi (Lynx)
Diesel
Print
Special Tool(s)
303-397 (24-003)
General Equipment
WARNINGS:
in personal injury.
Do not carry out any repairs to the fuel injection system without checking that the
fuel pressure has dropped to zero and that the fuel temperature has reached ambient
temperature or is below 30°C, whichever is greater. Failure to follow these instructions
Wait at least one minute after the engine stops before commencing any repair to the
fuel injection system. Failure to follow this instruction may result in personal injury.
CAUTIONS:
with these components. Always install blanking plugs to any open orifices or lines.
ultrasonic cleaner. Always install a new fuel injection supply manifold when required.
Always carry out the cleaning process before carrying out any repairs to the fuel
injection system components. Failure to follow this instruction may result in foreign
1. Using datalogger in WDS, check that the fuel
pressure has dropped to zero and that the fuel
temperature has either reached ambient
temperature or is below 30°C, whichever is
greater.

4. CAUTION: The generator must be

protected from contamination. Failure to
follow this instruction may cause premature
failure of the generator.
Protect the generator with lint-free material to
5. CAUTION: Protect the fuel injector

electrical connectors with lint-free material to
prevent contamination from the cleaning
fluid.
Clean the fuel injectors, high-pressure fuel
supply lines and surrounding areas. For
additional information, refer to Fuel Injection
Component Cleaning in this Section.
(s).

1 - Camshaft position (CMP) sensor electrical connector
2 - Positive crankcase ventilation (PCV) hose retaining clamp
3 - PCV hose
4 - PCV hose retaining clamp
5 - PCV hose

See Removal Detail
8 - High-pressure fuel supply line clamp
See Removal Detail
9 - High-pressure fuel supply line to number four fuel injector union
See Removal Detail
10 - High-pressure fuel supply line to fuel injection supply manifold union
See Removal Detail
11 - Number four fuel injector, high-pressure fuel supply line
See Removal Detail
12 - Number four fuel injector & fuel injection supply manifold blanking
caps
13 - Number four fuel injector clamp retaining bolt
14 - Number four fuel injector retaining clamp
15 - Number four fuel injector

See Removal Detail
16 - Number four fuel injector sealing washer
See Removal Detail
8. Using WDS, configure the fuel injector(s) to the

PCM.
Removal Details
Item 6 : Fuel return line
1. Install a blanking cap to the fuel injector fuel

return line spigot.
Item 8 : High-pressure fuel supply line clamp
1. Make a note of the orientation of the clamp to

make sure it is positioned in exactly the same
position when installed.
Item 9 : High-pressure fuel supply line to number four fuel injector union
CAUTIONS:
Use an open-ended wrench to prevent the component from turning.
Make sure that the high-pressure fuel supply line remains in contact with the fuel
injector until both unions have been detached and cleaned. Failure to follow this
instruction may result in foreign matter ingress to the fuel injection system.
Make sure that the tool used to loosen the high-pressure fuel supply line union is
used at the top of the union as this is where there is most material. Failure to follow this
instruction may result in damage to the union.
Item 10 : High-pressure fuel supply line to fuel injection supply manifold union
CAUTIONS:
Make sure that the high-pressure fuel supply line remains in contact with the fuel
injector until both unions have been detached and cleaned. Failure to follow this

Make sure that the tool used to loosen the high-pressure fuel supply line union is
used at the top of the union as this is where there is most material. Failure to follow this
instruction may result in damage to the union.
Item 11 : Number four fuel injector, high-pressure fuel supply line
NOTE: Using the engine vacuum cleaner, vacuum foreign material from the high-pressure
fuel supply line, the fuel injector and the fuel injection supply manifold.
1. Install a blanking caps to the open threaded
ports of the fuel injector and the fuel injection
supply manifold.
Item 15 : Number four fuel injector
NOTE: Clean the area around the fuel injector. For additional information, refer to Fuel
Injection Component Cleaning in this Section.
Item 16 : Number four fuel injector sealing washer
NOTE: Discard the fuel injector sealing washer.
Item 16 : Number four fuel injector sealing washer
NOTE: Install a new fuel injector sealing washer.
1. Install the fuel injector sealing washer.
Item 15 : Number four fuel injector

NOTE: Remove and discard the fuel injector nozzle blanking plug.
1. Record the identification code from the new fuel
injector to upload into WDS during configuration
(the graphic shows an example of the
identification code only).
Item 13 : Number four fuel injector clamp retaining bolt

1. Install the fuel injector bolts.
Stage 1: 5 Nm
Stage 2: 90 degrees
Item 12 : Number four fuel injector & fuel injection supply manifold blanking caps
CAUTION: Remove the blanking plugs from the fuel injector and the fuel injection
supply manifold at the last possible moment. Failure to follow this instruction may result
in foreign matter ingress to the fuel injection system.
1. Remove and discard the blanking plugs.
Item 11 : Number four fuel injector, high-pressure fuel supply line
CAUTIONS:
Remove the blanking plugs from the high-pressure fuel supply line at the last
possible moment. Failure to follow this instruction may result in foreign matter ingress to
Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure
to follow this instruction may result in damage to the ends of the line and allow foreign
material to enter the fuel injection system.
NOTE: Lubricate the high-pressure fuel supply line union threads with clean lubricant.
NOTE: To aid installation of the high-pressure fuel supply line, the union at the fuel
injector end is etched with the cylinder number.
NOTE: Install a new high-pressure fuel supply line.
1. Remove and discard the blanking plugs.
Item 9 : High-pressure fuel supply line to number four fuel injector union
CAUTION: Use an open-ended wrench to prevent the component from turning.

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel - Fuel Injectors—1.8L
Duratorq-TDCi (Lynx) Diesel (75 PS/90 PS/110 PS), Vehicles
Built From: 08/2006
Print
General Equipment
Long nose pliers
Removal
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description
and Operation).
3.
4. Clean the fuel injectors, high-pressure fuel supply lines and surrounding areas.
Refer to: Fuel Injection Component Cleaning - Vehicles With: Common Rail Fuel Injection (303-04B
Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel,
5. CAUTIONS:

both ends until both unions nuts have been
unscrewed and the area around the joints thoroughly
cleaned.

blanking caps.
Make sure that the fuel line union does not

rotate.
Make sure that all openings are sealed. Use new

blanking caps.
Discard the the high-pressure fuel supply lines.
Discard the fuel injector clamps and bolts.
Discard the fuel injector sealing washers.
Installation

Discard the blanking caps.
Torque: 37 Nm
2. General Equipment: Long nose pliers

3. Loosen the bolts.

NOTE: Only tighten the union nuts finger tight at this stage.
5. Torque: 24 Nm
6. CAUTION: Make sure that the fuel line union does not rotate.
Tighten in the sequence shown.
Torque: 25 Nm
7. Tighten in the sequence shown.
Torque: 38 Nm
9. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

10. Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter
union, making sure that the arrow on the hand pressure pump indicating the direction of flow is
pointing towards the fuel filter.
11. Operate the hand pressure pump at least 30 times.
12. CAUTION: The starter motor operation must not exceed 10 seconds at a time. After 10
seconds turn the ignition switch to position 0 and allow the starter motor to cool for 30 seconds
before operating the starter motor again.
Start the engine and allow it to idle until it reaches normal operating temperature.
13. Stop the engine.
15. Connect the fuel tank to fuel filter fuel supply line to the fuel filter.
Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

Injection One-Way Valve
Print
Special Tool(s)
310-110
General Equipment
Small screwdriver
Removal

working with these components. Always install blanking plugs to any open orifices or
lines.
2. Using the pneumatic vacuum gun, clean the area
around the high-pressure fuel supply lines.
3. Disconnect the high-pressure fuel supply lines
from the fuel injection pump.

around the high-pressure fuel supply lines.
5. Remove the high-pressure fuel supply lines.
Discard the supply lines.

6. NOTE: Fuel injection pump shown removed
for clarity.
Remove the fuel injection one-way valves.
Discard the fuel injection one-way valves.

for clarity.
Using a clean small screwdriver, carefully remove
the sealing washers.
Installation

lines.
1. Lubricate the fuel injection one-way valves with
Renap 220 oil (supplied in the parts kit).
2. Position the sealing washers onto the end of the

fuel injection one-way valves.

for clarity.
Install the fuel injection one-way valves.

lines.
supply lines at this stage.
Connect the high-pressure fuel supply lines to
the fuel injection pump.
6. NOTE: Do not tighten the high-pressure fuel

supply lines at this stage.
Connect the high-pressure fuel supply lines to
the fuel injectors.

lines.
Tighten the high-pressure fuel supply lines to the
fuel injection pump.
8. Disconnect the fuel tank to fuel filter fuel supply

line from the fuel filter.

9. CAUTION: Make sure that the fuel filter
connection is not damaged with the
installation of the special tool, as this may
cause air ingress to fuel lines.
Install the hand pressure pump special tool
adapter to the fuel filter.
10. NOTE: Make sure that the hand primer arrow

indicating the direction of fuel flow is pointing
towards the fuel filter.
Install the hand pressure pump special tool to
the hand pressure pump special tool adapter on
the fuel filter.
11. Install the hand pressure pump special tool

adapter to the fuel tank to fuel filter fuel supply
line.
12. NOTE: Make sure that the hand primer arrow

indicating the direction of fuel flow is
the hand pressure pump special tool adapter on
the fuel tank to fuel filter fuel supply line.
13. Operate the fuel hand pressure pump special tool

until fuel starts to flow through the fuel filter and
fuel pump and the hand pressure pump special
tool becomes firm.
14. NOTE: Only one high-pressure fuel supply

line will show signs of fuel escaping.
Operate the hand pressure pump special tool and
tighten the high-pressure fuel supply line union
which shows signs of fuel escaping.

Using the paint mark as a reference, slowly turn
the engine through 180 degrees.
16. Repeat steps 14 and 15 to bleed the three
remaining high-pressure fuel supply lines.
17. Remove the lint-free material from the
generator.
18. CAUTION: Do not operate the starter

motor for more than 10 seconds at a time.
After 10 seconds, turn the ignition switch to
position 0 and allow the starter motor to cool
for 30 seconds before attempting to start the
engine again.
Start the engine and allow it to idle until it
reaches normal operating temperature.
19. Switch the engine off.
20. Remove the hand pressure pump special tool
from the hand pressure pump special tool
adapter on the fuel tank to fuel filter fuel supply
line.

adapter from the fuel tank to fuel filter fuel
supply line.

adapter on the fuel filter.

adapter from the fuel filter.
24. Connect the fuel tank to fuel filter fuel supply

line to the fuel filter.


Injection Pump—1.8L Duratorq-TDDi
(Lynx) Diesel
Print
Special Tool(s)
Hand Vacuum/Pressure Pump
(416-D001) 23-036A
General Equipment
Materials
Name Specification
Silicon Sealer WSE-M4G323-A4
Gasket Sealer WSK-M2G348-A5
All vehicles

lines.
information, refer to Section 303-01A Engine /
303-01B Engine.

2. Detach the air conditioning (A/C) compressor and
secure it to one side.
3. Remove the A/C compressor retaining bracket.

(s).

1 - Generator electrical connector retaining nut
2 - Battery positive cable
3 - Generator electrical connector
4 - Special tool (303 193) 21-104
See Removal Detail
5 - Generator retaining bolts
6 - Generator
7 - Generator bracket retaining nut
8 - Generator bracket retaining bolts
9 - Generator retaining bracket

10 - Fuel injection pump support bracket retaining bolts
11 - High-pressure fuel injection pipe to fuel injector unions
See Removal Detail
12 - High-pressure fuel injection pipe to fuel injection pump unions
13 - High-pressure fuel injection pipes
See Removal Detail
14 - High-pressure fuel injection pipe to fuel injector unions
15 - High-pressure fuel injection pipe to fuel injection pump unions
16 - High-pressure fuel injection pipes
See Removal Detail
17 - Fuel injection pump supply line
See Removal Detail
18 - Fuel injection pump return line
See Removal Detail
19 - Fuel injection pump electrical connector
20 - Fuel injection pump support bracket retaining bolts
21 - Fuel injection pump support bracket

22 - Fuel injection pump pulley retaining bolts
See Removal Detail
23 - Fuel injection pump pulley
See Removal Detail
24 - Fuel injection pump seal retaining nuts
25 - Fuel injection pump seal
See Removal Detail
26 - Fuel injection pump sprocket retaining bolts
27 - Fuel injection pump retaining bolts
See Removal Detail
28 - Fuel injection pump
29 - Fuel injection pump gasket
See Removal Detail
6. Configure the fuel injection pump to the

powertrain control module (PCM). For additional
information, refer to WDS.
7. Using the special tool, prime the fuel injection
pump until clean fuel is seen entering the
vacuum pump reservoir.

9. Turn the ignition switch to position three (engine
cranking). Crank the engine until clean fuel
escapes from the high-pressure fuel injection
pipe unions.
10. Tighten the high-pressure fuel injection pipe
unions.
Removal Details
Item 4 : Special tool (303 193) 21-104

Item 13 : High-pressure fuel injection pipes
NOTE: Discard the high-pressure fuel injection pipes.
NOTE: Discard the high-pressure fuel injection pipes.
Item 17 : Fuel injection pump supply line

00A Fuel System - General Information / 310-
00B Fuel System - General Information.
Item 18 : Fuel injection pump return line

Item 22 : Fuel injection pump pulley retaining bolts
1. The fuel injection pump retaining bolts are sealed

to the fuel injection pump sprocket and will
require thorough cleaning before installation.
Item 23 : Fuel injection pump pulley
1. The fuel injection pump pulley is sealed to the

fuel injection pump sprocket and will require
thorough cleaning before installation.
Item 25 : Fuel injection pump seal
NOTE: Discard the fuel injection pump seal.

Item 27 : Fuel injection pump retaining bolts
1. Access the bolts through the holes provided. The

fuel injection pump bolts cannot be removed
completely.
Item 29 : Fuel injection pump gasket

NOTE: Discard the fuel injection pump gasket.
Item 29 : Fuel injection pump gasket
NOTE: Install a new fuel injection pump gasket.
Item 25 : Fuel injection pump seal
NOTE: Install a new fuel injection pump seal.
Item 24 : Fuel injection pump seal retaining nuts
1. Tighten the nuts in the sequence shown.
Item 23 : Fuel injection pump pulley
1. Using sealer seal the fuel injection pump pulley

to the fuel injection pump sprocket.
Item 22 : Fuel injection pump pulley retaining bolts
1. Using sealer apply a thin bead of sealer to the

outer edge of the fuel injection pump pulley
retaining bolt holes.

Item 18 : Fuel injection pump return line
NOTE: Do not install the fuel return line at this stage.
NOTE: Install new high-pressure fuel injection pipes.
Item 14 : High-pressure fuel injection pipe to fuel injector unions
NOTE: Do not tighten the high-pressure fuel injection pipe unions at this stage.
NOTE: Install new high-pressure fuel injection pipes.
Item 11 : High-pressure fuel injection pipe to fuel injector unions
NOTE: Do not tighten the high-pressure fuel injection pipe unions at this stage.
Item 4 : Special tool (303 193) 21-104

Injection Pump—1.8L Duratorq-TDCi FGT
(66kW/90PS) - Lynx/1.8L Duratorq-TDCi Transit/Tourneo Connect 2002.5 (06/2002-)
FGT (66kW/90PS) - Lynx/1.8L Duratorq-
Duratorq-TDCi VNT (55kW/75PS) -
Lynx/1.8L Duratorq-TDCi (81kW/110PS)
- Lynx, Vehicles Built Up To: 03/2008
Print
Special Tool(s)
(416-D001) 23-036A
General Equipment
Materials
Name Specification
Silicone Gasket and WSE-M4G323-A4
sealant
WSE-M4G323-A4
Gasket Maker WSK-M2G348-A5
WSK-M2G348-A5
High-pressure fuel TBD
supply line union
WARNINGS:
lubricant
TBD
Do not smoke or carry lighted tobacco or open flame of any
type when working on or near any fuel related components. Highly flammable mixtures
are always present and may ignite. Failure to follow these instructions may result in
personal injury.
This procedure involves fuel handling, Be prepared for fuel spillage at all times and
in personal injury.
CAUTIONS:

Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner.
Always install a new fuel pump when required.
greater.
303-01B Engine.

4. CAUTION: Protect the fuel metering

valve and fuel temperature sensor electrical
connectors to prevent contamination with the
cleaning fluid.
Clean the fuel pump, fuel injection supply
manifold, high-pressure fuel supply line and
surrounding areas.
Component Cleaning in this section.
(s).

1 - High-pressure fuel supply line support bracket retaining nut
2 - High-pressure fuel supply line support bracket retaining bolt
3 - High-pressure fuel supply line support bracket
See Removal Detail
4 - High-pressure fuel supply line to fuel pump union
See Removal Detail
5 - High-pressure fuel supply line to fuel injection supply manifold union
See Removal Detail
6 - High-pressure fuel supply line assembly
See Removal Detail
7 - Fuel pump high-pressure fuel outlet blanking cap
8 - Fuel injection supply manifold high-pressure fuel inlet blanking cap
See Removal Detail
-

10 Fuel metering valve electrical connector
11 - Fuel temperature sensor electrical connector
12 - Fuel pump support bracket retaining bolts
13 - Fuel pump to fuel filter fuel return line connector
See Removal Detail
14 - Fuel pump to fuel filter fuel return line pump union blanking cap
15 - Fuel pump to fuel filter fuel supply line connector
See Removal Detail
16 - Fuel pump to fuel filter fuel supply line pump union blanking cap
17 - Fuel pump venturi to fuel injector fuel return line connector
See Removal Detail

18 - Fuel pump pulley retaining bolts
See Removal Detail
19 - Fuel pump pulley
See Removal Detail
20 - Fuel pump sprocket seal retaining nuts
21 - Fuel pump sprocket seal
See Removal Detail
-

-
22 Fuel pump sprocket retaining bolts

23 - Fuel pump retaining bolts
See Removal Detail
24 - Fuel pump
25 - Fuel pump gasket
See Removal Detail
26 - Fuel pump shield retaining bolts
27 - Fuel pump shield
7. CAUTION: Make sure that a new clean

piece of plastic pipe is used with the special
tool.
Remove the blanking plug from the fuel pump
fuel return line connector, and using the special
tool, prime the fuel pump until clean fuel is seen
entering the vacuum pump reservoir.
Discard the blanking plug.

9. Connect the fuel pump to fuel filter fuel return
line.
Removal Details
Item 3 : High-pressure fuel supply line support bracket
1. Clean the fuel pump, fuel injection supply

surrounding areas.
Component Cleaning in this section.
Item 4 : High-pressure fuel supply line to fuel pump union
CAUTION: Make sure that the high-pressure fuel supply line remains in contact with
the fuel pump and the fuel injection supply manifold until all unions have been detached
and cleaned. Failure to follow this instruction may result in foreign matter ingress to the
the fuel pump and the fuel injection supply manifold until all unions have been detached
and cleaned. Failure to follow this instruction may result in foreign matter ingress to the

supply line, the fuel pump and the fuel injection
supply manifold.
Item 6 : High-pressure fuel supply line assembly

foreign material from the fuel pump and the fuel
injection supply manifold open threaded ports.
1. Make a note of the orientation of the clamp to

make sure it is positioned in exactly the same
position when installed.
Item 13 : Fuel pump to fuel filter fuel return line connector

Item 15 : Fuel pump to fuel filter fuel supply line connector

Item 17 : Fuel pump venturi to fuel injector fuel return line connector
1. Install blanking plugs to the fuel pump fuel

return line and the fuel return line venturi.
Item 18 : Fuel pump pulley retaining bolts
1. The fuel pump pulley is sealed to the fuel pump

sprocket and the fuel pump pulley retaining bolts
will require thorough cleaning before installation.
Item 19 : Fuel pump pulley
1. The fuel pump pulley is sealed to the fuel pump

sprocket and will require thorough cleaning
Item 21 : Fuel pump sprocket seal
1. Discard the fuel pump sprocket seal.

Item 23 : Fuel pump retaining bolts
1. Access the bolts through the holes provided. The

fuel pump bolts cannot be removed completely.

Item 25 : Fuel pump gasket
1. Discard the fuel pump gasket.
Item 25 : Fuel pump gasket
1. Install a new fuel pump gasket.

Item 24 : Fuel pump
1. Align the hole in the fuel pump drive with the

etched line on the fuel pump body.
Item 23 : Fuel pump retaining bolts
1. Tighten the bolts evenly, in order to pull the fuel

pump squarely into position.
Item 21 : Fuel pump sprocket seal
1. Install a new fuel pump sprocket seal.

Item 20 : Fuel pump sprocket seal retaining nuts
1. Tighten the nuts in the sequence shown.
Item 19 : Fuel pump pulley
1. Using loctite RTV 5910 seal the fuel pump pulley

to the fuel pump sprocket.

Item 18 : Fuel pump pulley retaining bolts
1. Using loctite 518 apply a thin bead of sealer to

the outer edge of the fuel pump pulley retaining
bolt holes.
Item 17 : Fuel pump venturi to fuel injector fuel return line connector
1. Discard the blanking plugs.

Item 16 : Fuel pump to fuel filter fuel supply line pump union blanking cap

Item 14 : Fuel pump to fuel filter fuel return line pump union blanking cap
1. Do not remove the fuel pump to fuel filter fuel

return line pump union blanking cap at this
stage.
Item 13 : Fuel pump to fuel filter fuel return line connector
1. Do not install the fuel pump to fuel filter fuel

return line connector at this stage.
1. Make sure the clamp is installed on the new

High-pressure fuel supply line in the same
position as removed.
Item 8 : Fuel injection supply manifold high-pressure fuel inlet blanking cap
1. Do not remove the fuel injection supply manifold

high-pressure fuel inlet blanking cap at this
stage.
Item 7 : Fuel pump high-pressure fuel outlet blanking cap
1. Do not remove the fuel pump high-pressure fuel

outlet blanking cap at this stage.
Item 6 : High-pressure fuel supply line assembly
1. Lubricate the high pressure fuel supply line union

threads with clean lubricant.

CAUTIONS:
matter to enter the fuel injection system.
Remove the blanking plugs from the high-pressure fuel supply line, the fuel pump
and the fuel injection supply manifold at the last possible moment. Failure to follow this
NOTE: Do not tighten the high-pressure fuel supply line unions until both unions are
installed.
NOTE: Maintain pressure on the high-pressure fuel supply line to keep the line in contact
with the fuel pump and fuel injection supply manifold cones while installing the unions.
Item 4 : High-pressure fuel supply line to fuel pump union
CAUTION: Make sure the tool used to tighten the high-pressure fuel supply line
unions is used at the top of the union as this is where there is most material. Failure to
follow this instruction may result in damage to the union.
NOTE: When both high-pressure fuel supply line unions have been installed, the fuel
supply line union to fuel pump should be tightened first.
1. Tighten the high-pressure fuel supply line to fuel
pump union and the high-pressure fuel supply
line to fuel injection supply manifold union.

Injection Supply Manifold—1.8L Duratorq-
TDCi (Lynx) Diesel
Print
Special Tool(s)
303-397 (24-003)
General Equipment
Engine vacumm cleaner
WARNINGS:
in personal injury.
CAUTIONS:
ultrasonic cleaner. Always install a new fuel injection supply manifold when required.
greater.

4. Using the special tool, detach the positive
crankcase ventilation (PCV) hoses from the valve
cover.

6. CAUTION: Protect the fuel injector

electrical connectors with lint-free material to
prevent contamination from the cleaning
fluid.
Clean the fuel injectors, fuel injection supply
manifold, high-pressure fuel supply lines and
surrounding areas. For additional information,
refer to Fuel Injection Component Cleaning in
this Section.
(s).

1 - Camshaft position (CMP) sensor electrical connector
2 - Fuel pressure sensor electrical connector
3 - Fuel injection wiring harness retaining clip

-

-
5 High-pressure fuel supply line support bracket retaining nut

6 - High-pressure fuel supply line support bracket retaining bolt
7 - High-pressure fuel supply line support bracket
See Removal Detail
8 - High-pressure fuel supply line and clamp
See Removal Detail
See Removal Detail

10 - Fuel injector high-pressure fuel supply lines clamp
See Removal Detail
11 - Fuel injector high-pressure fuel supply line
See Removal Detail
See Removal Detail
13 - Fuel injector high-pressure fuel supply lines clamp
See Removal Detail

See Removal Detail
See Removal Detail
16 - Fuel injection supply manifold
9. Tighten the fuel system components in the

following order:
supply line to fuel injector unions.
supply line to fuel injection supply manifold
unions.
3. Tighten the high-pressure fuel supply line
to fuel pump union.
4. Tighten the high-pressure fuel supply line
to fuel injection supply manifold union.
5. Tighten the fuel injection supply manifold
retaining bolts.
Removal Details
Item 7 : High-pressure fuel supply line support bracket
1. Clean the fuel pump, fuel injection supply

surrounding areas.
Component Cleaning - Vehicles With: Common
Rail Fuel Injection in this section.
Item 8 : High-pressure fuel supply line and clamp
the fuel pump and fuel injection supply manifold until all unions have been detached and
cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel
injection system.
1. Detach the unions. Using the engine vacuum
cleaner, vacuum foreign material from the high-
pressure fuel supply line, the fuel pump and the
fuel injection supply manifold prior to removing
the high-pressure fuel supply line.
2. Remove the high-pressure fuel supply line and
clamp. Using the engine vacuum cleaner,
vacuum foreign material from the fuel pump and
the fuel injection supply manifold open threaded
ports.
3. Install new blanking caps to the open threaded
ports on the fuel pump and the fuel injection
supply manifold.
NOTE: Make a note of the position of the high-pressure fuel supply line clamp.
Item 10 : Fuel injector high-pressure fuel supply lines clamp

NOTE: Make a note of the position of the fuel injection high-pressure fuel supply line
clamps.
Item 11 : Fuel injector high-pressure fuel supply line
CAUTION: Make sure that the fuel injector high-pressure fuel supply line remains in
contact with the fuel injector and fuel injection supply manifold until all unions have been
detached and cleaned. Failure to follow this instruction may result in foreign matter
1. Detach the unions. Using the engine vacuum
cleaner, vacuum foreign material from the high-
pressure fuel supply line, the fuel injector and
the fuel injection supply manifold prior to
removing the fuel injector high-pressure fuel
supply line.
2. Remove the high-pressure fuel supply line and
clamp. Using the engine vacuum cleaner,
vacuum foreign material from the fuel injector
and the fuel injection supply manifold open
threaded ports.
3. Install new blanking caps to the open threaded
ports on the fuel injector and the fuel injection
supply manifold.
Item 16 : Fuel injection supply manifold
NOTE: Do not tighten the fuel injection supply manifold retaining bolts at this stage.
CAUTIONS:
Do not allow the unions to hit the ends of the fuel injector high-pressure fuel supply
line. Failure to follow this instruction may result in damage to the ends of the line and
allow foreign material to enter the fuel injection system.
Remove the blanking plugs from the fuel injector high-pressure fuel supply line at the
last possible moment. Failure to follow this instruction may result in foreign matter
NOTE: To aid identification of the fuel injector high-pressure fuel supply lines, the unions
at the fuel injector end are etched with the cylinder number.
NOTE: Maintain pressure on the fuel injector high-pressure fuel supply line to keep the
line in contact with the fuel injector cone, while installing the union.
NOTE: Do not tighten the fuel injector high-pressure fuel supply line unions at this stage.
1. Lubricate the fuel injector high-pressure fuel
supply line union threads with clean lubricant.

2. Remove and discard the blanking caps from the
fuel injector and the fuel injection supply
manifold.
NOTE: Do not tighten the fuel injector high-pressure fuel supply lines clamp at this stage.
NOTE: Make sure the fuel injector high-pressure fuel supply lines clamp is installed in the
same position as removed.

NOTE: Make sure the high-pressure fuel supply line clamp is installed in the same position
as removed.
Item 8 : High-pressure fuel supply line and clamp

CAUTIONS:
material to enter the fuel injection system.
Remove the blanking plugs from the high-pressure fuel supply line at the last
possible moment. Failure to follow this instruction may result in foreign matter ingress to
NOTE: Maintain pressure on the high-pressure fuel supply line to keep the line in contact
with the fuel pump and fuel injection supply manifold cone, while installing the union.

NOTE: Do not tighten the high-pressure fuel supply line unions at this stage.
1. Lubricate the high-pressure fuel supply line
union threads with clean lubricant.
2. Remove and discard the blanking caps from the

fuel pump and the fuel injection supply manifold.

Injection Timing Solenoid—1.8L Duratorq-
TDDi (Lynx) Diesel
Print
General Equipment
Heat gun
Blunt plastic tool
Cable-ties
Removal
WARNINGS:
in personal injury.

working with these components.
2. Remove the fuel injection pump back plate and
support bracket retaining bolts.

TDDi (Lynx) Diesel, Vehicles Built Up To:
05/2003 (414-02 Generator and Regulator,
Generator - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel,
Vehicles Built From: 05/2003 (414-02 Generator
and Regulator, Removal and Installation) /
Generator - 1.8L Duratorq-TDCi (Lynx) Diesel,
and Regulator, Removal and Installation).
4. Remove the air conditioning A/C compressor

support bracket (if equipped).
5. Remove the generator support bracket.
6. Detach the coolant transfer pipe.

Remove the coolant transfer pipe retaining
bolts.
7. Remove the fuel injection pump support bracket

retaining bolts.
8. Remove the fuel injection pump back plate and

support bracket assembly.
Remove the fuel injection pump back plate
retaining bolts.
9. Detach the fuel injection timing solenoid.

Remove and discard the fuel injection
timing solenoid retaining bolts.

10. CAUTION: O-ring seals must only be
removed from the fuel injection pump, using
a blunt plastic tool. Failure to follow this
instruction may result in damage to the fuel
injection pump.
Inspect the fuel injection timing solenoid to make
sure both O-ring seals are still fitted. If the fuel
injection timing solenoid O-ring seal(s) is missing
from the fuel injection timing solenoid, the
missing fuel injection timing solenoid O-ring seal
(s) must be removed from the fuel injection
pump using a suitable blunt plastic tool.
11. Remove the fuel injection timing solenoid.
Cut the fuel injection timing solenoid wiring
harness as close to the fuel injection
timing solenoid as possible.
Installation
WARNINGS:
in personal injury.

working with these components.
1. CAUTION: Do not remove the fuel

injection timing solenoid protective cover
supplied with the new fuel injection timing
solenoid at this stage. Failure to follow this
instruction may result in failure of the fuel
injection solenoid or fuel injection pump.
Remove the fuel injection timing solenoid

Cut the new fuel injection timing solenoid
wiring harness as close to the fuel injection
timing solenoid electrical connector as
possible.
Discard the fuel injection timing solenoid
2. Secure the new fuel injection timing solenoid to
the fuel injector high-pressure fuel supply line
using a cable-tie.
Route the fuel injection timing solenoid
wiring harness between the high-pressure
fuel lines and the cylinder block.
3. Install the new fuel injection timing solenoid

wiring harness protective cover supplied in the
service kit over the fuel injection pump fuel
injection timing solenoid wiring harness.
4. NOTE: The fuel injection timing solenoid
wiring harness can be connected either way
round and it will not affect the function of the
new fuel injection timing solenoid.
Connect the new fuel injection timing solenoid
wiring harness.
1. Route the wiring harness of the new fuel
injection timing solenoid between the fuel
injection pump and engine block.
2. Connect the fuel injection timing solenoid
wiring harness.
1. Trim the new fuel injection timing
solenoid wiring harness and the fuel
injection pump fuel injection timing
solenoid wiring harness to produce
staggered joints.
2. Using the pink crimp electrical
connectors, supplied in the service kit,
join the new fuel injection timing
solenoid wiring harness to the fuel
injection pump fuel injection timing
solenoid wiring harness.
3. Using a heat gun, heat shrink the two
electrical connectors to the fuel
injection timing solenoid wiring harness.
3. Position the fuel injection timing solenoid

wiring harness protective cover over the
wiring harness crimped connectors.
Operation).
6. Using the pneumatic vacuum gun, clean the fuel
injection pump fuel injection timing solenoid
bore.
7. Install the fuel injection timing solenoid.
1. Remove and discard the fuel injection
timing solenoid retaining cable-tie.
2. Remove the fuel injection timing solenoid

protective cover.
3. Install new fuel injection timing solenoid
retaining bolts.
8. Install the fuel injection pump back plate and

support bracket assembly.
Install the fuel injection pump back plate
retaining bolts hand tight.
9. Install the fuel injection pump support bracket

retaining bolts.
10. Tighten the fuel injection pump back plate

retaining bolts.
11. Install the coolant transfer pipe retaining bolts.
12. Install the generator support bracket.

13. Install the A/C compressor support bracket (if
equipped).

TDDi (Lynx) Diesel, Vehicles Built Up To:
05/2003 (414-02 Generator and Regulator,
and Regulator, Removal and Installation) /
Generator - 1.8L Duratorq-TDCi (Lynx) Diesel,
and Regulator, Removal and Installation).
15. Install the fuel injection pump back plate and
support bracket retaining bolts.
CAUTION: Secure the excess fuel injection timing solenoid wiring harness using a
cable-tie. Failure to follow this instruction may result in the failure of the fuel injection
timing solenoid wiring harness.
16. Using a cable-tie, secure the fuel injection timing
solenoid wiring harness.
Make a loop with the excess fuel injection
timing solenoid wiring harness and using a
cable-tie secure the loop.


Metering Valve—1.8L Duratorq-TDCi
(Lynx) Diesel (75 PS/90 PS)
Print
General Equipment
Removal
WARNINGS:
in personal injury.
fuel pressure has dropped to zero and that the fuel temperature has either reached
ambient temperature or is below 30º C. whichever is the greater. Failure to follow these
CAUTIONS:
Make sure the workshop area in which the vehicle is being worked on is as clean and
as dust free as possible. Foreign matter from work on clutches, brakes or from machining
or welding operations can contaminate the fuel system and may result in later
malfunction.
greater.



cleaning fluid.
Clean the fuel pump and surrounding areas.
temperature sensor electrical connectors (high-
pressure fuel supply line shown removed for
clarity).
7. Using the Pneumatic vacuum gun, vacuum

foreign material from the area around the fuel
metering valve.
8. Remove the fuel metering valve (fuel pump
Install a new blanking plug to the open
port of the fuel pump.
Installation
WARNINGS:

in personal injury.
CAUTIONS:
dust free as possible. Foreign matter from work on clutches, brakes or from machining or
welding operations can contaminate the fuel system and may result in later malfunction.
NOTE: Install a new fuel metering valve and O-ring seal.
1. Remove and discard the blanking plug from the
fuel pump.
foreign material from the fuel pump open port.
3. CAUTION: The fuel metering valve must

be installed correctly into the fuel pump so
that the mating faces are in contact with
each other. Failure to follow this instruction
may result in damage to the fuel metering
valve.
NOTE: Using a suitable multipurpose
lubricant spray, lubricate the O-ring seal.
Install the fuel metering valve and O-ring seal
(fuel pump shown removed for clarity).
Install the fuel metering valve retaining
bolts finger tight.
4. CAUTION: The fuel metering valve

retaining bolts must be tightened in the
following stages. Failure to follow this
instruction may result in damage to the fuel
metering valve.
Tighten the fuel metering valve retaining bolts in
two stages.
Stage 1: 2.5 Nm.
Stage 2: 5.5 Nm
clarity).

6. Remove the lint-free material protecting the
generator.

Metering Valve—75 PS/90 PS/110 PS,
Print
Special Tool(s)
Wrench, Fuel Pump Solenoid
303-1286
General Equipment
Bench vice fitted with soft jaws
Small screwdriver
Heat gun
Removal

lines.
1. Remove the fuel injection pump.
For additional information, refer to: Fuel Pump -
75 PS/90 PS/110 PS, Vehicles Built From:
2. CAUTIONS:
Soft jaws must be used to prevent

damage to the fuel injection pump.
The fuel injection pump must not be

retained by any machined faces or the fuel
injection pump control unit.
Using the cast mounting flange only, mount the
fuel injection pump into a suitable bench vice
fitted with soft jaws.
3. Remove the mounting plate.

around the fuel injection one-way valves.
5. Remove the fuel injection one-way valves.
Discard the fuel injection one-way valves.
6. Using a clean small screwdriver, carefully remove

the sealing washers.
7. Pull back the protection sleeve to expose the fuel

injection pump wiring.
8. Cut the wiring at the fuel metering valve.
9. Using the special tool, loosen the fuel metering

valve by 4 turns.
10. Twist and pull the fuel metering valve to loosen

the O-ring sealing washers.

11. Remove the fuel metering valve.
Discard the fuel metering valve.
Installation

lines.
1. To aid installation, lightly lubricate the two fuel
metering valve O-ring seals with Renap 220 oil
(supplied in the parts kit).
2. Install the sealing washer to the fuel metering

valve (unless already pre-assembled).
3. Finger tighten the fuel metering valve in a 10

o'clock position.

4. Using the special tool, tighten the fuel metering
valve.
Take a note of the amount that the fuel
metering valve turns.
5. Loosen the fuel metering valve. Turn the fuel

metering valve back by the amount noted in the
previous step, in order for the fuel metering
valve to tighten in the 12 o'clock position.
6. NOTE: The fuel metering valve must be in
the 12 o'clock position after final tightening.
Using the special tool, tighten the fuel metering
valve in two stages.
Stage 1: 25 Nm.
7. If the fuel metering valve is not in the 12 o'clock

position after final tightening, remove it, install a
new sealing washer and repeat the installation
steps.
8. Lubricate the fuel injection one-way valves with
Renap 220 oil (supplied in the parts kit).
9. Position the sealing washers onto the end of the

fuel injection one-way valves.

10. Install the fuel injection one-way valves.
11. Cut the wires that connect into the fuel injection
pump. Trim the end of the insulation to expose
the wiring.
12. Cut the wires that connect into the new metering
valve. Trim the end of the insulation to expose
the wiring.
13. NOTE: The fuel metering valve wiring can be

connected to the fuel injection pump wiring
either way round and it will not affect the
function of the new fuel metering valve.
Slide the protection sleeve and connector
insulation sleeves (supplied in the parts kit) over
the wiring. Join the fuel injection pump wiring to
the fuel metering valve wiring by crimping the
electrical connectors (supplied in the parts kit).
14. CAUTION: The electrical connectors

must be correctly sealed to prevent water
ingress which could affect the operation of
the fuel metering valve.
Using a heat gun, heat shrink the connector
insulation sleeves over the electrical connectors.
15. Install the protection sleeve over the fuel

injection pump wiring harness.

16. Install the mounting plate.
17. Install the fuel injection pump.

For additional information, refer to: Fuel Pump -

Pump—75 PS/90 PS/110 PS, Vehicles
Built From: 08/2006
Print
Special Tool(s)
205-072
303-249
Remover, Crankshaft Timing Pulley
Materials
Name Specification
Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA
Thread Locking MS WSK-M2G349-A7 / 2U7J-M2G349-AA
Removal
WARNINGS:
Make sure that the fuel pressure has dropped to zero and that the fuel temperature
is at ambient temperature.
Wait for a minimum of 1 minute after the engine has stopped before commencing
any repair to the fuel injection system.
1. Refer to: Diesel Fuel System Health and Safety
Precautions (100-00 General Information,
Refer to: Timing Belt - 1.8L Duratorq-TDCi

(Lynx) Diesel (75 PS/90 PS/110 PS), Vehicles
Built From: 08/2006 (303-01B Engine - 1.8L
(Lynx) Diesel, In-vehicle Repair).
3. CAUTION: Use lint free cloth.

Protect the generator to prevent contamination.
4. Clean the fuel pump, fuel rail, high-pressure fuel
supply line and surrounding areas.
Refer to: Fuel Injection Component Cleaning -

5. CAUTIONS:
Make sure that the fuel line remains in

contact at both ends until both unions nuts

have been unscrewed and the area around
the joints thoroughly cleaned.
Vacuum any foreign material from the

fuel pump and fuel rail unions before sealing
the unions with blanking caps.
Make sure that all openings are sealed.

Use new blanking caps.

6. Discard the fuel pump seal.
7. NOTE: Access the fuel pump bolts through

the holes provided. The bolts cannot be
removed.

9.

10.
11.
Installation
Torque: 45 Nm

2. Material: Thread Locking MS (WSK-M2G349-A7 /
2U7J-M2G349-AA)
3. NOTE: Access the fuel pump bolts through

the holes provided. The bolts cannot be
removed.
Torque: 20 Nm
4. Torque: 24 Nm

5. Torque:
1: 26 Nm
2: 50 Nm

All vehicles
installed.
Torque: 10 Nm
7. Material: Silicone Sealant LB (WSE-M4G323-A4 /

2U7J-M4G323-AA)
8. Material: Thread Locking MS (WSK-M2G349-A7 /

2U7J-M2G349-AA)
9. Torque: 42 Nm

installed.

Torque:
Fuel pump high-pressure fuel supply line
union 25 Nm
Fuel rail high-pressure fuel supply line
union 38 Nm
Fuel pump bracket bolts 23 Nm
11. Remove the lint-free material.

Refer to: Timing Belt - 1.8L Duratorq-TDCi

Built From: 08/2006 (303-01B Engine - 1.8L
13. Install a new fuel filter element.
Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx)

Diesel (310-01A Fuel Tank and Lines, Removal
and Installation).

Duratorq-TDDi (Lynx) Diesel - Fuel Rail— Transit/Tourneo Connect 2002.5 (06/2002-)
08/2006
Print
General Equipment
Removal
WARNINGS:
Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Make sure that the fuel pressure has dropped to zero and that the fuel temperature
is at ambient temperature.
Wait for a minimum of 1 minute after the engine has stopped before commencing
any repair to the fuel injection system.
1. Remove the charge air cooler
Refer to: Charge Air Cooler - 1.8L Duratorq-TDCi

Built From: 08/2006 (303-12 Intake Air
Distribution and Filtering, Removal and
Installation).
2. CAUTION: Use lint free cloth.

Protect the generator to prevent contamination.
3. Clean the fuel pump, fuel rail, high-pressure fuel
supply line and surrounding areas.

4. NOTE: Note the orientation of the clamp to
aid installation.
General Equipment: Hose clamp
remover/installer
5.

6. CAUTIONS:
Make sure that the fuel line remains in

contact at both ends until both unions nuts
have been unscrewed and the area around
the joints thoroughly cleaned.
Vacuum any foreign material from the

fuel pump and fuel rail unions before sealing
the unions with blanking caps.
Make sure that the fuel line union does

not rotate.
Make sure that all openings are sealed.

Use new blanking caps.
Discard the high-pressure fuel supply lines.
7.
Installation
1. NOTE: Only tighten the bolts finger tight at

this stage.

installed.
NOTE: Only tighten the union nuts finger

3. Torque: 24 Nm
4. CAUTION: Make sure that the fuel line

union does not rotate.
Tighten in the sequence shown.
Torque: 25 Nm
5. Torque: 38 Nm
6. Torque: 23 Nm

7. Remove the lint-free material.
8. NOTE: Make sure that the clamp is installed
to the same orientation as when removed.
remover/installer
Refer to: Charge Air Cooler - 1.8L Duratorq-TDCi

Built From: 08/2006 (303-12 Intake Air
Installation).
10. Refer to: Quick Release Coupling (310-00A Fuel
Procedures).
11. Install the special tool between the fuel filter fuel
supply line quick release coupling and the fuel
filter union, making sure that the arrow on the
hand pressure pump indicating the direction of
flow is pointing towards the fuel filter.
12. Operate the hand pressure pump at least 30

times.

13. CAUTION: The starter motor operation
must not exceed 10 seconds at a time. After
10 seconds turn the ignition switch to
position 0 and allow the starter motor to cool
for 30 seconds before operating the starter
motor again.
reaches normal operating temperature.
14. Stop the engine.
16. Connect the fuel tank to fuel filter fuel supply line
to the fuel filter.
Refer to: Quick Release Coupling (310-00A Fuel

Procedures).

Duratorq-TDDi (Lynx) Diesel - Fuel Return Transit/Tourneo Connect 2002.5 (06/2002-)
Line Venturi—1.8L Duratorq-TDCi (Lynx)
Diesel
Print
General Equipment
Removal
WARNINGS:
in personal injury.
fuel pressure has dropped to zero and that the fuel temperature has either reached
ambient temperature or is below 30º C. whichever is the greater. Failure to follow these
CAUTIONS:
malfunction.
greater.



cleaning fluid.
clarity).
7. Remove the fuel pump support bracket bolts

(high-pressure fuel supply line shown removed
for clarity).
8. Disconnect the fuel pump to fuel filter fuel return

line from the fuel return line venturi (high-
clarity).
Install blanking plugs to the fuel pump fuel

return line and the fuel return line venturi.
9. Disconnect the fuel injector fuel return line from

the fuel return line venturi.
Install blanking plugs to the fuel injector
fuel return line and the fuel return line
venturi.
10. Remove the fuel pump shield from the fuel pump
11. Using the pneumatic vacuum gun, vacuum

return line venturi.
12. Remove the fuel return line venturi (fuel pump
Install a blanking plug to the open port on
the fuel pump.
Installation
WARNINGS:
in personal injury.
CAUTIONS:

fuel pump.
3. Using a suitable multipurpose lubricant spray,
lubricate the new fuel return line venturi O-ring
seal.
4. Install the fuel return line venturi (fuel pump
5. Install the fuel pump shield to the fuel pump

6. Remove the blanking plugs and connect the fuel

injector fuel return line to the fuel return line
venturi.


clarity).
8. Tighten the fuel pump support bracket bolts

(high-pressure fuel supply line shown removed
for clarity).
9. Connect the fuel pump to fuel filter fuel return

line.

generator.

Fuel Charging and Controls -
Turbocharger - Specifications
Print

Charge air cooler hose clamps 4.5 - 40
Charge air cooler intake pipe nuts 9 - 80
Exhaust gas recirculation (EGR) cooler clamp bolt 10 – 89
Turbocharger oil supply pipe and oil return tube bolts 10 - 89
EGR cooler to EGR valve bolts 20 15 –
EGR cooler bolt 23 17 –
Exhaust manifold bolts 24 18 –
Exhaust manifold nuts 24 18 -
Catalytic converter support bracket bolt 25 18 –
Turbocharger oil supply pipe bolt 40 30 -
Catalytic converter to turbocharger nuts - vehicles with M10 nuts 47 35 -
Flexible pipe flange to muffler nuts 47 35 -
Support insulator retaining bolt 48 35 –
lb- lb-
Description Nm ft in
Charge air cooler hose clamps 4 - 35
Exhaust gas recirculation (EGR) cooler clamp bolt 5 - 44
Charge air cooler intake pipe nuts 9 - 80
Turbocharger oil supply pipe and oil return tube bolts - vehicles with fixed vane 10 - 89
turbocharger
Turbocharger oil return tube bolts - vehicles with variable vane turbocharger 10 - 89
EGR cooler bolt 23 17 –
Knock sensor (KS) shield bolt 23 17 -
Turbocharger oil supply pipe bracket bolt 23 17 -
Exhaust manifold bolts 24 18 -
Exhaust manifold nuts 24 18 -
Turbocharger bracket bolts - vehicles with variable vane turbocharger 25 18 -
Turbocharger oil supply pipe union bolt, turbocharger side - vehicles with variable 35 26 -
vane turbocharger
Turbocharger oil supply pipe union bolt, engine block side - vehicles with variable 15 11 -
vane turbocharger

Turbocharger - Turbocharger—75 PS/90 Transit/Tourneo Connect 2002.5 (06/2002-)
PS/110 PS, Vehicles Built From: 08/2006
Print
Variable Vane Turbocharger

1 - Turbocharger oil supply pipe
2 - Turbocharger retaining clamp
3 - Turbocharger
4 - Turbocharger oil return pipe
5 - Turbocharger inlet hose
6 - Charge air cooler inlet pipe
The engine is fitted with an electronically controlled variable vane turbocharger. The
turbocharger is fixed to the exhaust manifold by a retaining clamp. The turbocharger
consists of two elements, a turbine and a compressor both installed on a single shaft.
The turbocharger bearings are supplied with oil from the engine.
The turbine uses the flow of the exhaust gas to drive the compressor. The compressor
draws air through the air cleaner and forces it into the intake manifold.
The turbocharger is designed to improve engine induction and engine performance. The list
below details the possible concerns relating to turbocharger performance.
High engine speed produces excessive turbine speed and therefore creates excessive
turbocharger boost pressure.
Low engine speed does not produce sufficient turbine speed and therefore not enough
turbocharger boost pressure is achieved.
The turbocharger does not have a wastegate control valve. Instead, it has variable
turbocharger vanes, which are located in the turbocharger turbine housing and these direct
the exhaust gas flow into the turbocharger turbine. The turbocharger vanes act as the
control for the turbocharger boost pressure.

The turbocharger produces its full turbocharger boost pressure over the entire engine speed
range, not just at high engine speed. This is achieved through the adjustment of the vanes
and the resulting change in the flow of the exhaust gas.
The speed of the exhaust gas flow within the turbocharger is increased independent of
engine speed by varying the intake cross section in front of the turbocharger turbine. This
is achieved by adjusting the angle of the vanes controlling the exhaust gas flow into the
turbocharger turbine and this drives the turbocharger turbine faster. The higher
turbocharger speed produces a high turbocharger boost pressure at all engine speeds.
The powertrain control module (PCM) controls the turbocharger vanes by means of an
electronic vane adjustment solenoid attached to the turbocharger.
Regulation at Low Engine Speed
At low engine speeds the PCM operates the vane adjustment solenoid. The vane adjustment
solenoid moves the adjusting ring so that the vanes are set at a shallow angle. The shallow
intake cross section this creates for the stream of exhaust gas allows the turbocharger
boost pressure to build up rapidly and easily at low engine speeds.
Regulation at Moderate Engine Speed
As the engine speed increases and the quantity of exhaust gas increases, the vane
adjustment solenoid moves the adjusting ring so that the vanes are set at a steeper angle.
The steeper angle opens the intake cross section effectively reducing the gas flow and
turbine speed, while maintaining constant turbocharger boost pressure.
Regulation at Maximum Engine Speed
As the engine speed increases the intake cross section in front of the turbocharger turbine
is continuously enlarged. The turbine speed and hence the quantity of the air supplied to
the engine, is adjusted to suit the engine speed. This means that the turbocharger boost
pressure remains optimized over all engine speeds.
The maximum position of the turbocharger vanes (maximum opening cross section) is also
an emergency position, in the event of an electrical concern. This lowers the chance of
engine damage due to excessive boost in the event of a turbocharger control concern.
Fixed Vane Turbocharger

-

1 Charge air cooler inlet pipe
2 - Turbocharger
3 - Turbocharger oil supply pipe
4 - Turbocharger oil return pipe
5 - Turbocharger inlet hose
The turbocharger consists of two elements, a turbine and a compressor both installed on a
single shaft and are contained within a housing.
The turbocharger bearings are supplied oil from the engine through the oil supply pipe. The
oil is returned to the oil pan through the oil return tube.
The turbine element of the turbocharger uses the energy of the exhaust gas to drive the
compressor. The compressor draws in air through the charge air cooler.
The turbocharger is governed by means of a wastegate. The wastegate redirects some of
the exhaust gas past the turbine. The wastegate is controlled by a waste gate control
solenoid which is preset during manufacture and must not be tampered with.

Turbocharger - Turbocharger—75 PS/90 Transit/Tourneo Connect 2002.5 (06/2002-)
PS, Vehicles Built Up To: 08/2006
Print
Special Tool(s)
Boost Pressure Gauge
310 - 020 (23 - 021)

NOTE: It is normal for a small amount of combustion gas to pass into the crankcase. This
gas is scavenged into the air intake system through the positive crankcase ventilation
(PCV) system, which incorporates an oil separator. Some engine oil, in the form of a
vapor is carried into the air intake system with the blow-by gases (this engine oil also
contributes to valve seat durability). This means that oil will collect inside the air intake
components and the turbocharger. This is not an indication that the turbocharger oil seal
has failed. The turbocharger oil seal will not fail unless the bearings fail first, which will
cause the turbocharger to become noisy or seize. Do not install a new turbocharger due
to oil inside the turbocharger or the air intake components. If a leak is detected in the oil
supply or return tubes or connections, locate and rectify the source. Do not install a new
turbocharger due to an oil leak.
2. 2. Visually inspect for obvious signs of mechanical damage.
Mechanical
Oil leak(s)
Air cleaner element
Turbocharger intake tube
Air cleaner intake pipe
Turbocharger oil supply or oil return tube
Wastegate control valve
Turbocharger housing
Wastegate control pipe
Catalytic converter
Chart.
Symptom Chart
Symptom Chart

Blue smoke with * Turbocharger * GO to Pinpoint Test A. .
excessive compressor rubbing
turbocharger noise on housing walls.

* Turbocharger
bearings and oil seal
(s).
* Turbocharger oil
supply tube blocked
or damaged.
Blue smoke without * Turbocharger oil * GO to Pinpoint Test B. .
excessive return tube blocked
turbocharger noise or damaged.
Poor engine * Wastegate control * CHECK the wastegate control valve actuator rod
performance valve actuator rod. moves freely, If the wastegate control valve
actuator rod does not move freely. CHECK for
signs of damage or signs of foreign material.
INSTALL a new turbocharger.
REFER to Turbocharger in this section.
* Turbocharger boost * The boost pressure is factory set and must not
pressure incorrect. be adjusted. CHECK the paint seal on the
actuator rod has not been broken. If the paint
seal has been broken, INSTALL a new
turbocharger.
* If the paint seal has not been broken, GO to
Pinpoint Test C.
Pinpoint Tests
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE

A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
1 Detach the turbocharger intake pipe.
1. Release the retaining clip.
2. Detach the turbocharger intake pipe.
2 Inspect the turbocharger rotor vanes for damage.
Is there visible damage to the rotor vanes?

Yes
GO to A2. .
No
GO to A3. .
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
1 Check the intake air system components for signs
of foreign material.

Are there any signs of foreign material?
Yes
CLEAN the intake air system components. INSTALL
a new turbocharger.
No
GO to A4. .
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE: A small amount of movement in the bearings is normal.
1 Make sure the turbocharger rotor spins freely
within the housing.
1. With the turbocharger stationary, gently lift

the shaft (the shaft will naturally lay in the
bottom of the bearings).
2. Make sure the rotor spins freely within the

housing.
Does the rotor spin freely within the housing with no

excessive movement?
Yes
GO to A4. .
No
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
1 Disconnect the oil supply tube from the
turbocharger.
2 Attach a small piece of known good hose to the oil

supply tube and gently blow down the hose.
Are there any signs of blockage?
Yes
INSTALL a new turbocharger oil supply tube. TEST
the system for normal operation.
No
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER

NOISE
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
1 Disconnect the oil supply tube from the
turbocharger.

2 Remove the turbocharger oil return pipe.
3 Check the turbocharger oil return tube and pipe for

a blockage or signs of damage.
Are the turbocharger oil return tube and pipe OK?
Yes
GO to Fuel Charging and Controls for further
diagnostics. REFER to Section 303-04A Fuel
Charging and Controls / 303-04B Fuel Charging and
Controls / 303-04C Fuel Charging and Controls -
Controls.
No
INSTALL a new turbocharger oil return tube or pipe.
PINPOINT TEST C : POOR ENGINE PERFORMANCE

C1: CHECK THE BOOST PRESSURE
NOTE: The boost pressure is factory set and must not be adjusted.
1 Using the special tool, connect the boost pressure
gauge between the wastegate control actuator and
the turbocharger.
2 Start and run the engine until the cooling fan has
operated.
3 Raise the engine speed to 3000 rpm and observe
the reading.
Is the boost pressure 0.5 bar?
Yes
diagnostics. REFER to Section 303-04A Fuel
Charging and Controls / 303-04B Fuel Charging and

Controls.
No

Turbocharger - Turbocharger—75 PS/90
PS/110 PS, Vehicles Built From: 08/2006,
Vehicles With: Fixed Vane Turbocharger
Print
Special Tool(s)
416-D001 (23-036A)
General Equipment

NOTE: The turbocharger uses engine oil as a lubricant and coolant. Due to the high
operating temperatures of the turbocharger and with the expansion and contraction of the
internal components a proportion of engine oil may enter the air intake system. This is
not an indication that the turbocharger oil seal has failed. The turbocharger oil seal will
not fail unless the bearings fail first, which will cause the turbocharger to become noisy.
Do not install a new turbocharger due to oil inside the turbocharger or the air intake
components. If a leak is detected in the supply or return tubes or connections, locate and
rectify the source. Do not install a new turbocharger due to an oil leak.
Mechanical
Oil leak(s)
Air cleaner element
Air cleaner outlet pipe
Turbocharger oil supply tube
Turbocharger oil return tube
Wastegate control valve
Charge air cooler
Charge air cooler intake pipe and hose(s)
Charge air cooler outlet pipe and hose(s)
Chart.
Symptom Chart
CAUTION: On vehicles with a fixed vane turbocharger the wastegate control valve
and actuator rod are fixed parts of the turbocharger and must not be adjusted or renewed
separately.

Blue smoke with * Turbocharger * GO to Pinpoint Test A.
excessive compressor rubbing
turbocharger noise on housing walls.
* Turbocharger turbine
rubbing on housing
walls.
* Turbocharger
bearings and oil seal
(s).
* Turbocharger oil
supply tube blocked or
damaged.
Blue smoke * Turbocharger oil * GO to Pinpoint Test B.
without excessive return tube blocked or
turbocharger noise damaged.
Poor engine * Charge air cooler * CHECK the charge air cooler and charge air
performance system. cooler pipe(s) for leaks and obstructions.
REPAIR as necessary.
* Air cleaner intake * CHECK the air cleaner intake pipe for
pipe. obstructions. REPAIR as necessary.
* Unauthorized * The wastegate control valve actuator rod is
adjustment of the factory set and must not be adjusted. CHECK
wastegate control the paint seal on the wastegate control valve
valve actuator rod. actuator rod has not been broken. If the paint
seal has been broken, INSTALL a new
turbocharger.
REFER to: Turbocharger - 1.8L Duratorq-TDCi
(Kent) Diesel (110 PS), Vehicles With: Fixed
Vane Turbocharger (303-04C, Removal and
Installation).
* Wastegate control * GO to Pinpoint Test C.
valve actuator.
Pinpoint Tests

CAUTION: Make sure that the inside of the pipe

ends are clean and free of oil residue.
1 Remove the turbocharger intake pipe.

Yes
GO to A2.
No
GO to A3.
1 Check the intake air system components for signs of
foreign material.
Yes
CLEAN the intake air system components. INSTALL a
new turbocharger.
(81kW/110PS) - Lynx (303-04C Fuel Charging and
Controls - Turbocharger, Removal and Installation).
No
GO to A4.
NOTE: The initial rotor rotation of a cold turbocharger may feel rough and uneven but
should rotate freely after a few turns.
1 Make sure that the turbocharger rotor spins freely
within the housing.
1. With the turbocharger stationary, gently lift the

shaft (the shaft will naturally lay in the bottom of
the bearings).
2. Make sure that the rotor spins freely within the

housing.
Does the rotor spin freely within the housing?

Yes
GO to A4.
No
1 Remove the turbocharger oil supply tube.
2 Using workshop compressed air and a compressed

air nozzle, check the oil supply tube for blockage.
Is there any signs of blockage?
Yes
GO to A5.
No
INSTALL a new turbocharger and turbocharger oil

supply tube.
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE
1 Visually inspect the oil supply tube oil gallery in the
cylinder block for blockage.
Is the oil supply tube oil gallery free from blockage?

Yes
supply tube.
No
REMOVE the blockage. INSTALL a new turbocharger.

NOISE
B1: CHECK THE TURBOCHARGER OIL RETURN TUBE
1 Remove the turbocharger oil return tube.
2 Check the turbocharger oil return tube for a blockage

or signs of damage.
Is the turbocharger oil return tube blocked?
Yes
GO to Fuel Charging and Controls for further blue
smoke diagnostics.
REFER to: Fuel Charging and Controls - 75 PS/90
PS/110 PS, Vehicles Built From: 08/2006 (303-04B
Fuel Charging and Controls - 1.8L Duratorq-TDCi
No
INSTALL a new turbocharger oil return tube. TEST

PINPOINT TEST C : POOR ENGINE PERFORMANCE.
C1: CHECK THE WASTEGATE ACTUATOR CONTROL LINE FOR BLOCKAGE
1 Remove the wastegate actuator control line.
2 Install the special tool to one end of the wastegate
actuator control line.
Operate the hand vacuum pump and observe the

3
reading.
Is a reading present?
Yes
INSTALL a new wastegate actuator control line. TEST
No
GO to C2.
C2: CHECK THE WASTEGATE ACTUATOR DIAPHRAGM FOR LEAKS
1 Connect the free end of the wastegate control line to
the wastegate actuator.
2 Operate the hand vacuum pump and observe the

reading.
Does the pump hold vacuum?
Yes
diagnostics.
No

Turbocharger - Turbocharger—75 PS/90
PS/110 PS, Vehicles Built From: 08/2006, Transit/Tourneo Connect 2002.5 (06/2002-)
Vehicles With: Variable Vane
Turbocharger
Print
General Equipment

NOTE: It is normal for a small amount of combustion gas to pass into the crankcase. This
gas is scavenged into the air intake system through the positive crankcase ventilation
(PCV) system, which incorporates an oil separator. Some engine oil, in the form of a
vapor is carried into the air intake system with the blow-by gases (this engine oil also
contributes to valve seat durability). This means that oil will collect inside the air intake
components and the turbocharger. This is not an indication that the turbocharger oil seal
has failed. The turbocharger oil seal will not fail unless the bearings fail first, which will
cause the turbocharger to become noisy or seize. Do not install a new turbocharger due
to oil inside the turbocharger or the air intake components. If a leak is detected in the oil
supply or return tubes or connections, locate and rectify the source. Do not install a new
turbocharger due to an oil leak.
Oil leak(s) Wiring harness
Air cleaner element Turbocharger electronic actuator
Air cleaner outlet pipe PCM
Turbocharger oil supply pipe
Turbocharger oil return tube
Turbocharger intake pipe
Charge air cooler
Charge air cooler intake pipe and hose(s)
Charge air cooler outlet pipe and hose(s)
Chart.
Symptom Chart

Blue smoke with * Turbocharger * GO to Pinpoint Test A.
excessive compressor rubbing on
turbocharger noise housing walls.
* Turbocharger turbine
rubbing on housing
walls.

* Turbocharger bearings
and oil seal(s).
* Turbocharger oil
supply tube blocked or
damaged.
Blue smoke without * Turbocharger oil return * GO to Pinpoint Test B.
excessive tube blocked or
turbocharger noise damaged.
Poor engine * Charge air cooler * CHECK the charge air cooler, charge air
performance system. cooler pipes and charge air cooler hoses for
leaks and obstructions. REPAIR as
necessary.
* Air cleaner intake pipe. * CHECK the air cleaner intake pipe for
obstruction. REPAIR the necessary.
* Turbocharger * REFER to the WDS.
electronic actuator.
Pinpoint Tests

CAUTION: Make sure that the inside of the pipe

ends are clean and free of oil residue.
1 Remove the turbocharger intake pipe.

Yes
GO to A2.
No
GO to A3.
1 Check the intake air system components for signs of
foreign material.
Yes
CLEAN the intake air system components. INSTALL a
new turbocharger.
REFER to: Turbocharger - 1.8L Duratorq-TDCi (Kent)
Diesel (110 PS), Vehicles With: Variable Vane
Turbocharger (303-04C, Removal and Installation).
No

GO to A4.
NOTE: The initial rotor rotation of a cold turbocharger may feel rough and uneven but
should rotate freely after a few turns.
1 Make sure that the turbocharger rotor spins freely
within the housing.
1. With the turbocharger stationary, gently lift the

shaft (the shaft will naturally lay in the bottom of
the bearings).
2. Make sure that the rotor spins freely within the

housing.
Does the rotor spin freely within the housing with no

excessive movement?
Yes
GO to A4.
No
1 Remove the turbocharger.
2 Using workshop compressed air and a compressed
air nozzle, check the oil supply tube for blockage.
Is the oil supply tube free from blockage?
Yes
GO to A5.
No
supply tube.
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE
1 Visually inspect the oil supply tube oil gallery for
blockage.
Is the oil supply tube oil gallery free from blockage?

Yes
INSTALL a new turbocharger and oil supply pipe.

No
REMOVE the blockage. INSTALL a new turbocharger.

NOISE
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
1 Raise and support the vehicle.
REFER to: Lifting (100-02 Jacking and Lifting,
NOTE: Discard the gasket(s).
2 Remove the turbocharger oil return pipe.
3 Check the turbocharger oil return pipe for blockage

or signs of damage.
Is the turbocharger oil return pipe free from blockage
and signs of damage?
Yes
diagnostics.
No
INSTALL a new turbocharger oil return pipe. TEST the
system for normal operation.

Turbocharger - Turbocharger—1.8L
Duratorq-TDCi FGT (55kW/75PS) -
Lynx/1.8L Duratorq-TDCi FGT Transit/Tourneo Connect 2002.5 (06/2002-)
TDCi VNT (55kW/75PS) - Lynx
Print

General Equipment
Cable ties
Removal
1. Refer to: Battery Disconnect and Connect (414-
01 Battery, Mounting and Cables, General
Procedures).
2. Refer to: Air Cleaner (303-12 Intake Air
Installation).
3. CAUTION: Make sure that the inside of

the pipe ends are clean and free of oil
residue.
NOTE: Make sure that the positive crankcase
ventilation (PCV) hose and the turbocharger
intake pipe are not disturbed.
4. NOTE: Install all the bolts finger tight before

final tightening.
Torque: 47 Nm
5. Refer to: Lifting (100-02 Jacking and Lifting,

6. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent or twisted.
General Equipment: Cable ties

7. NOTE: Make sure that the exhaust flanges
are correctly aligned.
NOTE: Install all the bolts finger tight before
final tightening.
Torque: 47 Nm
8. NOTE: Install all the bolts finger tight before

final tightening.
Torque: 25 Nm

installed.
Torque: 10 Nm
10. NOTE: Make sure that new components are

installed.
Torque: 20 Nm

installed.
Installation

2. NOTE: Make sure that the clamp is installed
to the same orientation as when removed.
NOTE: Make sure that a new component is
installed.
Torque: 5 Nm

Fuel Charging and Controls - Turbocharger -
Turbocharger—1.8L Duratorq-TDCi (81kW/110PS) - Transit/Tourneo Connect 2002.5 (06/2002-)
Lynx
Print

General Equipment
Cable ties
Removal
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and
Cables, General Procedures).
2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
3.
4. CAUTION: Make sure that the exhaust flexible pipe is not forcibly
bent or twisted.
5.
6.
7. CAUTION: Make sure that the inside of the pipe ends are clean and
free of oil residue.
8.

9.
10.
11.
12.
Installation
1. NOTE: Make sure that a new component is installed.

Torque: 35 Nm

3. NOTE: Install all the bolts finger tight before final tightening.
1. Torque: 10 Nm
2. Torque: 10 Nm
3. Torque: 25 Nm
4.
1. Torque: 23 Nm
2. Torque: 23 Nm
3. Torque: 35 Nm
5. NOTE: Make sure that a new

component is installed.
NOTE: Make sure that the clamp
is installed to the same
orientation as when removed.
Torque: 5 Nm
6. CAUTION: Make sure that the inside of the pipe ends are clean and
free of oil residue.
7. Torque: 47 Nm
8. Torque: 25 Nm
9. NOTE: Install all the bolts finger tight before final tightening.

NOTE: Make sure that the exhaust flanges are correctly aligned.
Torque: 25 Nm
10. CAUTION: Make sure that the exhaust flexible pipe is not forcibly
bent or twisted.

Duratec-DOHC (85kW/115PS) - Zetec,
Liquefied Petroleum Gas (LPG) -
Specifications
Print

Alternative fuel control module bracket retaining bolts 10 - 89
Fuel vaporizer fuel supply line union 17 13 -
Fuel vaporizer retaining bolts 10 - 89
Fuel vaporizer bracket retaining nuts 23 17 -
Fuel vaporizer filter element retaining nut 36 27 -

Liquefied Petroleum Gas (LPG) - Fuel
Print

1 - LPG select switch
2 - Alternative fuel control module
3 - LPG fuel vaporizer and filter
4 - LPG fuel injection supply manifold
5 - LPG injector(s)
6 - Alternative fuel system Data Link Connector (DLC)

LPG Select Switch
The LPG select switch is located in the center console. The switch outputs a 12 volt signal to
the alternative fuel control module which opens the LPG fuel shutoff solenoid inside the fuel
vaporizer and the fuel tank solenoid valve inside the fuel tank. An integrated light emitting
diode indicator (LED) is illuminated when the switch is activated. The LPG select switch will
not illuminate if the vehicle is running on petrol.
LPG Fuel Injectors
The sequential LPG fuel injectors are located on the underside of the intake manifold and
are controlled by the LPG alternative fuel control module.
LPG Fuel Vaporizer
The LPG fuel vaporizer changes liquid gas from the LPG tank to a dry gas. The vaporizer is
connected to the engine coolant system and will only switch to LPG if the coolant
temperature is above 10 degrees centigrade.
Alternative Fuel Control Module
The alternative fuel control module monitors the various engine sensors when the vehicle is
operating on LPG. If the LPG fuel tank runs dry or the engine is operating on a weak fuel
mixture the alternative fuel control module will pick up a signal from the heated oxygen
sensor (HO2S) and switch the vehicle to petrol operation.
LPG Fuel System DLC
The LPG fuel system is diagnosed through a separate DLC. WDS connects to this DLC and
will diagnose any alternative fuel system concerns. The DLC is located in the glove
compartment area.

Print
Special Tool(s)
Terminal Probe Kit
418-S035
General Equipment
Worldwide Diagnostic System (WDS) (418-
F224)

WARNINGS:
Do not modify the system configuration or components, or install components not

specially designed for use with alternative fuels. Ford Motor Company Ltd has specially
designed the materials, components and system configuration for alternative fuel
vehicles, and each particular system is precisely calibrated for efficient operation. The use
of incorrect parts or materials can produce an untested configuration that could result in
fire, or cause engine damage. Failure to follow these instructions may result in personal
injury.
Fuel supply lines will remain pressurized after shutdown. When servicing fuel related
components, do not smoke or carry lighted tobacco or any open flame of any type.
Flammable gases may be present and ignite. Failure to follow these instructions may
The fuel tank must be evacuated prior to tank removal. Failure to follow this
Eye, hand and ear protection are required to be worn during depressurizing or
removal and installation of fuel system components. Failure to follow this instruction may
Always ground the vehicle and alternative fuel system. High pressure gas escaping
can cause static electricity buildup and subsequent sparking. Failure to follow this
Never attempt to tighten or adjust fittings while system is pressurized. Failure to

All gas lines must be installed prior to reconnecting the battery. Failure to follow this
CAUTIONS:
If the alternative fuel system is being disconnected for an extended length of time,
cover all open hose fittings and electrical connections to avoid contamination.
The engine will always start using petrol regardless of what fuel type is currently
selected. If the vehicle is in LPG mode when starting the LPG indicator lamp will flash to
indicate it is running on petrol and then switch over to LPG after a short period of time.

The vehicle must have petrol present in the fuel tank at all times. Failure to follow this
instruction may result in damage to the vehicle.
NOTE: The engine will not use LPG until a minimum coolant temperature of 10 degrees
centigrade has been reached.
NOTE: If a weak LPG mixture is detected by the alternative fuel control module (AFCM)
then the system automatically switches over to petrol to prevent overheating of the
2. 2. If the concern is present in both LPG and petrol operation, refer to fuel charging
and controls.
REFER to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.8L
Duratec-DOHC (85kW/115PS) - Zetec, Diagnosis and Testing).
If the concern is only present when switched to LPG, proceed to the next step.
Fuel filter element(s) Fuse(s)
LPG distributor Relay(s)
LPG fuel vaporizer Circuit(s)
LPG fuel injector(s) Wiring harness
Vacuum lines Electrical connector(s)
Fuel Tank valves Throttle position (TP) sensor
LPG fuel line(s) Manifold absolute pressure (MAP) sensor
LPG select switch
Fuel injection supply manifold stepper motor
Fuel tank solenoid(s)
AFCM
Diagnostic Trouble Code DTC Index Chart.
Diagnostic Trouble Codes (DTC's) Index Chart

NOTE: The WDS must be used to communicate with the AFCM. It is not possible to use
the IDS to communicate with the AFCM.
NOTE: The secondary data link connector (DLC) must be used for alternative fuel system
diagnostics. On left-hand drive vehicles the secondary DLC is located behind the glove
compartment. On right-hand drive vehicles the secondary DLC is located below the
steering column behind the primary DLC.
NOTE: The WDS will only communicate with the AFCM if the petrol fuel pump relay is
removed and pins 3 and 5, harness side, are bridged with a 10 amp fused jumper wire.
1. 1. Remove the petrol fuel pump relay.
2. 2. Install a 10 amp fused jumper wire between pins 3 and 5 of the petrol fuel pump
relay, harness side.
3. 3. Connect the WDS to the secondary DLC and follow the AFCM self test help screen.
4. 4. Retrieve any DTC's and refer to the DTC Index Chart.

5. 5. If no DTC's are retrieved, proceed to the Symptom Chart to continue diagnosis.
DTC Index Chart
DTC Description Possible Source Action

P0107 MAP sensor low MAP sensor GO to Pinpoint Test C.
input
P0108 MAP sensor high MAP sensor GO to Pinpoint Test C.
input
P0117 Fuel system coolant Fuel vaporizer GO to Pinpoint Test A.
temperature sensor coolant
circuit low input temperature
sensor
P0118 Fuel system coolant Fuel vaporizer GO to Pinpoint Test A.
temperature sensor coolant
circuit high input temperature
sensor
P0122 TP sensor circuit low TP sensor GO to Pinpoint Test D.
input
P0123 TP sensor circuit TP sensor GO to Pinpoint Test D.
high input
P0134 Heated exhaust gas HO2S CHECK the HO2S for correct operation REFER to
oxygen sensor the WDS.
(HO2S) circuit
inoperative
P0170 Fuel trim concern Incorrect CHECK and ADJUST the differential pressure
differential settings in the fuel vaporizer/distributor.
pressure settings REFER to: Fuel System Differential Pressure
Check (310-00B Fuel System - General
Information - 1.8L Duratec-DOHC (85kW/115PS)
- Zetec, Liquefied Petroleum Gas (LPG), General
Procedures).
P0200 LPG fuel injector LPG fuel GO to Pinpoint Test B.
circuit concern injectors
P0336 Crankshaft position CKP sensor GO to Pinpoint Test E.
(CKP) sensor circuit
P0340 Camshaft position CMP sensor REFER to the WDS
(CMP) sensor circuit
P1230 Main power relay Main power relay INSTALL a new main power relay CHECK the
primary circuit system for normal operation.
P1231 Main power relay LPG fuel GO to Pinpoint Test B.
secondary circuit injectors
P0650 Malfunction MIL CHECK the MIL circuit.
indicator lamp (MIL) REFER to: Instrument Cluster (413-01 Instrument
circuit Cluster, Diagnosis and Testing).
Symptom Chart

Engine does not switch * No LPG in fuel tank. * CHECK that LPG is present in the fuel tank.
over to LPG (LPG * The engine does not * REFER to: Engine Cooling (303-03 Engine
indicator lamp flashing reach an operating Cooling, Diagnosis and Testing).
continuously) temperature over 10
degrees Celsius.
* LPG mixture is too * CHECK and ADJUST the differential pressure
weak. settings in the fuel vaporizer/distributor.
REFER to: Fuel System Differential Pressure
Information - 1.8L Duratec-DOHC

(85kW/115PS) - Zetec, Liquefied Petroleum
Gas (LPG), General Procedures).
The engine starts but * Fuel filter element. * CHECK and INSTALL a new fuel filter as
immediately stops necessary.
when switched to LPG REFER to: Fuel Filter (310-01B Fuel Tank and
Lines - 1.8L Duratec-DOHC (85kW/115PS) -
Zetec, Liquefied Petroleum Gas (LPG),
* Kinked or restricted * CHECK the fuel lines from the fuel distributor
fuel lines. to the fuel injectors for signs of damage or
restriction. INSTALL new fuel lines as
necessary. TEST the system for normal
operation.
* Incorrect differential * CHECK and ADJUST the differential pressure
pressure settings. settings in the fuel vaporizer/distributor.
* AFCM. * RESET the AFCM. REMOVE the AFCM Keep
alive memory (KAM) fuse from the fuse box
for 30 seconds. INSTALL the KAM fuse. TEST
The LPG indicator lamp * LPG switch. * CHECK the operation of the LPG select
does not illuminate switch. REPAIR as necessary. TEST the
when switched to LPG system for normal operation.
* LPG mixture is * CHECK and ADJUST the differential pressure
Excessive fuel * Incorrect differential * CHECK and ADJUST the differential pressure
consumption running pressure settings. settings in the fuel vaporizer/distributor.
on LPG REFER to: Fuel System Differential Pressure
* LPG Fuel injector(s) * REMOVE and INSPECT the fuel injectors.
are inoperative. INSTALL new LPG gas injectors as necessary.
REFER to: Fuel Injectors (303-04D Fuel

Charging and Controls - 1.8L Duratec-DOHC
Gas (LPG), Removal and Installation).
Poor idling when * Incorrect differential * CHECK and ADJUST the differential pressure
running on LPG pressure settings. settings in the fuel vaporizer/distributor.

* Fuel filter element * CHECK and INSTALL a new fuel filter as
blocked. necessary.
REFER to: Gas Fuel Vaporizer Filter Element
(303-04D Fuel Charging and Controls - 1.8L
Liquefied Petroleum Gas (LPG), Removal and
Installation).
fuel lines. to the injectors for signs of damage or
operation.
* AFCM. * RESET the AFCM. REMOVE the AFCM KAM
fuse from the fuse box for 30 seconds.
INSTALL the KAM fuse. TEST the system for
normal operation.
are inoperative. INSTALL new LPG fuel injectors as necessary.

Engine misfire when * Incorrect differential * CHECK and ADJUST the differential pressure
running on LPG pressure settings. settings in the fuel vaporizer/distributor.
operation.

Lack of power during * Incorrect differential * CHECK and ADJUST the differential pressure
acceleration when pressure settings. settings in the fuel vaporizer/distributor.
vehicle is switched to REFER to: Fuel System Differential Pressure
LPG Check (310-00B Fuel System - General
* Fuel filter element. * CHECK and INSTALL a new fuel filter as
necessary.

REFER to: Gas Fuel Vaporizer Filter Element
(303-04D Fuel Charging and Controls - 1.8L
Installation).
operation.

Automatically switches * Vehicle has run out * CHECK and REFILL the LPG fuel tank.
to petrol when driving of LPG.
on LPG * LPG mixture is * CHECK and ADJUST the differential pressure
The LPG indicator lamp * Switch. * CHECK the switch electrical connector is
is constantly correctly installed. REPAIR as necessary.
illuminated TEST the system for normal operation.
* LPG mixture is rich. * CHECK and ADJUST the differential pressure
settings in the fuel vaporizer/distributor.
* AFCM. * INSTALL a new AFCM.
REFER to: Gas Control Module (303-04D Fuel
PINPOINT TEST A : DTC P0117, DTC P0118 - ENGINE WILL NOT SWITCH
TO LPG
A1: CHECK THE FUEL VAPORIZER COOLANT TEMPERATURE SENSOR CIRCUIT
1 Disconnect AFCM C405 and C406.
3 With the engine coolant at approximately 20
degrees Celsius measure the resistance between
the AFCM C406 pin 28, circuit 8-RJ5 (WH), harness
side and AFCM C405 pin 34, circuit 9-RJ5 (BN),
harness side.

Is the resistance between 2375 and 2625 ohms?
Yes
INSTALL a new AFCM.
(85kW/115PS) - Zetec, Liquefied Petroleum Gas
(LPG), Removal and Installation).
No
GO to A2.
A2: CHECK CIRCUIT 8-RJ5 FOR OPEN
1 Disconnect fuel vaporizer coolant temperature
sensor C653.
2 Measure the resistance between the fuel vaporizer
coolant temperature sensor C653 pin 1, circuit 8-
RJ5 (WH), harness side and AFCM C406 pin 28,
circuit 8-RJ5 (WH), harness side.
Is the resistance less than 5 ohms?

Yes
GO to A3.
No
REPAIR the circuit, TEST the system for normal
operation.
A3: CHECK CIRCUIT 9-RJ5 FOR OPEN
1 Measure the resistance between the fuel vaporizer
coolant temperature sensor C653 pin 2, circuit 9-
RJ5 (BN), harness side and AFCM C405 pin 34,
circuit 9-RJ5 (BN), harness side.

Yes
INSTALL a new fuel vaporizer coolant temperature
sensor, TEST the system for normal operation.
No
operation.

PINPOINT TEST B : DTC P0200 - POOR PERFORMANCE WHEN RUNNING
ON LPG
B1: CHECK CIRCUITS 31S-RL10A, 31S-RL10D, 31S-RL11A, 31S-RL11D, 31S-RL12A,
31S-RL12D, 31S-RL13A AND 31S-RL13D FOR GROUND
2 Disconnect AFCM C406.
3 Disconnect LPG fuel injector C671.
7 Measure the resistance between the following
electrical connectors and ground.
AFCM C406 pin 25, circuit 31S-RL10D (BK/WH),

harness side.
AFCM C406 pin 22, circuit 31S-RL11D (BK/YE),

harness side.
AFCM C406 pin 24, circuit 31S-RL12D (BK/BU),

harness side.
AFCM C406 pin 11, circuit 31S-RL13D (BK/OG),

harness side.
Are the resistances greater than 10,000 ohms?
Yes
GO to B2.
No
REPAIR the circuit(s). TEST the system for normal
operation.
B2: CHECK FOR POWER TO THE LPG FUEL INJECTORS
6 Measure the voltage between the following
electrical connectors and ground.
LPG fuel injector C671 pin 1, circuit 15-RL10A

(GN/WH), harness side.

(GN/YE), harness side.

(GN/BU), harness side.

(GN/RD), harness side.
Are the voltages greater than 10 volts?

Yes
GO to B3.
No

GO to B5.
B3: CHECK CIRCUITS 31S-RL10A, 31S-RL10D, 31S-RL11A, 31S-RL11D, 31S-RL12A,
31S-RL12D, 31S-RL13A AND 31S-RL13D FOR OPEN
AFCM C406 pin 25, circuit 31S-RL10D (BK/WH),

harness side and LPG fuel injector C671 pin 2,
circuit 31S-RL10A (BK/WH), harness side.
AFCM C406 pin 22, circuit 31S-RL11D (BK/YE),

AFCM C406 pin 24, circuit 31S-RL12D (BK/BU),

AFCM C406 pin 11, circuit 31S-RL13D (BK/OG),

Are the resistances less than 5 ohms?
Yes
GO to B4.
No
REPAIR the circuit(s). TEST the system for normal
operation.
B4: CHECK THE LPG FUEL INJECTORS FOR OPEN
1 REMOVE the LPG fuel injectors.
REFER to: Fuel Injectors (303-04D Fuel Charging
and Controls - 1.8L Duratec-DOHC (85kW/115PS) -
Zetec, Liquefied Petroleum Gas (LPG), Removal and
Installation).
2 Measure the resistance across the following LPG
fuel injectors.
LPG fuel injector C671 pin 1, component side and

LPG fuel injector C671 pin 2, component side.



Are the resistances 18 ohms?
Yes
GO to B5.
No
INSTALL new LPG fuel injectors.
REFER to: Fuel Injectors (303-04D Fuel Charging
and Controls - 1.8L Duratec-DOHC (85kW/115PS) -
Zetec, Liquefied Petroleum Gas (LPG), Removal and
Installation).

B5: CHECK CIRCUITS 15-RN4, 15-RN5, 15-RL10A, 15-RL11A, 15-RL12A AND 15-
RL13A FOR OPEN
1 Disconnect LPG main relay C725.
LPG fuel injector C671 pin 1, harness side and

LPG main relay C725 pin 5, harness side.



Yes
GO to B6.
No
REPAIR the circuit(s), TEST the system for normal
operation.
B6: CHECK CIRCUIT 15-RH28 FOR POWER
2 Measure the voltage between LPG main relay C725
pin 3, circuit 15-RH28 (GN/OG), harness side and
ground.
Is the voltage greater than 10 volts?

Yes
GO to B7.
No
operation.
B7: CHECK THE LPG MAIN RELAY
Carry out the relay component test on LPG main
2
relay K274.
Does the LPG main relay pass the component test?
Yes
GO to B8.
No
INSTALL a new LPG main relay, TEST the system
B8: CHECK CIRCUIT 91S-RH27 FOR OPEN
2 Measure the resistance between AFCM C405 pin 10,
circuit 91S-RH27 (BK/GN), harness side and LPG
main relay C725 pin 2, circuit 91S-RH27 (BK/GN),
harness side.

Yes
INSTALL a new AFCM.
No
operation.
PINPOINT TEST C : DTC P0107, DTC P0108 - MAP SENSOR CIRCUIT LOW
INPUT, MAP SENSOR CIRCUIT HIGH INPUT
C1: TEST THE MAP SENSOR
With the engine switched to petrol operation and
1
using the WDS, check the operation of the MAP
sensor.
Is the MAP sensor operating correctly?
Yes
GO to C2.
No
INSTALL a new MAP sensor, TEST the system for
normal operation.
C2: CHECK CIRCUITS 7-RJ20, 8-RJ20 AND 9-RJ20 FOR OPEN
3 Disconnect MAP sensor C833.
AFCM C406 pin 16, circuit 7-RJ20 (YE/GN), harness

side and MAP sensor C833 pin C, circuit 7-RJ20
(YE/GN), harness side.
AFCM C406 pin 8, circuit 8-RJ20 (WH/GN), harness

side and MAP sensor C833 pin B, circuit 8-RJ20
(WH/GN), harness side.
AFCM C406 pin 48, circuit 9-RJ20 (BN/GN),

harness side and MAP sensor C833 pin A, circuit 9-
RJ20 (BN/GN), harness side.
Yes
INSTALL a new AFCM.

No
operation.
PINPOINT TEST D : DTC P0122, DTC P0123 - TP SENSOR CIRCUIT LOW

INPUT, TP SENSOR CIRCUIT HIGH INPUT
D1: TEST THE TP SENSOR
1
using the WDS, check the operation of the TP sensor.
Is the TP sensor operating correctly?
Yes
GO to D2.
No
INSTALL a new TP sensor, TEST the system for
normal operation.
D2: CHECK CIRCUITS 8-RJ28 AND 8-RJ28B FOR OPEN
3 Disconnect TP sensor C703.
4 Measure the resistance between AFCM C406 pin 6,
circuit 8-RJ28B (WH), harness side and TP sensor
C703 pin 2, circuit 8-RJ28 (WH), harness side.

Yes
INSTALL a new AFCM.
No
operation.
PINPOINT TEST E : DTC P0336 - CKP SENSOR CIRCUIT

E1: TEST THE CKP SENSOR
1
using the WDS, check the operation of the CKP
sensor.
Is the CKP sensor operating correctly?
Yes
GO to E2.
No
INSTALL a new CKP sensor, TEST the system for
normal operation.
E2: CHECK CIRCUITS 8-RJ4, 8-RJ4B, 9-RJ4 AND 9-RJ4B FOR OPEN

3 Disconnect CKP sensor C643.
AFCM C406 pin 21, circuit 8-RJ4B (WH/RD),

harness side and CKP sensor C643 pin 1, circuit 8-
RJ4 (WH/RD), harness side.
AFCM C406 pin 5, circuit 9-RJ4B (BN/RD), harness

side and CKP sensor C643 pin 2, circuit 9-RJ4
(BN/RD), harness side.
Yes
INSTALL a new AFCM.
No
operation.

Injectors
Print
Removal
1. Evacuate the fuel lines. For additional
3. Disconnect the fuel injection supply manifold fuel
supply line.
4. Remove the intake manifold. For additional

303-01B Engine.
5. NOTE: The fuel injector electrical connectors
are numbered with each cylinder.
Disconnect the fuel injector electrical connectors
and remove from the bracket.
6. Remove the fuel injectors and fuel injection

supply manifold.
Installation
1. NOTE: The fuel injector electrical connectors
are numbered with each cylinder.
NOTE: Install a new retaining clip.

2. WARNING: Before the vehicle is tested
for normal operation, carry out the fuel
system leak test. Failure to follow this
Check the fuel system for leaks. For additional

Liquefied Petroleum Gas (LPG) - Gas Fuel
Vaporizer
Print
General Equipment
Brake hose clamp(s)
Removal
4. Disconnect the fuel vaporizer to fuel filter supply
5. Disconnect the alternative fuel control module

6. Disconnect the fuel vaporizer fuel supply line

union from the fuel vaporizer.
7. Disconnect the heater hoses from the fuel

vaporizer.
1. Using a suitable Brake hose clamp(s),
clamp off the heater hoses.
2. Disconnect the heater hoses from the fuel

vaporizer.
Allow the coolant to drain into a suitable
container.
8. Disconnect the fuel vaporizer vacuum lines from

the fuel vaporizer and manifold absolute
pressure (MAP) sensor.
9. Detach the brake fluid reservoir.
10. Disconnect the fuel vaporizer electrical

connector.
11. Remove the fuel vaporizer bracket retaining bolt.
12. Remove the fuel vaporizer bracket retaining nut.

13. Remove the fuel vaporizer bracket retaining bolt
and remove the fuel vaporizer.
14. Disconnect the fuel vaporizer and MAP sensor

15. Remove the fuel vaporizer retaining bracket.
16. Disconnect the fuel supply line from the

vaporizer.
1. Discard the O-ring seal.
Installation
1. NOTE: Install a new retaining clip.

2. Fill the cooling system. For additional
Cooling.

4. CAUTION: If a new fuel vaporizer has

been installed the fuel system differential
pressure setting will have to be checked and
adjusted to specification. Before the vehicle
is tested for normal operation, carry out the
fuel system differential pressure check.
Check the fuel system differential pressure
settings. For additional information, refer to
Section 310-00A Fuel System - General
Information.

Liquefied Petroleum Gas (LPG) - Gas Fuel
Vaporizer Filter Element
Print
General Equipment
29mm Spanner
Removal
1. Remove the fuel vaporizer.
For additional information, refer to Fuel Vaporizer
- in this section.
2. Remove the fuel vaporizer solenoid.
3. Remove and discard the fuel vaporizer filter

element.
1. Hold the fuel vaporizer filter housing with
a 29mm Spanner spanner to prevent the
fuel vaporizer filter housing from turning.
2. Remove the fuel vaporizer filter element
retaining nut.
Discard the fuel vaporizer filter element O-
ring seal.
Installation
1. NOTE: Install a new fuel vaporizer filter
element O-ring seal.
NOTE: Install a new fuel vaporizer filter
element.
Install the fuel vaporizer filter element.
1. Hold the fuel vaporizer filter housing with
a 29mm Spanner spanner to prevent the
fuel vaporizer filter housing from turning.
2. Install the fuel vaporizer filter element
retaining nut.
2. Install the fuel vaporizer solenoid.

3. Install the fuel vaporizer.
For additional information, refer to Fuel Vaporizer
- in this section.


Liquefied Petroleum Gas (LPG) - Gas
Control Module
Print
Removal
3. Disconnect the alternative fuel control module
Release the locking tangs.
4. Remove the alternative fuel control module.
Installation

Injection Supply Manifold
Print
Removal
1. For additional information, refer to Fuel Injectors
- in this section.

Accessory Drive - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Torque Specifications - vehicles with diesel engines

Accessory drive belt idler pulley retaining bolt 48 35 -
Accessory drive belt tensioner retaining nuts 48 35 -
Charge air cooler outlet pipe retaining nuts 9 - 80
Power steering line support bracket retaining nut 5 - 44
Power steering pump retaining bolts 25 18 -
Torque Specifications - all except vehicles with diesel engines

Accessory drive belt idler pulley retaining bolt 48 35 -
Accessory drive belt tensioner retaining bolts 25 18 -

Accessory Drive - Accessory Drive—1.8L
Print
1.8L Zetec E
All accessories are driven by a multi-groove drive belt.
The illustration shows the versions with and without air conditioning.
NOTE: Please refer to the current service literature for the change interval for the multi-
groove belt.
An automatic belt tensioner is used to tension the belt. To release the tension on the multi-
groove belt, press the belt-tensioner counter clockwise against the force of the spring.

A - Vehicles without air conditioning
B - Vehicles with air conditioning
1 - Generator
2 - Idler pulley
4 - Coolant pump
5 - Multi-groove belt
6 - Crankshaft vibration damper
7 - Automatic belt tensioner
8 - A/C compressor

Accessory Drive - Accessory Drive—1.8L
Print
1.8L Duratorq DI and 1.8L Duratorq TDCi

The layout of the accessories is identical on both diesel engine variants.
All accessories are driven by a multi-groove belt.
NOTE: Please refer to the current service literature for the change interval for the multi-
groove belt.
An automatic belt tensioner is used to tension the belt. To release the tension on the multi-
groove belt, press the tension roller of the belt-tensioner counter clockwise against the
force of the spring.

A - Vehicles without air conditioning
B - Vehicles with air conditioning
2 - Automatic belt tensioner
3 - Coolant pump
4 - Multi-groove belt
5 - Generator
6 - Idler pulley
7 - Crankshaft vibration damper
8 - A/C compressor

Accessory Drive - Accessory Drive Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Mechanical
Damaged or contaminated accessory drive belt
Damaged or contaminated pulley(s)
Incorrect accessory drive belt
Incorrect fitment of the accessory drive belt
Accessory drive belt tensioner
Accessory drive belt idler pulley
Generator
Generator decoupler
Power steering pump
Power steering pump leakage
Air conditioning (A/C) compressor
Pulley(s)
Loose hardware
Accessory Drive Belt Concerns
CAUTION: Do not lubricate the accessory drive belt, accessory drive belt tensioner or
idler pulley(s) as potential damage to the accessory drive belt material construction,
accessory drive belt tensioner damping mechanism, accessory drive belt tensioner pulley
bearing and idler pulley(s) bearing may occur.
Cracking
Accessory drive belts are made from rubber which hardens with time and can develop
cracks. As the accessory drive belt runs on the back of some of the pulleys, the cracks are
opened up. Small cracks are not considered to be a failure of the accessory drive belt. Only
if the crack is deep enough to reach the bottom of the groove to expose the cord or any
chunks are found to be missing from the accessory drive belt, is the accessory drive belt
condition considered to be unacceptable.
1. 1. Check the accessory drive belt for cracks. If the damage exceeds the acceptable
limit, install a new accessory drive belt.
REFER to: Accessory Drive Belt - 1.8L Duratec-DOHC (85kW/115PS) - Zetec (303-05
REFER to: Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi
(Lynx) Diesel (303-05 Accessory Drive, Removal and Installation).
Chunking
Chunking describes the condition where long lengths of rubber become detached from the
ribs of the accessory drive belt. This is considered to be a failure of the accessory drive belt.

2. 2. Check the accessory drive belt for damage. If any chunks are found to be missing,
install a new accessory drive belt.
REFER to: Accessory Drive Belt - 1.8L Duratec-DOHC (85kW/115PS) - Zetec (303-05
REFER to: Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi
Pilling
Pilling is dust that forms in between the ribs of the accessory drive belt from rubber that is
worn off the accessory drive belt when it is new. There may also be loose particles left on
the accessory drive belt during the manufacturing process. These are worn off and form
into small balls of rubber that then get trapped in the grooves of the accessory drive belt.
This condition will usually clear itself within 4800 km - 8000 km (3000 miles - 5000 miles)
of normal driving.
3. 3. Check the accessory drive belt for pilling. The condition of the accessory drive belt
should be compared against the illustration.
1. Small scattered pills. Not considered a concern. No action required.
2. Small scattered pills. Not considered a concern. No action required.
3. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
REFER to: Accessory Drive Belt - 1.8L Duratec-DOHC (85kW/115PS) - Zetec (303-

05 Accessory Drive, Removal and Installation) /
Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi
4. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
5. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new
accessory drive belt.
6. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new
accessory drive belt.
Fraying - Vehicles without accessory drive belt tensioner built up to 02/2003

Due to the manufacturing process, the accessory drive belt edge may appear frayed, but
this frayed appearance does not necessarily affect the durability or performance of the
accessory drive belt. If a concern is raised during a service or repair over the level of
fraying, the condition of the accessory drive belt should be compared against the
illustrations.

4. 4. Check the accessory drive belt for fraying.
1. No fraying (new accessory drive belt). Not considered a concern. No action

required.
2. Fraying just starting. Not considered a concern. No action required.
3. Slight fraying. Not considered a concern. No action required.
4. High amount of fraying without cord cuts. INSTALL a new accessory drive belt.
5. High amount of fraying with cord cuts. INSTALL a new accessory drive belt.
Incorrect fitment
Accessory drive belt noise can be generated by the accessory drive belt being incorrectly
fitted on the pulley as shown in the following illustration. Make sure that all the V grooves
on the accessory drive belt contact correctly with the pulley.
Chart.

Symptom Chart
Symptom Chart

Accessory drive belt * Accessory drive * CHECK the system with the engine running and
noise system - Vehicles the accessory drive belt removed (only run the
with accessory engine for a very short period). If a noise is
drive belt apparent, the cause is not the accessory drive
tensioner system. If a noise is not apparent, the cause is
the accessory drive system. CHECK where the
noise is coming from. Use a stethoscope or
other listening device to determine the source of
the noise. INSTALL new components as
operation.
* Accessory drive * Use a stethoscope or other listening device to
system - Vehicles determine the source of the noise. INSTALL new
without accessory components as necessary. TEST the system for
drive belt normal operation.
tensioner
* Accessory drive * CHECK the accessory drive belt is correctly
belt incorrectly installed in the pulley grooves. INSTALL a new
installed. accessory drive belt as necessary.
REFER to: Accessory Drive Belt - 1.8L Duratec-
DOHC (85kW/115PS) - Zetec (303-05 Accessory
Drive, Removal and Installation) /
Accessory Drive Belt - 1.8L Duratorq-TDCi
(303-05 Accessory Drive, Removal and
Installation).
* Pulley(s). * CHECK the pulley(s) for damage, freedom of
rotation, stone entrapment and alignment.
INSTALL new components as necessary. TEST
* Lubricant or * CHECK the accessory drive belt for
other contamination or damage. RECTIFY the source
contamination. of the leak and INSTALL a new accessory drive
belt.
REFER to: Accessory Drive Belt - 1.8L Duratec-
DOHC (85kW/115PS) - Zetec (303-05 Accessory
Installation).
* Generator * CHECK the generator decoupler for correct
decoupler seized. operation or damage. REFER to the Generator
Decoupler Component Test in this procedure.
NOTE: Squeal is * Accessory drive * CHECK the accessory drive belt tensioner for
defined as a belt tensioner correct operation, damage or contamination.
continuous shriek, worn, damaged REFER to the Accessory Drive Belt Tensioner
most noticeable or contaminated Component Test in this procedure. INSTALL a
when the engine is with oil. new accessory drive belt tensioner as
being accelerated or necessary.
with electrical load. REFER to: Accessory Drive Belt Tensioner - 1.8L
Accessory drive belt Duratec-DOHC (85kW/115PS) - Zetec (303-05
squeal Accessory Drive, Removal and Installation) /

Accessory Drive Belt Tensioner - 1.8L Duratorq-
Diesel (303-05 Accessory Drive, Removal and
Installation).
NOTE: Whine is * Poor surface * REMOVE the accessory drive belt.
defined as a finish on REFER to: Accessory Drive Belt - 1.8L Duratec-
continuous noise at accessory drive DOHC (85kW/115PS) - Zetec (303-05 Accessory
the same frequency, belt idler pulley Drive, Removal and Installation) /
generally associated flat surface(s). Accessory Drive Belt - 1.8L Duratorq-TDCi
with plastic pulleys. (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel
Accessory drive belt (303-05 Accessory Drive, Removal and
whine Installation).
INSPECT the idler pulley(s) for surface finish.
INSTALL a new idler pulley(s) as necessary.
* Accessory drive * REMOVE the accessory drive belt.
belt idler pulley REFER to: Accessory Drive Belt - 1.8L Duratec-
bearing failure. DOHC (85kW/115PS) - Zetec (303-05 Accessory
Installation).
INSPECT the idler pulley(s) for smooth rotation.
INSTALL a new idler pulley(s) as necessary.
NOTE: Chirp is * Pulley * CHECK that the accessory drive belt is running
defined as a misalignment centrally on the flat pulleys. TEST the system
twittering noise, (usually evident for normal operation.
often intermittent at idle). * CHECK the pulleys for excessive end float and
Accessory drive belt bent flanges.
chirp * With the engine running at idle, use a
stethoscope to identify the source of the noise.
INSTALL new components as necessary. TEST
NOTE: Rattle is * Accessory drive * CHECK the accessory drive belt tensioner for
defined as a metallic belt tensioner correct operation or damage. REFER to the
knocking noise hitting the end Accessory Drive Belt Tensioner Component Test
Accessory drive belt stops. in this procedure. INSTALL a new accessory
rattle drive belt tensioner as necessary.
REFER to: Accessory Drive Belt Tensioner - 1.8L
Duratec-DOHC (85kW/115PS) - Zetec (303-05
Accessory Drive, Removal and Installation) /
Accessory Drive Belt Tensioner - 1.8L Duratorq-
Installation).
* Loose * CHECK the components or hardware for correct
components or installation and tighten as necessary. TEST the
hardware. system for normal operation.
Accessory drive belt * Accessory drive * CHECK the extent of the fraying by referring to
fraying belt. the illustrations shown in the Visual Inspection

* Pulley(s). section. Only INSTALL a new accessory drive
belt if the fraying is within the criteria quoted in
the Visual Inspection section. TEST the system
* CHECK the pulley(s) for damage, freedom of
rotation and alignment. INSTALL new
components as necessary. TEST the system for
normal operation.
Component Tests
Accessory Drive Belt Tensioner - Static Check
The accessory drive belt tensioner may be checked statically as follows:
1. 1. Inspect the area surrounding the accessory drive belt tensioner for lubricant or
other contamination. Rectify any leaks before installing a new accessory drive belt
tensioner. If the accessory drive belt tensioner is contaminated, do not attempt to
clean it as the damping mechanism inside may be damaged. INSTALL a new
accessory drive belt tensioner as necessary.
REFER to: Accessory Drive Belt Tensioner - 1.8L Duratec-DOHC (85kW/115PS) -
Zetec (303-05 Accessory Drive, Removal and Installation) /
Accessory Drive Belt Tensioner - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-
TDDi (Lynx) Diesel (303-05 Accessory Drive, Removal and Installation).
2. 2. Detach the accessory drive belt in the area of the accessory drive belt tensioner.
3. NOTE: The accessory drive belt tensioner has a damping feature, which is usually a
friction device, therefore some friction within the system is normal.
3. Using the correct tool, move the accessory drive belt tensioner from its relaxed
position through its full stroke and back to the relaxed position to make sure there
is no excessive stick, grab or bind, and to make sure there is tension on the
accessory drive belt tensioner spring.
4. 4. Rotate the accessory drive belt tensioner pulley and check for damage, freedom of
rotation and alignment. INSTALL a new accessory drive belt tensioner as necessary.

5. 5. If the accessory drive belt tensioner meets the above criteria, proceed to test the
accessory drive belt tensioner dynamically. If the accessory drive belt tensioner
does not meet the above criteria, INSTALL a new accessory drive belt tensioner.
Accessory Drive Belt Tensioner - Dynamic Check
The accessory drive belt tensioner may be checked dynamically as follows:
1. 1. With the engine running, observe the accessory drive belt tensioner movement.
The accessory drive belt tensioner should move (respond) when the engine is
accelerated rapidly or when the A/C clutch cycles ON and OFF (the degree of

movement can be up to 4 mm). If the accessory drive belt tensioner movement is not
constant without engine acceleration or A/C clutch cycling, a pulley or shaft is
possibly bent, out of round, or the damping mechanism inside the accessory drive
belt tensioner may be damaged. INSTALL a new accessory drive belt tensioner as
necessary.
2. 2. Excessive accessory drive belt rideout (uneven depth of grooves in the accessory
drive belt) may cause excessive accessory drive belt tensioner movement. Check
the condition by installing a new accessory drive belt.
Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx)
Diesel (303-05 Accessory Drive, Removal and Installation).
Generator Decoupler
1. 1. Remove the accessory drive belt.

Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx)
Diesel (303-05 Accessory Drive, Removal and Installation).
2. 2. Using an Allen key or appropriate tool to prevent the generator center shaft from
rotating, attempt to rotate the generator decoupler both clockwise and
counterclockwise.
3. 3. Make sure that the generator decoupler rotates freely in a counterclockwise

direction and is locked in the clockwise direction (as viewed from the crankshaft
pulley end of the engine). If the generator decoupler is seized or rotates freely in
both directions, install a new generator decoupler.

Accessory Drive - Accessory Drive Belt—
Zetec
Print
Removal
Lifting.

clockwise.
Installation

Vehicles without air conditioning

Accessory Drive - Accessory Drive Belt—
1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
Lifting.

clockwise.
Installation


Accessory Drive - Accessory Drive Belt
Tensioner—1.8L Duratec-DOHC Transit/Tourneo Connect 2002.5 (06/2002-)
(85kW/115PS) - Zetec
Print

For additional information, refer to Accessory
Drive Belt in this section.
it to one side.
(s).

1 - Accessory drive belt tensioner retaining bolts
2 - Accessory drive belt tensioner

Accessory Drive - Accessory Drive Belt
Tensioner—1.8L Duratorq-TDCi (Lynx) Transit/Tourneo Connect 2002.5 (06/2002-)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel
Print

charge air cooler outlet pipe retaining
clamps.

it to one side.
3. Detach the power steering fluid reservoir and

4. Detach the power steering pipe retaining

bracket.

5. Detach the fuel filter and the fuel filter retaining
bracket and position it to one side.
Press the fuel filter retaining clip.
Detach the fuel filter and the fuel filter
retaining bracket from the fuel filter
support bracket.

(s).
CAUTION: The accessory drive belt tensioner and bracket are one assembly. Do not
remove the accessory drive belt tensioner or the accessory drive belt tensioner pulley
from the bracket. Failure to follow this instruction may result in failure of the accessory
drive belt tensioner.

1 - Power steering pump retaining bolts
2 - Accessory drive belt tensioner retaining nut
3 - Power steering pump retaining bolts
See Removal Detail
See Removal Detail
5 - Accessory drive belt tensioner retaining nuts
6 - Accessory drive belt tensioner

pipe retaining clamps must be installed in the
Install the charge air cooler outlet pipe retaining
clamps.

Removal Details
Item 3 : Power steering pump retaining bolts

Item 4 : Power steering pump
1. Detach the power steering pump and position to

one side.
Item 3 : Power steering pump retaining bolts

Starting System - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Starter motor power connection 12 9 -
Starter solenoid connection 6 - 53
Valve cover oil separator retaining bolt (2.0L Duretec RS) 25 18 -

Starting System - Starting System—
Vehicles Built Up To: 08/2006
Print

Refer to Wiring Diagrams Section 303-06, for schematic and connector
information.
2. 2. Visually inspect for obvious signs of electrical damage.
Electrical
Fuse(s)
Wiring harness
Electrical connector(s)
Relay
Central junction box (CJB)
Battery junction box (BJB)
Switch(es)
Battery
Starter motor
Chart.
Symptom Chart
Symptom Chart

The engine does not * Battery. * REFER to Section 414-00 Charging System -
crank/the relay does click General Information.
* Relay. * CARRY OUT the relay Component Test.
REFER to the wiring diagrams.
* Circuit(s). * GO to Pinpoint Test A.
* Starter motor. * CARRY OUT the starter motor Component
Test using WDS.
The engine does not * Battery. * REFER to Section 414-00 Charging System -
crank/the relay does not General Information.
click * Fuse(s). * INSTALL a new fuse as necessary. If the fuse
fails again check for short to ground.
* Passive anti-theft * REFER to Section 419-01A Anti-Theft -
system (PATS). Active / 419-01B Anti-Theft - Passive.
* Ignition switch. * GO to Pinpoint Test B.
* Circuit(s).
The engine cranks slowly * Battery. * REFER to Section 414-00 Charging System -
* Starter motor. * CARRY OUT the starter motor Component
Test using WDS.
* Circuit(s). * GO to Pinpoint Test C.

Unusual starter noise * Starter motor. * REMOVE the starter motor.
REFER to Starter Motor - 1.8L /
Starter Motor - 1.8L Diesel in this section.
INSPECT the starter motor gear for damage.
INSTALL a new starter motor as necessary.
* Flywheel ring * INSPECT the flywheel for damage. REFER to
gear. Section 303-00 Engine System - General
Information.
The starter spins but the * Starter motor. * REMOVE the starter motor.
engine does not crank REFER to Starter Motor - 1.8L /
* Flywheel ring * INSPECT the flywheel for damage. REFER to
gear. Section 303-00 Engine System - General
Information.
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical measurements.
PINPOINT TEST A : THE ENGINE DOES NOT CRANK/THE RELAY DOES
CLICK
A1: CHECK VOLTAGE TO STARTER SOLENOID
2 Measure the voltage between starter motor
terminal 50, harness side and ground.

Yes
GO to A2.
No
GO to A3.
A2: CHECK THE VOLTAGE DROP
1 Measure the voltage between starter motor
terminal 30, component side and the battery
positive terminal.
Is the voltage less than 0.5 volts?

Yes
GO to A4.
No
CLEAN and TIGHTEN all battery positive cable
connections. TEST the system for normal operation.
If the concern persists, INSTALL a new starter

motor to battery cable. REFER to Section 414-01
Battery, Mounting and Cables. TEST the system for
normal operation.
A3: CHECK CIRCUIT 30-BB9 (RD) FOR OPEN
2 Disconnect Starter Relay C1017.
3 Measure the voltage between starter relay C1017
pin 3, circuit 30-BB9 (RD), harness side and
ground.

Yes
REPAIR circuit 50-BB12 (GY). TEST the system for
normal operation.
No
REPAIR circuit 30-BB9 (RD). TEST the system for
normal operation.
A4: CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN
1 Measure the resistance between the starter motor
casing and battery ground terminal.
Is the resistance less than 0.5 ohms?

Yes
INSTALL a new starter motor.
No
CLEAN and TIGHTEN all battery and engine ground
cable connections. TEST the system for normal
operation.
PINPOINT TEST B : THE ENGINE DOES NOT CRANK/RELAY DOES NOT

CLICK
B1: CHECK THE SWITCHED POWER TO THE STARTER RELAY
1 Disconnect Starter Relay C1017.
3 Measure the voltage between the starter motor
relay C1017 pin 1, harness side and ground.

Yes
GO to B3.
No
GO to B2.
B2: CHECK CIRCUIT 50-BB16 (GY/BK) FOR OPEN
2 Disconnect Ignition Switch C456.
3 Measure the resistance between the ignition switch
C456 pin 7, circuit 50-BB16 (GY/BK), harness side
and the starter relay C1017 pin 1, circuit 50-BB16
(GY/BK), harness side.

Yes
INSTALL a new ignition switch. REFER to Section
211-05 Steering Column Switches. TEST the system
No
REPAIR the circuit. TEST the system for normal
operation.
B3: CHECK CIRCUIT 31S-BB16 (BK/RD) FOR OPEN
2 Measure the resistance between the starter relay
C1017 pin 2, circuit 31S-BB16 (BK/RD), harness
side and ground.

Yes
INSTALL a new starter relay. TEST the system for
normal operation.
No
Vehicles with 1.8L (75 PS) diesel engines. GO to
B4.
Vehicles with 1.8L (90 PS) diesel engines. GO to
B5.

All except vehicles with diesel engines. GO to B6.
2 Disconnect PCM C415.
side and PCM C415 pin 27, 31S-BB16 (BK/RD),
harness side.

Yes
CHECK the PCM. REFER to WDS.
No
operation.
harness side.

Yes
No
operation.
harness side.

Yes
No

operation.
PINPOINT TEST C : THE ENGINE CRANKS SLOWLY

C1: CHECK FOR VOLTAGE DROP
positive terminal.

Yes
GO to C2.
No
If the concern persists, INSTALL a new battery to
starter motor solenoid cable. REFER to Section
414-01 Battery, Mounting and Cables. Test the
C2: CHECK FOR GROUND CONNECTION
case and the battery ground terminal.

Yes
No
CLEAN and TIGHTEN all battery ground cable
connections, starter motor mounting and body to
ground straps. TEST the system for normal
operation. If the concern persists, INSTALL a new
battery ground cable. Test the system for normal
operation.

Starting System - Starting System—
Print

information.
Electrical
Fuse(s)
Wiring harness
Relay
Switch(es)
Battery
Starter motor
Chart.
Symptom Chart

The engine does not * Battery. * REFER to: Battery (414-01 Battery, Mounting
crank/the relay does and Cables, Diagnosis and Testing).
click * Relay. * CARRY OUT the relay Component Test. REFER to
the wiring diagrams.
* Starter motor. * CARRY OUT the starter motor Component Test
using the WDS.
The engine does not * Battery. * REFER to: Battery (414-01 Battery, Mounting
crank/the relay does and Cables, Diagnosis and Testing).
not click * Fuse(s). * INSTALL a new fuse as necessary. If the fuse
fails again check for short to ground.
* Passive anti- * REFER to: Anti-Theft - Passive (419-01B Anti-
theft system Theft - Passive, Diagnosis and Testing).
(PATS).
* Ignition switch. * GO to Pinpoint Test B.
* Circuit(s).
The engine cranks * Battery. * REFER to: Battery (414-01 Battery, Mounting
slowly and Cables, Diagnosis and Testing).
* Starter motor. * CARRY OUT the starter motor Component Test
using the WDS.

Unusual starter noise * Starter motor. * REMOVE the starter motor.
REFER to: Starter Motor - Vehicles Built From:
08/2006 1.8L Duratorq-TDCi (Kent) Diesel (303-
06, Removal and Installation).
* Flywheel ring * INSPECT the flywheel for damage.
gear. REFER to: Flywheel Inspection (303-00 Engine
Procedures).
The starter spins but * Starter motor. * REMOVE the starter motor.
the engine does not REFER to: Starter Motor - Vehicles Built From:
crank 08/2006 1.8L Duratorq-TDCi (Kent) Diesel (303-
06, Removal and Installation).
* Flywheel ring * INSPECT the flywheel for damage.
gear. REFER to: Flywheel Inspection (303-00 Engine
Procedures).
Pinpoint Tests
PINPOINT TEST A : THE ENGINE DOES NOT CRANK/THE RELAY DOES
CLICK
A1: CHECK VOLTAGE TO STARTER SOLENOID
terminal 50, harness side and ground.

Yes
GO to A2.
No
GO to A3.
A2: CHECK THE VOLTAGE DROP
positive terminal.

Yes
GO to A4.

No
If the concern persists, INSTALL a new starter
motor to battery cable.
REFER to: Battery Cables - 1.8L Duratorq-TDCi
and Installation).
A3: CHECK CIRCUIT 30-BB12 (RD) FOR OPEN
2 Disconnect Starter Relay R13.
3 Measure the voltage between the starter relay R13
pin 3, circuit 30-BB12 (RD), harness side and
ground.

Yes
REPAIR circuit 50-BB12 (GY). TEST the system for
normal operation.
No
REPAIR circuit 30-BB12 (RD). TEST the system for
normal operation.
A4: CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN
1 Measure the resistance between the starter motor
casing and the battery ground terminal.
Is the resistance less than 0.5 ohms?

Yes
08/2006 1.8L Duratorq-TDCi (Kent) Diesel (303-06,
No
CLEAN and TIGHTEN all battery and engine ground
cable connections. TEST the system for normal
operation.
PINPOINT TEST B : THE ENGINE DOES NOT CRANK/RELAY DOES NOT

CLICK
B1: CHECK THE SWITCHED POWER TO THE STARTER RELAY
1 Disconnect Starter Relay R13.

3 Measure the voltage between the starter motor relay
R13 pin 1, circuit 50-BB16 (GY/BK), harness side
and ground.

Yes
GO to B3.
No
GO to B2.
B2: CHECK CIRCUIT 50-BB16 (GY/BK) FOR OPEN
2 Disconnect Ignition switch C456.
3 Measure the resistance between the ignition switch
C456 pin 7, circuit 50-BB16 (GY/BK), harness side
and the starter relay R13 pin 1, circuit 50-BB16
(GY/BK), harness side.
Is the resistance less than 1 ohm?

Yes
INSTALL a new ignition switch.
REFER to: Ignition Switch (211-05 Steering Column
Switches, Removal and Installation).
No
operation.
R13 pin 2, circuit 31S-BB16 (BK/RD), harness side
and ground.

Yes
INSTALL a new starter relay. TEST the system for
normal operation.
No
GO to B4.

2 Disconnect Powertrain Control Module (PCM) C417.
C1017 pin 2, circuit 31S-BB16 (BK/RD), harness side
and the PCM C415 pin 27, 31S-BB16 (BK/RD),
harness side.

Yes
CHECK the PCM. REFER to the WDS.
No
operation.
PINPOINT TEST C : THE ENGINE CRANKS SLOWLY

C1: CHECK FOR VOLTAGE DROP
positive terminal.

Yes
GO to C2.
No
If the concern persists, INSTALL a new battery to
starter motor solenoid cable.
REFER to: Battery Cables - 1.8L Duratorq-TDCi
and Installation).
C2: CHECK FOR GROUND CONNECTION
case and the battery ground terminal.

Yes
08/2006 1.8L Duratorq-TDCi (Kent) Diesel (303-06,
No
CLEAN and TIGHTEN all battery ground cable
connections, starter motor mounting and body to
ground straps. TEST the system for normal
operation. If the concern persists, INSTALL a new
battery ground cable. Test the system for normal
operation.

Starting System - Starter Motor—1.8L
Print

(s).

1 - Starter motor retaining bolts
-

-
2 Battery to transaxle ground cable
3 - Ignition switch and battery to starter motor solenoid cable electrical
connector
See Removal Detail
4 - Starter motor retaining bolt
5 - Starter motor
Removal Details
Item 3 : Ignition switch and battery to starter motor solenoid cable electrical connector

Lifting.
2. Disconnect the ignition switch and battery to
starter motor solenoid cable electrical connector
retaining nuts.

Starting System - Starter Motor—1.8L
Duratorq-TDDi (Lynx) Diesel, Vehicles
Built Up To: 08/2006
Print

Lifting.
(s).

1 - Ignition switch and battery to starter motor solenoid cable electrical
connector
See Removal Detail
2 - Starter motor retaining bolts
3 - Battery to transaxle ground cable
-

-
4 Starter motor retaining bolt
5 - Starter motor
Removal Details
1. Disconnect and detach the ignition switch and

battery to starter motor solenoid cable electrical
connector:
1. Detach the ignition switch and battery to
starter motor cable retaining clip.
2. Remove the ignition switch to starter
motor solenoid cable electrical connector
retaining nut.
3. Remove the battery to starter motor
solenoid cable electrical connector
retaining nut.

Starting System - Starter Motor—Vehicles
Built From: 08/2006
Print
Removal
Refer to: Battery Disconnect and Connect (414-

Procedures).

3.
1. Torque: 12 Nm
2. Torque: 6 Nm
3. Torque: 35 Nm
4. Torque: 35 Nm
Installation

Engine Ignition - 1.8L Duratec-DOHC
(85kW/115PS) - Zetec - Specifications
Print

Ignition coil retaining bolts 6 - 53
Ignition coil bracket retaining bolts 20 15 -
Spark plugs 15 11 -

Engine Ignition - 1.8L Duratec-DOHC
(85kW/115PS) - Zetec - Engine Ignition
Print
General Equipment
Electrical
Wiring harness
Spark plug(s)
Spark plug wire(s)
Ignition coil pack
Powertrain control module (PCM)
Chart.
Symptom Chart
Symptom Chart

Engine misfire * Spark plug(s). * CARRY OUT a KV test using WDS.
* Spark plug wire(s).
* Ignition coil pack. * REFER to WDS.
* PCM.
* PCM calibration.
Engine stumbling * Spark plug(s). * CARRY OUT a KV test using WDS.
* PCM.
* PCM calibration.
Engine lacks power * Spark plug(s). * CARRY OUT a KV test using WDS.

Glow Plug System - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
lb- lb-
Item Nm ft in
Glow plug 15 11 -
Glow plug electrical connector retaining nut 2 - 18
Glow plug relay to glow plug wire terminal block cable electrical connector 4 - 35
retaining nut

Glow Plug System - Glow Plug System Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Electrical
Fuse(s)
Relay
Wiring harness
Glow plug(s)
Glow plug wire

Glow Plug System - Glow Plug Wire—1.8L
Print
Special Tool(s)
303-397 (24-003)

(s).

1 - Glow plug relay to glow plug wire terminal block cable electrical
connector retaining nut
-

-
2 Glow plug relay to glow plug wire terminal block cable
3 - Glow plug wire terminal block retaining bolt
4 - Oil level indicator tube retaining bolt
See Removal Detail
See Removal Detail
7 - PCV hose
8 - Glow plug wire electrical connector retaining nut
9 - Glow plug wire
Removal Details

to one side.
Item 6 : Positive crankcase ventilation (PCV) hose retaining clamp
1. Using the special tool, detach the PCV hose

retaining clamp.

Glow Plug System - Glow Plug—1.8L Duratorq-TDCi
(Lynx) Diesel (75 PS/90 PS/110 PS), Vehicles Built Transit/Tourneo Connect 2002.5 (06/2002-)
From: 08/2006
Print

General Equipment
Removal
Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and
CAUTION: Make sure that all openings are sealed.

3.
1. Torque: 4 Nm
2. Torque: 7 Nm
3. Torque: 2 Nm
4. Torque: 15 Nm
Installation

Engine Emission Control - 1.8L Duratec-
DOHC (85kW/115PS) - Zetec - Transit/Tourneo Connect 2002.5 (06/2002-)
Specifications
Print

Positive crankcase ventilation (PCV) pipe retaining bolt 10 - 89

DOHC (85kW/115PS) - Zetec - Engine Transit/Tourneo Connect 2002.5 (06/2002-)
Emission Control
Print
Electrical
Vacuum line(s)
Hose(s)/hose joints
Gasket(s)
Positive crankcase ventilation (PCV) valve
Crankcase vent oil separator
Symptom Chart.
Symptom Chart
Symptom Chart

Excessive * Blocked or damaged * CHECK the PCV system components for
crankcase PCV pipe(s)/hose(s). blockages, CLEAN or INSTALL new components
pressure * Blocked PCV valve. as necessary.
* Blocked crankcase vent
oil separator.

DOHC (85kW/115PS) - Zetec - Positive Transit/Tourneo Connect 2002.5 (06/2002-)
Crankcase Ventilation (PCV) Hose
Print

Cooling.
(s).

1 - PCV hose to intake manifold retaining clip
2 - PCV hose to intake manifold
See Removal Detail

See Removal Detail
6 - PCV pipe retaining bolt
7 - PCV hose to PCV valve
8 - PCV pipe and hoses
Removal Details
Item 3 : Thermostat housing retaining bolts

Item 3 : Thermostat housing retaining bolts

Engine Emission Control - 1.8L Duratorq-
TDCi (Lynx) Diesel/1.8L Duratorq-TDDi Transit/Tourneo Connect 2002.5 (06/2002-)
(Lynx) Diesel - Specifications
Print

Charge air cooler hose clamps 4.5 - 40
Charge air cooler intake pipe nut 9 – 80
Charge air cooler outlet pipe nut 9 – 80
EGR cooler clamp 10 - 89
Exhaust gas recirculation (EGR) cooler to EGR valve bolts 20 15 -
Charge air cooler intake pipe support bracket nut 23 17 -
Positive crankcase ventilation (PCV) oil separator bolt 23 17 -
EGR cooler bolt 23 17 -
Intake manifold bolts 25 18 -
Intake manifold nuts 25 18 -

Charge air cooler hose clamps 4 - 35
EGR cooler clamp 4 - 35
Charge air cooler intake pipe nut 9 - 80
Charge air cooler outlet pipe nut 9 - 80
EGR cooler bolt 10 - 89
EGR cooler nut 10 - 89
EGR cooler to turbocharger bolts 23 17 -
Charge air cooler intake pipe support bracket nut 23 17 -
Positive crankcase ventilation (PCV) oil separator bolt 23 17 -
Intake manifold bolts 24 18 -
Intake manifold nuts 24 18 -

TDCi (Lynx) Diesel/1.8L Duratorq-TDDi Transit/Tourneo Connect 2002.5 (06/2002-)
(Lynx) Diesel - Engine Emission Control
Print

1 - Exhaust gas recirculation (EGR) valve
2 - EGR cooler to intake manifold gasket
3 - EGR cooler
4 - EGR cooler tube to exhaust manifold gasket
The EGR system allows a measured quantity of exhaust gas to be directed back to the
intake manifold. The exhaust gas is introduced to the incoming charge air in the intake
manifold, where it mixes with the air/fuel mixture and lowers the peak gas temperature,
reducing nitrogen oxide (NOx) exhaust emissions. The EGR valve is electrically operated
and is controlled through an input from the powertrain control module (PCM). The EGR
valve must not be disassembled or removed from the intake manifold.
The EGR system is fitted with an EGR cooler. The EGR cooler reduces the temperature of
the exhaust gasses being returned to the intake system. By reducing the EGR temperature,
the intake air charge density is not adversely affected, so maintaining the optimum fueling
characteristics.

1 - Valve cover and crankcase to crankcase vent oil separator positive
crankcase ventilation (PCV) hose
2 - Crankcase vent oil separator to valve cover PCV hose
3 - Crankcase vent oil separator
4 - Crankcase vent oil separator to crankcase PCV hose

1 - PCV valve cover
2 - PCV valve diaphragm
3 - PCV valve bush
4 - Valve cover
-

5 Valve cover to air intake pipe PCV hose
6 - PCV valve spring
The PCV system consists of a crankcase vent oil separator connected to the crankcase and
valve cover by hoses.
The crankcase pressure is controlled by a diaphragm operated PCV valve built into the valve
cover and cannot be removed. As the pressure in the crankcase vent oil separator reduces,
the diaphragm valve closes against the force of the PCV valve spring, so closing the PCV
valve. As the crankcase pressure rises, the PCV valve is pushed open assisted by the PCV
valve spring. This allows the positive crankcase gasses to be scavenged by the air intake
system.

TDCi (Lynx) Diesel/1.8L Duratorq-TDDi
(Lynx) Diesel - Engine Emission Control—
75 PS/90 PS
Print
Special Tool(s)
416-D001 (23-036A)
Mechanical
Exhaust gas recirculation (EGR) valve
EGR tube
EGR tube clamps
Gaskets/seals
Positive crankcase ventilation (PCV) hoses
EGR vacuum regulator valve
Chart.
Symptom Chart
Symptom Chart

Excessive exhaust * EGR valve. * GO to Pinpoint Test A. .
black smoke * EGR vacuum
regulator valve.
Excessive * Blocked or damaged * CHECK the PCV system components for
crankcase PCV hose(s). blockages, CLEAN or INSTALL new components
pressure * Blocked crankcase as necessary.
vent oil separator.
Pinpoint Tests
PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE

A1: CHECK VACUUM TO THE EGR VALVE
1 Disconnect the vacuum line from the EGR valve.

2 Connect the special tool to the disconnected
vacuum line.
4 Using the special tool, measure the vacuum at the
EGR vacuum line.
With the engine at idle and below 30°C, is no vacuum

indicated on the vacuum gauge?
Yes
GO to A2. .
No
Using WDS, CHECK the Exhaust Gas Recerculation
Valve Duty Cycle input signal to the EGR vacuum
regulator valve. If the result is 0%, INSTALL a new
vacuum regulator valve. TEST the system for
normal operation. If the result is not 0% continue
the diagnostic with WDS.
A2: CHECK THE EGR VALVE
1 Remove the charge air cooler outlet pipe.
2 Detach the power steering fluid reservoir and

position to one side.

3 Connect the special tool to the EGR valve.
4 Using the special tool, apply a vacuum to the EGR
valve.
5 Release the vacuum and observe the movement of

the EGR valve.
Does the EGR valve open and return to the fully closed
position?
Yes
GO to A3. .
No
INSTALL a new EGR valve. REFER to Section 303-
01A Engine / 303-01B Engine. TEST the system for
normal operation.
1 Using the special tool, apply a vacuum to the EGR
valve.
2 Inspect the EGR valve and valve seat for damage.
Is the EGR valve and valve seat undamaged?
Yes
REFER to Section 303-04A Fuel Charging and
Controls / 303-04B Fuel Charging and Controls /
303-04C Fuel Charging and Controls -
Controls.
No
INSTALL a new EGR valve. REFER to Section 303-
01A Engine / 303-01B Engine. TEST the system for
normal operation.

(Lynx) Diesel - Engine Emission Control— Transit/Tourneo Connect 2002.5 (06/2002-)
75 PS/90 PS, Vehicles Built From:
08/2006
Print
General Equipment
Ford approved diagnostic tool
Exhaust Gas Recirculation (EGR) system
To maintain the standards of low exhaust emission levels required, the EGR system is fully
electronically controlled.
The EGR valve is a proportional electric motor controlled directly by a duty-cycle signal
from the powertrain control module (PCM). Integrated into the EGR valve is a valve position
sensor. The signal from the EGR valve position sensor allows for the precise control of the
timing and the quantity of exhaust gas to be recirculated. If the EGR valve becomes
inoperative or fails to close completely, the PCM will raise a diagnostic trouble code (DTC)
and the instrument cluster malfunction indicator lamp (MIL) will be illuminated.
The EGR system is fitted with an EGR cooler. The EGR cooler reduces the temperature of
the exhaust gasses being returned to the intake system. By reducing the EGR temperature,
the intake air charge density is not adversely affected, so maintaining the optimum fuelling
characteristics.
Positive Crankcase Ventilation (PCV) system

1 - PCV valve cover
2 - PCV valve diaphragm
3 - PCV valve bush
4 - PCV valve spring
5 - Valve cover

The PCV system consists of a crankcase vent oil separator connected to the crankcase and
valve cover by hoses.
The crankcase pressure is controlled by a diaphragm operated PCV valve built into the valve
cover and cannot be removed. As the pressure in the crankcase vent oil separator reduces,
the diaphragm valve closes against the force of the PCV valve spring, so closing the PCV
valve. As the crankcase pressure rises, the PCV valve is pushed open assisted by the PCV
valve spring. This allows the positive crankcase gasses to be scavenged by the air intake
system.
EGR valve Electrical connector
EGR cooler Wiring harness
Gasket(s)
PCV hoses
(if possible) before proceeding to the next step
4. 4. If the cause is not visually evident, verify the symptom and refer to the diagnostic
trouble code (DTC) Index Chart.
Diagnostic Trouble Code (DTC) Index Chart
DTC Description/Condition Possible Source Action

P1402 EGR metering orifice restricted EGR valve stuck closed or leaking GO to Pinpoint Test A.
1. 1. If no DTCs are retrieved, verify the symptom and refer to the Symptom Chart.
Symptom Chart

Excessive * EGR valve. * GO to Pinpoint Test A.
exhaust black
smoke
Excessive * Blocked or damaged * GO to Pinpoint Test B.
crankcase PCV hose(s).
pressure * Blocked crankcase
vent oil separator.
* Worn or damaged * REFER to: Engine (303-01B Engine - 1.8L
engine components. Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi
Pinpoint Tests
PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE

CONDITIONS
1 Using the WDS, CHECK for DTC P1402.

Is DTC P1402 retrieved?
Yes
INSTALL a new EGR valve.
REFER to: Exhaust Gas Recirculation (EGR) Valve - 110 PS (303-08B
Engine Emission Control - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-
No
Continue the diagnostic using the Ford approved diagnostic tool.
PINPOINT TEST B : EXCESSIVE CRANKCASE PRESSURE

B1: CHECK THE PCV HOSES FOR BLOCKAGE
1 Remove the PCV hoses.
2 Inspect the PCV hoses and connections for blockage.

Are the PCV hoses and connections free from blockage?
Yes
INSTALL a new valve cover.
REFER to: Valve Cover (303-01B Engine - 1.8L
No
CLEAN or INSTALL new PCV hoses as necessary.
TEST the system for normal operation. If the concern
persists, CLEAN or INSTALL a new crankcase vent oil
separator as necessary. TEST the system for normal
operation.

(Lynx) Diesel - Crankcase Vent Oil
Separator—75 PS/90 PS
Print

Special Tool(s)
303-397 (24-003)

3. NOTE: Make note of the positions of the
charge air cooler intake hose retaining clamp
to make sure it is positioned in exactly the
same position when installing.
2. Detach the turbocharger outlet hose
retaining clamp.
3. Remove the charge air cooler intake pipe.
(s).

See Removal Detail
2 - PCV hose
3 - Engine coolant temperature (ECT) sensor electrical connector
5 - PCV hose
6 - Cylinder head temperature (CHT) sensor electrical connector
7 - CHT sensor electrical connector retaining clip
9 - PCV hose
10 - Charge air cooler intake pipe support bracket retaining nut
11 - Charge air cooler intake pipe support bracket
12 - Crankcase ventilation oil separator retaining bolt
13 - Crankcase ventilation oil separator
See Removal Detail

6. CAUTION: The turbocharger to charge
air cooler intake pipe hose retaining clamp
must be installed in the same position as
removed. Failure to follow this instruction
components.
Install a new turbocharger to charge air cooler
pipe hose and clamp.
Remove and discard the turbocharger to
charge air cooler pipe hose and clamp.
Install a new turbocharger to charge air
cooler pipe hose.
cooler pipe hose clamp in the same
position as when removed.

air cooler.
intake hose.
when removed.
Removal Details
Item 1 : Positive crankcase ventilation (PCV) hose retaining clamp
1. Using the special tool, detach the PCV hose

retaining clamp.
Item 13 : Crankcase ventilation oil separator
1. Slide the crankcase ventilation oil separator off

of the retaining bracket to remove.

Engine Emission Control - 1.8L Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel - Crankcase
Vent Oil Separator—75 PS/90 PS/110 PS, Vehicles Built
From: 08/2006
Print

General Equipment
Removal

inside of the pipe ends are clean
and free of oil residue.
1. Torque: 4 Nm
2. Torque: 9 Nm
3. General Equipment: Hose
clamp remover/installer
3. Torque: 23 Nm
Installation

(Lynx) Diesel - Exhaust Gas Recirculation
(EGR) Cooler—75 PS/90 PS
Print

Special Tool(s)
303-397 (24-003)

4. NOTE: Make note of the position of the

charge air cooler intake hose retaining clamp
to make sure it is positioned in exactly the
same position when installing.
2. Detach the turbocharger outlet hose
retaining clamp.
3. Remove the charge air cooler intake pipe.
(s).

1 - EGR cooler to EGR valve retaining bolts
2 - EGR cooler retaining clamp
See Removal Detail
3 - EGR cooler retaining bolt
See Removal Detail
4 - EGR cooler outlet hose retaining clamp
See Removal Detail
5 - EGR cooler outlet hose
6 - EGR cooler inlet hose retaining clamp
7 - EGR cooler inlet hose
8 - EGR cooler

8. Tighten the EGR cooler retaining bolt.

10. CAUTION: The turbocharger to charge

components.
Install a new turbocharger to charge air cooler
Remove and discard the turbocharger to
cooler pipe hose.

air cooler.
intake hose.
when removed.
12. Refill the cooling system.

Removal Details
Item 2 : EGR cooler retaining clamp
NOTE: Make a note of the position of the EGR cooler clamp.
NOTE: Discard the EGR cooler clamp.

Item 3 : EGR cooler retaining bolt

Item 4 : EGR cooler outlet hose retaining clamp
1. Using the special tool, detach the EGR cooler

Item 3 : EGR cooler retaining bolt
NOTE: Do not fully tighten the EGR cooler retaining bolt at this stage.
Item 2 : EGR cooler retaining clamp
NOTE: Install a new EGR cooler clamp.
NOTE: Make sure the clamp is installed in the same position as removed. The hinge of the
clamp should be obscured by the EGR cooler when viewed from the top of the engine.
This is to allow access to the catalytic convertor retaining nuts.

(Lynx) Diesel - Exhaust Gas Recirculation Transit/Tourneo Connect 2002.5 (06/2002-)
(EGR) Cooler—75 PS/90 PS/110 PS,
Print
General Equipment
Removal
1. Remove the fuel filter.
Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx)

Diesel (310-01A Fuel Tank and Lines, Removal
and Installation).

residue.
NOTE: Make a note of the orientation of the
charger air cooler clamp.
1. Torque: 4 Nm
2. Torque: 9 Nm
3. NOTE: The gaskets are to be reused unless

damaged.
remover/installer
Installation
1. NOTE: Only tighten the nut and bolts finger

2.
1. Torque: 23 Nm
2. Torque: 10 Nm
3. Torque: 10 Nm
4. Torque: 4 Nm


(EGR) Valve—75 PS/90 PS
Print

1. Loosen the retaining clamps.
Discard the hose retaining clamp.
2. Disconnect the EGR valve electrical connector.
3. Disconnect the intake manifold and EGR valve

vacuum lines.
4. Remove the turbocharger.

For additional information, refer to: Turbocharger
- 1.8L Duratorq-TDCi FGT (55kW/75PS) -
Lynx/1.8L Duratorq-TDCi FGT (66kW/90PS) -
Lynx (303-04C Fuel Charging and Controls -
Turbocharger, Removal and Installation).
(s).

1 - Intake manifold retaining nuts
See Removal Detail
2 - Intake manifold retaining bolts
3 - Intake manifold and EGR valve
4 - Intake manifold gasket
See Removal Detail
7. CAUTION: The intake manifold to charge

components.
Install a new intake manifold to charge air cooler
Remove and discard the intake manifold to
Install a new intake manifold to charge air
cooler pipe hose.


cooler.
outlet hose.
Install a new charge air cooler outlet hose
when removed.
Removal Details
Item 1 : Intake manifold retaining nuts
NOTE: Discard the intake manifold retaining nuts.
Item 4 : Intake manifold gasket
NOTE: Discard the intake manifold gasket.
Item 4 : Intake manifold gasket
NOTE: Install a new intake manifold gasket.
Item 1 : Intake manifold retaining nuts
NOTE: Install new intake manifold retaining nuts.

(EGR) Valve—110 PS
Print
Removal
CAUTION: The intake manifold and exhaust gas recirculation (EGR) valve must not
be separated.
1. Remove the exhaust manifold.
Refer to: Exhaust Manifold (303-01B Engine -

Refer to: Exhaust Gas Recirculation (EGR) Cooler

- 75 PS/90 PS/110 PS, Vehicles Built From:
08/2006 (303-08B Engine Emission Control -
3. Torque:
10 Nm
4. NOTE: Make sure that new components are

installed.
NOTE: The gaskets are to be reused unless
damaged.
Discard the nuts.
Torque: 24 Nm
Installation


Intake Air Distribution and Filtering -
Intake Air Distribution and Filtering
Print
Air cleaner condition indicator

NOTE: The basic function of the air cleaner condition indicator is the same for both petrol
engines and diesel engines.
The illustration shows a variant with a petrol engine.

1 - Air cleaner condition indicator
2 - Reset button
3 - Vacuum piston
4 - Spring
5 - Red zone
6 - Clear zone
7 - Green zone
The air cleaner is equipped with an air cleaner condition indicator.
The air cleaner condition indicator is a mechanical pressure gauge with a vacuum piston
which acts as a display and indicates the condition of the air cleaner element.
The air cleaner condition indicator is mounted on the air cleaner, directly behind the air
cleaner element.
It uses the available vacuum in the air intake system to continuously measure the air
permeability of the air cleaner element.
The measurement of the air permeability of the air cleaner element is performed under full
load, as this is when the maximum vacuum acts against the spring of the vacuum piston in
the air cleaner condition indicator.
If the permeability of the air cleaner element is reduced, then the vacuum in the air intake
system is increased, which pulls the vacuum piston down against the force of the spring

under full load.
A mechanism above the vacuum piston immobilises it in this position.
If the permeability of the air cleaner element is reduced even further, then the vacuum
increases again and the vacuum piston is pulled further down again.
The display on the indicator is divided into three areas with the following significance:
Green zone - air cleaner element is OK.
Clear zone - air cleaner element should be replaced.
Red zone - air cleaner element must be replaced.
NOTE: Under the effects of extreme humidity it is possible for the air cleaner condition
indicator to give an incorrect reading. If the air cleaner element has only recently been
replaced, but the vacuum piston is in the clear zone or the red zone, then press the reset
button. The air cleaner element does not need to be replaced.
After replacing the air cleaner element, the vacuum piston must be released by pressing
the reset button, which returns it to its starting position.

Intake Air Distribution and Filtering—75
PS/90 PS/110 PS, Vehicles Built From:
08/2006
Print

1 - Charge air cooler outlet pipe
2 - Intake air temperature (IAT) sensor
3 - Charge air cooler intake pipe
5 - Mass air flow (MAF) sensor
6 - Air cleaner cover
7 - Air cleaner element
8 - Air cleaner intake pipe
9 - Air cleaner housing
10 - Positive crankcase ventilation (PCV) hose
11 - Charge air cooler

Intake Air Distribution and Filtering
Print
Mechanical
Air cleaner outlet pipe
Air cleaner
Air cleaner element
Charge air cooler
Charge air cooler intake pipe
Charge air cooler outlet pipe
Chart.
Symptom Chart
NOTE: Some engine oil will be found in the intake components. This is normal and does
not indicate that the turbocharger has failed.
Excessive * Detached air cleaner * CHECK the pipe(s) for security and leaks to
intake air intake pipe. atmosphere. INSTALL new intake air system
noise * Detached air cleaner components as necessary. TEST the system for
outlet pipe. normal operation.
* Detached charge air
cooler intake pipe
(vehicles with diesel
engines).
* Detached charge air
cooler outlet pipe
(vehicles with diesel
engines).
Oil in the air * Blocked positive * All except vehicles with diesel engine.
intake crankcase ventilation REFER to: Engine Emission Control (303-08A Engine
system (PCV) valve - all except Emission Control - 1.8L Duratec-DOHC
vehicles with diesel (85kW/115PS) - Zetec, Diagnosis and Testing).
engine. Vehicles with diesel engine.
* Blocked or damaged REFER to: Engine Emission Control - 75 PS/90 PS
PCV pipe(s)/hose(s). (303-08B Engine Emission Control - 1.8L Duratorq-
* Blocked crankcase vent TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx)
oil separator. Diesel, Diagnosis and Testing) /
Engine Emission Control - 110 PS (303-08B Engine
Emission Control - 1.8L Duratorq-TDDi (Kent)
Diesel/1.8L Duratorq-TDCi (Kent) Diesel, Diagnosis
and Testing).

* Turbocharger * REFER to: Turbocharger - 75 PS/90 PS (303-04C,
Diagnosis and Testing) / Turbocharger - 110 PS,
Vehicles With: Fixed Vane Turbocharger (303-04C,
Diagnosis and Testing) / Turbocharger - 110 PS,
Vehicles With: Variable Vane Turbocharger (303-
04C, Diagnosis and Testing).

Intake Air Distribution and Filtering - Air
Cleaner
Print
(s).

1 - Air cleaner outlet pipe retaining clamp
See Removal Detail
2 - Intake air temperature (IAT) sensor electrical connector
See Removal Detail
3 - Engine breather pipe
See Removal Detail
4 - Air cleaner
See Removal Detail
Removal Details
Item 1 : Air cleaner outlet pipe retaining clamp

NOTE: Detach and position the air cleaner outlet pipe to one side.
Item 2 : Intake air temperature (IAT) sensor electrical connector
1. Vehicles with 1.8L petrol engine, disconnect the

mass air flow (MAF) sensor electrical connector.
Item 3 : Engine breather pipe
1. Vehicles with 1.8L petrol engine, disconnect the

breather pipe.
Item 4 : Air cleaner
NOTE: Make sure the three locating pegs on the air cleaner housing are located into the
rubber grommets on the support bracket.

Charge Air Cooler—1.8L Duratorq-TDCi
(Lynx) Diesel/1.8L Duratorq-TDDi (Lynx)
Diesel (75 PS/90 PS)
Print
(s).

1 - Charge air cooler air duct retaining screws
2 - Charge air cooler air duct
3 - Charge air cooler intake hose retaining clamp
See Removal Detail
4 - Charge air cooler intake hose
5 - Charge air cooler outlet hose retaining clamp
See Removal Detail
6 - Charge air cooler outlet hose
7 - Intake air temperature (IAT) sensor electrical connector
8 - Charge air cooler retaining bolts
-

-
9 Charge air cooler
Removal Details
Item 3 : Charge air cooler intake hose retaining clamp
NOTE: Make a note of the position of the charge air cooler intake hose retaining clamp.
Item 5 : Charge air cooler outlet hose retaining clamp
NOTE: Make a note of the position of the charge air cooler outlet hose retaining clamp.
Item 5 : Charge air cooler outlet hose retaining clamp
CAUTION: The charge air cooler outlet hose retaining clamp must be installed in the
same position as removed. Failure to follow this instruction may cause premature failure
NOTE: Make sure that the inside of the charge air cooler outlet hose is clean and free from
any oil residue, as this will reduce the installation grip of the hose to the charge air cooler.
Item 3 : Charge air cooler intake hose retaining clamp
CAUTION: The charge air cooler intake hose retaining clamp must be installed in the
same position as removed. Failure to follow this instruction may cause premature failure
NOTE: Make sure that the inside of the charge air cooler intake hose is clean and free
from any oil residue, as this will reduce the installation grip of the hose to the charge air
cooler.

Charge Air Cooler—1.8L Duratorq-TDCi
Print
Removal
1. Torque: 3 Nm

residue.
1. Torque: 4 Nm
2. Torque: 9 Nm
Installation

Evaporative Emissions - Evaporative
Emissions
Print
Vacuum line(s) Fuse(s)
Evaporative emission (EVAP) system canister Wiring harness
EVAP system hose(s) Electrical connector(s)
EVAP system canister purge valve

Evaporative Emissions - Evaporative
Emission Canister
Print
1. Remove the fuel tank. For additional information,

refer to Section 310-01A Fuel Tank and Lines /
310-01B Fuel Tank and Lines.
(s).

1 - Evaporative emission canister outlet pipe quick release coupling
See Removal Detail
2 - Evaporative emission canister inlet pipe
3 - Evaporative emission canister retaining clip
See Removal Detail
4 - Evaporative emission canister
Removal Details
Item 1 : Evaporative emission canister outlet pipe quick release coupling
1. Disconnect the evaporative emission canister

outlet pipe. For additional information, refer to
Information.
Item 3 : Evaporative emission canister retaining clip

1. Remove the evaporative emission canister.
1. Release the evaporative emission canister
retaining clip.
2. Slide the evaporative emission canister off
of the evaporative emission canister
retaining bracket.

Electronic Engine Controls - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Torque Specifications - all except vehicles with diesel engine

Powertrain control module (PCM) electrical connector retaining bolt 4 - 35
Crankshaft position (CKP) sensor retaining bolt 8 - 71
Cylinder head temperature (CHT) sensor 9 - 80
Idle air control (IAC) valve retaining bolts 10 - 89
Camshaft position (CMP) sensor retaining bolt 20 15 -
Power steering pressure switch 20 15 -
Heated oxygen sensor (HO2S) 48 35 -

Powertrain control module (PCM) electrical connector retaining bolt 4 - 35
Fuel temperature sensor 15 11 -
Knock sensor (KS) retaining bolt 20 15 -
Heated oxygen sensor (HO2S) 48 35 -

Camshaft position (CMP) sensor retaining bolt 10 - 89
Powertrain control module (PCM) bracket retaining bolt 10 - 89
PCM retaining nuts 10 - 89
Knock sensor (KS) retaining bolt 20 15 -

Electronic Engine Controls - Electronic
Engine Controls—1.8L Duratec-DOHC Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Components of the engine management system

1 - Mass Air Flow (MAF) sensor with integrated Intake Air Temperature
(IAT) sensor
2 - Throttle Position (TP) sensor
3 - Cylinder Head Temperature (CHT) sensor
4 - Crankshaft position (CKP) sensor
5 - Camshaft Position (CMP) Sensor
6 - Pre-cat Heated Oxygen Sensor (HO2S)

7 - Post-cat HO2S
8 - Power Steering Pressure (PSP) switch
9 - Vehicle Speed Sensor (VSS)
10 - Clutch Pedal Position (CPP) switch
11 - Power supply relay
12 - Ignition switch
13 - Battery
15 - EEC V Powertrain Control Module (PCM)
16 - Generator control
17 - Fuel pump relay
18 - Inertia fuel cut-off switch
19 - Fuel level indicator and fuel pump
20 - Fuel injectors
21 - Solenoid valve Evaporative emissions (EVAP)
22 - Idle Air Control (IAC) valve
23 - A/C compressor clutch / radiator fan circuit
24 - Coil Electronic Ignition (EI)
25 - Instrument cluster (communicates with the PCM via the SCP data bus)
26 - Malfunction Indicator Lamp (MIL)
Locations of PCM and inertia fuel cut-off switch

The PCM is located under a cover on the right-hand A-pillar (RHD vehicle shown).
The inertia fuel cut-off switch is located on the driver's side underneath a cover on the A-
pillar.
The inertia fuel cut-off switch interrupts the circuit from the fuel pump relay to the fuel
pump in the event of a serious crash.
Part Number

Item Description
1 - PCM
2 - Inertia fuel cut-off switch

Engine Controls—1.8L Duratorq-TDDi Transit/Tourneo Connect 2002.5 (06/2002-)
(55kW/75PS) - Lynx
Print

3 - Intake Air Temperature (IAT) sensor in the intercooler
4 - IAT sensor in front of the turbocharger
5 - Ignition lock
6 - Battery
-

-
7 Manifold Absolute Pressure (MAP) sensor
8 - Accelerator Pedal Position (APP) sensor
9 - Brake Pedal Position (BPP) switch
10 - Position sensor in the Exhaust Gas Recirculation (EGR) valve
11 - VP 30 distributor injection pump with pump control unit
13 - EEC V Powertrain Control Module (PCM)
15 - A/C compressor and radiator fan control
16 - Pre-glow module
17 - EGR solenoid valve
18 - Instrument cluster
19 - Pre-glow indicator lamp/fault lamp

Engine Controls—1.8L Duratorq-TDCi FGT
FGT (66kW/90PS) - Lynx/1.8L Duratorq- Transit/Tourneo Connect 2002.5 (06/2002-)
Duratorq-TDCi VNT (55kW/75PS) -
Lynx/1.8L Duratorq-TDCi (81kW/110PS)
- Lynx, 1.8L Duratorq-TDCi (Lynx) Diesel
Print

1 - Manifold Absolute Pressure (MAP) sensor
-

-
3 Intake Air Temperature (IAT) sensor in the intercooler

4 - IAT sensor in front of the turbocharger
6 - Knock Sensor (KS)
9 - Camshaft Position Sensor (CMP)
10 - Vehicle Speed Sensor (VSS)
11 - Accelerator Pedal Position (APP) sensor
12 - Clutch Pedal Position (CPP) switch
13 - Brake Pedal Position (BPP) switch
15 - Powertrain Control Module (PCM) with 121 pins
16 - Position sensor in the Exhaust Gas Recirculation (EGR) valve
19 - Fuel injectors
20 - EGR solenoid valve
21 - Pre-glow module
23 - Pre-glow indicator lamp/fault lamp
24 - A/C compressor and radiator fan control
PCM
The 1.8L Duratorq TDCi installed in the 2002.5 onward Transit Connect is now only
regulated by one PCM.
In this PCM the functions of the PCM and the functions of the Injector Driver Module (IDM)
are combined. This is referred to as the so-called "One-Box-System".
The strategies for engine management and for actuation of the injectors are very similar to
those found on the system with a PCM and an IDM (the so-called "Two-Box-System"), which
is already used on the 2001.5 Focus with a 1.8L Duratorq TDCi engine.
The PCM controls:

Injected fuel quantity and injection timing for the pilot injection and the main injection
EGR system,
Position of the fuel metering solenoid
System pressure in the high-pressure fuel system
Glow control
Radiator fan
'Smart charge' alternator control system
The PCM can be diagnosed through the DLC using WDS.

1 - Conventional PCM
2 - IDM
3 - PCM for the 1.8L Duratorq TDCi engine in the 2002.5 onward Transit
Connect

Engine Controls—1.8L Duratec-DOHC
(85kW/115PS) - Zetec, Liquefied
Petroleum Gas (LPG)
Print
Vehicles with LPG fuel system

1 - Powertrain control module (PCM)
2 - Clutch pedal position (CPP) switch
3 - Throttle position (TP) sensor
4 - Fuel vaporizer coolant temperature sensor
-

-
5 Manifold absolute pressure (MAP) sensor
6 - Alternative fuel control module
7 - Mass air flow (MAF) sensor
8 - Idle air control (IAC) valve
9 - Vehicle speed sensor (VSS)
10 - Camshaft position (CMP) sensor
12 - Catalyst monitor sensor
13 - Heated oxygen (HO2S) sensor
14 - Power steering pressure (PSP) switch
15 - Cylinder head temperature (CHT) sensor

Engine Controls
Print
European On-Board Diagnostics
European On-Board Diagnostics (EOBD) is a diagnostic system integrated into the
powertrain control module (PCM). This system continuously monitors vehicle emission
components. The system includes a malfunction indicator lamp (MIL) which indicates when
there is a concern that can affect emissions or the system malfunctions. Data stored within
the module DTC memory can be accessed using a generic scan tool or WDS.
EOBD is mandated within European Union regulations from the year 2000 with petrol
engines and from 2003 onwards for passenger vehicles with diesel engines.
EOBD Functions:
Establishes when and how emissions control faults must be indicated.
Actuates emission control malfunction indicator lamp (MIL) and fault memory.
Indicates operating conditions in which the concern occurred (freeze frame data).
Standardized output of operating data such as engine speed, engine coolant temperature
etc.
Standardized names/abbreviations for components and systems.
Standardized DTCs for all manufacturers.
Standardized communication with the diagnostic equipment.
Standardized 16-pin data link connector (DLC) in area of the instrument panel.
Concern display must be possible using a generic scan tool.
EOBD consists of the following elements:

Drive Cycle
A drive cycle commences when the engine is started (cold or warm) and ends when the
engine is switched off.
Trip
A trip begins when the engine is started and is complete when all the EOBD monitors have
completed a self-test. This may take place over a number of drive cycles. On diesel
variants, the information gathered from one drive cycle is not carried over to a subsequent
cycle or cycles.
When a concern has been rectified, particularly after electronic engine control components
have been changed, the DTC memory, which is part of the keep alive memory (KAM) must
be cleared of all trouble codes. When the DTC memory has been cleared, the code P1000
(known as the readiness code) is set in the PCM memory, which indicates that since the
KAM has been cleared, not all of the monitoring systems have completed their tests. P1000
can only be cleared by carrying out a trip, which includes driving the vehicle under variable
conditions of speed, load and time so that all of the monitors are completed. As P1000 will
not illuminate the MIL it is not necessary to carry out the trip before returning the vehicle
to the customer.
Warm-up Cycle
The warm-up cycle is an operation that consists of key on, engine start and a coolant
temperature increase of 22°C, exceeding 71°C on completion.
Freeze Frame Data
When a concern is detected, various data is stored depending on application including:

Diagnostic trouble code.
Vehicle speed.
Engine coolant temperature.
Engine speed.
Engine load.
Mixture formation trim value (trim value for engine wear) (All except vehicles with diesel
engine).
State of oxygen sensor control (open/closed loop) (All except vehicles with diesel
engine).
Distance covered since the concern was first registered.
Monitors
The purpose of the monitors is to continuously check the operation of the emission related
sensors and actuators. It then establishes if they are operating within specified tolerances.
All monitors carry out their functions in such a way as to be unnoticeable by the driver of
the vehicle. Each one is carried out under specific conditions of load, speed and engine
temperature. On petrol variants, the Comprehensive Component Monitor, Combustion
Misfire Monitor and Air/Fuel Ratio Monitor operate continuously. The remaining monitors are
only invoked under certain operating conditions. On diesel variants, all of the monitors
operate under normal driving conditions: There are no monitors which intervene and cause
special operating modes to enable the monitors to work. Some diesel monitors are non-
continuous. This means that in a drive cycle, monitoring is done as and when suitable
driving conditions exist and potential faults are accumulated and compared with acceptance
criteria. Examples of this type are the turbocharger boost pressure and Exhaust gas
recirculation (EGR) monitors on vehicles with common rail fuel injection.
Comprehensive Component Monitor (CCM)
When the CCM detects a component operating out of tolerance, it sets a Diagnostic Trouble
Code (DTC), which is stored in the KAM. If the same concern is confirmed during the next
trip the MIL will be switched on. The CCM monitors many components, sub-systems and
signals. The following is a list of those that can effect emissions depending on application:
Electronic Ignition (EI) System

Crankshaft Position (CKP) signal
Ignition Coil
Camshaft Position (CMP) signal
Air Conditioning (A/C) Clutch
Idle Air Control (IAC).
Mass Air Flow (MAF)
Manifold Absolute Pressure (MAP) sensor
Intake Air Temperature (IAT)
Engine Coolant Temperature (ECT)
Cylinder Head Temperature (CHT)
Charge air temperature sensor
Throttle Position (TP)
Vehicle Speed Sensor (VSS) signal
Boost Pressure Sensor
Cam-Crank Phasing Sensor
Keep Alive Memory (KAM)
High pressure fuel injection pump
Exhaust gas recirculation (EGR) valve lift potentiometer
Fuel injectors
Turbocharger
Combustion noise monitor
Barometric pressure sensor
Combustion Misfire Monitor (All except vehicles with diesel engine)

The combustion misfire monitor operates independently of the others, and can detect

misfires caused by the ignition system, fuel system or mechanical engine components. As
each cylinder fires, a characteristic crankshaft acceleration is produced. The monitor detects
irregularities in the acceleration pattern using the Crankshaft Position (CKP) Sensor, thus
detecting the misfire. It can also detect which cylinder has misfired. Combustion misfires
can be categorized as follows:
Type A: These can cause catalytic converter damage due to excessive internal
temperatures. If a certain number of misfires occur over a pre-determined number of
engine revolutions, the MIL will flash to alert the driver of the concern.
Type B: These can lead to an increase in emissions to a point above the EOBD threshold. If
the misfire is detected during a second trip, over a pre-determined number of engine
revolutions, the MIL will flash. If the misfire does not occur over the next three trips, the
MIL will be extinguished
Air/Fuel Ratio (AFR) Monitor (All except vehicles with diesel engine)
The HO2S fitted before the catalytic converter (upstream) measures the oxygen content of
the exhaust gas and the variations in it. This then enables the PCM to adjust the opening
tomes of the fuel injectors to maintain the correct AFR. This is known as Short Term Fuel
Trim (STFT). If the same variation is registered a pre-determined number of times, a
permanent correction factor is applied. This is known as Long Term Fuel Trim (LTFT), which
is stored in the KAM. When the correction factors exceed pre-determined limits a DTC will
be set in the KAM. If a concern is detected in either the STFT or LTFT, and it is still present
on a second trip, the MIL will flash.
Heated Oxygen Sensor (HO2S) Monitor (All except vehicles with diesel engine)
This monitors the operation of the pre (upstream) and post (downstream) catalytic
converter HO2S sensors. It will detect deviations in air/fuel ratios (AFR) and sensor faults.
Upstream HO2S response test: This checks if the upstream HO2S is able to switch fast
enough and whether the voltage output is correct. The operation of the sensor heating
element is also checked. This test is carried out under closed loop control.
Downstream HO2S test: This test is only started when the upstream HO2S test has been
successfully completed. To protect the downstream HO2S, it is only switched on when it has
reached a pre-determined minimum temperature and switched off when it reaches a pre-
determined maximum temperature. The test consists of checking whether the minimum
and maximum output voltages are within certain limits. If they are not, the fuel system is
switched to open loop and controlled using either a rich or lean mixture until they are within
limits.
Catalytic Converter Efficiency Monitor (All except vehicles with diesel engine)
The efficiency of a catalytic converter is measured by its ability to store and later release
oxygen to convert harmful gases. The efficiency is reduced if the converter becomes
contaminated, as it ages, and at high gas flow rates because the exhaust gas does not
remain in the converter long enough to complete the conversion process.
The monitor operates by comparing the number of times the upstream and downstream
HO2S switch between rich to lean cycles. If the converter is operating correctly this ratio
should be near zero. As it approaches one, it indicates inefficient conversion. At this point,
no significant conversion is taking place and the downstream HO2S is being made to switch
at nearly the same rate as the upstream HO2S. Therefore, the lower the number or
switches of the downstream HO2S, the more efficient the conversion process.
Combustion Noise Monitor (Vehicles with common rail fuel injection)
In diesel variants, the Combustion Noise Monitor is used to trim the fuel injection pulse
lengths. Each fuel injector has an associated set of correction data that is determined
during a production end of line test. The Combustion Noise Monitor is used to determine
how the fuel injector charateristic changes from this initial calibration over the life of the
fuel injector.

EGR Monitor (Vehicles with diesel engine)
The functionality of the EGR system is checked by comparing either the MAP sensor output
or EGR valve lift potentiometer output (depending upon application) with expected values.
Turbocharger Boost Pressure Monitor (Vehicles with variable vane turbocharger)
The functionality of the turbocharger is determined by measuring the MAP sensor output
under selected operating conditions. The output value is then compared with expected
values.
Diagnostic Requirements
Vehicles equipped with EOBD, can be diagnosed using the Worldwide Diagnostic System
(WDS). In order for the EOBD system to be invoked, a number of criteria must be met.
Together these make up a drive cycle. After any repair, which could affect emissions, a
dealer test cycle must be carried out on the vehicle, to make sure that engine management
system operates correctly.
Malfunction Indicator Lamp (MIL)
The MIL is located in the instrument cluster and is fitted to alert the driver to the fact that
an abnormal condition has developed in the engine management system, that is having an
adverse effect on emissions. In cases of misfires which are likely to cause catalytic
converter damage, it flashes immediately. With all other faults it will illuminate continuously
from the second trip after the condition occurred. Under normal operation it should
illuminate at key-on and go out almost as soon as the engine is started.
Diagnostic Trouble Codes (DTCs)
The DTCs given by the PCM are standardized, which means that generic scan tools can read
results from all vehicles.
The DTC is always a 5 digit alphanumerical code, for example ”P0100".

The first digit of a code (letter) identifies the system which has set the code. Provision
has been made for a total of four systems to be identified although only the 'P' code is
required for EOBD.
- 'B' for the body
- 'C' for the chassis
- 'P' for the powertrain
- 'U' for the network communications systems
All of the ”x0xxx" codes are standardized codes. However, any manufacturer can use
additional codes over and above the standardized codes. These will be labelled ”x1xxx",
"x2xxx" and so on.
The third digit of a code (numeric) identifies the sub-system which has set the code.
- 'Px1xx' for metering of fuel and air supply
- 'Px2xx' for metering of fuel and air supply
- 'Px3xx' for ignition system – combustion misfires
- 'Px4xx' for auxiliary emission control equipment
- 'Px5xx' for vehicle speed, idle setting and other related inputs
- 'Px6xx' for trip computer and other related outputs
- 'Px7xx' for transmission.
- 'Px8xx' for transmission.
- 'Px9xx' category to be determined
- 'Px0xx' category to be determined
When a concern occurs, the actions taken include storage of the relevant information and
actuation of the MIL occurs in line with the relevant legislation.
1. 1. Verify the customer concern by operating the system.

Sensors Fuse(s)
Actuators Wiring harness
4. 4. If the cause is not visually evident, verify the symptom and refer to WDS or
equivalent scan tool for further diagnostics.

Electronic Engine Controls - Powertrain
Control Module (PCM)—1.8L Duratorq-
TDDi (55kW/75PS) - Lynx/1.8L Duratec- Transit/Tourneo Connect 2002.5 (06/2002-)
DOHC (85kW/115PS) - Zetec, LHD FWD,
Print
NOTE: If a new PCM is being installed connect WDS. Upload the PCM configuration
information using the programmable modules installation routine prior to commencing the
removal of the PCM.
(s).

1 - Glovebox retaining bolts
2 - Glovebox
3 - Passenger side instrument panel lower footwell trim panel retaining
clips
4 - Passenger side instrument panel lower footwell trim panel

5 - PCM retaining bracket
6 - PCM security bracket shear bolt
See Removal Detail
7 - PCM security bracket
8 - PCM electrical connector
9 - PCM
NOTE: If a new PCM is being installed connect WDS. Download the PCM configuration
information using the programmable modules installation routine after the installation of
the PCM.
Removal Details
Item 6 : PCM security bracket shear bolt
CAUTION: When removing the PCM security bracket, do not place excessive strain on
the wiring harness.
NOTE: Make sure the floor covering is protected before drilling is started.

1. Remove the PCM security bracket shear bolt.
Drill a 3mm pilot hole in the center of the
security bracket welded nut.
Drill a 8mm hole in the security bracket
welded nut and remove the security
bracket shear bolt.

TDDi (55kW/75PS) - Lynx/1.8L Duratec- Transit/Tourneo Connect 2002.5 (06/2002-)
DOHC (85kW/115PS) - Zetec, RHD FWD,
Print
removal of the PCM.
(s).

1 - Instrument panel lower panel retaining screws
2 - Instrument panel lower panel retaining clips
3 - Headlamp switch electrical connector
4 - Instrument panel lower panel

See Removal Detail
9 - PCM
the PCM.
Removal Details
the wiring harness.

Drill a 3mm pilot hole in the center of the
security bracket welded nut.
bracket shear bolt.

TDCi (Lynx) Diesel, Vehicles Built Up To:
06/2006, LHD
Print
removal of the PCM.
(s).

1 - Glovebox retaining bolts
2 - Glovebox
3 - Passenger side instrument panel lower footwell trim panel retaining
clips
4 - Passenger side instrument panel lower footwell trim panel

See Removal Detail
9 - PCM
the PCM.
Removal Details
the wiring harness.
1. File a flat across the PCM security bracket welded
nut.

Drill a 2mm pilot hole 3mm from the outer
edge of the security bracket welded nut at
an angle inwards of approximately 2°.
bracket shear bolt.

Control Module (PCM)—RHD FWD, 1.8L
Duratorq-TDCi (Lynx) Diesel, Vehicles
Print
removal of the PCM.
(s).


See Removal Detail
9 - PCM
the PCM.
Removal Details
the wiring harness.
1. File a flat across the PCM security bracket welded
nut.

Drill a 2mm pilot hole 3mm from the outer
edge of the security bracket welded nut at
an angle inwards of approximately 2°.
bracket shear bolt.

Control Module (PCM)—Vehicles Built Transit/Tourneo Connect 2002.5 (06/2002-)
From: 08/2006
Print
General Equipment
Removal
1. NOTE: This step is only necessary when
installing a new component.
Upload the PCM configuration information using
the Programmable Modules Installation routine.
General Equipment: Worldwide Diagnostic

System (WDS)
Refer to: Battery Disconnect and Connect (414-

Procedures).
3. Remove the right-hand side wheel and tire.
Refer to: Wheel and Tire (204-04 Wheels and

Tires, Removal and Installation).
4.
5. Remove the PCM security shield (if equipped).

6. Torque:
10 Nm

7. Torque: 10 Nm
Installation

Download the PCM configuration information
using the Programmable Modules Installation
routine.
General Equipment: Worldwide Diagnostic

System (WDS)

Electronic Engine Controls - Idle Air
Control (IAC) Valve—1.8L Duratec-DOHC Transit/Tourneo Connect 2002.5 (06/2002-)
Print

(s).

1 - Mass air flow (MAF) sensor electrical connector
3 - Air cleaner outlet pipe to throttle body
4 - Engine breather pipe
5 - Air cleaner and outlet pipe

6 - IAC valve electrical connector
7 - IAC valve retaining bolts
8 - IAC valve
9 - IAC valve seal
See Removal Detail
Removal Details
Item 9 : IAC valve seal
NOTE: Discard the IAC seal.
Item 9 : IAC valve seal
NOTE: Install a new IAC seal.

Electronic Engine Controls - Heated
Oxygen Sensor (HO2S)—1.8L Duratec- Transit/Tourneo Connect 2002.5 (06/2002-)
DOHC (85kW/115PS) - Zetec
Print
Special Tool(s)
Socket, Fuel Injector (22 mm)
310-063 (23-050)
CAUTION: When installing a new HO2S, it is possible that the new component will be
supplied with a longer cable than the one removed. It is important that the cable is
routed and secured in such a way that it cannot be damaged by heat or moving
components and will not cause a noise, vibration or harshness (NVH) issue.
(s).

1 - Expansion tank coolant pipe retaining clips
2 - Bypass tube retaining clips
3 - Bypass tube
4 - HO2S electrical connector
5 - HO2S
See Removal Detail
Removal Details
Item 5 : HO2S

1. Using the special tool remove the HO2S.

Electronic Engine Controls - Cylinder Head
Temperature (CHT) Sensor—1.8L Duratec- Transit/Tourneo Connect 2002.5 (06/2002-)
DOHC (85kW/115PS) - Zetec
Print

Special Tool(s)
303-680 (21-239)
1. Remove the generator. For additional

information, refer to Section 414-02 Generator
and Regulator.
(s).

1 - CHT sensor electrical connector
See Removal Detail
2 - CHT sensor
See Removal Detail

Removal Details
Item 1 : CHT sensor electrical connector
1. Detach and disconnect the CHT sensor electrical

connector.
Item 2 : CHT sensor
1. Using the special tool, remove the CHT sensor.

Electronic Engine Controls - Cylinder Head
Temperature (CHT) Sensor—1.8L
Print
Special Tool(s)
303-680 (21-239)
Removal
oil separator.
For additional information, refer to: Crankcase
Vent Oil Separator - 75 PS/90 PS (303-08B
Engine Emission Control - 1.8L Duratorq-TDCi
2. Using the special tool, remove the CHT sensor.
Installation
NOTE: Make sure that a new component is installed.

Electronic Engine Controls - Crankshaft
Position (CKP) Sensor—1.8L Duratorq- Transit/Tourneo Connect 2002.5 (06/2002-)
TDCi (Lynx) Diesel
Print
Special Tool(s)
303-193 (21-104)
Removal
2. Disconnect the CKP sensor electrical connector.
3. Remove the CKP sensor retaining bolt.
4. Remove the CKP sensor.

Discard the CKP sensor.
Installation
NOTE: Install a new CKP sensor.
1. If the new CKP sensor has a raised feature on
the tip, follow steps 2 through to 4. If the new
CKP sensor has a flat tip, follow steps 5 through
to 10.
2. CAUTION: The CKP sensor tip must rest

on the flywheel. Incorrect installation may
result in the CKP sensor being damaged.
NOTE: Make sure that the CKP sensor
housing is clean and free from foreign
material.
Install the CKP sensor.
3. Install the CKP sensor retaining bolt.
5. Install the CKP sensor against the flywheel.
6. Using suitable feeler gauges, take note of the

measurement of the gap between the CKP sensor
and the CKP sensor housing.
7. Set the CKP sensor gap to the flywheel.

1. Add 1.2 mm to the measurement recorded
in step 11. Using suitable feeler gauges set
to the calculated figure, set the gap
between the CKP sensor and the CKP
sensor housing.
2. Finger tighten the CKP sensor bolt.

8. Tighten the CKP sensor retaining bolt.


Electronic Engine Controls - Fuel
Temperature Sensor—1.8L Duratorq-TDCi Transit/Tourneo Connect 2002.5 (06/2002-)
(Lynx) Diesel
Print
General Equipment
Removal
WARNINGS:
in personal injury.
fuel pressure has dropped to zero. Failure to follow this instruction may result in personal
injury.
CAUTIONS:
malfunction.
pressure has dropped to zero.


cleaning fluid.
6. Disconnect the fuel temperature sensor electrical
connector (high-pressure fuel supply line shown

temperature sensor.
8. Remove the fuel temperature sensor (fuel pump
Install a blanking plug to the open port on
the fuel pump.
Installation
WARNINGS:
in personal injury.
CAUTIONS:

NOTE: Install a new O-ring seal and fuel temperature sensor.
fuel pump.
3. Using a suitable multipurpose lubricant spray,
lubricate the new fuel temperature sensor O-ring
seal.
4. Install the O-ring seal and fuel temperature
sensor (fuel pump shown removed for clarity).
5. Connect the fuel temperature sensor electrical

connector (high-pressure fuel supply line shown

generator.

Electronic Engine Controls - Knock Sensor
(KS)
Print
Removal
Refer to: Catalytic Converter - 1.8L Duratorq-

Diesel (309-00 Exhaust System, Removal and
Installation).
2. Torque: 23 Nm

before removal.
Torque: 20 Nm
Installation
1. CAUTION: A new component may be

supplied with a longer cable than the one
removed. Make sure that the cable cannot be
damaged or cause a noise, vibration or
harshness (NVH) concern.
NOTE: Make sure that the sensor is installed
in the same location as when removed.
NOTE: Make sure that a new component is
installed.

Electronic Engine Controls - Fuel
Temperature Sensor—1.8L Duratorq-TDCi
Print
Removal
1. Clean the fuel temperature sensor and

surrounding areas.

2.
Installation
1. NOTE: Make sure that the sensor housing is

clean and free of foreign material.

Electronic Engine Controls - Camshaft
Position (CMP) Sensor—1.8L Duratorq- Transit/Tourneo Connect 2002.5 (06/2002-)
TDCi (Lynx) Diesel
Print
(s).

1 - CMP sensor electrical connector
2 - CMP sensor retaining bolt
3 - CMP sensor
Item 3 : CMP sensor
CAUTION: Make sure that the CMP sensor locating hole is free from foreign matter,
before installing the CMP sensor. Failure to follow this instruction may result in incorrect
installation of the CMP sensor and will not allow the engine to run.

Manual Transmission/Transaxle and
Clutch - General Information - Transit/Tourneo Connect 2002.5 (06/2002-)
Specifications
Print
Parts Specification
Manual transmission fluid WSD-M2C200-C
High-temperature grease ESD-M1C220-A
Capacities
Liters
MTX 75 manual transaxle (0 - 5 mm below the lower edge of the oil level check bore) 1.9
Clutch
Decription mm
Pedal travel 133 ± 3
Torque specifications

Clutch slave cylinder bleed nipple 21 15 –

Clutch - General Information - Manual Transit/Tourneo Connect 2002.5 (06/2002-)
Transaxle and Clutch
Print
General Equipment
Ultraviolet fluid leak detection equipment
Mechanical
Oil leaks.
Visibly damaged or worn components.
Loose or missing nuts or bolts.
4. 4. If the cause is not evident, verify the symptom and REFER to Symptom Chart.
The following checks should be carried out before repairing or installing a new transaxle.
The inspection and verification of manual transaxle concerns can be considered in three
main areas.
Gear shifting concerns
1. 1. Check the operation of the clutch: Lay a block of wood approximately 25 mm thick
under the clutch pedal and depress the clutch pedal as far as the stop. If first or
second gear can be selected with the engine running and the parking brake applied,
without any concerns, the clutch is OK.
2. 2. If the gear(s) cannot be selected, REFER to Symptom Chart.
Transaxle noise concerns
1. 1. Check the engine and transaxle support for insufficient gap between the transaxle
and the body.
2. 2. Road test the vehicle.

Operation).
3. 3. If a noise occurs in various gears at the same engine speed, check if the noise also
occurs in the neutral position. If it does, the noise is not caused by the transaxle.
4. 4. REFER to Symptom Chart.
Oil leakage concerns

1. 1. Check the transaxle fluid level. If necessary, drain off any excess fluid.
2. 2. Clean the transaxle and the adjacent areas carefully and road test the vehicle.
Operation).
3. 3. Using suitable ultraviolet fluid leak detection equipment, locate the leak and check
whether the leaking fluid is transaxle fluid, brake fluid (from the hydraulically
operated clutch) or engine oil.
4. 4. REFER to Symptom Chart.
Symptom Chart

Clutch *
Clutch master cylinder. * GO to Pinpoint Test A.
slippage *
Clutch slave cylinder.
*
Clutch pressure plate.
*
Clutch disc.
*
Engine or transaxle
housing oil or fluid leak
(s).
Clutch * Engine and transaxle * REFER to: Noise, Vibration and Harshness (NVH)
chatter or mounts. (100-04 Noise, Vibration and Harshness, Diagnosis
shudder and Testing).
* Clutch pressure plate. * GO to Pinpoint Test B.
* Clutch disc.
* Flywheel.
Clutch drag * Insufficient brake fluid. * FILL the brake master cylinder reservoir to the
MAX mark. INSPECT the brake and clutch hydraulic
systems for leaks. REPAIR as necessary.
* Air in the clutch * BLEED the system.
hydraulic system. REFER to: Clutch System Bleeding (308-00 Manual
* Clutch pedal free * GO to Pinpoint Test C.
travel.
* Clutch pressure plate.
* Clutch disc.
* Crankshaft end play.
Clutch pedal * Clutch pressure plate. * INSTALL a new clutch disc and pressure plate.
pulsation * Clutch disc. REFER to: Clutch Disc and Pressure Plate (308-01
Clutch, Removal and Installation).
* Crankshaft end play. * CHECK the crankshaft end play.
REFER to: Crankshaft End Play (303-00 Engine
Procedures).
Hard shifting * Clutch drag. * GO to Pinpoint Test C.
* Gearshift cable * CHECK the gearshift cable adjustment.
adjustment REFER to: Gearshift Cable Adjustment (308-00
Manual Transmission/Transaxle and Clutch -
* External controls. * CHECK the external controls for wear or damage.
INSTALL new components as necessary.
* Gear wheels. * DISASSEMBLE the transaxle.
REFER to: Transaxle (308-03 Manual
Transmission/Transaxle - Vehicles With: Manual
Transaxle, Vehicles With: MTX-75, Disassembly).

* Selector mechanism. * DISASSEMBLE the transaxle.
* Synchronizer(s). * DISASSEMBLE the transaxle.
Excessive * Engine vibrations * REFER to: Noise, Vibration and Harshness (NVH)
noise inadequately damped. (100-04 Noise, Vibration and Harshness, Diagnosis
and Testing).
* Transaxle fluid level * CHECK the transaxle for leaks. TOP UP the
low. transmission fluid.
* Engine or transaxle is * REFER to: Powertrain/Drivetrain Mount Neutralizing
in contact with the (100-04 Noise, Vibration and Harshness, General
chassis or body. Procedures).
* Engine and transaxle * REFER to: Powertrain/Drivetrain Mount Neutralizing
out of alignment. (100-04 Noise, Vibration and Harshness, General
Procedures).
* External controls. * CHECK the external controls for wear or damage.
* Gear wheels and * DISASSEMBLE the transaxle.
bearings. REFER to: Transaxle (308-03 Manual
* Clutch pedal. * GO to Pinpoint Test D.
* Clutch release bearing.
Fluid leakage * Clutch master cylinder. * INSPECT the brake and clutch hydraulic systems
* Clutch slave cylinder. for leaks. REPAIR as necessary.
* Clutch hydraulic lines.
* Halfshaft seal. * INSTALL a new halfshaft seal. REFER to: (308-03
Manual Transmission/Transaxle - Vehicles With:
Manual Transaxle, Vehicles With: MTX-75)
Halfshaft Seal LH (In-vehicle Repair),
Halfshaft Seal RH (In-vehicle Repair).
* Fluid leak between the * DISASSEMBLE the transaxle and clean the mating
transaxle housing faces. CHECK the mating faces for damage. SEAL
sections. the transaxle with sealant.
Transaxle, Vehicles With: MTX-75, Assembly).
PINPOINT TEST A : CLUTCH SLIPPAGE
CONDITIONS
A1: TEST CLUTCH SLIPPAGE
1 Lock the wheels and apply the parking brake.
2 Start the engine and engage fourth gear.
3 Run the engine at approximately 2000 rpm.
4 Release the clutch pedal slowly.
Does the engine stall when the clutch pedal is fully released?
Yes
Clutch OK.
No
GO to A2.

A2: CHECK THE CLUTCH PEDAL OPERATION
1 Depress clutch pedal and allow it to return.
Does the pedal return to the initial position?
Yes
GO to A3.
No
GO to A4.
A3: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and
Installation).
Is the clutch disc or pressure plate contaminated with oil or hydraulic fluid?
Yes
CHECK the engine and transaxle for leaks. INSTALL new components as
necessary. TEST the system for normal operation.
No
INSTALL a new clutch disc and pressure plate.
Installation).
A4: CHECK THE CLUTCH HYDRAULIC SYSTEM
1 Release the clutch slave cylinder bleed nipple.
Does the pedal return to the initial position?
Yes
INSTALL a new clutch slave cylinder.
REFER to: Clutch Slave Cylinder (308-02 Clutch Controls, Removal and
Installation).
No
INSTALL a new clutch master cylinder.
REFER to: Clutch Master Cylinder (308-02 Clutch Controls, Removal and
Installation).
PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER

CONDITIONS
B1: TEST FOR CLUTCH SHUDDER
1 Start the engine.
2 Engage the clutch and select fourth gear.
3 Run the engine at approximately 2000 rpm.
4 Release the clutch pedal slowly.
Does the clutch take up the drive smoothly?
Yes
Clutch is OK.
No
GO to B2.
B2: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
Installation).
Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid?
Yes
No
GO to B3.

B3: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Visually check the clutch disc and pressure plate.
Is the clutch disc and pressure plate worn or damaged?
Yes
Installation).
No
CARRY OUT the flywheel clutch surface inspection.
REFER to: Flywheel Inspection (303-00 Engine System - General
PINPOINT TEST C : CLUTCH DRAG

CONDITIONS
C1: CHECK THE OPERATION OF THE CLUTCH PEDAL
1 Bleed the clutch system.
REFER to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle
and Clutch - General Information, General Procedures).
Does the clutch properly disengage after bleeding?
Yes
Clutch system is OK.
No
GO to C2.
C2: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
Installation).
Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid?
Yes
No
GO to C3.
C3: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Visually check the clutch disc and pressure plate.
Is the clutch disc and pressure plate worn or damaged?
Yes
Installation).
No
GO to C4.
C4: CHECK THE SPLINES ON THE CLUTCH DISC FOR INSUFFICIENT LUBRICATION
AND/OR SIGNS OF CORROSION
CAUTION: Do not use solvent cleaners to clean the inside of the clutch housing or
the transmission input shaft. A lint-free damp cloth should be used for cleaning. Failure
to follow this instruction may result in incorrect clutch operation.
1 CHECK the splines on the clutch disc for insufficient or no grease and/or
signs of corrosion.
Is there insufficient or no grease and/or signs of corrosion on the splines of the

clutch disc?
Yes

CLEAN the splines of the clutch disc.
No
CHECK the splines of the transmission input shaft for damage or insufficient
or no grease and signs of corrosion. CLEAN and lubricate the splines on the
clutch disc with the specified lubricant as required. CLEAN the splines of the
transmission input shaft. If the transmission input shaft is damaged,
REPLACE the components as required. TEST the system for normal
operation.
PINPOINT TEST D : EXCESSIVE NOISE

CONDITIONS
D1: STATIC CHECK
1 Depress and release the clutch pedal.
Is the noise apparent when the clutch is operated?
Yes
LUBRICATE the clutch and brake pedal shaft. TEST the system for
normal operation.
No
GO to D2.
D2: DYNAMIC CHECK
1 Start the engine.
2 Depress the clutch pedal.
Is the noise apparent when the clutch pedal is depressed?
Yes
REFER to: Engine (303-00 Engine System - General Information,
No
INSTALL a new clutch slave cylinder and release bearing assembly.
REFER to:
Clutch Disc and Pressure Plate (308-01 Clutch, Removal and
Installation),
Clutch Slave Cylinder (308-02 Clutch Controls, Removal and
Installation).

Clutch - General Information - Clutch Transit/Tourneo Connect 2002.5 (06/2002-)
Slave Cylinder Check
Print
General Procedures
1. Check the clutch slave cylinder and release

bearing assembly:
For leaks.
Bellows.

Clutch - General Information - Clutch Transit/Tourneo Connect 2002.5 (06/2002-)
System Bleeding
Print
General Procedures
Special Tool(s)
416-001D (23-036A)
Materials
Name Specification
All vehicles
CAUTIONS:
If brake fluid comes into contact with the paintwork, rinse off the affected areas with
cold water without delay.
The brake fluid reservoir cap must not become contaminated.

NOTE: If proprietary brake bleeding equipment is available, this can be used to bleed the
clutch control in accordance with the following method and at a maximum operating
pressure of 1.5 bar.
NOTE: The clutch control system is self-venting. The components are arranged in such a
way that small amounts of air trapped in the system are removed automatically.
1. Extract brake fluid from the brake fluid reservoir
until the level is at the MIN mark.
2. Fill the reservoir of the special tool with approx.

100 ml of new Super DOT 4 brake fluid.
3. NOTE: The reservoir of the special tool must
be below the bleed nipple and the hose
connection of the riser must be installed
pointing towards the bleed nipple.
Install the special tool, open the bleed nipple and
use the special tool to pump approx. 80ml of
Super DOT 4 brake fluid into the clutch system.

4. Tighten the clutch slave cylinder bleed nipple.

Vehicles built from 10/2004
5. Tighten the clutch slave cylinder bleed nipple by
hand.
Vehicles built from 02/2007

6. Tighten the clutch slave cylinder bleed nipple by
hand.
All vehicles
8. In order to remove any small amounts of trapped
air remaining in the system, operate the clutch
pedal several times (max. 4-5 times), using the
full clutch pedal travel.
9. Check the brake fluid level.
The brake fluid level must be between the
MIN and MAX marks. If the level drops
below the MIN mark the brake warning
light comes on.
If necessary, top up the brake fluid
reservoir with Super DOT 4 brake fluid.

10. NOTE: Carefully engage reverse gear.
Check operation of the clutch control.
Start the engine, depress the clutch pedal
and wait approx. 2 seconds before
carefully engaging reverse gear. If gear
engagement is excessively noisy, remove
the small amounts of trapped air remaining
in the system by operating the clutch pedal
several times (max. 4-5 times), using the
full clutch pedal travel.
After waiting approx. 30 seconds, check
the operation of the clutch again. If gear
engagement is still excessively noisy,
repeat the previous steps.

Clutch - General Information - Gearshift Transit/Tourneo Connect 2002.5 (06/2002-)
Cable Adjustment
Print
General Procedures
Special Tool(s)
Aligner, Gearshift Lever
308-436 (16-097)
All vehicles
1. Detach the gearshift lever boot and trim panel
from the floor console.

3. Using the special tool, lock the gearshift lever.
1. Pull the reverse gear release.
4. Rotate the special tool approximately 45 degrees

clockwise to lock the gearshift mechanism.

1. Detach the gearshift cable from the
gearshift linkage.
2. Detach the selector cable from the selector
lever.
6. Release the locking tabs from the gearshift cable

and the selector cable.

7. NOTE: 3rd gear is engaged when the lever
elbow is parallel to the linkage base plate as
shown.
Shift the transaxle into 3rd gear.
8. NOTE: The selector cable is colored black.

Attach the selector cable to the selector lever.
9. Adjust the selector cable.

Press the locking tab.
10. Shift the transaxle into neutral.
11. NOTE: The gearshift cable is colored white.

Attach the gearshift cable to the gearshift
linkage.

12. Adjust the gearshift cable.
Press the locking tab.
13. Rotate the special tool approximately 45 degrees

counterclockwise to unlock the gearshift
mechanism.

1. Pull the reverse gear release.

15. Using the special tool, lock the gearshift lever.
16. Detach the selector cable from the selector lever.

1. Release the selector cable adjuster.
2. Press the selector cable catch.

17. Detach the gearshift cable from the gearshift
lever.
Press the gearshift cable catch.
18. Shift the transmission into 3rd gear.
19. Adjust the selector cable.

1. Press the selector cable catch and attach
the selector cable to the selector lever.
2. Lock the selector cable adjuster.
20. Attach the gearshift cable to the gearshift lever.

1. Shift the transmission into neutral.
2. Press the gearshift cable catch and attach
the gearshift cable to the gear lever.

All vehicles
23. Attach the gearshift lever boot and trim panel to
the floor console.

Clutch - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Clutch
Type Single-plate dry clutch

Operation Hydraulic
External diameter (1.8L Zetec-E, 1.8L Endura-DI) 228 mm
Pedal travel (not adjustable) 133 ± 3 mm

Clutch pressure plate retaining bolts 29 21 -

Clutch - Clutch Transit/Tourneo Connect 2002.5 (06/2002-)
Print
REFER to: Manual Transaxle and Clutch (308-00 Manual Transmission/Transaxle and Clutch
- General Information, Diagnosis and Testing).

Clutch - Clutch Disc and Pressure Plate Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
308-204 (16-067)
Locking Tool, Crankshaft

303-393 (21-168)
Removal
1. Remove the transmission. For additional
2. CAUTION: If the clutch pressure plate is

to be re-used, undo the bolts evenly in
stages working diagonally until the
diaphragm spring is no longer under
pressure (about two turns).
Detach the clutch from the flywheel.
Remove the bolts and lift the clutch
pressure plate and disc from the guide
pegs.
Discard the bolts.
Installation
1. Centre the clutch disc on the pressure plate.
2. CAUTION: Tighten the bolts evenly,

working diagonally, until the pressure plate is
fully in contact with the flywheel.
NOTE: Install new clutch pressure plate
bolts.
Install the clutch disc with the clutch pressure
plate.
1. Position the clutch pressure plate together
with the special tool and centred clutch
disc onto the guide pegs on the flywheel.
2. Tighten the clutch pressure plate bolts,
working diagonally.

4. Install the transmission. For additional

Clutch Controls - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Item Specification
Slave cylinder sealer ESK-M4G269-A
Brake fluid (Super DOT 4) ESD-M6C57-A
Clutch Controls
Operation Hydraulic
Adjustment Automatic
Pedal travel (not adjustable) 133 ± 3 mm

Clutch master cylinder bolts 9 80
Clutch slave cylinder 10 89

Clutch Controls - Clutch Controls Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Clutch Controls - Clutch Master Cylinder Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Syringe
Removal
1. Remove the battery.
and Installation).
3. Remove the central junction box (CJB).
4. Remove the brake fluid reservoir cap.

Using a suitable syringe, remove brake fluid from
the brake fluid reservoir until the brake fluid level
is at MIN mark.
7. CAUTION: Cap the clutch slave cylinder

supply line to prevent fluid loss and dirt
ingress.
NOTE: Remove the locking plates to
disconnect the hoses.
NOTE: Do not remove the bolt between the
two hoses.
Disconnect the clutch master cylinder hoses.
1. Detach the clutch master cylinder supply
hose from the clutch master cylinder and

2. Disconnect the clutch slave cylinder supply
line from the clutch master cylinder and
container.
8. Remove the clutch master cylinder retaining
bolts.
9. Remove the clutch master cylinder.

Release the clutch master cylinder from
the pedal assembly.
Detach the clutch master cylinder
actuating rod from the clutch pedal.
Installation
1. Install the clutch master cylinder.
Attach the clutch master cylinder actuating
rod to the clutch pedal.
Lock the clutch master cylinder to the
pedal assembly.
2. Install the clutch master cylinder retaining bolts.
3. NOTE: Make sure that the locking plates are

correctly seated.
Connect the clutch master cylinder hoses.
1. Connect the clutch master cylinder supply
line to the clutch master cylinder.
2. Connect the clutch slave cylinder supply
line to the clutch master cylinder.
Install the locking plates.

4. Install the central junction box (CJB).

6. Install the battery.
and Installation).
7. Bleed the clutch system.
For additional information, refer to: Clutch
System Bleeding (308-00 Manual

Clutch Controls - Clutch Slave Cylinder Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Materials
Name Specification
ESK-M4G269-A
Removal
1. Remove the
transmission.
For additional
information, refer to:
Transaxle - 1.8L
Duratorq-TDCi (Lynx)
Diesel/1.8L Duratorq-
TDDi (Lynx) Diesel,
Vehicles Built Up To:
03/2009 (308-03
Manual
Transmission/Transaxle
- Vehicles With:
Manual Transaxle,
Vehicles With: MTX-75,
Removal) /
Transmission - 1.8L
TDDi (Lynx) Diesel,
Vehicles Built From:
04/2009 (308-03
Manual
- Vehicles With:
Manual Transaxle,
Removal) /
Transaxle - 1.8L
Duratec-DOHC
(308-03 Manual
- Vehicles With:
Manual Transaxle,
Removal).
2. Degrease
the input
shaft
splines.
3. CAUTION:
Wrap the
input shaft
splines with
adhesive tape
to protect the
input shaft oil
seal.
Undo the bolts
and remove the
clutch slave
cylinder.
The clutch
slave
cylinder is
to be
reused
unless
damaged
Installation
1. CAUTIONS: 2. Install
the
Do not clutch

oil the slave
clutch cylinder
slave with a
cylinder. new oil
seal
Make and
sure that sealant.
new bolts
are
installed.
The clutch
slave cylinder
is to be
reused unless
damaged
3. Remove
the
adhesive
tape
from the
input
shaft
splines.
4. Install the
transmission.
For additional
information, refer to:
Transaxle - 1.8L
TDDi (Lynx) Diesel,
Vehicles Built Up To:
03/2009 (308-03
Manual
- Vehicles With:
Manual Transaxle,
Installation) /
Transmission - 1.8L
TDDi (Lynx) Diesel,
Vehicles Built From:
04/2009 (308-03
Manual
- Vehicles With:
Manual Transaxle,
Installation) /
Transaxle - 1.8L
Duratec-DOHC
(308-03 Manual
- Vehicles With:
Manual Transaxle,
Installation).

Manual Transmission/Transaxle - Vehicles
With: Manual Transaxle, Vehicles With: Transit/Tourneo Connect 2002.5 (06/2002-)
MTX-75 - Specifications
Print
Item Specification
High-temperature grease ESD-M1C220-A
Sealer, transaxle housing WSK-M2G348-A5
Sealer, clutch slave cylinder ESK-M4G269-A
Manual transmission fluid WSS-M2C200-D2
Super DOT4 brake fluid ESD-M6C57-A
Capacities
Litres
Manual transmission fluid (0-5 mm below the lower edge of the filler hole) 1.9
Transmission Ratios
1.8L Endura-DI-Diesel engine (75 PS+90 PS) 1.8L Zetec-E-Engine

First gear 3.667 3.667
Second gear 2.048 2.136
Third gear 1.258 1.488
Fourth gear 0.921 1.028
Fifth gear 0.705 0.767
Reverse gear 3.727 3.727
Final Drive 4.060 4.060
Required Shim Thickness
Type Input Shaft (mm) Output Shaft (mm) Differential (mm)

Measuring shims 1.00 1.00 1.10
Determined end + 0.22 + 0.33 + 0.36
float
Preload figure – + 0.13 + 0.33
End float - 0.05 – –
Required shim 1.17 1.46 1.79
thickness
Shims available 1.15 - 1.71 (in 0.01 1.31 - 1.91 (in 0.02 1.40 - 2.20 (in 0.05 mm
mm steps) mm steps) steps)

Lower arm to wheel knuckle retaining bolt 150 111 –
Intermediate shaft center bearing retaining nuts 25 18 –
Transaxle retaining bolts 47 35 –
Engine rear mount retaining nuts 48 35 –
Engine rear mount center retaining nut 133 98 –
Charge air cooler pipe 10 – 89
Strut and spring assembly top mount retaining nuts 25 18 –
Crankcase ventilation unit upper retaining nut 25 18 –
Fender retaining bolts 10 – 89
Engine rear mount retaining bracket 80 59 –
Ring gear to differential case retaining bolts 88 65 –
Reverse gear idler shaft retaining bolts 34 25 –
Transaxle housing retaining bolts 32 24 –
Clutch slave cylinder retaining bolts 10 – 89

Transmission fluid filler plug 45 33 –
Subframe front retaining bolts 200 148 –
Subframe rear retaining bolts 115 85 –
Starter motor to transaxle housing 35 26 –
Cooling fluid tube bracket retaining nuts 25 18 –

MTX-75 - Manual Transaxle
Print
At a glance
Transmission construction
5-speed manual transmission for FWD

Transmission with different axes (input and output shafts)
Input shaft with single synchronisation for 3rd gear
The output shaft and output pinion are made as one component.
Synchronised reverse gear
Bearing bracket for reverse gear idler shaft for all engine variants
High-mounted transmission breather for the prevention of water ingress when driving
through water up to 450 mm deep
The final drive is integrated into the transmission housing.
Gearshift mechanism
Modified shift mechanism for improved smoothness
Transmission ratios
1.8L Duratorq-DI 1.8L Duratorq-TDCi 1.8L Zetec-E

1st gear 3.667 3.667 3.667
2nd gear 2.048 2.048 2.136

3rd gear 1.258 1.258 1.448
4th gear 0.921 0.921 1.028
5th gear 0.705 0.705 0.767
Reverse gear 3.727 3.727 3.727
Output ratio 4.06 4.06 4.06
Input shaft
3rd and 4th gears are located on the input shaft.
The input shaft runs on separate taper roller bearings on the clutch side and the
transmission housing side halves of the housing.
The 3rd and 4th gears use simple synchronisation.

1 - Input shaft
2 - 2nd gear wheel
3 - 1st gear wheel
4 - Taper roller bearing (transmission housing side)
5 - 3rd gear needle roller bearing
6 - 3rd gear wheel
7 - 3rd gear synchroniser ring
8 - Complete synchroniser assembly for 3rd/4th gear
9 - Snap ring
10 - 4th gear synchroniser ring
11 - 4th gear needle roller bearing
12 - 4th gear wheel
13 - 5th gear wheel
14 - Snap ring
15 - Taper roller bearing (clutch housing side)
Output shaft

The output shaft forms a unit with the output pinion. All of the remaining parts are pressed
or mounted on the output shaft.
The 1st, 2nd, 5th and reverse gear are all located on the output shaft.
1st and 2nd gear are both double-synchronised.
The output shaft runs on separate taper roller bearings on the clutch housing side and the
transmission housing side halves of the housing.

1 - Taper roller bearing (clutch housing side)
2 - Output pinion (inseparable)
3 - Output shaft
4 - 1st gear needle roller bearing
5 - 1st gear wheel
6 - Inner synchroniser ring - 1st gear
7 - Synchroniser cone - 1st gear
8 - Outer synchroniser ring - 1st gear
9 - Complete synchroniser assembly for 1st/2nd gear
10 - Snap ring
11 - Outer synchroniser ring - 2nd gear
12 - 2nd gear synchroniser cone
-

13 Inner synchroniser ring - 2nd gear
14 - 2nd gear wheel
15 - 2nd gear needle roller bearing
16 - 3rd gear wheel
17 - 4th gear wheel
18 - Snap ring
19 - 5th gear needle roller bearing
20 - 5th gear wheel
21 - 5th gear synchroniser ring
22 - Complete 5th/reverse gear synchroniser assembly
23 - Snap ring
24 - Reverse gear synchroniser ring
25 - Reverse gear needle roller bearing
26 - Reverse gear wheel
27 - Taper roller bearing (transmission housing side)
Bearing bracket for reverse gear idler

1 - Reverse gear idler
2 - Reverse gear idler shaft
3 - Bearing bracket for reverse gear idler shaft
The MTX-75 is equipped with a bearing bracket for the reverse gear idler.
The provides significant additional strength for the reverse gear idler, allowing it to absorb
even the high torque peaks (particularly on the 1.8L Duratorq-TDCi engine) without
problems.
Transmission breather

1 - Transmission breather
-

2 Transmission breather hose
Transmission ventilation is arranged into the upper part of the engine compartment.
This makes is possible to drive the vehicle through water up to 450 mm deep without
transmission operation being adversely affected by water entry.
Repositioning of the transmission breather

1 - Retaining clip
2 - Transmission breather
3 - Transmission breather hose
4 - Retaining clip
NOTE: During service repairs it is important to ensure that the transmission breather hose
is routed according to the instructions and is therefore securely clipped in place (refer to
the current service literature).
The transmission breather is connected via a hose to the manual transmission.

MTX-75 - Manual Transaxle
Print

MTX-75 - Bearing Check
Print
General Procedures
1. NOTE: Establish the cause of the damage

and resolve it.
Check whether the bearing cage is damaged at
the top, side or at the openings is damaged
because of the unprofessional use of a special
tool or of the wrong tool.
Install a new bearing if necessary.
2. Check whether the ends of the taper rollers are

discoloured as a result of inadequate lubrication
or overheating, possibly through excessive pre-
load.
Install a new bearing and new seals if
necessary.
Check the bearing is correctly lubricated.
3. Check whether the ends of the taper rollers are

worn away due to incorrect installation,
excessive pre-load or faulty bearing seating.
necessary.
4. Check whether the bearing surfaces are grey or

grey/black with deposits between the rollers.
necessary.
5. Check whether the bearing ring surfaces are

grooved caused by static impact.
Install a new bearing if its surface is
rough, or if it is noisy.

6. NOTE: Overheating can cause loss of surface
hardness.
Check for a dark blue colour caused by
overheating (yellow or brown is normal) due to
excessive pre-load or inadequate lubrication.
Install a new bearing, new seals and check
other components as necessary.
7. Check the surfaces for abrasion due to metal

fatigue.
Install a new bearing and clean all other
affected components as necessary.

With: Manual Transaxle, Vehicles With:
MTX-75 - Transmission Draining and
Filling
Print
General Procedures
Materials
Name Specification
Transmission Oil 75W FE WSS-M2C200-D2 / 7U7J-M2C200-BA
Filling
1. NOTE: Make sure that the vehicle is standing
on a level surface.
Refer to: Health and Safety Precautions (100-00
General Information, Description and Operation).
3.

escaping fluid.
2. Torque: 35 Nm
4.
5. Material: Transmission Oil 75W FE (WSS-

M2C200-D2 / 7U7J-M2C200-BA)

6. Torque: 35 Nm

MTX-75 - Transmission Fluid Level Check
Print
General Procedures
Materials
Name Specification
Transmission Oil 75W FE WSS-M2C200-D2 / 7U7J-M2C200-BA
Check
1. NOTE: Make sure that the vehicle is standing
on a level surface.
Refer to: Health and Safety Precautions (100-00

escaping fluid.
4. Material: Transmission Oil 75W FE (WSS-

M2C200-D2 / 7U7J-M2C200-BA)
5. Torque: 35 Nm

MTX-75 - Halfshaft Seal LH
Print
In-vehicle Repair
Special Tool(s)
Remover, Front Halfshaft
204-226 (16-092)
Extension
204-226-01 (16-092-01)
Slide Hammer
205-047 (15-011)
Installer, Front Halfshaft Oil Seal

205-115 (15-058)

211-020 (13-006)
Extractor, Front Halfshaft Oil Seal

308-208 (16-074)
Materials
Name Specification
fluid
Removal
1. Loosen the strut top mount retaining nuts by
four turns.
2. Remove the wheel. For additional information,

3. CAUTION: Do not unscrew the track rod

end retaining nut from the ball joint in order
to protect the thread.
mm Allen key.

Loosen the left track rod end retaining nut.
4. CAUTION: Protect the ball joint gaiter

Detach the track rod end from the spindle carrier
1. Release the track rod end.
2. Remove and discard the track rod end
retaining nut.
5. Loosen the lower suspension arm ball joint

retaining nut.
6. CAUTIONS:
Do not unscrew the lower suspension

arm ball joint retaining nut in order to
protect the thread.
Protect the ball joint gaiter using a soft


to prevent damage.
Using a suitable two-legged puller, detach the
lower suspension arm from the spindle carrier.
lower suspension arm.
7. CAUTIONS:

constant velocity joint must not be bent
more than 18 degrees. The outer constant
velocity joint must not be bent more than
45 degrees.
Close off the transmission openings to

Detach the left-hand halfshaft from the
transmission using the special tools and secure
it to one side.
container.
8. Using the special tool, remove the halfshaft oil

seal.
Installation
1. Using the special tool, install the halfshaft oil
seal.
Drive the seal home.
2. CAUTIONS:

constant velocity joint must not be bent more
than 18 degrees. The outer constant velocity
joint must not be bent more than 45
degrees.
Ensure that the halfshaft oil seal is not

damaged.
Ensure that the snap ring is correctly

located in the groove.
NOTE: Fit a new halfshaft snap-ring.
Attach the halfshaft to the transmission.
3. WARNING: Install a new lower

suspension arm ball joint retaining nut.
Failure to observe this instruction can lead to
injury.

Attach the lower suspension arm to the spindle
carrier.
4. NOTE: Install a new track rod end retaining

nut.
mm Allen key.
Attach the track rod end to the spindle carrier.
5. Check the transmission fluid level and top up the

manual transmission fluid if necessary. For
6. Install the wheel. For additional information,
7. Tighten the strut top mount retaining nut.

MTX-75 - Vehicle Speed Sensor (VSS)
Print
In-vehicle Repair
Removal
All vehicles
Lifting.
All except vehicles with diesel engine

2. Remove the vehicle speed sensor (VSS).
Disconnect the VSS electrical connector.
Remove the retaining bolt.

3. Remove the VSS.
1. Remove the retaining pin.
2. Disconnect the VSS electrical connector.
Installation
1. Install the vehicle speed sensor (VSS).
1. Connect the VSS electrical connector.
2. Install the retaining pin.

2. Install the VSS.
Install the retaining bolt.
Connect the VSS electrical connector.

All vehicles

MTX-75 - Transaxle—1.8L Duratec-DOHC
Print
Removal
Special Tool(s)
Remover, Halfshaft
204-226 (16-092)
Adapter for 204-226

204-226-01 (16-092-01)
Slide Hammer
205-047 (15-011)
Support Bar, Engine

303-290A (21-140A)

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)
General Equipment
Transmission jack
Retaining straps
Syringe
Removal
1. Remove the battery. For additional information,
refer to Section 414-01 Battery, Mounting and
Cables.
nuts by three turns on both sides.

5. Using a suitable syringe, remove the fluid from
the power steering fluid reservoir.
container.

connector.
7. Disconnect the transaxle breather tube from the

transaxle.
Unclip the breather tube.
8. Detach the engine wiring harness from the

support bracket.

Lifting.
10. Remove the accessory drive belt cover.

11. Remove the crossmember. For additional
cap.
locknuts.
13. CAUTIONS:

degrees.
Plug the transaxle to prevent oil loss or

dirt ingress.
it to one side.
container.
14. CAUTIONS:

45 degrees.
Plug the transaxle to prevent oil loss or

dirt ingress.
Using the special tools, detach the left-hand
side.
container.

1. Detach the gearshift cables from the
gearshift and selector lever.
16. Disconnect the vehicle speed sensor (VSS)


18. NOTE: Do not disconnect the starter motor
Remove the starter motor upper retaining bolts.
19. Remove the transaxle upper retaining studs.

nut.
Discard the nut.

23. Remove the transaxle right-hand retaining bolts.
24. Using the special tools, lower the engine and

transaxle assembly.
25. Remove the engine rear mount bracket.

Lifting.

Disconnect the clutch slave cylinder supply line
from the transaxle.
28. NOTE: Do not disconnect the starter motor

Detach the starter motor from the transaxle and
29. NOTE: Support the transaxle with wooden

blocks.
NOTE: Use suitable retaining straps to secure
the transaxle on the transmission jack.
transaxle.
31. Remove the transaxle right-hand lower retaining

bolt.
32. Using a suitable transmission jack, lower the

transaxle.


MTX-75 - Transaxle—1.8L Duratorq-TDCi Transit/Tourneo Connect 2002.5 (06/2002-)
Diesel, Vehicles Built Up To: 03/2009
Print
Removal
Special Tool(s)
Remover, Halfshaft
204-226 (16-092)
Adapter for 204-226

204-226-01 (16-092-01)
Slide Hammer
205-047 (15-011)
Support Bar, Engine

303-290A (21-140)
Adapter for 303-290

303-290-02 (21-140-02)
Adapter for 303-290

303-290-03 (21-140-03)
Adapter for 303-290

303-290-01 (21-140-01)
Remover/Installer, cooling hose clamp

303-397 (24-003)
General Equipment
Transmission jack
Securing straps
Removal
1. Shift the gearshift lever to the neutral position.
2. Disconnect the battery ground cable from the
battery terminal clamp.
3. Remove the charge air cooler left-hand pipe.

4. Detach the air cleaner outlet pipe and the
positive crankcase ventilation (PCV) hose from
the engine.

Disconnect the intake air temperature
(IAT) sensor electrical connector.

NOTE: Plug the clutch slave cylinder supply
line.
Disconnect the clutch slave cylinder supply line
from the clutch slave cylinder.
7. Detach the vehicle speed sensor (VSS) electrical

wiring harness from the transaxle.

connector.

retaining nuts by three turns on both sides.
10. Remove the cooling fluid tube bracket retaining

nuts.
Detach the central electrical connector
bracket from the transaxle.
11. Detach the power steering line bracket from the

transaxle.
12. Remove the PCV unit upper retaining nut.

Detach the PCV unit from the transaxle
and secure it to one side.
Detach the cooling fluid tube bracket from
the transaxle and secure it to one side.
13. Remove the transaxle upper retaining studs.

14. NOTE: Note the installing position of the
engine support bar adapters.
Install the special tools on both sides.
1. Remove the fender retaining bolts.
2. Loose the fender retaining bolts.
4. Tighten the fender retaining bolts.

Operation).
17. Remove the crossmember.
Crossmember (502-00 Uni-Body, Subframe and
Mounting System, Removal and Installation).
1. Detach the gearshift cables from the
gearshift and selector lever.
19. CAUTIONS:

45 degrees.

or dirt ingress.
Detach the left-hand halfshaft from the
transaxle and secure it to one side.
container.

cap.
locknuts.
21. CAUTIONS:

degrees.

or dirt ingress.
it to one side.
container.
22. Disconnect the VSS electrical connector.
23. Remove the accessory drive belt cover.

nut.
Discard the retaining nut.
26. Remove the engine rear mount.
27. Using the special tools, lower the engine and

transaxle assembly.

Operation).
29. Remove the engine rear mount bracket retaining
bolts.

31. Detach the starter motor from the transaxle.
Detach the engine ground cable from the
transaxle.
Detach the starter motor cable bracket
from the transaxle.
Detach the starter and secure it to one
side.
32. Remove the transaxle right-hand lower retaining

bolt.
33. Using suitable securing straps, secure the

transaxle on a transmission jack.
34. Remove the transaxle right-hand upper retaining

bolts.

MTX-75 - Transmission—1.8L Duratorq-
(Lynx) Diesel, Vehicles Built From:
04/2009
Print
Removal
Special Tool(s)
204-226
Remover, Halfshaft
204-226-01
Adapter for 204-266
204-605
Separator, Lower Arm Ball Joint
205-047
Slide Hammer
211-020
303-290-01
303-290-02
303-290-06
303-290A
Support Bar, Engine
General Equipment
Cable ties
Retaining Strap
Tire lever
Transmission jack
Two leg puller
Wooden Block

1. Refer to: Health and Safety Precautions (100-00
Procedures).
3. On both sides.
Loosen: 3 turn(s)
4. If equipped.
5.

Installation).
7.

8.
9.
10.

11. Install
the
Special
Tool
(s):
303-
290A,
303-
290-
01,
303-
290-
02,
303-
290-06
12. Refer to: Wheel and Tire (204-04 Wheels and

13.

14.
15.
16.

17.

On both sides.

On both sides.

On both sides.

On both sides.
General Equipment: Two leg puller
22. On both sides.

escaping fluid.
Special Tool(s): 204-226, 204-226-01, 205-047
24. Secure to one side.

escaping fluid.

27.
28.
29.

31.
CAUTION: Make sure that the

exhaust flexible pipe is not forcibly
bent.
33. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent.
General Equipment: Tire lever
34. Lower the Vehicle.

escaping fluid.

are sealed.

36.
37.
38. Special
Tool
(s):
303-
290A

40.

1. General Equipment: Wooden Block

General Equipment: Transmission jack
General Equipment: Retaining Strap
43.
44.

45. WARNING: This step requires the aid of
another technician.

MTX-75 - Transaxle
Print
Disassembly
Special Tool(s)
Remover, Bearing Outer Races
205-078 (15-048)
Adapter
205-078-01 (15-048-01)
Remover, Bearing Outer Races

205-176 (15-074)
Mounting Bracket, Engine/Differential

205-329 (15-105A)
Transmission Mounting Bracket (in conjunction with 303-435)

303-435-06 (21-031B)
Remover, Halfshaft Oil Seal

308-208 (16-074)
Disassembly
All vehicles
2. NOTE: Make sure the gearshift mechanism is

in neutral.
Remove the gearshift mechanism.

3. Using the special tool, remove the front halfshaft
oil seals.

4. NOTE: Only required for sealing repairs.
Remove the speedometer drive pinion.
All except vehicles with a diesel engine

5. NOTE: Only required for sealing repairs.
Remove the vehicle speed sensor (VSS).
All vehicles
6. NOTE: Do not remove the locating dowels.
Undo the transmission housing bolts.

7. CAUTION: Do not damage the
transmission housing.
Separate the transmission housing sections.
1. Use a block underneath the lever to avoid
damaging the housing.
2. Separate the transmission housing
sections using two levers on opposite
sides.
8. NOTE: Slightly tilt the differential assembly.

Remove the differential assembly.
Remove the magnetic disc.
9. Remove the selector rods and the first and

second gear selector fork.
10. Remove the selector forks.

1. Swivel the fifth and reverse gear selector
fork to the side and remove it.
2. Turn the third and fourth gear selector fork
and remove it.
11. Remove the snap ring from the reverse gear

idler.
12. Remove the input shaft and the output shaft.

Lever the input and output shafts together
out of the transmission housing.
Take out the reverse gear idler togeth er
with the needle roller bearing and the
thrust washers.

13. Remove the differential bearing outer race.
Locate the special tool in the recesses in
the housing.
14. Remove the outer races of the input and output

shaft bearings.
the housing.
15. Degrease the input shaft splines.
16. CAUTIONS:
Do not allow brake fluid to come into

contact with the skin or eyes. If brake fluid
contacts the skin or eyes, rinse the affected
area immediately with water. Failure to
observe these instructions can lead to
personal injury.
Wrap the input shaft splines with

adhesive tape to protect the input shaft oil
seal from damage.
NOTE: Discard the clutch slave cylinder.
Remove the clutch slave cylinder (with release

bearing).
17. Remove the adhesive tape from the input shaft
splines.
18. Remove the bearing outer races and shims of the
differential and input shaft.
the housing.
19. Remove the output shaft bearing outer race with

the shim.
the housing.
20. NOTE: Only when damaged or leaking.

Remove the reverse gear idler shaft.
21. NOTE: Only when damaged or leaking.

Remove the reverse gear idler shaft.
Drive it out using a block of hard wood.

MTX-75 - Input Shaft
Print
Special Tool(s)
Remover, Bearing (Main Tool)
205-295 (15-050A)
Collet for 205-295

308-195 (16-060)
Collet for 205-295

308-196 (16-061)
Support Plate, Gear Removal

308-198 (16-063)
Support Plate, Gear Removal (Dia 85.1 mm)

308-230 (16-077)
General Equipment
Press
Materials
Name Specification
Transmission fluid WSS-M2C200-D2
Disassembly
All vehicles
1. CAUTION: The inner synchronizer ring

and the synchronizer cone must be handled
very carefully.
General note
Graphical overview of the input shaft:
For additional information, refer to: Manual
Transaxle (308-03 Manual
Transmission/Transaxle - Vehicles With:
Manual Transaxle, Vehicles With: MTX-75,
2. CAUTION: Use vice with soft jaw

protectors.
Clamp the input shaft in the vice.
3. Pull off the taper roller bearing on the clutch
side.

4. Pull off the taper roller bearing on the
transmission housing side.

5. NOTE: Remove the gear wheels using a
suitable press.
NOTE: Discard the snap ring.
Remove the fifth gear wheel.
1. Remove the snap ring.
2. Remove the gear wheel using the special
tool.

6. NOTE: Remove the gear wheels using a

suitable press.
NOTE: Discard the snap ring.
Remove the fifth gear wheel.
2. Remove the gear wheel using the special
tool.
All vehicles
7. Remove the fourth gear wheel.
1. Remove the gear wheel.
2. Remove the needle roller bearing.
3. Remove the synchronizer ring.
8. NOTE: Discard the snap ring.

Remove the third and fourth gear synchronizer.
2. Remove the synchronizer assembly.
9. NOTE: Mark the position of the selector ring

with respect to the synchronizer hub for
installation. Components are paired.
NOTE: Carefully pull the selector ring off the
synchronizer hub. The detent balls are spring
loaded.
Disassemble the third and fourth gear
synchronizer.
1. Pull off the selector ring.
2. Synchronizer hub
3. Compression spring
4. Blocker bar
5. Detent ball
10. Remove the third gear wheel.
2. Remove the gear wheel.
Assembly

1. NOTE: Install new taper roller bearings
untreated.
Carefully clean and check all parts and coat with
transmission fluid before reassembly.
2. Press the taper roller bearing on at the clutch
end.
Press on the taper roller bearing using a
suitable tube and a press.
3. Install the third gear wheel.

1. Install the needle roller bearing.
2. Install the third gear wheel.
3. Install the synchronizer ring.
4. NOTE: Pay attention to the mark.

Assemble the third and fourth gear synchronizer.
1. Insert the compression springs.
2. Insert the blocker bar with the detent balls
against the spring pressure.
3. Push on the selector ring.
5. NOTE: Renew the snap ring (use a snap ring

with a collar height of 2.5 mm).
NOTE: Fit the synchronizer hub with the
large collar towards the outside and the ring
groove facing the small collar.
Attach the complete 3rd/4th gear synchronizer
assembly.
1. Fit the complete synchronizer assembly.
2. Install a new snap ring.
6. Install the fourth gear wheel.

3. Install the fourth gear wheel.
7. NOTE: Install the fifth gear wheel with the

large collar facing outwards.

Press on the 5th gear wheel.
Press on the fifth gear wheel using a
Install a new snap ring.
8. Press on the transmission-side taper roller

bearing.
Press the taper roller bearing on using a

MTX-75 - Output Shaft
Print
Special Tool(s)
Installer, Drive Pinion Bearing
205-068 (15-042)
205-310 (15-091)
Materials
Name Specification
Transmission oil. WSS-M2C200-D2
Disassembly
1. Press off the transmission housing roller bearing
together with the reverse gear gearwheel using
the special tool.
2. Remove the reverse gear synchronizer ring.

3. NOTE: If gear changes are difficult, carefully

remove the synchronizer hub assembly and
the fifth gear gearwheel
Remove the fifth and reverse gear synchronizer
hub assembly.
2. Remove the synchronizer hub assembly.
4. Remove the fifth gear gearwheel.

2. Remove the fifth gear gearwheel.

5. NOTE: Use the special tool with the flat side
upwards.
Remove the fourth gear gearwheel using the
special tool.
Remove the circlip.
6. NOTE: Use the special tool with the flat side

upwards.
Remove the second and third gear wheels using
the special tool.
7. CAUTION: Be careful when handling the

inner synchronizer ring and the synchronizer
cone.
Remove the second gear synchronizer rings.
2. Remove the synchronizer inner ring.
3. Remove the synchronizer cone.
4. Remove the synchronizer outer ring.
8. Remove the first and second gear synchronizer

hub assembly.
2. Remove the synchronizer hub assembly.

inner synchronizer ring and the
synchronizer cone.
Remove the first gear gearwheel.
1. Remove the synchronizer outer ring.

2. Remove the synchronizer cone.
3. Remove the synchronizer inner ring.
4. Remove the first gear gearwheel.
10. NOTE: Only remove the bearing if it is to be

renewed.
Remove the transmission housing roller bearing
11. CAUTION: Carefully remove the selector

ring from the synchronizer hub assembly.
The detent balls are spring-loaded.
NOTE: Mark the installed position of the
selector ring.
Disassemble the synchronizer assembly.
1. Remove the selector ring.
2. Remove the gear synchronizer hub.
3. Remove the compression springs.
4. Remove the blocker bars.
5. Remove the check balls.
Assembly

cone. Lubricate the synchronizer rings with
transmission fluid prior to installation.
NOTE: If installing new roller bearings, do
not lubricate the bearings.
Carefully clean and check all parts and coat
sliding surfaces with transmission fluid before
reassembly.

cone.
Install the first gear gearwheel.
2. Install the first gear gearwheel.
3. Install the synchronizer inner ring.
4. Install the synchronizer cone.
5. Install the synchronizer outer ring.
3. NOTE: Observe the markings.
Assemble the gear synchronizer.

1. Install the compression springs.
2. Install the blocker bar and the detent balls
in the gear synchronizer hub against the
force of the spring.
3. Install the spring ring the correct way
round and push it on.
4. NOTE: Install the synchronizer hub assembly

with the wider collar facing outwards
(towards the second gear gearwheel).
Install the first and second gear synchronizer
hub assembly.
1. Install the synchronizer hub assembly.
2. Install the snap ring.
5. Install the second gear gearwheel.

2. Install the synchronizer outer ring.
3. Install the synchronizer cone.
4. Install the synchronizer inner ring.
5. Install the second gear gearwheel.
6. Install the third gear gearwheel using the special

tool.
7. NOTE: Install a new snap ring.

Install the fourth gear gearwheel using the
special tool.
8. Install the fifth gear gearwheel.

2. Install the fifth gear gearwheel.

9. NOTE: Install the synchronizer hub
assembly with the narrower collar and the
annular groove facing outwards.
Installation position of fifth and reverse gear
synchronizer hub assembly.
10. NOTE: Install the synchronizer hub assembly

with the narrower collar and the annular
groove facing outwards.
Install the fifth and reverse gear synchronizer
hub assembly.
1. Install the synchronizer hub assembly.
2. Install a new snap ring.
11. Install the reverse gear gearwheel.

3. Install the reverse gear gearwheel.
12. Install the transmission housing roller bearing

using a suitable tube.
13. Install the clutch housing roller bearing using a

suitable tube.

MTX-75 - Differential
Print
Special Tool(s)
Thrust Pad
205-071-01 (15-026A-01)
Installer, Differential Taper Roller Bearing

205-081 (15-032)
Remover, Taper Roller Bearing (Main Tool)

205-295 (15-050A)
Collet for 205-295

308-197 (16-062)
General Equipment
Press
Materials
Name Specification
Disassembly
1. Pull off the taper roller bearings from the
differential (illustration shows 1.8L diesel
engine).
1. Fit the special tool.
2. Pull off the taper roller bearings.
Take off the speedometer worm gear (1.8L
diesel engine) or vehicle speed sensor ring
(VSS ring) (1.8L engine).
2. NOTE: Use a copper mallet.

Detach the spur gear.
Unscrew the bolts.
Detach the spur gear by tapping lightly on

it.
Assembly
1. NOTE: Do not oil taper roller bearings which
are to be used again. Install new taper roller
bearings untreated.
Carefully clean and check all parts and coat with
transmission fluid before reassembly.
2. Fit the spur gear to the differential.
Tighten the bolts evenly, working
diagonally.
3. NOTE: The speedometer worm gear / sensor

ring for the vehicle speed sensor must
engage in the recess on the housing.
Press on the taper roller bearing (illustration
shows 1.8L diesel engine).
1. Attach the speedometer worm gear (1.8L
diesel engine) or VSS ring (1.8L engine).
2. Press on the taper roller bearing using a
press and the special tool.
4. CAUTION: Do not use the taper roller

bearing as a support.
Install the taper roller bearing (spur gear end)
(illustration shows 1.8L diesel engine).
Support the differential under the spur
gear.
Press on the taper roller bearing using the

special tool and a press.

MTX-75 - Transaxle
Print
Assembly
Special Tool(s)
Remover/Installer, Front Hub Bearing Race
204-017 (14-010)
Installer, Front Hub Bearing Race/Oil Seal

204-050 (14-024)
Preload Gauge
205-067 (15-041)
Installer, Rear Hub Oil Seal

205-075 (15-036)
Installer, Drive Pinion Oil Seal

205-115 (15-058)
Socket, Drive Pinion Nut

205-175 (15-073)

303-060 (21-024)
Adapter for 303-060

303-060-02 (21-024-02)
Adapter for 303-060

303-060-07 (21-024-07)

303-435-14A (21-212A)
Installer, Input Shaft Oil Seal

307-210 (17-041)
Holding Fixture, Dial Indicator Gauge (Output Shaft End Float)

308-194B (16-059B)
General Equipment

Press
Magnetic base for dial indicator gauge
Materials
Name Specification
Sealer, slave cylinder ESK-M4G269-A
High-temperature ESDM-1C220-A
grease
Assembly
All vehicles
1. Clean and check all parts carefully before
reassembly.
Coat all running surfaces with transmission
fluid.
2. NOTE: Only if removed.
Install the reverse gear idler shaft.
1. Coat the mating surface of the reverse
gear idler shaft with sealer.
2. Position the reverse gear idler shaft with
the locating bolt and drive it in.
3. Unscrew the locating bolt and fit the
original bolts.
3. CAUTION: The press force must not

exceed 15kN.
Fit the bearing races on the transmission
housing side.
Heat up the transmission housing locally to
approximately 80°C using a hot air blower.
Cool the bearing races with temperature
reduction spray and fit them.
Fit the bearing races using the press:
1. Input shaft using 307-210 (17-041).
2. Output shaft using 205-075 (15-036).
3. Differential using 204-050 (14-024).
4. Measuring shim to be fitted:

Input shaft: 1.00 mm.
Output shaft: 1.00 mm.
Differential: 1.10 mm.
5. CAUTION: The press force must not

exceed 15kN.
Fit the measuring shims and the bearing races in
the clutch-end housing section.
Heat up the transmission housing to
approximately 80°C using a hot air blower.
Cool the bearing races with temperature
reduction spray.
1. Fit the measuring shims.
2. Fit the bearing races.

Fit the bearing races using the press:
1. Input shaft using 204-017 (14-010).
2. Output shaft using 205-075 (15-036).
3. Differential using 204-050 (14-024).

bearings untreated.
Fit the input shaft and the output shaft in the
transmission housing.
Engage fourth gear.
Fit the input shaft and the output shaft
together in the transmission housing.

bearings untreated.
Install the differential (illustration shows 1.8L
diesel engine).
8. NOTE: Check that the mating surface is

clean.
Position the clutch-end housing section.
Attach the special tool to the transmission
housing flange using the longer bolt.
9. Install the clutch-end housing sections.

Tighten the 16 flange bolts uniformly.

Position the measuring bar on the 4th gear
wheel.
11. Prepare the input shaft for measuring.

Turn the input shaft to and fro
approximately 20 times to settle the
bearings.
12. Set up the dial indicator gauge.

1. Attach the special tool to the transmission.
2. Set up the magnetic dial indicator gauge
base.
3. Set the dial indicator to "0".
13. NOTE: Carry out both the previous and this

step three times and calculate the average
measurement.
Measure the input shaft end float.
1. Lift the input shaft with a lever.
2. Note the resulting measurement (e.g.
0.22mm).
Example: 0.22 mm + 0.23 mm + 0.21 mm
divided by three = 0.22 mm.

14. Prepare the output shaft for measuring.
Turn the output shaft back and forth 20
times to settle the bearings (see previous
step).
Set up the dial indicator gauge.
Set the dial indicator to "0".
15. NOTE: Carry out both this and the following

measurement.
Measure the output shaft end float.
Lift the output shaft with a lever and note
the resulting measurement, e.g. 0.32mm.
Example: 0.32 mm + 0.34 mm + 0.33
mm divided by three = 0.33mm.
16. Prepare the differential for measuring.

Turn the input shaft backwards and
forwards 20 times and at the same time
press down the differential.
Set up the dial indicator and set it to "0".

17. NOTE: Carry out both this and the following
measurement.
Measure the differential end float.
Lift the differential with the special tool
and note the resulting measurement, e.g.
0.34mm.
Example: 0.34 mm + 0.36 mm + 0.38
mm divided by three = 0.36 mm.
18. Calculate the required input shaft shim thickness.

Required shim thickness, 1.00 mm.
Measured end float (see previous step),
0.22 mm.
End float dimension = 0.05 mm.
Required shim: 0.22 mm - 0.05 mm +
1.00 mm = 1.17 mm.
19. Calculate the required output shaft shim
thickness.
Required shim thickness, 1.00 mm.
0.33 mm.
Preload dimension = 0.13 mm.
Required shim: 1.00 mm + 0.33 mm +
0.13 mm = 1.46 mm.
20. Calculate the required differential shim thickness.
Required shim thickness, 1.10mm.
0.36 mm.
Preload dimension = 0.33 mm.
Required shim: 1.10 mm + 0.36 mm +
0.33 mm = 1.79 mm.
21. Remove the bearing races again.
Fit the bearing races of the:
1. Input shaft

2. Output shaft
3. Differential
22. Fit the shims and bearing races.

1. Fit the required shims.
2. Fit the bearing races of the:
1. Input shaft
2. Output shaft
3. Differential
23. Fit the reverse gear idler wheel.

1. Lower thrust washer
2. Needle roller bearing
3. Reverse gear idler wheel (smaller collar
faces downwards)
4. Upper thrust washer
5. Snap ring
24. Install the input and output shafts together.

Coat the taper roller bearing with
transmission fluid.
25. Install selector fork.

Move the fourth gear selector ring to the
neutral position.
Insert the fifth and reverse gear selector
fork and swivel it to the side.
26. Install the third and fourth gear selector fork.

Swivel back the fifth and reverse gear

selector fork.
27. NOTE: When fitted correctly, the selector

rods are the same height.
Install the first and second gear selector fork and
selector rods.
28. Install the differential (illustration shows 1.8L

diesel engine).
1. Fit the differential.
2. Place the clean magnetic disc in the
recess.
29. Coat the mating surface with sealant.

The mating surface must be dry and free
of oil. Apply sealant evenly to the inside of
the mating surface (even 2 mm bead of
sealant).
30. NOTE: The transmission housing must not be

turned over to tighten the bolts.
Fit the clutch-end housing section.
Tighten the 16 flange bolts within
15minutes, working diagonally.
31. NOTE: Make sure the transmission is in

neutral (the gearshift lever and selector lever
must be vertical).
Install the selector mechanism.
The mating surface must be dry and free
of oil. Apply sealant evenly to the outside

of the mating surface (even 2 mm bead of
sealant).
32. Measure the turning torque.

Engage fourth gear.
Measure the turning torque.
If the turning torque is too high, all the
measurements (to establish the required
shim thickness) must be repeated.

33. Fit the speedometer drive pinion.
Insert the drive pinion.
Carefully drive in the roll pin.

34. Install the vehicle speed sensor (VSS).
All vehicles
35. Install the front driveshaft oil seals.

36. WARNING: Do not allow brake fluid to
come into contact with the skin or eyes. If
brake fluid contacts the skin or eyes, rinse
the affected area immediately with water.
Failure to observe this instruction can lead to
injury.
CAUTIONS:
Wrap the input shaft splines with

adhesive tape to protect the input shaft oil
seal.
Do not oil clutch slave cylinder.

NOTE: Install a new clutch slave cylinder.
Install the clutch slave cylinder with a new oil
seal and with slave cylinder sealer.
37. Remove the adhesive tape from the input shaft
splines.
38. Apply a thin film of high-temperature grease to
the input shaft splines.

MTX-75 - Transaxle—1.8L Duratorq-TDCi Transit/Tourneo Connect 2002.5 (06/2002-)
Diesel, Vehicles Built Up To: 03/2009
Print
Installation
Special Tool(s)
Support Bar, Engine
303-290A (21-140)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)

303-290-01 (21-140-01)
General Equipment
Transmission jack
Securing straps
Materials
Name Specification
fluid
Operation).
2. Using suitable securing straps, secure the
transaxle to a transmission jack.
3. Using the transmission jack, install the transaxle.
4. Install the transaxle right-hand upper retaining

bolts.

5. Remove the securing straps.
7. Install the transaxle right-hand lower retaining
bolt.
8. Attach the starter motor to the transaxle.

Attach the starter motor cable bracket to
the transaxle.
Attach the engine ground cable to the
transaxle.
10. Install the engine rear mount bracket.

12. Using the special tools, raise the engine and
transaxle assembly.

NOTE: Do not fully tighten the engine rear
mount retaining nuts at this stage.
Install the engine rear mount.
14. Remove the special tools on both sides.

1. Loose the fender retaining bolts.
3. Tighten the fender retaining bolts.
4. Install the fender retaining bolts.
15. Connect the transaxle breather tube to the

transaxle.
Clip the breather tube.

Operation).
17. Install the accessory drive belt cover.

19. CAUTIONS:

degrees.

NOTE: Install a new halfshaft center bearing
cap and new locknuts.
Install the halfshaft center bearing cap.
20. CAUTIONS:

degrees.

seated.
1. Attach the gearshift cable to the bracket
and turn the abutment sleeve
counterclockwise.
2. Attach the selector cable to the bracket
counterclockwise.
22. Adjust the gearshift cables.

23. Install the crossmember.
Crossmember (502-00 Uni-Body, Subframe and
Mounting System, Removal and Installation).

25. Install the transaxle upper retaining studs.
26. Attach the power steering pressure pipe bracket

to the transaxle.
27. Install the cooling fluid tube bracket retaining

nuts.
Attach the central electrical connector
bracket to the transaxle.
28. Install the positive crankcase ventilation (PCV)

unit upper retaining nut.
Attach the PCV unit to the transaxle.

retaining nuts on both sides.
30. Connect the reversing lamp switch electrical

connector.

31. Attach the VSS electrical wiring harness to the
transaxle.

Connect the clutch slave cylinder supply line to
the clutch slave cylinder.
Install the spring clip.

Connect the intake air temperature (IAT)
34. Attach the air cleaner outlet pipe and the PCV
hose to the engine.
35. Install the charge air cooler left-hand pipe.

36. Tighten the engine rear mount retaining nuts.
37. Bleed the clutch system.

For additional information, refer to: Clutch
System Bleeding (308-00 Manual
38. Connect the battery ground cable to the battery
terminal clamp.
Cables - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L
Duratorq-TDDi (Lynx) Diesel (414-01 Battery,
Mounting and Cables, Removal and Installation).
39. Check the transmission fluid level and top up
with manual transmission fluid, if necessary.

MTX-75 - Transaxle—1.8L Duratec-DOHC
Print
Installation
Special Tool(s)
Support Bar, Engine
303-290A (21-140A)

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)
General Equipment
Transmission jack
Retaining straps
Materials
Name Specification
fluid
Installation
Lifting.
2. NOTE: Use suitable retaining straps, secure
the transaxle on a transmission jack.
Using a suitable transmission jack, install the
transaxle.

4. Install the transaxle right-hand lower retaining
bolt.
5. Remove the retaining straps.

NOTE: Make sure the spring clip is correctly
seated.
Connect the clutch slave cylinder supply line to
the transaxle.
Install the spring clip.
8. Install the transaxle right-hand retaining bolts.
9. Attach the starter motor to the transaxle.

11. Install the transaxle upper retaining studs.
12. Install the engine rear mount bracket.
13. Using the special tools, raise the engine and

transaxle assembly.

NOTE: Do not fully tighten the engine rear
mount retaining nuts at this stage.
Install the engine rear mount.

16. Attach the engine wiring harness to the bracket.
17. Connect the transaxle breather tube to the

transaxle.
Clip the breather tube.
18. Connect the the reversing lamp switch electrical

connector.

Lifting.
1. Attach the gearshift cable to the bracket
counterclockwise.
2. Attach the selector cable to the bracket
counterclockwise.
21. Adjust the gearshift cables. For additional


Information.
23. CAUTIONS:

degrees.

seated.
24. CAUTIONS:

degrees.

NOTE: Install a new center bearing cap and
locknuts.
locknuts.
25. Install the crossmember. For additional
26. Install the accessory drive belt cover.

nuts on both sides.

29. Tighten the engine rear mount retaining nuts.
30. Install the battery tray. For additional

31. Install the battery. For additional information,
refer to Section 414-01 Battery, Mounting and
Cables.
32. With the vehicle on a level surface, fill the
transaxle with manual transmission fluid until the
oil level is just below the bottom of the filler
hole.
33. Bleed the hydraulic clutch system. For additional
Information.
and Filtering.

MTX-75 - Transmission—1.8L Duratorq-
(Lynx) Diesel, Vehicles Built From:
04/2009
Print
Installation
Special Tool(s)
204-605
Separator, Lower Arm Ball Joint
205-775
Protector Halfshaft Seal
303-290-01
303-290-02
303-290-06
303-290A
Support Bar, Engine
Materials
Name Specification
Grease K-HT ESD-M1C220-A / A88SX1C220AA
Grease KS-PS SA-M1C9107-A / YS5J-M1C9107-AA
General Equipment
Cable ties
Retaining Strap
Tire lever
Transmission jack
Wooden Block
1. Refer to: Health and Safety Precautions (100-00
2. CAUTION: Make sure that the locating

dowels remain installed.
Coat the input shaft splines with a thin coating of
grease.

Material: Grease K-HT (ESD-M1C220-A /
A88SX1C220AA)
3. WARNING: This step requires the aid of

another technician.
4. Perform this and the following operation

simultaneously.
Torque: 47 Nm
5. Torque: 47 Nm

General Equipment: Retaining Strap


8. Torque: 80 Nm

10. Special
Tool
(s):
303-
290A
11. Torque: 80 Nm

12.
13.
1. Torque: 133 Nm
2. Torque: 48 Nm
14. Refer to: Clutch System Bleeding (308-00 Manual



16.
1. Material: Grease KS-PS (SA-M1C9107-A /
YS5J-M1C9107-AA)
2. NOTE: Make sure that a new
component is installed.

exhaust flexible pipe is not forcibly
bent.
General Equipment: Tire lever
Torque: 48 Nm

18. Torque: 47 Nm
19. Torque: 35 Nm

20. Torque: 47 Nm
21. Torque: 47 Nm
22. Remove the special tool before completely

installing the halfshaft.

23.
1. Torque: 10 Nm
2. Torque: 10 Nm
3. Torque: 25 Nm
4. Torque: 25 Nm

installed.
Remove the special tool before completely
installing the halfshaft.
25.
26. On both sides.
27. CAUTIONS:
Make sure that a new nut is installed.
Make sure that the ball joint ball does not

rotate.
On both sides.
Torque: 150 Nm
28. CAUTIONS:

Make sure that a new nut is installed.
Make sure that the ball joint ball does not

rotate.
On both sides.
Torque: 47 Nm

On both sides.
Torque: 50 Nm
30.
31.
1. Torque: 47 Nm
2. Torque: 80 Nm
32.

33. Refer to: Gearshift Cable Adjustment (308-00
Manual Transmission/Transaxle and Clutch -
34.
35. Refer to: Wheel and Tire (204-04 Wheels and

37. Remove the Special Tool(s): 303-290A, 303-290-
01, 303-290-02, 303-290-06
38.
1. Torque: 47 Nm
2. Torque: 25 Nm

39.
40.
41.

Installation).
43. Torque: 10 Nm
44. If equipped.
45. On both sides.
Torque: 25 Nm

Procedures).
Torque: 8 Nm

48. Refer to: Transmission Fluid Level Check (308-03

Manual Transmission/Transaxle - Vehicles With:
Manual Transaxle, Vehicles With: MTX-75, General
Procedures).

Manual Transmission/Transaxle External
Controls - Specifications
Print

Shift and selector cable bushing. 9 80
Gearshift mechanism to floor assembly 9 80
Shift lever bearing housing to gearshift housing 9 80
Exhaust flange bolts 47 35

Controls - External Controls
Print
Gearshift mechanism
The gearshift mechanism is operated by a revised gearshift mechanism cable.
Here, the individual gears are shifted directly, without any relay action on the internal
gearshift mechanism. In order to make this possible, the mounting point of the gearshift
cable was moved to above the pivot point on the gear lever.
Because of this change, the friction between the affected components could be significantly
reduced, as a result of which the gearshift action was noticeably improved.
At the same time, this also requires a modified internal gearshift mechanism which can
transfer the direct gearshift action accordingly to the shift forks.
The ends of the gearshift cables are different in design, to prevent them being confused
with each other. Furthermore, the selector cable is marked black and the shift cable is
marked white.

1 - Internal gearshift mechanism
2 - Gearshift cable mounting point on the internal gearshift mechanism
3 - Damper weight
4 - Shift cable
5 - Retaining clip on the vehicle floor
6 - Gearshift cable mounting point on the shift lever
7 - Mounting point on the selector lever
8 - Gear lever housing
9 - Pivot point of the gear lever
10 - Body seal
11 - Selector cable
-

-
12 Gearshift cable mounting point on the selector lever shaft
13 - Selector shaft lever

Controls - External Controls
Print
Symptom Chart
Symptom Chart

External controls * Gearshift cables * ADJUST the gearshift cables.
do not operate incorrectly REFER to: Gearshift Cable Adjustment (308-00
freely adjusted Manual Transmission/Transaxle and Clutch - General
* Gearshift lever * GO to Pinpoint Test A.
damaged
* Transaxle
selector
mechanism
damaged
Pinpoint Tests
PINPOINT TEST A : STIFF GEARSHIFT

CONDITIONS
A1: CHECK THE GEARSHIFT LEVER
1 Detach the gearshift cables from the gearshift lever.
Is the gearshift lever difficult to operate?
Yes
Install a new gearshift lever.
REFER to: Gearshift Lever (308-06 Manual Transmission/Transaxle
External Controls, Removal and Installation).
No
GO to A2.
A2: CHECK THE GEARSHIFT CABLES
1 Attach the gearshift cables to the gearshift lever.
2 Detach the gearshift cables from the transaxle.
Is the gearshift lever difficult to operate?
Yes
Install new gearshift cables.
REFER to: Gearshift Cables (308-06 Manual Transmission/Transaxle
No
Disassemble the transaxle and install new selector mechanism
components as necessary.
REFER to: Transaxle (308-03 Manual Transmission/Transaxle - Vehicles
With: Manual Transaxle, Vehicles With: MTX-75, Disassembly).

Controls - Gearshift Lever
Print
Removal
information, refer to: (501-12 Instrument Panel
and Console)
Floor Console (Removal and Installation),
Floor Console - Vehicles Built From: 04/2009
(Removal and Installation).
2. Remove the air duct.
3. Detach the gearshift cables from the retaining

bracket.
Turn the abutment sleeves clockwise and
detach the cable from the bracket.
4. Detach the gearshift cables from the gearshift

lever.
5. Remove the gearshift lever.
Installation


Controls - Gearshift Cables
Print
Removal
Operation).
2. CAUTION: Over bending of the exhaust

flexible pipe may cause damage resulting in
failure.
Support the exhaust flexible pipe with a suitable
support wrap or a suitable splint.
3. Remove the exhaust flange retaining bolts.

Detach the exhaust flexible pipe from the
support insulators.
4. Detach the exhaust heat shield from the floor

panel and push it backwards.
Unclip the shift and selector cables from
the floor panel.

1. Detach the gearshift cable and the selector
cable from the selector levers.

information, refer to: (501-12 Instrument Panel
and Console)
Floor Console (Removal and Installation),
Floor Console - Vehicles Built From: 04/2009
(Removal and Installation).
9. Remove the air distribution channel.
10. Cut the carpet and the insulation pad to gain

access to the gearshift cables.
11. Detach the gearshift cables from the retaining

bracket.
Turn the abutment sleeves clockwise and
detach the cable from the bracket.
12. Detach the gearshift cables from the gearshift

lever.
13. Remove the gearshift cables.

1. Remove the nuts.
2. Pull the cables through to the interior.

Installation
1. NOTE: Do not bend or kink the gearshift
cables.

Controls - Gearshift Lever
Print
Disassembly
1. NOTE: Location of the spring.
Remove the bracket lever.
Remove the snap-ring.
2. Dismantle the bracket lever.

1. Retaining clip
2. Spring
3. Sleeve
4. Bracket lever
3. Detach the bearing housing and bearing shell.
Assembly
1. Reassemble the parts in reverse order.

Exhaust System - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Item Specification
Lubricant ESE-M99B144
Anti-seize grease SAM1C9107A
lb- lb-
Description Nm ft in
Catalytic converter to turbocharger nuts - vehicles with variable vane 25 18 -
turbocharger
Flexible pipe flange nuts 47 35 -
Muffler assembly flange nuts 47 35 -
Clamp nuts 47 35 -
HO2S 47 35 -
Support bracket nuts 22 16 -
Catalytic converter support bolt - diesel 25 18 -
Manifold heatshield bolts 10 - 89
Catalytic converter support strap nuts 22 16 -
Rear support strap to bracket bolts 47 35 -

Exhaust System - Catalytic Converter—
Zetec
Print
Materials
Name Specification
Anti-seize grease SAM-1C9107-A
Removal
2. Disconnect the heated oxygen sensor (H02S)

3. Remove the H20S.
4. Detach the catalytic converter from the exhaust

manifold.
Discard the nuts.

Lifting.
6. Disconnect the catalyst monitor sensor electrical

connector.
7. Remove the catalyst monitor sensor.

failure.
support wrap or suitable splint.
9. Detach the exhaust flexible pipe from the

Discard the gasket and nuts.
10. CAUTION: The catalytic converter must

be supported while the support strap is
removed.
Remove the catalytic converter support bracket.
Installation
1. CAUTION: Never use jointing compound

forward of the catalytic converter.
NOTE: Coat the catalytic converter and
exhaust flexible pipe studs with anti-seize
grease.
NOTE: Install new gaskets and nuts.

Exhaust System - Catalytic Converter—
Print
Materials
Name Specification
Grease SA-M1C9107-A
Removal
1. Remove and discard the catalytic converter to
turbocharger nuts.
All vehicles
Operation).
Vehicles with variable vane turbocharger

3. Remove and discard the catalytic converter to
turbocharger nuts.
All vehicles

failure.
support wrap or splint.
5. CAUTION: Using suitable cable ties,

support the exhaust muffler and exhaust
tailpipe assembly to prevent damage to the

exhaust hanger insulators.
Detach the exhaust flexible pipe from the tailpipe
and muffler assembly.
Discard the nuts.
6. Detach the catalytic converter from the cylinder

block.
Installation
All vehicles
1. NOTE: Only tighten the bolt finger tight at
this stage.
Attach the catalytic converter to the cylinder
block.
2. NOTE: Only tighten the nuts finger tight at

this stage.
Attach the exhaust flexible pipe to the tailpipe
and muffler assembly.
Coat the studs with grease.
Install new nuts.
Vehicles with variable vane turbocharger
3. CAUTION: Jointing compound must not

be used forward of the catalytic converter.
NOTE: Only tighten the nuts finger tight at
this stage.
NOTE: Make sure that the exhaust flanges
Install the catalytic converter to turbocharger
nuts in the sequence shown.
Coat the studs with grease.
Install new nuts.

4. NOTE: Make sure that the exhaust flanges
Tighten the catalytic converter to turbocharger
nuts in the sequence shown.
All vehicles
6. WARNING: Make sure that new nuts are

installed.
Tighten the catalytic converter to turbcharger
nuts:
Vehicles with M8 nuts tighten to 25 Nm.
Vehicles with M10 nuts tighten to 47 Nm.
All vehicles
Operation).
8. Tighten the catalytic converter to cylinder block
bolt.
9. Tighten the exhaust flexible pipe to the tailpipe

and muffler assembly nuts.
10. Remove the exhaust flexible pipe support wrap

or splint.


Exhaust System - Diesel Particulate Filter (DPF) Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Ford diagnostic equipment
Removal
1.
1. CAUTION: If
the component is loose, a
new component must be
installed.
Torque: 48 Nm
Installation

2.
Carry out the powertrain control module (PCM) Reset the Diesel
Particulate Filter Learned Values service function.
Carry out the powertrain control module (PCM) Reset the Diesel
Particulate Filter Differential Pressure Sensor Learned Values service
function.
General Equipment: Ford diagnostic equipment

Exhaust System - Exhaust Flexible Pipe—
Zetec
Print
Materials
Name Specification
Grease SA-M1C9107-A
Removal
Operation) /
and Operation).

failure.
support wrap or suitable splint.
3. CAUTION: Using suitable cable ties,

support the exhaust tailpipe and muffler
assembly to prevent damage to the exhaust
hanger insulators.
Detach the exhaust flexible pipe from the
exhaust tailpipe and muffler assembly.
Discard the gasket and nuts.
4. Remove the exhaust flexible pipe.
Installation
1. NOTE: Coat the muffler and tail pipe
assembly studs with anti-seize grease.
NOTE: Install new catalytic converter gasket
and nuts.

1.8L Duratorq-TDDi (Lynx) Diesel,
Vehicles With: Two-Piece Catalytic
Converter and Exhaust Flexible Pipe
Print
Materials
Name Specification
Grease SA-M1C9107-A
Removal
Lifting)

failure.
Support the exhaust flexible pipe with a support
wrap or splint.
3. Loosen the exhaust flexible pipe to catalytic

converter clamp retaining nut.
4. CAUTION: Using cable ties, support the

muffler and tailpipe assembly to prevent
damage to the exhaust hanger insulators.
Detach the exhaust flexible pipe from the muffler
and tailpipe assembly.
Discard the exhaust flexible pipe to muffler
and tailpipe assembly gasket and retaining
nuts.
5. Remove the exhaust flexible pipe.

Installation
1. NOTE: Do not fully tighten the exhaust
flexible pipe to catalytic converter clamp
retaining nut at this stage.
NOTE: Make sure that the exhaust flexible
pipe locating cut out is aligned with the
locating dowel on the catalytic converter.
Install the exhaust flexible pipe.
2. NOTE: Coat the muffler and tailpipe

assembly studs with grease.
NOTE: Install a new exhaust flexible pipe to
muffler and tailpipe assembly gasket and
retaining nuts.
NOTE: Remove the cable ties.
Attach the exhaust flexible pipe to the muffler
and tailpipe assembly.
3. Tighten the exhaust flexible pipe to catalytic


failure.
Remove the exhaust flexible pipe support wrap
or splint.

1.8L Duratorq-TDDi (Lynx) Diesel,
Vehicles With: One-Piece Catalytic
Converter and Exhaust Flexible Pipe
Print
General Equipment
Exhaust pipe cutter
Materials
Name Specification
Grease SA-M1C9107-A
Removal
For additional information, refer to: Catalytic
Converter - 1.8L Duratorq-TDCi (Lynx)
Exhaust System, Removal and Installation).
2. Using an exhaust pipe cutter, cut the exhaust
flexible pipe from the catalytic converter in the
position shown.
Installation
1. CAUTION: Never use jointing compound

forward of the catalytic converter.
NOTE: Do not fully tighten the catalytic
converter to cylinder block retaining bolt at
this stage.
Install the catalytic converter.
2. NOTE: Do not fully tighten the exhaust

flexible pipe to catalytic converter clamp
retaining nut at this stage.
NOTE: Make sure that the exhaust flexible
pipe locating cut out is aligned with the
locating dowel on the catalytic converter.
Install the exhaust flexible pipe.
3. NOTE: Coat the muffler and tail pipe

assembly studs with grease.
NOTE: Install a new exhaust flexible pipe to
muffler and tailpipe assembly gasket and
retaining nuts.
NOTE: Do not fully tighten the exhaust
flexible pipe to muffler and tailpipe assembly

Attach the exhaust flexible pipe to the muffler
and tail pipe assembly.

5. NOTE: Install new catalytic converter to
exhaust manifold retaining nuts.
Attach the catalytic converter to the exhaust
manifold.

Lifting)
7. Tighten the catalytic converter to cylinder block
retaining bolt.
8. NOTE: Remove the cable ties.

Tighten the exhaust flexible pipe to muffler and
tailpipe assembly retaining nuts.
9. Tighten the exhaust flexible pipe to catalytic


failure.
Remove the exhaust flexible pipe support wrap
or splint.

Fuel System - General Information - Fuel
System—75 PS/90 PS
Print
Special Tool(s)
416-D001 (23-036A)

WARNINGS:
Fuel level Fuse(s)
Fuel leak(s) Relay(s)
Fuel line(s) Wiring harness
Fuel filler cap Electrical connector(s)
Fuel filter Inertia fuel shutoff (IFS) switch - all except vehicles with
Fuel tank diesel engine
Fuel tank ventilation Fuel level sensor - vehicles with diesel engine
hose Fuel pump module - all except vehicles with diesel engine
Fuel tank filler hose Engine
Chart.
Symptom Chart
Symptom Chart

Engine cranks but * Fuel charging and * REFER to Section 303-04A Fuel Charging and
does not start - controls. Controls / 303-04B Fuel Charging and
vehicles with diesel Controls / 303-04C Fuel Charging and Controls
engine - Turbocharger / 303-04D Fuel Charging and

Controls.
* Air ingress into the * GO to Pinpoint Test A. .
fuel lines.
* Contaminated fuel. * INSTALL a new fuel filter. DRAIN and RENEW
the fuel.
REFER to Fuel Tank Draining in this section.
Engine cranks but * Fuel charging and * REFER to WDS.
does not start - all controls.
except vehicles with * IFS switch. * REFER to WDS.
diesel engine * Contaminated fuel. * INSTALL a new fuel filter. DRAIN and RENEW
the fuel.
Poor starting - * Fuel charging and * REFER to Section 303-04A Fuel Charging and
vehicles with diesel controls. Controls / 303-04B Fuel Charging and
engine Controls / 303-04C Fuel Charging and Controls
Controls.
fuel lines.
the fuel.
Poor starting - all * Fuel charging and * REFER to WDS.
except vehicles with controls.
the fuel.
Engine starts but * Fuel charging and * REFER to Section 303-04A Fuel Charging and
immediately stops - controls. Controls / 303-04B Fuel Charging and
Controls.
fuel lines.
Engine starts but * Fuel charging and * REFER to WDS.
immediately stops - controls.
all except vehicles
with diesel engine
Poor idling - vehicles * Fuel charging and * REFER to Section 303-04A Fuel Charging and
with diesel engine controls. Controls / 303-04B Fuel Charging and
Controls.
fuel lines.
the fuel.
Poor idling - all * Fuel charging and * REFER to WDS.
except vehicles with controls.
the fuel.
Engine lacks power - * Fuel tank to fuel * CHECK the fuel supply lines for damage.
vehicles with diesel filter supply line INSTALL a new fuel filter supply line.
engine blocked. * CHECK the fuel supply line for blockage. Using
the special tool, APPLY a vacuum to the fuel
filter supply line at the fuel filter inlet. If fuel

does not draw easily from the fuel tank,
REPAIR the fuel filter supply line as necessary.
* Fuel filter blocked. * INSTALL a new fuel filter. REFER to Section
310-01A Fuel Tank and Lines / 310-01B Fuel
Tank and Lines.
* Fuel charging and * REFER to Section 303-04A Fuel Charging and
controls. Controls / 303-04B Fuel Charging and
Controls.
fuel lines.
the fuel.
Engine lacks power - * Ignition system. * REFER to Section 303-07A Engine Ignition /
all except vehicles 303-07B Glow Plug System.
with diesel engine * Fuel filter blocked. * INSTALL a new fuel filter. REFER to Section
Tank and Lines.
* Fuel charging and * REFER to WDS.
controls.
the fuel.
Engine misfire - * Fuel charging and * REFER to Section 303-04A Fuel Charging and
vehicles with diesel controls. Controls / 303-04B Fuel Charging and
engine Controls / 303-04C Fuel Charging and Controls
Controls.
fuel lines.
Engine misfire - all * Ignition system. * REFER to Section 303-07A Engine Ignition /
except vehicles with 303-07B Glow Plug System.
diesel engine * Fuel charging and * REFER to WDS.
controls.
Excessive fuel * Fuel charging and * REFER to Section 303-04A Fuel Charging and
consumption - controls. Controls / 303-04B Fuel Charging and
Controls.
fuel lines.
the fuel.
Excessive fuel * Fuel charging and * REFER to WDS.
consumption - all controls.
except vehicles with * Contaminated fuel. * INSTALL a new fuel filter. DRAIN and RENEW
diesel engine the fuel.
Fuel filler nozzle * Fuel tank ventilation * CHECK the fuel tank ventilation hose for
shuts off prematurely hose or pipe obstruction or damage. INSTALL a new fuel
blocked. tank ventilation pipe. for additional information,
* Fuel tank ventilation REFER to Section 310-01A Fuel Tank and
hose or pipe Lines / 310-01B Fuel Tank and Lines.
collapsed.
* Fuel tank filler pipe * CHECK the fuel tank filler pipe or hose for

or hose blocked. obstruction or damage. INSTALL a new fuel
* Fuel tank filler pipe tank filler pipe. for additional information,
or hose collapsed. REFER to Section 310-01A Fuel Tank and
Lines / 310-01B Fuel Tank and Lines.
* Fuel gauge * CHECK the fuel level in the fuel tank. CHECK
indication. the fuel indication system. For additional
information, REFER to Section 413-01
Instrument Cluster.
* Fuel filler nozzle at * VERIFY condition by using a known good fuel
fuel filling station filler nozzle.
not functioning
correctly.
Fuel loss after nozzle * Fuel tank filler pipe * CHECK the fuel tank filler pipe and hose for
shutoff or during or hose leaking. evidence of a fuel leak. If a fuel leak is evident,
refilling INSTALL a new fuel tank filler pipe and hose.
For additional information, REFER to Section
Tank and Lines.
* Fuel tank leaking. * CHECK the fuel tank for evidence of a fuel
leak. If a fuel leak is evident, INSTALL a new
fuel tank. For additional information, REFER to
Section 310-01A Fuel Tank and Lines / 310-
01B Fuel Tank and Lines.
* Fuel tank ventilation * CHECK the fuel tank ventilation pipe and hose
pipe or hose leaking. for evidence of a fuel leak. If a fuel leak is
evident, INSTALL a new fuel tank ventilation
pipe and hose. For additional information,
REFER to Section 310-01A Fuel Tank and
Lines / 310-01B Fuel Tank and Lines.
Pinpoint Tests
PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES

A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNINGS:
always observe fuel handling precautions. Failure to follow this instruction may result in
personal injury.
CAUTION: The generator must be protected from contamination. Failure to follow

this instruction may cause premature failure of the generator.
1 Using a suitable piece of clear plastic pipe,
manufacture and install a pipe between the fuel
injection pump and the fuel injection pump to fuel
filter fuel return line.
2 Start the engine, wait a few minutes and then

observe the clear plastic pipe for signs of air
ingress.
Are any signs of air present in the clear plastic pipe?
Yes
GO to A2. .
No
REMOVE the clear plastic pipe and connect the fuel
injection pump to fuel filter fuel return line. For
additional diagnostics for Fuel Charging and
Controls REFER to Section 303-04A Fuel Charging
and Controls / 303-04B Fuel Charging and
Controls.
A2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1 Using suitable clean engine oil, apply the oil to
each of the fuel supply line and fuel return line
connections, unions and joints in turn and observe
the clear plastic pipe for visible signs of air after
each oil application.
Did the amount of air in the clear plastic pipe decrease
when any of the connectors, unions or joints were
oiled?
Yes
INSTALL a new fuel pipe(s) as necessary. Test the
No
REMOVE the clear plastic pipe from between the
fuel injection pump and the fuel injection pump to
fuel filter fuel return line.GO to A3. .
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1 Drain the fuel tank.
2 Fill the fuel tank with 10 liters of diesel.
3 Disconnect the fuel tank to fuel filter fuel supply
filter and the fuel tank to fuel filter supply line.
5 Using the special tool, prime the fuel pump until

clean air-free fuel is seen entering the vacuum
pump reservoir.
6 Remove the special tool and connect the fuel

injection pump to fuel filter fuel return line.

NOTE: Make sure the engine is at normal operating
temperature.
7 Start the engine, wait a few minutes and then
observe the clear plastic pipe for signs of air
ingress.
Yes
INSTALL a new fuel level sensor or fuel tank to fuel
filter supply pipe as necessary. REFER to Section
310-01A Fuel Tank and Lines / 310-01B Fuel Tank
and Lines.
No
INSTALL a new fuel filter. REFER to Section 310-
01A Fuel Tank and Lines / 310-01B Fuel Tank and
Lines.

System—1.8L Duratorq-TDCi (Lynx) Diesel
(75 PS/90 PS/110 PS), Vehicles Built
From: 08/2006
Print
Special Tool(s)
310-110
General Equipment
Fuel level Wiring harness
Fuel leak(s) Electrical connector(s)
Fuel line(s) Fuel level sensor
Fuel filler cap
Fuel filter
Fuel tank
Fuel tank ventilation hose
Fuel tank filler hose
Chart.
Symptom Chart

Engine cranks but * Fuel charging and * REFER to: Fuel Charging and Controls - 75
does not start controls. PS/90 PS/110 PS, Vehicles Built From: 08/2006
Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-
TDDi (Lynx) Diesel, Diagnosis and Testing).
* Air ingress into the * GO to Pinpoint Test A.
fuel lines.
* Contaminated fuel. * DRAIN and REFILL the fuel system with fresh
fuel. INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi
(Lynx) Diesel (310-01A Fuel Tank and Lines,
Poor starting * Fuel charging and * REFER to: Fuel Charging and Controls - 75
controls. PS/90 PS/110 PS, Vehicles Built From: 08/2006

fuel lines.
Engine starts but * Fuel charging and * REFER to: Fuel Charging and Controls - 75
immediately stops controls. PS/90 PS/110 PS, Vehicles Built From: 08/2006
fuel lines.
Poor idling * Fuel charging and * REFER to: Fuel Charging and Controls - 75
fuel lines.
Engine lacks * Fuel tank to fuel filter * CHECK the fuel supply lines for damage.
power fuel supply line INSTALL a new fuel filter fuel supply line as
blocked. necessary.
* GO to Pinpoint Test B.
* Fuel filter blocked. * INSTALL a new fuel filter.
* Fuel charging and * REFER to: Fuel Charging and Controls - 75
fuel lines.
Engine misfire * Fuel charging and * REFER to: Fuel Charging and Controls - 75
fuel lines.
Excessive fuel * Fuel charging and * REFER to: Fuel Charging and Controls - 75
consumption controls. PS/90 PS/110 PS, Vehicles Built From: 08/2006

fuel lines.
Fuel filler nozzle * Fuel tank ventilation * CHECK the fuel tank ventilation hose for
shuts off hose or pipe blocked. obstruction or damage. INSTALL a new fuel
prematurely * Fuel tank ventilation tank ventilation pipe as necessary.
hose or pipe collapsed.
* Fuel tank filler pipe or * CHECK the fuel tank filler pipe or hose for
hose blocked. obstruction or damage. INSTALL a new fuel
* Fuel tank filler pipe or tank filler pipe as necessary.
hose collapsed.
* Fuel gauge indication. * CHECK the fuel level in the fuel tank. CHECK
the fuel indication system. For additional
information,
REFER to: Instrument Cluster (413-01
Instrument Cluster, Diagnosis and Testing).
* Fuel filler nozzle at the * VERIFY the condition by using a known good
fuel filling station not fuel filler nozzle.
functioning correctly.
Fuel loss after * Fuel tank filler pipe or * CHECK the fuel tank filler pipe and hose for
nozzle shutoff or hose leaking. evidence of a fuel leak. If a fuel leak is evident,
during refilling INSTALL a new fuel tank filler pipe or hose as
necessary.
* Fuel tank leaking. * CHECK the fuel tank for evidence of a fuel leak.
If a fuel leak is evident, INSTALL a new fuel
tank.
REFER to: Fuel Tank - 1.8L Duratorq-TDCi
(310-01A Fuel Tank and Lines, Removal and
Installation).
* Fuel tank ventilation * CHECK the fuel tank ventilation pipe and hose
pipe or hose leaking. for evidence of a fuel leak. If a fuel leak is
evident, INSTALL a new fuel tank ventilation
pipe or hose as necessary.
Pinpoint Tests
PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES

A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNINGS:
personal injury.
CAUTIONS:

system components to prevent foreign material ingress to the components.
1 Disconnect the fuel filter fuel supply line quick
release coupling.
System - General Information, General Procedures).

manufacture and install a pipe between the fuel filter
fuel supply line and the fuel filter.
Start the engine, wait a few minutes and observe the

3
clear plastic pipe for signs of air ingress.
Yes
GO to A2.
No
For additional diagnostics,
A2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1 Using suitable clean engine oil, apply the oil to each
of the fuel supply line and fuel return line
connections, unions and joints in turn and observe
the clear plastic pipe for visible signs of air after each
oil application.
Did the amount of air in the clear plastic fuel pipe
decrease when any of the connectors, unions or joints
were oiled?
Yes
INSTALL a new fuel pipe(s) as necessary. Test the
No
GO to A3.
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1 Drain the fuel tank.
REFER to: Fuel Tank Draining (310-00A Fuel System
- General Information, General Procedures).
2 Fill the fuel tank with 10 liters of diesel.
3 Disconnect the fuel filter to fuel pump fuel supply
System - General Information, General Procedures).

manufacture and install a pipe between the fuel filter
to fuel pump fuel supply line and the fuel filter.
NOTE: Make sure that the engine is at normal

operating temperature.
5 Start the engine, wait a few minutes and observe the
clear plastic pipe for signs of air ingress.
Yes
INSTALL a new fuel level sensor or fuel tank to fuel
filter supply pipe as necessary.
No
INSTALL a new fuel filter.
Installation).
PINPOINT TEST B : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE

B1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE
WARNINGS:
personal injury.
CAUTIONS:
injection system components to prevent foreign material ingress to the components.
The generator must be protected from contamination. Failure to follow this

instruction may result in failure of the generator.
Disconnect the fuel filter fuel supply line quick

1 release coupling.
Procedures).
NOTE: Make sure that the hand pressure pump

arrow indicating the direction of fuel flow is
2 Install the special tool between the fuel filter fuel
supply line quick release coupling and the fuel
filter union.
3 Operate the hand pressure pump at least 30

times.
4 Disconnect the fuel pump fuel return line quick

release coupling.
Procedures).

pump fuel return line and the fuel return line
union.
6 Observe the flow of fuel in the clear plastic pipe.

Does the fuel from the fuel tank flow freely with no
restrictions?
Yes
GO to Pinpoint Test A.
No
REPAIR or INSTALL a new fuel filter fuel supply line
as necessary.

System Pressure Release
Print
General Procedures
Release
1. WARNINGS:


The fuel pressure must be released before
attempting any repairs. Failure to follow this
Remove the fuel pump fuse.
2. Start the engine and allow to idle until the engine
stalls.
3. Crank the engine for approximately five seconds
to make sure the fuel injection supply manifold
pressure has been released.
4. Install the fuel pump fuse.

Fuel System - General Information - Quick
Release Coupling
Print
General Procedures
General Equipment
Disconnection
WARNINGS:
Do not carry lighted tobacco or open flame of any type when working on or near any
fuel related components. Highly flammable vapors are always present and can ignite.
in personal injury.
CAUTION: Fuel injection equipment is manufactured to very precise tolerances and

fine clearances. It is therefore essential that absolute cleanliness is observed when
lines.
NOTE: Fuel supply line connectors are white or are identified by a white band. Fuel return
line connectors are red or are identified by a red band.
1. Release the fuel system pressure.
For additional information, refer to: Fuel System
Pressure Release (310-00A Fuel System -
2. Disconnect the fuel line quick release coupling.
1. Press the fuel line quick release coupling
locking tangs.
2. Disconnect the fuel line quick release
coupling.

1. Pull the fuel line quick release coupling
locking tang.
2. Push the clip through the fuel line quick
release coupling to release the fuel line.

locking tangs.
2. Disconnect the fuel line quick release
coupling.

Press the fuel line quick release coupling
buttons and pull the fuel line to
disconnect.
6. Release the fuel tank vent line quick release

coupling.
Press the fuel tank vent line quick release
coupling locking release collar.
7. Disconnect the fuel tank vent line quick release

coupling.
8. Release the fuel line quick release coupling.

Press the fuel line quick release coupling
locking release collar.

10. Using a suitable Flat-bladed screwdriver release
the fuel line quick release coupling secondary
locking tang.
11. Operate the fuel line quick release coupling

primary locking tang.
Push the fuel line quick release coupling
primary locking tang into from the fuel line
quick release coupling.
12. Disconnect the fuel line from the fuel line quick
release coupling.
13. Disconnect the fuel line from the fuel filter.

1. Press the collar into the connector body.
2. Disconnect the fuel line from the fuel filter.
Connect
WARNINGS:
Do not carry lighted tobacco or open flame of any type when working on or near any
fuel related components. Highly flammable vapors are always present and can ignite.

in personal injury.
CAUTION: Fuel injection equipment is manufactured to very precise tolerances and

fine clearances. It is therefore essential that absolute cleanliness is observed when
lines.
NOTE: Fuel supply line connectors are white or are identified by a white band. Fuel return
line connectors are red or are identified by a red band.
1. Push the connector on to the fuel filter.
2. Install the fuel line to the fuel line quick release

coupling.
3. CAUTION: Make sure the quick release

coupling primary locking tang clicks into
place when installing.
Insert the fuel line quick release coupling
secondary locking tang into the fuel line quick
release coupling.
4. CAUTION: After installation, to make

sure that the fuel line is fully seated, pull on
the line.
Install the fuel line quick release coupling.
5. CAUTION: After installation , to make

sure that the vent line is fully seated, pull on
the line.
Install the fuel tank vent line quick release
coupling.

6. CAUTION: Make sure the fuel line clicks
into place when installing the line. To make
sure that the fuel line is fully seated, pull on
the line.
7. NOTE: Make sure the collar on the fuel line is

inserted fully into the fuel line quick release
coupling.

coupling before the locking tang is locked.
1. Install the fuel line quick release coupling
locking tang.
2. Rotate the fuel line quick release coupling
locking tang into position.

coupling before the locking tang is locked.
1. Install the fuel line quick release coupling.
locking tang into position.

Fuel System - General Information -
Spring Lock Couplings
Print
General Procedures
Special Tool(s)
Disconnect Tool, Spring Lock Coupling (3/8”yellow)
310-D004 (23-039)
Disconnect Tool, Spring Lock Coupling (1/2”green)

310-D005 (23-040)
Disconnect Tool, Spring Lock Coupling (5/8” black)

412-038 (34-003)
Disconnect Tool, Fuel Line (5/16”)

310-040 (23-041)
Lösewerkzeug, Kraftstoffleitung
310-137
Disconnection
WARNINGS:
near any fuel related components. Highly flammable vapors are always present and may
The fuel system remains pressurized for a long time after the ignition is switched off.
The fuel pressure must be released before attempting any repairs. Failure to follow these
in personal injury.
1. Release the fuel system pressure.
Pressure Release (310-00A Fuel System -
2.
1. Position the two half shells (310-137/1)
onto the fuel line.
2. Slide the tool hand grip (310-137/2) onto
the half shells and release the fuel
connection.

3. Install the special tool to the fuel line.
4. NOTE: Both sides of the spring lock coupling

fuel line must be pushed together to enable
the special tool to release the spring lock
coupling locking tangs.
Slide the special tool into the spring lock coupling
to release the locking tangs.
5. Disconnect the fuel line from the spring lock

coupling.
Allow the fuel to drain into a suitable
container.
6. Remove the safety clips from the fuel line spring

lock couplings.

7. Install the special tool onto the fuel line spring
lock coupling.
8. Close and push the fuel line spring lock coupling

tool into the open side of the cage.
9. Separate the fuel line spring lock coupling.
Installation
WARNINGS:

in personal injury.
1. Inspect and clean both fuel line spring lock
coupling ends. Install new O-rings and garter
springs if necessary.
2. NOTE: Lubricate the O-rings seals with clean

engine oil.
Insert the male fitting into the female end and
push until the garter spring snaps over the flared
end of the female fitting.
3. Make sure the fuel line spring lock coupling is

engaged by pulling on the lines.

inserted fully into the fuel line spring lock
coupling and an audible click is heard.
Install the spring lock coupling to the fuel line.

Tank Draining
Print
General Procedures
General Equipment
Fuel tank drainer
All vehicles
1. WARNINGS:


attempting any repairs. Failure to follow
injury.
The evacuating area must be clearly

identified with signs warning against smoking
and the use of naked lights or flames within
the vicinity. Highly flammable vapors are
personal injury.
Always disconnect the vehicle battery

ground cable before commencing any service
or repair procedure. Failure to follow this
2. Remove the fuel filler cap.
3. WARNING: Always connect the fuel tank

drainer ground cable to the vehicle before
proceeding to the next step. Failure to follow
this instruction may result in personal injury.
Connect the fuel tank drainer ground cable to the
vehicle.
4. NOTE: Fuel filler hoses on petrol variants are
fitted with a secondary fuel filler pipe spit
back valve.
NOTE: To enable the hose to enter the fuel
tank it must pass through the fuel filler pipe
spit back valve/valves (if equipped).
Insert the fuel tank drainer evacuation pipe down
the fuel tank filler pipe and into the fuel tank.

5. WARNING: The fuel tank drainer must
be operated in accordance with the
manufacturer's instructions. Failure to follow
Drain the fuel tank.
6. Remove the pipe and disconnect the fuel tank

drainer ground cable.
Vehicles with global closing

8. Initialize the door window motors.
For additional information, refer to in this
section.

Fuel System - General Information - 1.8L
System
Print
This bi-fuel vehicle runs on either petrol or Liquefied Petroleum Gas (LPG) and will always
start on petrol. The LPG system can be manually selected and deselected using the LPG
select switch which is located in the centre console. If a weak air/fuel mixture has been
detected, or if the LPG fuel tank runs dry, the engine will revert to petrol operation. The
LPG system operates by injecting LPG in dry gas form through the fuel injection supply
manifold to the injectors which are located on the outside of the intake manifold. When the
vehicle is operating on LPG the petrol system is disabled.
LPG Leak Test
There are two methods that are used to identify leaks in the fuel system:
Electronic leak detector

Liquid leak test
Electronic Leak Detector

This type of equipment is very sensitive to the presence of any hydrocarbons, which may
give misleading results. If the electronic leak detector indicates a leak, verify the results
with a liquid leak test.
Liquid Leak Test
After applying the liquid to the LPG system, the suspected area must be watched very
closely. If bubbles begin to expand from an area, a leak has been detected.

System
Print
Fuel lines(s) Fuse(s)
Fuel connector(s) Wiring harness
Fuel tank Loose or corroded connector(s)
Filler valve Relay(s)
Fuel filter Solenoid(s)
Fuel vaporizer Fuel level sensor
Fuel distributor
Chart.
Symptom Chart

Engine cranks but * Fuel charging * REFER to: Fuel Charging and Controls (303-04D
does not start and controls. Fuel Charging and Controls - 1.8L Duratec-DOHC
(LPG), Diagnosis and Testing).
Poor starting * Fuel charging * REFER to: Fuel Charging and Controls (303-04D
and controls. Fuel Charging and Controls - 1.8L Duratec-DOHC
* Air ingress into * REFER to: Fuel System (310-00B Fuel System -
the fuel lines General Information - 1.8L Duratec-DOHC
Engine starts but * Fuel charging * REFER to: Fuel Charging and Controls (303-04D
immediately stops and controls. Fuel Charging and Controls - 1.8L Duratec-DOHC
when switched to LPG (85kW/115PS) - Zetec, Liquefied Petroleum Gas
Poor idling when * Fuel charging * REFER to: Fuel Charging and Controls (303-04D
running on LPG and controls. Fuel Charging and Controls - 1.8L Duratec-DOHC

Engine misfire when * Fuel charging * REFER to: Fuel Charging and Controls (303-04D
running on LPG and controls. Fuel Charging and Controls - 1.8L Duratec-DOHC
* Faulty spark plug * REFER to: Engine Ignition (303-07A Engine
or ignition coil Ignition - 1.8L Duratec-DOHC (85kW/115PS) -
Zetec, Diagnosis and Testing).
the fuel lines/fuel General Information - 1.8L Duratec-DOHC
system leak (85kW/115PS) - Zetec, Liquefied Petroleum Gas
Excessive fuel * LPG Fuel injector * REFER to: Fuel Charging and Controls (303-04D
consumption running (s) are Fuel Charging and Controls - 1.8L Duratec-DOHC
on LPG inoperative. (85kW/115PS) - Zetec, Liquefied Petroleum Gas
* Faulty spark plug * REFER to: Engine Ignition (303-07A Engine
or ignition coil Ignition - 1.8L Duratec-DOHC (85kW/115PS) -
Zetec, Diagnosis and Testing).
the fuel lines/fuel General Information - 1.8L Duratec-DOHC
system leak (85kW/115PS) - Zetec, Liquefied Petroleum Gas

System Service Precautions
Print
General Procedures
1. WARNINGS:
Do not modify the system configuration

or components, or install components not
specially designed for use with alternative
fuels. Ford Motor Company Ltd has specially
designed the materials, components and
system configuration for alternative fuel
vehicles, and each particular system is
precisely calibrated for efficient operation.
The use of incorrect parts or materials can
produce an untested configuration that could
result in fire, or cause engine damage.
in personal injury.
Fuel supply lines will remain pressurized

after shutdown. When servicing fuel related
components, do not smoke or carry lighted
tobacco or any open flame of any type.
Flammable gases may be present and ignite.
in personal injury.
Eye, hand and ear protection are

required to be worn during depressurizing or
removal and installation of fuel system
components. Failure to follow this instruction
Always ground the vehicle and

alternative fuel system. High pressure gas
escaping can cause static electricity buildup
and subsequent sparking. Failure to follow
Never attempt to tighten or adjust

fittings while system is pressurized. Failure to
injury.
All gas lines must be installed prior to

reconnecting the battery. Failure to follow
The fuel tank and lines must be

evacuated before the fuel line quick release
couplings and other fuel line connectors can
be disconnected. Failure to follow this

CAUTION: If the alternative fuel system
is being disconnected for an extended length
of time, cover all open hose fittings and
electrical connections to avoid contamination.

Tank Evacuation
Print
General Procedures
Special Tool(s)
Pressure Release Valve (PRV) Adaptor
310-108
Connector, fuel line

310-092 (23-065)
General Equipment
LPG recovery and transfer unit
1. WARNINGS:

The incorrect use of parts or materials can
in personal injury.

evacuated before attempting any repairs.
personal injury.

fittings while the system is pressurized.
personal injury.
The LPG fuel tank must not be evacuated

to atmosphere. Use recovery equipment at
all times. Failure to follow this instruction


in personal injury.

and the use of naked lights within the
vicinity. There must be no drains or pits
where LPG or vapor could accumulate. Highly
Allow the vehicle to stand for five

minutes after the evacuation procedure has
been carried out to allow LPG vapor to
disperse. Failure to follow this instruction
When evacuating an LPG system thermal

protection gloves and eye protection must be
worn at all times. Failure to follow these
Always disconnect the vehicle battery

ground cable before commencing any service
or repair procedure. Failure to follow this


Remove the fuel tank.
For additional information, refer to: Fuel Tank
(310-01B Fuel Tank and Lines - 1.8L Duratec-
DOHC (85kW/115PS) - Zetec, Liquefied
Petroleum Gas (LPG), Removal and Installation).
2. Install the fuel line connector special tool to the
PRV adaptor special tool.
3. NOTE: Make sure the PRV adaptor special

tool lift nut is positioned next to the PRV

adaptor special tool locking nut before
installation.
Install the PRV special tool and tighten the PRV
special tool locking nut.
4. WARNING: Always connect the LPG

recovery and transfer unit ground cable to
the vehicle before proceeding to the next
step. Failure to follow this instruction may
Connect the LPG recovery and transfer unit
ground cable and fuel line connector to the LPG
fuel tank.
5. Tighten the PRV adaptor special tool lift nut until
LPG gas begins to escape from the fuel tank
(LPG recovery and transfer unit fuel line
connector shown disconnected for clarity).
6. WARNING: Before the LPG fuel tank is

evacuated the fuel line connector and PRV
special tool must be checked for leaks.
personal injury.
Check the fuel system for leaks.
Leak Test (310-00B Fuel System - General
Procedures).
7. WARNINGS:
The LPG recovery and transfer unit

should not be disconnected from the vehicle
during the evacuation procedure. Failure to
injury.
The LPG recovery equipment must be

operated in accordance with the
manufacturer's instructions. Failure to follow
NOTE: The time taken to carry out the
evacuation of the fuel tank will depend on
ambient air temperature.
Using the LPG recovery and transfer unit

evacuate the fuel tank.
8. NOTE: Before any work can be carried out on
the LPG fuel tank, make sure the pressure
gauge on the LPG recovery equipment is at 0
bar. Failure to follow this instruction may
Loosen the PRV adaptor special tool lift nut (LPG
recovery and transfer unit fuel line connector
shown disconnected for clarity).
9. WARNING: The LPG recovery equipment

must be operated in accordance with the
manufacturer's operating instructions. Failure
personal injury.
Turn off the LPG recovery and transfer unit
equipment.
10. WARNING: Always disconnect the

recovery equipment fuel line from the vehicle
before proceeding to the next step. Failure to
injury.
Disconnect the LPG recovery and transfer unit
from the fuel line connector special tool.
Disconnect the LPG recovery and transfer
unit ground cable from the vehicle.
11. NOTE: Make sure the PRV lift nut is
positioned next to the PRV locking nut before
removal.
Loosen the PRV adaptor special tool locking nut
and remove the PRV adaptor special tool.
12. Remove the fuel line connector special tool from

the PRV adaptor special tool.

System Leak Test
Print
General Procedures
Special Tool(s)
Actuator Cable
310-090 (23-064)
WARNINGS:
Fuel supply lines will remain pressurized after shutdown. When servicing fuel related
components, do not smoke or carry lighted tobacco or any open flame of any type.
Flammable gases may be present and ignite. Failure to follow these instructions may
in personal injury.
Never attempt to tighten or adjust fittings while the system is pressurized. Failure to
All gas lines must be installed prior to reconnecting the battery. Failure to follow this
The fuel lines must be evacuated before attempting any repairs. Failure to follow
these instructions may result in personal injury.
Operation).
2. Disconnect the fuel tank electrical connector.
3. Install the special tool wiring harness and

connect to a 12V supply.
4. Check for leaks over all of the unions with an

electronic leak detector. If a leak is detected
identify the exact union with a liquid leak

detector.
5. Repair the detected leak. Test the system for
normal operation.

Liquefied Petroleum Gas (LPG) - Fuel Line Transit/Tourneo Connect 2002.5 (06/2002-)
Evacuation Without Using Recovery
Equipment
Print
General Procedures
1. WARNINGS:

in personal injury.

evacuated before attempting any repairs.
personal injury.

injury.


reaches normal operating temperature, and the
fuel system has been switched to LPG.
Lifting.

4. Allow the vehicle to idle for approximately 3 to 4
minutes until the engine stops.
5. Switch the engine off for approximately 1 to 2
minutes.
6. Start the engine and allow it to idle until the
engine stops or switches to petrol operation.

Liquefied Petroleum Gas (LPG) - Fuel Line
Evacuation Using Recovery Equipment
Print
General Procedures
Special Tool(s)
Actuator Cable
310-090 (23-064)
Fuel Vaporizer Actuator Cable
310-090-01
Fuel Vaporizer Evacuation Hose

310-107
Connector, fuel line

310-092 (23-065)
General Equipment
Differential pressure meter
LPG recovery and transfer unit
1. WARNINGS:

in personal injury.

required to be worn during depressurizing or
Always ground the vehicle and

alternative fuel system. High pressure gas
escaping can cause static electricity build-up
and subsequent sparking. Failure to follow

injury.


and the use of naked lights or flames within
the vicinity. There must be no drains or pits
where LPG or vapor could accumulate. Highly

3. WARNING: Always connect the recovery

equipment ground cable to the vehicle before
proceeding to the next step. Failure to follow
Using the LPG recovery and transfer unit connect
the ground cable to the vehicle.
4. Remove the blanking plug from the fuel
vaporizer.
5. Connect the fuel vaporizer evacuation hose

special tool to the fuel vaporizer.
6. Connect the fuel vaporizer evacuation hose

special tool to the fuel line connector special tool.
7. Connect the LPG recovery and transfer unit to

the fuel line connector special tool.
8. Disconnect the fuel vaporizer solenoid electrical
connector (fuel vaporizer shown removed for
clarity).
9. Install the fuel vaporizer actuator cable special

tool to the fuel vaporizer solenoid electrical
connector (Fuel vaporizer shown removed for
clarity).
10. Connect the fuel vaporizer actuator cable special

tool to the actuator cable special tool.
11. Connect the actuator cable special tool to an

independent 12 volt battery supply and energize
the fuel vaporizer solenoid.
12. WARNING: Before the LPG fuel tank is

evacuated the fuel line and special tools must
be checked for leaks. Failure to follow this
Procedures).

13. NOTE: The LPG recovery equipment must be
operated in accordance with the
Using the LPG recovery and transfer unit
evacuate the LPG fuel line.
14. WARNING: Always disconnect the

recovery equipment fuel line from the vehicle
before proceeding to the next step. Failure to
injury.
Disconnect the LPG recovery and transfer unit
from the fuel line connector special tool.
15. Disconnect the actuator cable special tool from
the independent 12 volt battery supply.
16. Disconnect the fuel vaporizer evacuation hose
special tool from the fuel line connector special
tool.
17. Disconnect the fuel vaporizer evacuation hose

special tool from the fuel vaporizer.
18. Install the blanking plug to the fuel vaporizer.
19. Disconnect the fuel vaporizer actuator cable

special tool from the actuator cable special tool.

20. Remove the fuel vaporizer actuator cable special
tool from the fuel vaporizer solenoid electrical
clarity).
21. Connect the fuel vaporizer solenoid electrical

clarity).
22. Disconnect the LPG recovery and transfer unit

ground cable from the vehicle.
23. CAUTION: The fuel system differential

pressure setting in the fuel vaporizer may
have been affected by this procedure. Before
the vehicle is tested for normal operation,
carry out the fuel system differential
pressure check. Failure to follow this
instruction may cause premature failure of
the fuel vaporizer.
Check the fuel system differential pressure
settings.
Differential Pressure Check (310-00B Fuel
System - General Information - 1.8L Duratec-
DOHC (85kW/115PS) - Zetec, Liquefied
Petroleum Gas (LPG), General Procedures).

System Differential Pressure Check
Print
General Procedures
Special Tool(s)
T-Connector, Evaporator Adjustment
310-126
General Equipment
Differential pressure meter
1. WARNINGS:

in personal injury.

required to be worn during evacuation or

Remove the air cleaner.
2. Remove the fuel vaporizer blanking plug and O-
ring seal.
3. Install the differential pressure meter connector

to the fuel vaporizer.

4. Connect the differential pressure meter hose to
the differential pressure meter connector on the
fuel vaporizer.

the differential pressure meter.
6. Disconnect the manifold absolute pressure (MAP)
sensor vacuum hose from the MAP sensor.
7. Connect the differential pressure meter T-piece

connector to the MAP sensor vacuum hose.

the differential pressure meter T-piece
connector.
9. Connect the differential pressure meter hose

between the T-piece connector and the MAP
sensor.

11. Start the engine and allow it to idle until it
reaches normal operating temperature and the
12. NOTE: If the display on the differential
pressure meter is negative the differential
pressure meter hoses are fitted incorrectly.
Turn the fuel vaporizer adjusting screw
clockwise to increase or counterclockwise to
decrease the differential pressure setting.
Using the pressure adjusting screw on the right-
hand side of the fuel vaporizer, set the pressure
setting on the differential pressure meter to
1400 +/- 50 millibar.
13. Raise the engine speed to 2,000 rpm for 5

seconds and then allow it to return to idle before
checking the pressure settings. If the pressure
settings are incorrect, repeat step 12.
14. Turn the ignition to position 0.
15. NOTE: Leave the differential pressure testing
equipment connected.
Evacuate the fuel lines.
For additional information, refer to: Fuel Line
Evacuation Without Using Recovery Equipment
(310-00B Fuel System - General Information -
1.8L Duratec-DOHC (85kW/115PS) - Zetec,
Liquefied Petroleum Gas (LPG), General
Procedures) /
Fuel Line Evacuation Using Recovery Equipment
Procedures).
17. Disconnect the differential pressure meter hose
from the differential pressure meter connector on
the fuel vaporizer.

18. Remove the differential pressure meter
connector from the fuel vaporizer.
19. Install the fuel vaporizer blanking plug and O-

ring seal.
20. Disconnect the fuel injection supply manifold fuel

supply line from the fuel filter.
Discard the fuel line retaining clip.
21. Install the special tool between the fuel injection

supply manifold fuel supply line and the fuel
filter.
22. Connect the differential pressure meter to the

differential pressure meter hose on the special
tool.

24. Start the engine and allow it to idle until it
reaches normal operating temperature and the
25. NOTE: If the display on the differential
pressure meter is negative the differential
pressure meter hoses are fitted incorrectly.
Turn the fuel vaporizer adjusting screw
clockwise to increase or counterclockwise to
decrease the differential pressure setting.
Using the pressure adjusting screw on the left-
hand side of the fuel vaporizer, set the pressure
settings on the differential pressure meter to
1000 +/- 10 millibar.
26. Raise the engine speed to 2,000 rpm for 5

seconds and then allow it to return to idle before
checking the pressure settings. If the pressure
settings are incorrect, repeat step 25.
27. Turn the ignition to position 0.
28. NOTE: Leave the differential pressure testing
equipment connected.
Evacuate the fuel lines.
For additional information, refer to: Fuel Line
Evacuation Without Using Recovery Equipment
Procedures) /
Fuel Line Evacuation Using Recovery Equipment
Procedures).
29. Disconnect the differential pressure meter from
the differential pressure meter hose on the
special tool.

30. Remove the special tool from the fuel injection
supply manifold fuel supply line and the fuel
filter.
31. NOTE: Install a new fuel line retaining clip.

Connect the fuel injection supply manifold fuel
supply line to the fuel filter.

from the differential pressure meter T-piece
connector and the MAP sensor.

from the differential pressure meter T-piece
connector.
35. Disconnect the differential pressure meter T-

piece connector from the MAP sensor vacuum
hose.
36. Connect the MAP sensor vacuum hose to the

MAP sensor.

38. WARNING: Before the system is tested

Procedures).

Fuel Tank and Lines - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Fuel tank support strap retaining bolts 25 18 -
Fuel tank filler pipe vent hose retaining clamp 4 - 35
Fuel tank filler pipe filler hose retaining clamp 4 - 35
Fuel filter retaining bolt 9 - 80
Fuel pump module locking ring 92 68 -
Wheel retaining nuts 120 89 -
Torque Specifications - vehicles with diesel engine

Fuel tank support strap retaining bolts 25 18 -
Fuel tank filler pipe vent hose retaining clamp 4 - 35
Fuel tank filler pipe filler hose retaining clamp 4 - 35
Fuel filter bracket retaining bolt 9 - 80
Fuel level sensor locking ring 92 68 -
Wheel retaining nuts 120 89 -

Fuel Tank and Lines - Fuel Tank and Lines Transit/Tourneo Connect 2002.5 (06/2002-)
Print

1 - Fuel supply and return lines
2 - Fuel level sensor locking ring
3 - Fuel level sensor
4 - Fuel tank filler pipe
5 - Fuel tank filler pipe breather pipe
6 - Fuel tank support straps
7 - Fuel tank
8 - Fuel tank vent valves
Fuel Tank Vent Valves
Fuel tank ventilation is achieved by two fuel tank vent valves. The fuel tank vent valves are
integral to the fuel tank and will prevent fuel loss from the fuel tank if the vehicle becomes
inverted.
Under normal working conditions, the pressure within the fuel tank is controlled by allowing
the fuel vapor to vent through the fuel tank vent valves to atmosphere. If the fuel tank

becomes inverted, the fuel tank vent valves close preventing fuel being lost from the fuel
tank.
If the fuel tank vent valves or the fuel vapor lines connected to the vent valves become
restricted, vehicle performance will become impaired. The inability of the fuel tank to
substitute the fuel demanded by the fuel charging system with air, will create a negative
pressure in the fuel tank which will result in reduced fuel flow to the fuel pump.
Fuel Level Sensor

2 - Fuel level sensor sealing ring
3 - Fuel level sensor
The fuel level sensor is located in the top of the fuel tank and is retained by a fuel level
sensor locking ring and seal.
The fuel level sensor consists of a mechanical float attached to a variable resistor card by
means of a rigid wire lever. The resistor card has two electrical elements. One element is
solid and one element is a variable resistor. The resistance value created by the resistor
card is sent to the central junction box (CJB) through a hard wired circuit. The CJB
distributes the information from the fuel level sensor to the instrument cluster and the
powertrain control module (PCM) using the controller area network (CAN) circuits.
The fuel level sensor resistor card can be susceptible to contaminated fuel, which can affect
electrical continuity. This condition is normally temporary and self-rectifying. If the fuel
level sensor has been removed, moving the rigid wire lever from empty to full a minimum
of 10 times will normally be as effective as installing a new fuel level sensor. The most
common symptom of contamination occurs after refuelling where the electrical contact
moves to an area of the resistor card which has not been used for several days. This results
in a very slow movement of the fuel gauge pointer from empty to full over approximately
15 minutes. In more extreme cases where the resistor card resistance is continuously
outside the permitted range for more than 33 seconds, a DTC will be set in the CJB and the
fuel gauge pointer will fall to its key-off position. In all cases where the fuel level sensor is
suspected of being inoperative, worn or damaged, the Worldwide Diagnostic System (WDS)
diagnostic procedures must be followed before any parts are dismantled.

The base of the fuel level sensor is a chamber that sits in the swirl bowl at the bottom of
the fuel tank. Built into the chamber is a filter element.
Fuel Filter

1 - Fuel filter element
2 - Fuel filter drain valve
Vehicles with petrol engine

1 - Fuel supply and return lines
2 - Fuel filter
3 - Fuel tank vent valve to evaporative emission canister fuel vapor line
4 - Fuel pump and sender unit locking ring
5 - Fuel pump and sender unit
6 - Fuel tank filler pipe breather pipe
8 - Evaporative emission canister
10 - Vent valves
-

-
11 Fuel tank
Fuel is stored in the fuel tank and delivered to the fuel injectors by means of a
submersed fuel pump through an inline fuel filter.
Fuel Return System

1 - Fuel filter
2 - Fuel line fuel return T-piece
4 - Fuel rail
6 - Fuel tank
7 - Fuel jet pump
8 - Fuel pump
The fuel pressure at the fuel injectors is controlled by a fuel pressure regulator mounted in
the fuel return system.
Fuel is pumped from the fuel tank, to the fuel filter. From the fuel filter, fuel is delivered to
the fuel rail. A T-piece is fitted into the fuel injector fuel supply line above the fuel tank. This
T-piece acts as the fuel return line and has a fuel pressure regulator fitted in the circuit.
By allowing excess fuel pressure to return to the fuel tank, a constant pressure can be
maintained at the fuel injectors.
Evaporative emission canister

Unlike the fuel tank on vehicles with diesel engine, the fuel vapor is not permitted to vent
to atmosphere. Instead the fuel vapor is collected in the evaporative emission canister until
the correct driving conditions permit the fuel vapor to be burnt in the engine combustion
chambers. This reduces the overall emissions from the vehicle.
If the fuel tank becomes inverted, the fuel tank vent valves close preventing the
evaporative emission canister being filled with fuel.
If the fuel tank vent valves, fuel vapor lines or the evaporative emission canister become
restricted, vehicle performance will become impaired. The inability of the fuel tank to
substitute the fuel demanded by the fuel pump with air, will create a negative pressure in
the fuel tank which could result in deformation of the fuel tank.
Fuel Pump and Sender Unit

2 - Fuel level sensor sealing ring
3 - Fuel level sensor resistor card
4 - Fuel jet pump and filter
The fuel pump and sender are a combined unit and cannot be serviced separately.
The fuel pump and sender unit is located in the top of the fuel tank and is retained by a fuel
pump and sender unit locking ring and seal.
The fuel pump and sender consists of a mechanical float attached to a variable resistor card

by means of a rigid wire lever. The resistor card has two electrical elements. One element is
solid and one element is a variable resistor. The resistance value created by the resistor
card is sent to the central junction box (CJB) through a hard wired circuit. The CJB
distributes the information from the fuel pump and sender to the instrument cluster and the
powertrain control module (PCM) using the controller area network (CAN) circuits.
The fuel pump and sender resistor card can be susceptible to contaminated fuel, which can
affect electrical continuity. This condition is normally temporary and self-rectifying. If the
fuel pump and sender has been removed, moving the rigid wire lever from empty to full a
minimum of 10 times will normally be as effective as installing a new fuel pump and
sender. The most common symptom of contamination occurs after refuelling where the
electrical contact moves to an area of the resistor card which has not been used for several
days. This results in a very slow movement of the fuel gauge pointer from empty to full
over approximately 15 minutes. In more extreme cases where the resistor card resistance
is continuously outside the permitted range for more than 33 seconds, a DTC will be set in
the CJB and the fuel gauge pointer will fall to its key-off position. In all cases where the fuel
pump and sender is suspected of being inoperative, worn or damaged, the Worldwide
Diagnostic System (WDS) diagnostic procedures must be followed before any parts are
dismantled.
The fuel pump supplies fuel to the fuel charging system at a constant regulated pressure.
The fuel pressure is controlled by the fuel pressure regulator, built into the fuel pump fuel
return circuit.
The fuel pump and sender also incorporates a fuel jet pump. The return fuel from the fuel
charging system is passed through a venturi in the jet pump which causes a pressure drop
across an open orifice. This draws in fuel through the base of the unit which then passes
through the sock filter to the fuel pump.
Fuel Filter
This vehicle is equipped with an in line fuel filter. The fuel filter is located to the rear of the
fuel tank and is secured to the vehicle chassis with a support bracket.
All vehicles
Fuel Tank
The fuel tank is of a plastic construction and has the capacity to hold 60 liters of fuel. The
fuel tank is secured to the vehicle by two metal support straps bolted to the underside of
the vehicle.
Fuel Tank Filler Pipe

The fuel tank filler pipe incorporates a fuel tank vent pipe. The fuel tank vent pipe is
connected to the top of the fuel tank and exits just below the top of the fuel tank filler pipe.
The fuel tank vent pipe allows the displaced air above the fuel in the fuel tank to escape
without pushing the fuel entering the fuel tank during refill back up the fuel tank filler pipe.
Fuel Filler Cap
This vehicle uses a lockable fuel filler cap.

The fuel filler cap is sealed to the fuel filler neck. This is to prevent the escape of fuel vapor
during normal operation and to prevent fuel loss in the event of a vehicle accident.

Fuel Tank and Lines - Fuel Tank and Lines Transit/Tourneo Connect 2002.5 (06/2002-)
Print
For additional information,

REFER to: Fuel System - 75 PS/90 PS (310-00A Fuel System - General Information,
Diagnosis and Testing) /
Fuel System - 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS/90 PS/110 PS), Vehicles Built From:
08/2006 (310-00A Fuel System - General Information, Diagnosis and Testing).

Fuel Tank and Lines - Fuel Tank—1.8L
Print
Special Tool(s)
Wrench, Fuel Tank Sender Unit
(310-069) 23-055
General Equipment
Transmission jack
Materials
Name Specification
Grease SA-M1C9107-A
WARNINGS:
in personal injury.
1. Release the fuel system pressure. For additional
3. Drain the fuel tank. For additional information,
Information.
Lifting.

failure.
Support the flex pipe with a support wrap or
suitable splint.
(s).

1 - Muffler

2 - Exhaust pipe center heat shield retaining nuts
3 - Exhaust pipe center heat shield
See Removal Detail
4 - Fuel filter heat shield
5 - Exhaust pipe rear heat shield
6 - Fuel tank heat shield

7 - Fuel tank filler hose
See Removal Detail
8 - Fuel tank vent hose
9 - Evaporative emissions canister line quick release coupling
See Removal Detail
See Removal Detail
11 - Fuel tank to fuel filter fuel supply line quick release coupling
See Removal Detail
See Removal Detail
- Fuel tank

13 See Removal Detail
14 - Fuel pump module electrical connector
See Removal Detail

17 - Evaporative emissions canister line
See Removal Detail
18 - Evaporative emissions canister
See Removal Detail
19 - Fuel pump module supply line
See Removal Detail
20 - Fuel pump module return line
See Removal Detail
21 - Fuel tank vent pipe
See Removal Detail
22 - Fuel pump module locking ring
See Removal Detail
23 - Fuel pump module seal
24 - Fuel pump module

See Removal Detail
25 - Fuel tank
Removal Details
Item 3 : Exhaust pipe center heat shield
1. Detach the exhaust pipe center heat shield.

Item 7 : Fuel tank filler hose
CAUTION: When removing the fuel tank filler hose or fuel tank vent hose, do not use
any sharp edged tools to lever off the hoses. Failure to follow this instruction may cause
damage to the filler hose or vent hose.
NOTE: Make a note of the position of the fuel tank filler hose retaining clamp.
Item 9 : Evaporative emissions canister line quick release coupling
Item 11 : Fuel tank to fuel filter fuel supply line quick release coupling

1. Detach the fuel return line quick release

coupling. For additional information, refer to
Information.
2. Detach the fuel return line from the fuel return
line retaining clip.
Item 12 : Fuel tank support straps
CAUTION: When supporting the fuel tank, use a suitable packing material to prevent
damage to the underside of the fuel tank.
1. Place a suitable transmission jack under the fuel

tank.
Item 13 : Fuel tank

CAUTION: When lowering the fuel tank, do not place excessive strain on the fuel
lines and wiring harness.
1. Partially lower the fuel tank.
Item 14 : Fuel pump module electrical connector
1. Disconnect the fuel pump module electrical

connector.
Item 17 : Evaporative emissions canister line
Item 19 : Fuel pump module supply line
Item 20 : Fuel pump module return line
1. Disconnect the quick release couplings. For

Item 18 : Evaporative emissions canister
1. Remove the evaporative emission canister.

1. Release the evaporative emission canister
retaining clip.
2. Slide the evaporative emission canister off
of the evaporative emission canister
retaining bracket.
Item 21 : Fuel tank vent pipe
1. Disconnect the fuel tank vent pipe quick release

couplings. For additional information, refer to
Information.

2. Press in the four fuel tank vent fuel separator
clips and remove the fuel separator and vent
pipes.
Item 22 : Fuel pump module locking ring

module locking ring.
Item 24 : Fuel pump module
CAUTION: Make sure the fuel tank level sensor float or arm are not damaged during
removal.
1. Remove the fuel pump module.

1. Rotate the fuel pump module
counterclockwise.
2. Remove the fuel pump module from the
fuel tank.
Item 13 : Fuel tank
CAUTION: When installing the fuel tank, make sure the fuel lines do not get kinked
or trapped.
1. Raise the fuel tank.

1. Install the fuel tank support strap retaining bolt
and remove the transmission jack.
NOTE: The fuel tank filler hose retaining clamp must be installed in the same position as
removed.

Fuel Tank and Lines - Fuel Tank—1.8L
Print

Special Tool(s)
Wrench, Fuel Tank Sender Unit
(310-069) 23-055
General Equipment
Transmission jack
Materials
Name Specification
Grease SA-M1C9107-A
WARNINGS:
in personal injury.
2. Drain the fuel tank.
Operation).

failure.
Support the exhaust flexible pipe with a support
wrap or suitable splint.
(s).

1 - Muffler

2 - Exhaust pipe center heat shield retaining nuts
3 - Exhaust pipe center heat shield
See Removal Detail
4 - Fuel lines heat shield
5 - Exhaust pipe rear heat shield
6 - Fuel tank heat shield

See Removal Detail
See Removal Detail
See Removal Detail
See Removal Detail
12 - Fuel tank
See Removal Detail
-

-
13 Fuel tank level sensor electrical connector
See Removal Detail

16 - Fuel tank level sensor fuel supply line
See Removal Detail
17 - Fuel tank level sensor fuel return line
See Removal Detail
18 - Fuel tank vent pipe
See Removal Detail
19 - Fuel tank level sensor locking ring
See Removal Detail
20 - Fuel tank level sensor seal
See Removal Detail
21 - Fuel tank level sensor
See Removal Detail
22 - Fuel tank
Removal Details
Item 3 : Exhaust pipe center heat shield

1. Detach the exhaust pipe center heat shield.
1. Detach the fuel return line quick release

coupling.
2. Detach the fuel supply and return lines from the
fuel line retaining clip.
1. Detach the fuel supply line quick release

coupling.
CAUTION: When supporting the fuel tank, use a suitable packing material to prevent
damage to the underside of the fuel tank.
1. Place a suitable transmission jack under the fuel

tank.
Item 12 : Fuel tank
CAUTION: When lowering the fuel tank, do not place excessive strain on the fuel
lines and wiring harness.
1. Partially lower the fuel tank.
Item 13 : Fuel tank level sensor electrical connector

1. Disconnect the fuel tank level sensor electrical
connector.
Item 16 : Fuel tank level sensor fuel supply line
1. Disconnect the quick release couplings.

Item 17 : Fuel tank level sensor fuel return line
1. Disconnect the quick release couplings.

Item 18 : Fuel tank vent pipe
1. Remove the fuel tank vent pipe and vent pipe

filter.
1. Remove the fuel tank vent pipe filter.
2. Press in the four fuel tank vent fuel
separator clips and remove the fuel
separator and vent pipes.
Item 19 : Fuel tank level sensor locking ring

module locking ring.
Item 21 : Fuel tank level sensor

CAUTION: Make sure the fuel tank level sensor float or arm are not damaged during
removal.
1. Remove the fuel tank level sensor.

1. Rotate the fuel tank level sensor
counterclockwise.
2. Remove the fuel tank level sensor from the
fuel tank.
Item 21 : Fuel tank level sensor
1. Install the fuel tank level sensor to the fuel tank.

Align the larger arrow (1) on the fuel pump
and sender unit with the align mark
(center of 3 dashes) (2) on the fuel tank.
The smaller arrow (3) on the fuel pump
and sender unit must be automatically
aligned to the align mark (arrow) (4) on
the fuel tank.
Item 12 : Fuel tank
CAUTION: When installing the fuel tank, make sure the fuel lines do not get kinked
or trapped.
1. Raise the fuel tank.

1. Install the fuel tank support strap retaining bolt

and remove the transmission jack.
removed.

Fuel Tank and Lines - Fuel Tank Filler Pipe Transit/Tourneo Connect 2002.5 (06/2002-)
Print
WARNINGS:
in personal injury.
1. Drain the fuel tank. For additional information,
Information.
2. Remove the right-hand rear road wheel. For
Wheels and Tires.
(s).

1 - Fender splash shield
-

-
2 Fuel tank filler cap
3 - Fuel tank filler pipe retaining bolt
See Removal Detail
See Removal Detail
Removal Details
Item 4 : Fuel tank vent hose

removed.
Item 4 : Fuel tank vent hose
1. Partially lower the vehicle.

Fuel Tank and Lines - Fuel Filter—1.8L
Print
WARNINGS:
in personal injury.
1. Depressurize the fuel system. For additional
Lifting.
(s).

2 - Fuel filter to fuel supply manifold fuel supply line quick release
coupling
See Removal Detail
See Removal Detail
4 - Fuel filter retaining bracket
5 - Fuel filter
Removal Details
Item 2 : Fuel filter to fuel supply manifold fuel supply line quick release coupling


Print
WARNINGS:
in personal injury.

and clearances. It is therefore essential that absolute cleanliness is observed when
(s).

1 - Fuel injection pump to fuel filter fuel return line
2 - Fuel filter to fuel injection pump fuel supply line quick release coupling
See Removal Detail
-

-
3 Fuel tank to fuel filter fuel supply line quick release coupling
See Removal Detail
4 - Fuel filter support bracket and fuel filter
See Removal Detail
5 - Fuel filter retaining screw
6 - Fuel filter
Removal Details
Item 2 : Fuel filter to fuel injection pump fuel supply line quick release coupling

Item 4 : Fuel filter support bracket and fuel filter
1. Press in the fuel filter support bracket retaining

clip and remove the fuel filter support bracket
and fuel filter.
2. Disconnect the water-in-fuel sensor electrical

connector (if equipped).
Item 6 : Fuel filter
1. NOTE: Make sure that the locating arrows on

the fuel filter and the fuel filter support
bracket are correctly aligned.
Fill the fuel filter with clean diesel.
CAUTION: The fuel filter support bracket is the ground connection for the fuel filter.
Make sure that the mating surfaces are clean and free from foreign material.

1. Install the fuel filter and the fuel filter support
bracket until an audible click is heard.

Duratorq-TDCi (Lynx) Diesel
Print

Special Tool(s)
310-110
WARNINGS:
in personal injury.

and clearances. It is therefore essential that absolute cleanliness is observed when
1. Clean the area around the fuel filter connections
and fuel lines.
(s).

1 - Fuel filter to fuel pump fuel supply line quick release coupling
See Removal Detail
2 - Fuel pump to fuel filter fuel return line quick release coupling
See Removal Detail
See Removal Detail
4 - Fuel filter support bracket and fuel filter
See Removal Detail
5 - Fuel filter retaining screw
6 - Fuel filter
4. CAUTION: Make sure that the fuel filter

connection is not damaged with the
installation of the special tool, as this may
cause air ingress to fuel lines.

Remove and discard the blanking plug from the
fuel filter fuel tank fuel supply line and install the
hand pressure pump special tool adapter to the
fuel filter.
5. Install the hand pressure pump special tool

adapter to the fuel tank to fuel filter fuel supply
line.
6. NOTE: Make sure that the hand pressure

pump arrow indicating the direction of fuel
flow is pointing towards the fuel filter.
the hand pressure pump special tool adapters.
7. Operate the fuel hand pressure pump special tool

until fuel starts to flow through the fuel filter and
fuel pump and the hand pressure pump becomes
firm.
8. CAUTION: Do not operate the starter

motor for longer than 10 seconds at a time.
After 10 seconds, turn the ignition to position
0 and allow the starter motor to cool for 30
seconds before attempting to start the
engine again.
Start the engine and allow to idle until it reaches
normal operating temperature.
9. Switch the engine off.
adapters.


supply line.

supply on the fuel filter.
13. Connect the fuel tank to fuel filter fuel supply

line to the fuel filter.
Removal Details
Item 1 : Fuel filter to fuel pump fuel supply line quick release coupling
1. For additional information, refer to: Quick

2. Install a blanking plug to the fuel pump fuel
supply line.
Item 2 : Fuel pump to fuel filter fuel return line quick release coupling


1. Press in the fuel filter support bracket retaining

clip and remove the fuel filter support bracket
and fuel filter.

2. Vehicles built for Turkey, disconnect the water-
in-fuel sensor electrical connector.
Item 6 : Fuel filter
1. NOTE: Make sure that the locating arrows on

the fuel filter and the fuel filter support
bracket are correctly aligned.
Fill the fuel filter with clean diesel.
CAUTION: The fuel filter support bracket is the ground connection for the fuel filter.
Make sure that the mating surfaces are clean and free from foreign material.
1. Install the fuel filter and the fuel filter support
bracket until an audible click is heard.
1. Clean the area around the fuel filter fuel line

connections.
2. Do not connect the fuel tank to fuel filter fuel
supply line at this stage.
Item 2 : Fuel pump to fuel filter fuel return line quick release coupling

fuel filter fuel return line.

Item 1 : Fuel filter to fuel pump fuel supply line quick release coupling

fuel filter fuel pump fuel supply line.
fuel filter to fuel pump fuel supply line
connection.

Fuel Tank and Lines - Inertia Fuel Shutoff
(IFS) Switch
Print

1. Remove the passenger side instrument panel
lower footwell trim panel.
All vehicles
2. Remove the right-hand side cowl side trim panel.
05 Interior Trim and Ornamentation.
(s).

1 - IFS switch electrical connector
2 - IFS switch retaining bolts
3 - IFS switch
Item 3 : IFS switch
NOTE: Make sure the IFS switch is in the reset position.

Fuel Tank and Lines - Fuel Supply Line—
Zetec
Print
Special Tool(s)
205-316 (15-097A)
Disconnect Tool Fuel Line (5/16")

310-040 (23-041)
General Equipment
Transmission jack
WARNINGS:
in personal injury.
1. Depressurize the fuel system. For additional
Centralize the steering wheel.

Discard the bolt.

6. Disconnect the fuel supply and return spring-lock
couplings. For additional information, refer to
Information.
7. Detach the fuel supply and fuel return lines from

the retaining clip.

Lifting.
9. Install the crossmember alignment pins.

crossmember.
(s).

1 - Crossmember, suspension and steering gear
See Removal Detail
3 - Fuel supply line to fuel filter fuel line quick release coupling
See Removal Detail
4 - Fuel line retaining clips
5 - Fuel line earth retaining clip
See Removal Detail
Removal Details
Item 1 : Crossmember, suspension and steering gear
1. NOTE: Take care not to place excessive

strain on the power steering pipes.
Lower the crossmember 75mm.
Item 3 : Fuel supply line to fuel filter fuel line quick release coupling
1. Disconnect the quick release coupling. For

Item 6 : Fuel supply line
1. Detach the fuel supply line from the bulkhead

fuel line retaining clip. Make a note of the routing
of the existing fuel supply line to assist with the
installation.
Item 5 : Fuel line earth retaining clip
1. The fuel pipe retaining clip acts as the fuel line

earthing connection and must be clean and
secure.

Fuel Tank and Lines - Fuel Supply Line—
Print
Special Tool(s)
205-316 (15-097A)
General Equipment
Transmission jack
WARNINGS:
in personal injury.
Diesel fuel injection equipment is manufactured to very precise tolerances and

Centralize the steering wheel.

Discard the bolt.

Lifting.
5. Install the crossmember alignment pins.

crossmember.
(s).

1 - Crossmember, suspension and steering gear
See Removal Detail
2 - Fuel line heat shield
3 - Fuel supply line to fuel level sensor fuel line quick release coupling
See Removal Detail
4 - Fuel line retaining clips
5 - Fuel line earth retaining clip
6 - Fuel supply line to fuel filter fuel supply line quick release coupling
See Removal Detail
See Removal Detail
Removal Details
Item 1 : Crossmember, suspension and steering gear
1. NOTE: Take care not to place excessive

strain on the power steering pipes.
Lower the crossmember 75mm.
Item 3 : Fuel supply line to fuel level sensor fuel line quick release coupling
1. Clean the area around the fuel supply line quick

release connector. For additional information,
Information.

Item 6 : Fuel supply line to fuel filter fuel supply line quick release coupling
1. Clean the area around the fuel supply quick

release coupling. For additional information, refer
to Section 310-00A Fuel System - General
Information.
Item 7 : Fuel supply line
1. Detach the fuel supply line from the bulkhead

fuel line retaining clip. Make a note of the routing
of the existing fuel supply line to assist with the
installation.
Item 5 : Fuel line earth retaining clip
1. The fuel pipe retaining clip acts as the fuel line

earthing connection and must be clean and
secure.

Fuel Tank and Lines - Fuel Return Line—
Zetec
Print
1. Remove the fuel supply line,

For additional information, refer to Fuel Supply
Line - 1.8L in this section.
(s).

1 - Fuel return line to fuel pump module fuel line quick release coupling
See Removal Detail
See Removal Detail
Removal Details
Item 1 : Fuel return line to fuel pump module fuel line quick release coupling

1. Detach the fuel return line from the fuel line

retaining clip and the brake pipe retaining clip.
Make a note of the routing of the existing fuel
return line to assist with the installation.

Fuel Tank and Lines - Fuel Return Line—
Print
WARNINGS:
in personal injury.
Diesel fuel injection equipment is manufactured to very precise tolerances and

1. Disconnect the fuel return line quick release
coupling. For additional information, refer to
Information.
2. Detach the fuel return line from the retaining

clip.
3. Remove the fuel supply line,

For additional information, refer to Fuel Supply
Line - 1.8L Diesel in this section.
(s).

1 - Fuel return line to fuel level sensor fuel line quick release coupling
See Removal Detail
2 - Fuel return pipe
See Removal Detail
Removal Details
Item 1 : Fuel return line to fuel level sensor fuel line quick release coupling

Item 2 : Fuel return pipe
1. Detach the fuel return line from the fuel line

retaining clip and the brake pipe retaining clip.
Make a note of the routing of the existing fuel
return line to assist with the installation.

Fuel Tank and Lines - Fuel Pump Module—
Zetec
Print
Removal
1. For additional information, refer to Fuel Tank -
1.8L in this section.
Installation

Fuel Tank and Lines - Fuel Level Sensor—
Print
Removal
1. For additional information, refer to Fuel Tank -
1.8L Diesel in this section.
Installation

Fuel Tank and Lines - 1.8L Duratec-DOHC
(85kW/115PS) - Zetec, Liquefied Transit/Tourneo Connect 2002.5 (06/2002-)
Petroleum Gas (LPG) - Specifications
Print

Fuel tank retaining bolts 48 35 -
Fuel filler pipe to fuel filler valve union 48 35 -
Fuel tank air tight housing retaining bolts 10 - 89
Fuel level sensor retaining bolts 10 - 89
Fuel tank one-way valve 100 74 -
Fuel tank solenoid valve 100 74 -

Petroleum Gas (LPG) - Fuel Tank and
Lines
Print

1 - Fuel tank and hoses
2 - Fuel filler valve
3 - Fuel filter

1 - Air tight housing cover
2 - Fuel tank level sensor gauge
3 - Fuel tank level sensor
4 - Fuel tank one-way valve
5 - Fuel tank fuel hoses
6 - Fuel tank
7 - Fuel tank solenoid valve
Fuel Tank
The ring fuel tank is fitted underneath the rear of the vehicle in the spare wheel area.
Fuel Filter
The fuel filter comprises of a paper element sealed within a canister and is located next to
the battery tray.
Fuel Tank Solenoid Valve
The fuel tank solenoid valve is controlled by the LPG select switch, when the ignition is
switched ON and LPG operation is selected the solenoid valve opens and pressurizes the
fuel line to the fuel vaporizer.

Fuel Tank Level Sensor
The fuel tank level sensor is magnetically controlled by the float mechanism and is used to
measure LPG fuel quantity.
Fuel Tank One-Way Valve
The fuel tank one-way valve opens when LPG fuel is pressurized into the fuel tank supply
line. When the fuel tank reaches 80% full, the mechanical float closes the one-way valve.
This is to allow expansion of the LPG in various temperatures.

Petroleum Gas (LPG) - Fuel Tank and
Lines
Print
REFER to: Fuel System (310-00B Fuel System - General Information - 1.8L Duratec-DOHC
(85kW/115PS) - Zetec, Liquefied Petroleum Gas (LPG), Diagnosis and Testing).

Petroleum Gas (LPG) - Gas Fuel Tank
Filler Valve
Print
Removal
Lifting.
2. Disconnect the fuel filler pipe dry break
connector.

4. Remove the luggage compartment left hand side
trim panel.
5. Remove the fuel filler pipe protective cover

retaining clip.
Slide the protective cover down the fuel
filler pipe to expose the fuel filler pipe
union.
6. Disconnect the fuel filler pipe union from the fuel

filler valve.
7. NOTE: Support the fuel filler valve housing.

Remove the fuel filler valve housing retaining
bolts and remove the fuel filler valve housing.

8. Remove the fuel filler valve from the fuel filler
valve housing.
Installation
1. NOTE: Install a new fuel filler pipe protective
cover retaining clip.


Petroleum Gas (LPG) - Fuel Tank
Print
General Equipment
Transmission stand
Removal
1. Drain the fuel lines. For additional information,
Information.
2. Remove the loadspace floor covering.
3. Remove the fuel tank upper retaining bolts.

Lifting.
6. Remove the air tight housing cover from the air

tight housing.

7. NOTE: A small amount of gas will escape
from the dry break connector when
disconnected.
Disconnect the fuel filler pipe dry break
connector.
Push the dry break connector forward and
then pull back on the dry break connector
collar to release.
8. NOTE: A small amount of gas will escape

from the dry break connector when
disconnected.
Disconnect the fuel tank to fuel vaporizer fuel
supply line dry break connector.
Push the dry break connector forward and
then pull back on the dry break connector
collar to release.
9. Using a suitable Transmission stand, support the

fuel tank.
10. Remove the fuel tank lower retaining bolts and

lower the fuel tank.
11. Evacuate the fuel tank. For additional

12. Disconnect the fuel tank level sensor electrical
connector.

13. Remove the air tight housing cover bracket.
14. Remove the fuel tank level sensor gauge.
15. Remove the fuel tank level sensor.

Discard the fuel tank level sensor gasket.
16. Disconnect the fuel tank fuel hose union from the
fuel tank solenoid valve.
Remove the retaining clip.
17. Disconnect the fuel tank fuel hose union from

the fuel tank one-way valve.
Remove the retaining clip.

18. Remove the air tight housing.
19. Disconnect the fuel tank solenoid valve electrical

connector and remove the fuel tank solenoid
valve from the fuel tank.
20. Remove the fuel tank one-way valve from the

fuel tank.
Installation
1. NOTE: Install a new fuel tank level sensor
gasket.


Petroleum Gas (LPG) - Fuel Filter
Print
Removal
2. Disconnect the fuel supply lines from the fuel
filter.
Discard the fuel supply line retaining clips.
3. NOTE: Direction of flow indicated by the

arrow on the fuel filter.
Loosen the clamp bolt and remove the fuel filter.
Installation
1. NOTE: Install new fuel supply line retaining
clips.


Petroleum Gas (LPG) - Fuel Level Sensor
Print
Removal
Operation).
2. Disconnect the fuel tank wiring harness electrical
connector.
3. Remove the air-tight housing cover from the air-

tight housing.
4. Evacuate the fuel tank.

For additional information, refer to: Fuel Tank
Evacuation (310-00B Fuel System - General
Procedures).
5. Disconnect the fuel level sensor gauge electrical
connector.
6. Remove the air-tight housing cover bracket.

7. Remove the fuel level sensor gauge.
8. Remove the fuel level sensor.

Discard the fuel level sensor gasket.
Installation
1. NOTE: Install a new fuel level sensor gasket.

Procedures).

Acceleration Control - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Accelerator pedal retaining nuts 9 - 80

Acceleration Control - Acceleration
Control
Print
Accelerator pedal Wiring harness
Linkage Electrical connector(s)
Accelerator cable Accelerator pedal
Chart.
Symptom Chart

Accelerator pedal is hard to * Damaged * INSTALL a new accelerator cable.
depress or has a rough/raspy or accelerator cable.
sticky feel - All except vehicles * Accelerator cable * CHECK the accelerator cable for the
with diesel engines incorrectly correct installation.
installed.
* Worn or * INSTALL a new throttle body.
damaged throttle REFER to: Throttle Body (303-04A
body. Fuel Charging and Controls - 1.8L
* Worn or * INSTALL a new accelerator pedal.
damaged
accelerator pedal.
Accelerator pedal is hard to * Worn or * INSTALL a new accelerator pedal.
depress or has a rough/raspy or damaged
sticky feel - Vehicles with diesel accelerator pedal.
engine
Accelerator pedal does not * Weak or broken * INSTALL a new throttle body.
return freely - All except throttle body REFER to: Throttle Body (303-04A
vehicles with diesel engines return spring. Fuel Charging and Controls - 1.8L
* Worn or * INSTALL a new throttle body.
damaged throttle REFER to: Throttle Body (303-04A
body. Fuel Charging and Controls - 1.8L
* Accelerator cable * CHECK the accelerator cable for the
incorrectly correct installation.

installed.
Accelerator pedal does not * Worn or * INSTALL a new accelerator pedal.
return freely - Vehicles with damaged
diesel engine accelerator pedal.
High engine idle speed - All * Damaged * INSTALL a new accelerator cable.
except vehicles with diesel accelerator cable.
engines * Accelerator cable * CHECK the accelerator cable for the
incorrectly correct installation.
installed.
High engine idle speed - Vehicles * Damaged * INSTALL a new accelerator pedal.
with diesel engine accelerator pedal.
* PCM calibration. * Refer to the WDS to diagnose the
system.

Acceleration Control - Accelerator Pedal—
Print
Removal
1.
2.
3.
4. Torque: 9 Nm

Installation

Zetec
Print
(s).

1 - Passenger compartment footwell air duct retaining clip
2 - Passenger compartment footwell air duct
3 - Accelerator cable to accelerator pedal
4 - Accelerator pedal retaining nuts
5 - Accelerator pedal
Item 4 : Accelerator pedal retaining nuts
NOTE: The accelerator pedal retaining nuts must be tightened evenly to prevent
distortion.

Print
(s).

1 - Passenger compartment footwell air duct retaining clip
2 - Passenger compartment footwell air duct
3 - Accelerator pedal position sensor electrical connector
4 - Accelerator pedal retaining nuts
5 - Accelerator pedal
Item 4 : Accelerator pedal retaining nuts
NOTE: The accelerator pedal retaining nuts must be tightened evenly to prevent
distortion.

Acceleration Control - Accelerator Cable—
Zetec
Print

General Equipment
Draw cord with a minimum length of one meter
(s).

1 - Accelerator cable inner cable
2 - Accelerator cable to throttle body accelerator cable retaining bracket
See Removal Detail
3 - Accelerator cable retaining clip
See Removal Detail
4 - Accelerator cable to coolant expansion tank hose retaining clips
5 - Accelerator cable retaining clip
See Removal Detail
6 - Accelerator cable inner cable
See Removal Detail
7 - Accelerator cable to bulkhead grommet
See Removal Detail
8 - Accelerator cable
See Removal Detail
Removal Details
Item 2 : Accelerator cable to throttle body accelerator cable retaining bracket

Item 3 : Accelerator cable retaining clip
1. For right-hand drive vehicles detach the

accelerator cable to engine lifting eye retaining
clip.
Item 5 : Accelerator cable retaining clip
1. For right-hand drive vehicles detach the

accelerator cable to power steering fluid return
pipe retaining clip.
Item 6 : Accelerator cable inner cable
1. Detach the accelerator cable inner cable from the

accelerator pedal.
Item 7 : Accelerator cable to bulkhead grommet

1. Detach the accelerator cable from the bulkhead.
1. Pull the accelerator cable out of the
accelerator cable grommet.
2. Detach the accelerator cable grommet
from the bulkhead.
Item 8 : Accelerator cable
1. Attach a suitable draw cord to the accelerator

cable to assist with installation.
Item 8 : Accelerator cable
1. Using the draw cord, install the accelerator cable.

Remove the draw cord.
Item 7 : Accelerator cable to bulkhead grommet
1. Install the accelerator cable and grommet.

1. Install the accelerator cable grommet into
the bulkhead.
2. Push the accelerator cable into the
accelerator cable grommet.

Climate Control System - General Information - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Lubricants, sealants and adhesives
Material Specification
Refrigerant R134a WSH-M17B19-A
Refrigerant oil WSH-M1C231-B
Refrigerant fill quantities
Grams
Air conditioning 905 ± 15
Refrigerant oil fill quantities
Milliliters
Air conditioning 200
Addition of Refrigerant Oil (When new components are installed)
CAUTIONS:
The refrigerant oil top-up quantity must not exceed the refrigerant oil fill quantity.
If other A/C components are being renewed in addition to the A/C compressor, there is no need to top up with additional refrigerant oil, apart from filling the compressor.
Because the fill quantities differ, the refrigerant oil must be drained from the new A/C compressor.
Milliliters
When all lines and components are replaced. add 200.
Air conditioning (A/C) compressor - if the quantity of refrigerant oil drained from the faulty compressor is less than 150 ml add 150.
Air conditioning compressor (if the amount of refrigerant oil drained from the faulty compressor is more than 150 ml) add 200.
Air conditioning condenser Add 30
Air conditioning evaporator Add 30
Air conditioning dehydrator Add 90
Always, if refrigerant was drained. Add the same quantity as the quantity that was collected.
Air conditioning (A/C) Clutch
mm
Air conditioning (A/C) clutch air gap 0.35 - 0.75
Tightening torques

Air conditioning (A/C) compressor drive plate retaining bolt 13 10 -

Climate Control System - General
Information - Climate Control System
Print

information.
Special Tool(s)
Terminal Probe Kit
418-S035
General Equipment
Service unit or manometer head
Digital Multimeter (compatible with K-type
thermocouple)
Thermometer - Fluke 80 PK-8 (FSE number 260
4102 001 07)
Inspection and Checking
1. 1. VERIFY customer concern.
2. 2. Visually CHECK for any obvious mechanical or electrical damage.
Visual Inspection
Drive belt Fuses
Refrigerant lines Wiring harness
Condenser core Connectors
Refrigerant compressor
3. 3. RECTIFY any obvious causes for a concern found during the visual inspection
before performing any further tests. CHECK the operation of the system.
4. 4. If the concern persists after the visual inspection, CARRY OUT a fault diagnosis on
the powertrain control module (PCM) and the instrument cluster with WDS and
RECTIFY any displayed faults in accordance with the fault description. CHECK the
operation of the system.
5. 5. If no fault is stored in the fault memory, PROCEED with the symptom chart
according to the fault symptom.
6. 6. Following checking or elimination of the fault and after completion of operations,

the fault memories of all vehicle modules must be READ OUT and any stored faults
must be DELETED. READ OUT all fault memories again following a road test.
Refrigerant Circuit - Quick Check
WARNING: The air conditioning system is filled with refrigerant R134a. Observe
"Health and Safety Precautions". For further information
REFER to: Health and Safety Precautions (100-00 General Information, Description and

Operation).
Refrigerant circuit check
WARNING: Under certain circumstances, refrigerant lines and A/C components may
be extremely hot or cold. Exercising care, touch the refrigerant lines or A/C components
in order to check this. Failure to observe this instruction can lead to injury.
When the A/C system is operating, the following conditions should apply:
The refrigerant line from the A/C compressor to the A/C condenser must be hot.
The refrigerant line from the A/C condenser to the fixed orifice tube must be warm, but
not so hot as the refrigerant line mentioned above.
Determine the difference in temperature upstream and downstream of the A/C condenser
by measuring the temperatures. Depending on the ambient temperature, the
temperature difference should be more than 20°. If the temperature difference is less,
check the condenser for contamination or damage to the fins as well as operation of the
radiator fan.
The refrigerant line between the fixed orifice tube and the evaporator must be cold from
the point where the fixed orifice tube is installed. Depending on the weather, the
refrigerant line may also have ice on its surface.
The refrigerant line between the evaporator and the A/C compressor including the
refrigerant accumulator must be cold.
Evaporator outlet temperature test

To test the power of the A/C system, the temperature of the evaporator outlet line must be
measured. To do this, the following preconditions must be met:
Open all windows.

Set the air distribution to the defrost/dashboard position and open all the ventilation
nozzles.
DO NOT switch on recirculated air.
Select lowest blower switch setting.
Select lowest temperature setting.
NOTE: The temperature measurement cannot be done with a thermometer which makes
no contact. The surface reflection from the metal line may cause incorrect readings.
Connect the temperature sensor (Fluke 80 PK-8) to the outlet line of the evaporator. The
temperature sensor must be positioned as closely as possible to the evaporator. Connect
the temperature sensor to the multimeter.
Start the engine and allow it to idle.
Switch on the air-conditioning system.
After three minutes, measure the surface temperature of the evaporator outlet line.
If the temperature measured is 2° C or less, the A/C system is working correctly. If the
temperature is higher, the A/C system may be under-filled. For further information, refer to
REFER to: (412-00 Climate Control System - General Information)
Air Conditioning (A/C) System Recovery, Evacuation and Charging (General Procedures).
Frequent faults and their causes

If the cooling power of the A/C system is not adequate, make certain that the temperature
control flaps are operating correctly.
No or poor cooling performance:

- Blockage or restriction in one of the refrigerant lines or in the suction accumulator. By
comparing temperatures at the refrigerant lines or at the suction accumulator, the

location of the blockage or restriction can easily be identified. The blockage or restriction
is located at the point where the temperature difference is identified. Note: A
temperature difference in the area of the fixed orifice tube is normal. Once the
location of the blockage or restriction has been detected, check the relevant component
and renew if necessary.
Sudden poor cooling performance. After the air conditioning has been switched off for
approx. 5 minutes, the cooling performance returns to normal:
- Fixed orifice tube iced up. The cause for an iced-up fixed orifice tube is moisture in the
refrigerant circuit. In order to ensure that moisture is completely removed from the
refrigerant circuit, the suction accumulator must be renewed and the evacuation time
must be extended to 2-3 hours. For further information, refer to REFER to:
Suction Accumulator (412-03 Air Conditioning, Removal and Installation),
Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate
Control System - General Information, General Procedures).
Symptom Chart
Symptom Chart

Blower motor inoperative / partly inoperative * Fuse(s) * GO to
* Circuit(s) Pinpoint
* Blower motor Test A.
* Blower switch
* Blower resistor
assembly
Blower motor running continuously * Blower switch * GO to
Test B.
Air conditioning inoperative (blower function OK) * Fuse(s) * GO to
* Refrigerant quantity Test C.
* Air conditioning clutch
* Refrigerant
compressor clutch
diode
* Refrigerant high-
pressure switch
* Refrigerant low-
pressure switch
* Air conditioning clutch
relay
* Powertrain control
module (PCM)
* Climate control system
control assembly
* instrument Cluster
Malfunction of the recirculated air flap * Circuit(s) * GO to
* Actuator – recirculated Pinpoint
air flap Test D.
* Recirculated air flap
control assembly
* Dehumidification
switch
Refrigerant compressor inoperative when switch set to * Circuit(s) * GO to
'Defrost/demist windshield' (other functions of the * Dehumidification Pinpoint
control panel for the climate control system OK) switch Test E.
control assembly

System Checks
PINPOINT TEST A : BLOWER MOTOR INOPERATIVE / PARTLY

INOPERATIVE
A1: CHECK ALL SPEED SETTINGS OF THE BLOWER MOTOR
2 Switch the blower switch through all speed
settings.
Is the blower motor inoperative in all the switch
positions?
Yes
GO to A2.
No
- The blower motor is only inoperative in switch
position 4:GO to A8.
- The blower motor is inoperative in switch positions
1, 2 and/or 3:GO to A9.
A2: CHECK FUSE F64
2 CHECK fuse F64 (BJB).
Is the fuse OK?
Yes
GO to A3.
No
RENEW fuse F64 (30 A). CHECK the operation of
the system. If the fuse blows again, LOCATE and
REPAIR the short using the Wiring Diagrams.
A3: CHECK THE VOLTAGE AT FUSE F64
1 Connect fuse F64 (BJB).
Measure voltage between fuse F64 (30 A) and
3
ground.
Does the meter display battery voltage?
Yes
GO to A4.
No
REPAIR the voltage supply to fuse F64 using the
Wiring Diagrams. CHECK the operation of the
system.
A4: CHECK THE VOLTAGE AT HEATER BLOWER MOTOR
2 Disconnect connector C789 from blower motor.
4 Measure the voltage between the blower motor,
connector C789, pin 1, circuit 15-FA18 (GN/OG),
wiring harness side and ground.

Yes

GO to A5.
No
LOCATE and REPAIR break in circuit 15-FA18
(GN/OG), between blower motor and fuse F64 using
the Wiring Diagrams. CHECK the operation of the
system.
A5: CHECK THE GROUND CONNECTION OF THE BLOWER MOTOR
2 Set the blower switch to position 4.
3 Measure the resistance between the blower motor,
connector C789, pin 2, circuit 31S-FA18 (BK/RD),
Is a resistance of less than 2 Ohm registered?

Yes
RENEW the blower motor. CHECK the operation of
the system.
No
GO to A6.
A6: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH
1 Disconnect connector C469 of heater blower
switch.
wiring harness side and the blower switch,
connector C469, pin 6, circuit 31S-FA33 (BK/OG),
wiring harness side.

Yes
GO to A7.
No
LOCATE and RECTIFY the open circuit in circuit 31S-
FA18 (BK/RD) between the blower motor and
soldered connection S24 with the aid of the Wiring
Diagrams. CHECK the operation of the system.
A7: CHECK THE GROUND CONNECTION OF THE BLOWER SWITCH
1 Measure the resistance between the blower switch,
connector C469, pin 2, circuit 31-FA25 (BK), wiring
harness side and ground.

Yes
INSTALL A NEW blower switch. CHECK the
No
LOCATE and RECTIFY the break in circuit 31-FA25
(BK) between the blower switch and ground
connection G14 using the Wiring Diagrams. CHECK
the operation of the system.
A8: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH
switch.
3 Disconnect connector C789 from blower motor.
wiring harness side and the blower switch,
connector C469, pin 6, circuit 31S-FA33 (BK/OG),

Yes
No
LOCATE and REPAIR the break in circuit 31S-FA33
(BK/OG) between the blower switch and soldered
connection S24 using the Wiring Diagrams. CHECK
A9: CHECK THE HEATER BLOWER SWITCH
switch.
4 Measure the voltage between the blower switch,
connector C469, pin 5, circuit 31S-FA32 (BK/BU),

connector C469, pin 3, circuit 31S-FA31 (BK/YE),
connector C469, pin 1, circuit 31S-FA30 (BK/WH),
Is battery voltage measured in all cases?

Yes

No
GO to A10.
A10: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER
RESISTOR
2 Disconnect connector C470 from blower resistor
assembly.
4 Measure the voltage between the blower resistor,

Yes
GO to A11.
No
(BK/BU) between soldered connection S24 and the
blower resistor assembly using the Wiring
A11: CHECK THE CIRCUIT BETWEEN THE BLOWER RESISTOR AND THE BLOWER
SWITCH
2 Measure the resistance between the blower resistor
assembly, connector C470, pin 4, circuit 31S-FA32
(BK/BU), wiring harness side and the blower switch,

Yes
GO to A12.
No
(BK/BU) between the blower resistor assembly and
the blower switch using the Wiring Diagrams.
CHECK the operation of the system.
SWITCH
(BK/YE), wiring harness side and the blower switch,

Yes
GO to A13.
No
(BK/YE) between the blower resistor assembly and
SWITCH
(BK/WH), wiring harness side and the blower
switch, connector C469, pin 1, circuit 31S-FA30
(BK/WH), wiring harness side.

Yes
RENEW the blower resistor assembly. CHECK the
No
(BK/WH) between the blower resistor assembly and
PINPOINT TEST B : BLOWER MOTOR RUNNING CONTINUOUSLY

CONDITIONS
B1: CHECK THE HEATER BLOWER SWITCH
2 Disconnect connector C469 of heater blower switch.
4 Check function of blower motor.
Does the blower motor run continuously?
Yes
GO to B2.
No
INSTALL A NEW blower switch. CHECK the operation of the system.
B2: CHECK THE CIRCUITS AT THE BLOWER RESISTOR
2 Disconnect connector C470 from blower resistor assembly.

4 Check function of blower motor.
Does the blower motor run continuously?
Yes
CHECK all circuits connected to soldered connection S24 for short to
ground using the Wiring Diagrams and REPAIR any short circuit(s) found.
No
CHECK all circuits between the blower resistor and the blower switch for a
short to ground using the Wiring Diagrams and RECTIFY any short circuit
(s) found. CHECK the operation of the system.
PINPOINT TEST C : AIR CONDITIONING INOPERATIVE (BLOWER

FUNCTION OK)
C1: CHECK THE REFRIGERANT PRESSURE IN THE REFRIGERANT CIRCUIT
CAUTIONS:
The refrigerant identification equipment must

be used before checking, otherwise the service unit
may become contaminated. Contaminated
refrigerant must be disposed of as hazardous
waste. Always follow the manufacturer's
instructions when using the service units.
When recovering the refrigerant do not allow it

to enter the atmosphere under any circumstances.
2 Connect the R-134a refrigerant center or the set of
R134a pressure gauges to the refrigerant circuit
and measure the refrigerant pressure in the
refrigerant circuit.
Is a refrigerant pressure of more than 3.2 bar
measured?
Yes
Vehicles built up to 07/2006:GO to C2.
Vehicles built from 07/2006:GO to C6.
No
PERFORM a leak test on the refrigerant circuit
REFER to: Fluorescent Dye Leak Detection (412-00
Climate Control System - General Information,
CHARGE the system with the correct amount of
refrigerant REFER to: (412-00 Climate Control
System - General Information)
Air Conditioning (A/C) System Recovery,
Evacuation and Charging (General Procedures).
C2: CHECK FUSE F59
1 CHECK fuse F59 (CJB).
Is the fuse OK?
Yes
GO to C3.
No
RENEW fuse F59 (7.5 A). CHECK the operation of
C3: CHECK THE VOLTAGE AT FUSE F59

1 Connect fuse F59 (CJB).
2 Measure the voltage between fuse F59 (7.5 A) and
ground.
Yes
GO to C4.
No
system.
C4: CHECK FUSE F34
Is the fuse OK?
Yes
GO to C5.
No
ground.
Yes
GO to C10.
No
system.
C6: CHECK FUSE F48
2 CHECK Fuse F48 (CJB).
Is the fuse OK?
Yes
GO to C7.
No
INSTALL a new fuse F48 (7.5 A). CHECK the
operation of the system. If the fuse blows again,
LOCATE and REPAIR the short using the Wiring
Diagrams.
1 Connect Fuse F48 (CJB).
ground.
Yes
GO to C8.
No
system.
C8: CHECK FUSE F60
Is the fuse OK?

Yes

GO to C9.
No
ground.
Yes
GO to C10.
No
REPAIR the voltage supply to fuse F60 with the aid
of the Wiring Diagrams. CHECK the operation of the
system.
C10: CHECK FUSE F26
Is the fuse OK?
Yes
GO to C11.
No
the system. If the fuse blows again after switching
the air conditioning on, CHECK the refrigerant
compressor clutch diode and RENEW as necessary.
If the refrigerant compressor clutch diode is OK,
LOCATE and RECTIFY the short circuit with the aid
of the Wiring Diagrams.
Measure the voltage between fuse F26 (10 A) and
2
ground.
Yes
GO to C12.
No
system.
C12: CHECK THE VOLTAGE AT THE A/C CLUTCH RELAY
1 Disconnect A/C clutch relay from socket C1011
(BJB).
2 Measure the voltage between the A/C clutch relay,
socket C1011, pin 3, circuit 30-FA12 (RD), wiring

Yes

GO to C13.
No
(RD) between the A/C clutch relay and fuse F26
using the Wiring Diagrams. CHECK the operation of
the system.
C13: CHECK THE CONTROL VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY
2 Measure the voltage between the air conditioning
clutch relay, socket C1011, pin 1, circuit 15-FA11
(GN/YE), wiring harness side and ground.

Yes
GO to C14.
No
(GN/YE) between the A/C clutch relay and soldered
connection S117 (vehicles built from 07/2006:
soldered connection S54) with the aid of the Wiring
C14: CHECK THE A/C CLUTCH ELECTRICAL CIRCUIT
2 Use a fused test cable (10 A) to bridge the air
conditioning clutch relay, socket C1011, pin 3 and
pin 5, wiring harness side.
Check that the A/C system clutch operates

3
correctly.
Does the air conditioning clutch work?
Yes
GO to C17.
No
GO to C15.
C15: CHECK THE ELECTRICAL CIRCUIT BETWEEN THE A/C CLUTCH RELAY AND THE
A/C CLUTCH FOR OPEN CIRCUIT
1 Disconnect Connector C952 from the A/C clutch.
2 Use a fused test cable (10 A) to bridge the air
conditioning clutch relay, socket C1011, pin 3 and

3 Measure the voltage between A/C clutch, connector
C952, pin 1, circuit 15S-FA6 (GN/YE), wiring

Yes
GO to C16.
No
LOCATE and REPAIR the open circuit between the
air conditioning clutch relay and air conditioning
clutch using the Wiring Diagrams. CHECK the
C16: CHECK THE GROUND CONNECTION OF THE A/C CLUTCH
1 Measure the resistance between the air
conditioning clutch, connector C952, pin 2, circuit
31-FA6 (BK), wiring harness side and ground.

Yes
INSTALL A NEW air conditioning clutch. CHECK the
No
LOCATE and REPAIR the break in circuit 31-FA6
(BK) between the A/C clutch and soldered
C17: CHECK THE VOLTAGE AT THE REFRIGERANT LOW PRESSURE SWITCH
1 Disconnect connector C692 from refrigerant low-
pressure switch.
3 Switch on the blower.
4 Switch on the air-conditioning system.
5 Measure the voltage between the refrigerant low-
pressure switch, connectorr C692, pin 4, circuit
15S-FA17 (GN/OG) (vehicles built from 07/2006:

circuit 91S-FA17 (BK/RD)), wiring harness side and
ground.

Yes
GO to C18.
No
GO to C26.
C18: CHECK REFRIGERANT LOW-PRESSURE SWITCH
2 Measure the resistance at the A/C low pressure
switch, connector C692, between pin 1 and pin 4,
component side.

Yes
- vehicles with 1.8L (55 KW) diesel engine and
vehicles with LPG fuel system:GO to C19.
- vehicles with 1.8L (66 KW) diesel engine:GO to
C21.
- vehicles with 85 KW engine, except vehicles with
LPG fuel system:GO to C23.
No
RENEW the refrigerant low-pressure switch. CHECK
C19: CHECK ELECTRICAL CIRCUIT BETWEEN A/C LOW PRESSURE SWITCH AND
POWERTRAIN CONTROL MODULE (PCM) FOR OPEN CIRCUIT - VEHICLES WITH 1.8L
(55 KW) DIESEL ENGINE AND VEHICLES WITH LPG FUEL SYSTEM:
1 Disconnect connector C415 from PCM.
2 Measure the resistance between PCM, connector
C415, pin 41, circuit 15S-RE8 (GN/YE), wiring
harness side and A/C low pressure switch,
connector C692, pin 1, circuit 15S-RE8 (GN/YE),

Yes
GO to C20.
No
LOCATE and REPAIR the break in circuit 15S-RE8

(GN/YE) between the A/C low pressure switch and
the PCM using the Wiring Diagrams. CHECK the
C20: CHECK ELECTRICAL CIRCUIT BETWEEN A/C CLUTCH RELAY AND PCM FOR OPEN
CIRCUIT - VEHICLES WITH 1.8L (55 KW) DIESEL ENGINE AND VEHICLES WITH LPG
FUEL SYSTEM
1 Measure the resistance between the PCM,
wiring harness side and the A/C clutch relay, socket
C1011, pin 2, circuit 31S-FA11 (BK/YE), wiring
harness side.

Yes
GO to C25.
No
LOCATE and RECTIFY the break in circuit 31S-FA11
(BK/YE) between PCM and the air conditioning
clutch relay using the Wiring Diagrams. CHECK the
POWERTRAIN CONTROL MODULE (PCM) FOR OPEN CIRCUIT - VEHICLES WITH 1.8L
(66 KW) DIESEL ENGINE
1 Disconnect connector C414 of PCM.

Yes
GO to C22.
No
CIRCUIT - VEHICLES WITH 1.8L (66 KW) DIESEL ENGINE
harness side.

Yes
GO to C25.
No
POWERTRAIN CONTROL MODULE (PCM) FOR OPEN CIRCUIT - VEHICLES WITH 85 KW
ENGINE EXCEPT VEHICLES WITH LPG FUEL SYSTEM:

Yes
GO to C24.
No
CIRCUIT - VEHICLES WITH 85 KW ENGINE EXCEPT VEHICLES WITH LPG FUEL
SYSTEM:
harness side.

Yes
GO to C25.
No
C25: CHECK AIR CONDITIONING CLUTCH RELAY
1 Check the A/C clutch relay according to the
component check at the end of the section.
Is the air conditioning clutch relay OK?

Yes
TEST the PCM and RENEW as necessary. CHECK the

No
RENEW the air conditioning clutch relay. CHECK and
if necessary RENEW the refrigerant compressor
clutch diode. CHECK the operation of the system.
C26: CHECK VOLTAGE AT REFRIGERANT HIGH-PRESSURE SWITCH
2 Disconnect connector C882 from refrigerant high-
pressure switch.
6 Measure the voltage between the A/C high
pressure switch, connector C882, pin 1, circuit
15S-FA38 (GN/RD), wiring harness side and
ground.

Yes
GO to C27.
No
Vehicles built from 07/2006:LOCATE and REPAIR
the break in circuit 91-FA38 (BK/OG) between the
refrigerant high-pressure switch and soldered
C27: CHECK REFRIGERANT HIGH-PRESSURE SWITCH
2 Measure the resistance at the A/C high pressure
switch, connector C882, between pin 1 and pin 4,
component side.

Yes
(GN/OG) (vehicles built from 07/2006: circuit 91S-
FA17 BK/RD)) between the refrigerant low-pressure
switch and the refrigerant high-pressure switch with
the aid of the Wiring Diagrams. CHECK the
No
RENEW the refrigerant high-pressure switch. CHECK
C28: CHECK THE VOLTAGE AT THE CONTROL PANEL OF THE CLIMATE CONTROL
SYSTEM - PIN 8

2 Disconnect Connector C380 from the control panel
for the climate control system.
3 Measure the voltage between the control panel for
the climate control system, connector C380, pin 8,
circuit 29-FA13 (OG), wiring harness side and
ground.

Yes
GO to C31.
No
C29: CHECK THE CIRCUIT BETWEEN THE CONTROL PANEL FOR THE CLIMATE
CONTROL SYSTEM AND THE CJB FOR OPEN CIRCUIT - VEHICLES BUILT UP TO
07/2006
1 Disconnect Connector C16 from CJB.
2 Measure the resistance between the control panel
for the climate control system, connector C380, pin
8, circuit 29-FA13 (OG), wiring harness side and
the CJB, connector C16, pin 9, circuit 29-FA13
(OG), wiring harness side.

Yes
CHECK the CJB and RENEW as necessary. CHECK
No
(OG) between the control panel for the climate
control system and the CJB using the Wiring
CONTROL SYSTEM AND THE CJB FOR OPEN CIRCUIT - VEHICLES BUILT FROM
07/2006
8, circuit 29-FA13 (OG), wiring harness side and
the CJB, connector C11, pin 8, circuit 29-FA13
(OG), wiring harness side.

Yes

No
(OG) between the control panel for the climate
control system and the CJB using the Wiring
C31: CHECK THE VOLTAGE AT THE CONTROL PANEL OF THE CLIMATE CONTROL
SYSTEM - PIN 10
the climate control system, connector C380, pin
10, circuit 15-FA13 (GN/RD), wiring harness side
and ground.

Yes
GO to C34.
No
CONTROL SYSTEM AND THE CJB FOR OPEN CIRCUIT - VEHICLES BUILT UP TO
07/2006
1 Disconnect connector C10 from CJB.
and the CJB, connector C10, pin 8, circuit 15-FA13
(GN/RD), wiring harness side.

Yes
No
(GN/RD) between the control panel for the climate
control system and the CJB with the aid of the
system.
CONTROL SYSTEM AND THE CJB FOR OPEN CIRCUIT - VEHICLES BUILT FROM
07/2006
and the CJB, connector C11, pin 15, circuit 15-FA13
(GN/RD), wiring harness side.

Yes
No
control system and the CJB with the aid of the
system.
C34: CHECK THE GROUND CONNECTION OF THE CONTROL PANEL FOR THE CLIMATE
CONTROL SYSTEM
12, circuit 91-FA13 (BK/OG), wiring harness side
and ground.

Yes
GO to C35.
No
LOCATE and RECTIFY the open circuit in circuit 91-
FA13 (BK/OG) between the control panel for the
climate control system and soldered connection S12
with the aid of the Wiring Diagrams. CHECK the
C35: CHECK GROUND CONNECTION THROUGH BLOWER SWITCH
1 Set the blower switch to position 1.
6, circuit 31S-FA26 (BK/RD), wiring harness side
and ground.

Yes
Vehicles built from 07/2006:CHECK and if

necessary RENEW the control panel for the climate
control system. CHECK the operation of the system.
No
(BK/RD) between the control panel for the climate
control system and the blower switch with the aid
of the Wiring Diagrams. CHECK the operation of the
system.
CONTROL SYSTEM AND THE REFRIGERANT HIGH-PRESSURE SWITCH FOR OPEN
CIRCUIT
9, circuit 15S-FA38 (GN/RD), wiring harness side
and the refrigerant high pressure switch, connector
C882, pin 1, circuit 15S-FA38 (GN/RD), wiring
harness side.

Yes
CHECK and if necessary RENEW the control panel
for the climate control system. CHECK the operation
of the system.
No
control system and the refrigerant high pressure
switch with the aid of the Wiring Diagrams. CHECK
C37: CHECK THE A/C REQUEST SIGNAL IN THE POWERTRAIN CONTROL MODULE
(PCM)
1 Connect the diagnostic tool.
4 Using the diagnostic unit, select the PCM and check
in the data logger whether an A/C request signal is
displayed.
Is an A/C request signal displayed in the data logger of
the PCM?
Yes
GO to C38.
No
GO to C40.
C38: CHECK THE CIRCUIT BETWEEN THE PCM AND THE REFRIGERANT LOW
PRESSURE SWITCH FOR OPEN CIRCUIT
2 Disconnect connector C419 from the PCM.
3 Measure the resistance between the refrigerant
low-pressure switch, connector C692, pin 1, circuit
91S-RE8 (BK/YE), wiring harness side and the PCM,
connector C419, pin E4, circuit 91S-RE8 (BK/YE),

Yes
GO to C39.
No
(BK/YE) between the refrigerant low-pressure
switch and the PCM using the Wiring Diagrams.
C39: CHECK FOR OPEN CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND
PCM
connector C418, pin F2, circuit 31S-FA11 (BK/YE),
harness side.

Yes
GO to C25.
No
(BK/YE) between the refrigerant low-pressure
switch and the PCM using the Wiring Diagrams.
C40: CHECK THE A/C REQUEST SIGNAL IN THE CENTRAL TIMER MODULE (CTM)
NOTE: The central timer module (CTM) is integrated in the instrument cluster.
Using the diagnostic unit, select the CTM and check
3
in the data logger whether an A/C request signal is
displayed.
Is an A/C request signal displayed in the data logger of
the CTM?
Yes
CHECK and if necessary RENEW the instrument
cluster. CHECK the operation of the system.
No
GO to C41.
C41: CHECK THE CONTROL VOLTAGE AT THE INSTRUMENT CLUSTER
2 Disconnect Connector C809 from instrument
cluster.

6 Measure the voltage at the instrument cluster,
connector C809, between pin 23, circuit 15S-FA38
(GN/RD), wiring harness side and ground.

Yes
cluster. CHECK the operation of the system.
No
GO to C42.
C42: CHECK FOR OPEN CIRCUIT BETWEEN THE CONTROL PANEL FOR THE CLIMATE
CONTROL SYSTEM AND THE INSTRUMENT CLUSTER
9, circuit 15S-FA38 (GN/RD), wiring harness side
and the instrument cluster, connector C809, pin 23,
circuit 15S-FA38 (GN/RD), wiring harness side.

Yes
GO to C28.
No
control system and the instrument cluster with the
aid of the Wiring Diagrams. CHECK the operation of
the system.
PINPOINT TEST D : MALFUNCTION OF THE RECIRCULATED AIR FLAP

NOTE: The recirculated air flap is actuated by means of a DC motor. This is activated for
a maximum of 7 seconds by the control panel for the climate control system following
actuation of the recirculated air button. Opening and closing of the recirculated air flap is
performed by reversing the polarity of the applied voltage.
NOTE: "Recirculated air" mode is not available when the "Defrost/demist windscreen"
function is active.
D1: CHECK THE VOLTAGE AT THE AIR RECIRCULATION FLAP ACTUATOR
2 Disconnect connector C375 from air recirculation
flap actuator.
4 Set the air distribution to footwell.

5 Measure the voltage at the air recirculation flap
actuator, connector C375, between pin 2 and pin
4, wiring harness side.
Actuate the recirculated air switch several times

6
during the measurement.
Is a voltage of at least 10 V measured with alternating
polarity?
Yes
CHECK the recirculated air flap for ease of
movement and correct operation. If the air
recirculation flap is OK, RENEW the air recirculation
flap actuator. CHECK the operation of the system.
No
Vehicles built up to 08/2004:GO to D2.
LHD vehicles built from 08/2004:GO to D4.
RHD vehicles built from 08/2004:GO to D6.
D2: CHECK THE CIRCUIT BETWEEN THE AIR RECIRCULATION FLAP ACTUATOR AND
THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR OPEN CIRCUIT -
VEHICLES BUILT UP TO 08/2004
recirculation flap actuator, connector C375, pin 2
(RHD vehicles: pin 4), circuit 32-FA76 (WH/BU),
wiring harness side and the control panel for the
climate control system, connector C380, pin 14,
circuit 32-FA76 (WH/BU), wiring harness side.

Yes
GO to D3.
No
(WH/BU) between the air recirculation flap actuator
and the control panel for the climate control
system with the aid of the Wiring Diagrams. CHECK
THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR OPEN CIRCUIT -
VEHICLES BUILT UP TO 08/2004
recirculation flap actuator, connector C375, pin 4
(RHD vehicles: pin 2), circuit 33-FA76 (YE/BU),
wiring harness side and the control panel for the
climate control system, connector C380, pin 16,
circuit 33-FA76 (YE/BU), wiring harness side.

Yes
GO to D8.
No
(YE/BU) between the air recirculation flap actuator
THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR OPEN CIRCUIT - LHD
VEHICLES BUILT FROM 08/2004
3 Measure the resistance between the recirculated
air flap actuator, connector C375, pin 2, circuit 32-
FA76 (WH/BU), wiring harness side and the control
panel for the climate control system, connector
C380, pin 14, circuit 32-FA76 (WH/BU), wiring
harness side.

Yes
GO to D5.
No
THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR OPEN CIRCUIT - LHD
FA76 (YE/BU), wiring harness side and the control
C380, pin 16, circuit 33-FA76 (YE/BU), wiring
harness side.

Yes
GO to D8.
No

THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR OPEN CIRCUIT - RHD
FA76R (YE/BU), wiring harness side and the control
C380, pin 16, circuit 33-FA76R (YE/BU), wiring
harness side.

Yes
GO to D7.
No
LOCATE and REPAIR the break in circuit 33-FA76R
THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR OPEN CIRCUIT - RHD
FA76R (WH/BU), wiring harness side and the
control panel for the climate control system,
connector C380, pin 14, circuit 32-FA76R (WH/BU),

Yes
GO to D8.
No
LOCATE and REPAIR the break in circuit 32-FA76R
THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR SHORT TO VOLTAGE
16, circuit 33-FA76 (YE/BU) (RHD vehicles: circuit
33-FA76R (YE/BU)), wiring harness side and
ground.

Measure the voltage between the control panel for
3
14, circuit 32-FA76 (WH/BU) (RHD vehicles: circuit
32-FA76R (WH/BU)), wiring harness side and
ground.
Is a voltage measured during any of these
measurements?
Yes
LOCATE and RECTIFY the short to voltage in the
relevant circuit between the recirculated air flap
actuator and the control panel for the climate
control system with the aid of the Wiring Diagrams.
No
GO to D9.
THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR SHORT TO GROUND
16, circuit 33-FA76 (YE/BU) (RHD vehicles: circuit
33-FA76R (YE/BU)), wiring harness side and
ground.
Measure the resistance between the control panel

3
14, circuit 32-FA76 (WH/BU) (RHD vehicles: circuit
32-FA76R (WH/BU)), wiring harness side and
ground.
Is a resistance greater than 10,000 Ohms measured in
both cases?
Yes
GO to D10.
No
LOCATE and RECTIFY the short to ground in the
relevant circuit between the control panel for the
climate control system and the recirculated air flap
actuator using the Wiring Diagrams. CHECK the
D10: CHECK THE DEHUMIDIFICATION SWITCH
1 Set the air distribution to footwell.
7, circuit 91S-FA20 (BK/YE), wiring harness side

and ground.

Yes
GO to D11.
No
for the climate control system. CHECK the
D11: CHECK THE CIRCUIT BETWEEN THE DEHUMIDIFICATION SWITCH AND THE
CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM FOR SHORT TO GROUND
and ground.
Is a resistance of more than 10,000 Ohm measured?

Yes
RENEW the dehumidification switch. CHECK the
No
LOCATE and REPAIR the short to ground in circuit
91S-FA20 (BK/YE) between the dehumidification
switch and the control panel for the climate control
system using the Wiring Diagrams. CHECK the
PINPOINT TEST E : REFRIGERANT COMPRESSOR INOPERATIVE WHEN

SWITCH SET TO 'DEFROST/DEMIST WINDSHIELD' (OTHER FUNCTIONS OF
THE CONTROL PANEL FOR THE CLIMATE CONTROL SYSTEM OK)
NOTE: If the temperature outside is less than 4° C the refrigerant compressor will not
switch on.
E1: CHECK THE CIRCUIT OF THE DEHUMIDIFICATION SWITCH FOR OPEN CIRCUIT
3 Set the air distribution to "Defrost/demist
windscreen".
and ground.

Yes
for the climate control system. CHECK the operation
of the system.
No
GO to E2.
E2: CHECK FOR OPEN CIRCUIT BETWEEN THE CONTROL PANEL OF THE CLIMATE
CONTROL SYSTEM AND THE DEHUMIDIFICATION SWITCH
1 Disconnect connector C376 from dehumidification
switch.
and the dehumidification switch, connector C376,
pin 3, circuit 91S-FA20 (BK/YE), wiring harness
side.

Yes
GO to E3.
No
LOCATE and RECTIFY the open circuit in circuit 91S-
FA20 (BK/YE) between the control panel for the
climate control system and the dehumidification
E3: CHECK THE GROUND CONNECTION OF THE DEHUMIDIFICATION SWITCH
1 Measure the resistance between the
dehumidification switch, connector C376, pin 1,
circuit 91-FA20 (BK/YE), wiring harness side and
ground.

Yes
RENEW the dehumidification switch. CHECK the
No
FA20 (BK/YE) between the dehumidification switch
and soldered connection S12 with the aid of the

system.
Component Tests
Air conditioning clutch relay
1. 1. Check the normally open contact in the unswitched state.
Measure the resistance at the air conditioning clutch relay, between pin 3 and pin
5, component side.
1. If yes, go to 2.
2. If no, RENEW the air conditioning clutch relay.
2. 2. Check the normally open contact in the switched state.
Use a fused test cable (1 A) to connect pin 1 of the air conditioning clutch relay,
component side, to the battery positive terminal.
Use a test cable to connect pin 2 of the air conditioning clutch relay, component
side, to the battery negative terminal.
Measure the resistance at the air conditioning clutch relay, between pin 3 and pin
5, component side.
1. If yes, then the air conditioning clutch relay is OK.
2. If no, RENEW the air conditioning clutch relay.

Information - Spring Lock Coupling
Print
General Procedures
1. NOTE: Select special tool to suit the line

diameter.
Fit the special tool.
Fit the special tool so that the inner collar
can be guided into the clamping spring.
2. Press the special tool into the clamping spring.
3. Disconnect the refrigerant line.

4. Connect the refrigerant line.

Check the clamping spring for damage.
Carefully pull out any damaged clamping
springs using a thin piece of wire and
install new one.
5. NOTE: Clean the connections using

refrigerant oil and a lint-free cloth.
Press the indicator ring into the clamping spring.
6. NOTE: Install new refrigerant line O-ring

seals.
NOTE: Coat the refrigerant line O-ring seals
in clean refrigerant oil prior to installation.
Connect the refrigerant lines.
Check that the clamping spring engages
correctly.

Information - Air Conditioning (A/C) Transit/Tourneo Connect 2002.5 (06/2002-)
Clutch Air Gap Adjustment
Print
General Procedures
Materials
Name Specification
Spacer washer set
1. Measurement for recessed pulley
Check the air gap A between the drive plate and
the pulley at 60 degree intervals around the
circumferance of the pulley, while operating the
A/C clutch several times by means of a 5A fused
jumper wire connected between the battery
positive terminal, A/C clutch and battery ground.
For additional information, refer to Specifications
in this section.
1. Belt pulley
2. Drive plate
Air gap A (the difference measured
between the A/C clutch engaged and
disengaged)
2. Measurement for non recessed pulley
Check the air gap A between the drive plate and
the pulley at 60 degrees intervals around the
circumference. For additional information, refer
to Specifications in this section.
1. Belt pulley
2. Spacer washer
3. Drive plate
Air gap A
3. Remove the drive plate.
4. Correct air gap A as necessary using spacer

washers.
5. Install the drive plate. For additional information,
refer to Specifications in this section.
6. Check air gap A as described in step 1 or step 2.
Repeat steps 3-5 if necessary.

Information - Fluorescent Dye Leak Transit/Tourneo Connect 2002.5 (06/2002-)
Detection
Print
General Procedures
General Equipment
UV Spot Lamp
Manifold Gauge Set
Fluorescent Dye Injector
NOTE: Vehicles built 07/1999 onwards have a fluorescent tracer dye tablet inserted into
the air conditioning (A/C) system. If tracer dye is present, there is a green cross on the
suction accumulator.
NOTE: On vehicles built up to 07/1999 tracer dye must be added.
1. Using the dye injector, add 7.4 ml of Fluorescent
Tracer Dye.
NOTE: Some vehicles may have signs of refrigerant oil at the spring lock couplers. This
may be caused from the assembly process which applies to the fittings before installation
to aid in assembly. When a spring lock coupler is suspected of leaking, always wipe the
fitting clean and verify the leak with R-134a Automatic Calibration Halogen Leak Detector.
NOTE: The exact location of leaks can be pinpointed by the bright yellow - green glow of
the tracer dye. Since more than one leak may exist, always inspect each component.
2. Check for leaks using a 120 Watt UV Spot Lamp.
Always scan all components, fittings and lines of
the A/C system.
3. After the leak is found and repaired, remove any
traces of dye with a general purpose oil solvent.
4. Verify the repair by operating the system for
some minutes and inspecting with the UV lamp
again.

Information - Electronic Leak Detection
Print
General Procedures
General Equipment
Automatic Calibration Halogen Leak Detector
Manifold Gauge Set
Refrigerant Identifier
WARNING: Good ventilation before leak detection is necessary in the area where it is
to be performed. If the surrounding air is contaminated with refrigerant gas, the leak
detector will indicate this gas all the time. Odors from other chemicals such as antifreeze,
diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem.
While leak detection air movement must be prevented.
1. CAUTION: The refrigerant identification

equipment must be used before the manifold
gauge set is installed, otherwise the manifold
gauge may become contaminated.
Contaminated refrigerant must be disposed
of as special waste. The manufacturer's
instructions must be followed when working
with the service unit.
NOTE: Both manifold gauges should indicate
4,1-5,5 bar at 24°C with the engine off.
Attach the manifold gauge set to the service
gauge port valves.
1. For the leak test, close the manual valves
on the gauge set.
2. If little or no pressure is indicated, charge
the system with approx. 300g of
refrigerant.
For additional information, refer to Air
Conditioning (A/C) System Recovery,
Evacuation and Charging in this section.
2. Use R-134a Automatic Calibration Halogen Leak
Detector to leak test the refrigerant system.
Follow the instructions included with leak
detector for handling and operation techniques.
3. If a leak is found, recover the A/C system.
Conditioning (A/C) System Recovery, Evacuation
and Charging in this section.

Information - Air Conditioning (A/C)
System Recovery, Evacuation and
Charging
Print
General Procedures
General Equipment
Refrigerant center
Refrigerant analyzer
1. CAUTION: The refrigerant analyzer must

be used before recovery, otherwise the
refrigerant center may become
contaminated. Contaminated refrigerant
must be disposed of as hazardous waste.
Always follow the manufacturer's instructions
when using the refrigerant center and the
refrigerant analyzer.
Remove the protective cap from the A/C high-
pressure charging connection.
2. Detach the right-hand wheel arch trim panel
(shown with wheel removed for clarity).
3. Remove the protective cap from the A/C low-

pressure charging connection.
4. Pull back the catches of the quick-fit unions on

the refrigerant center lines.
5. NOTE: Larger inner diameter for high-

pressure side. Smaller inner diameter for
low-pressure side.
Connect the refrigerant center lines to the A/C
charging connections.

6. WARNING: When recovering the
refrigerant do not allow it to enter the
atmosphere under any circumstances.
NOTE: When removing components of the air
conditioning system, calculate the residual
quantity of refrigerant oil.
Refrigerant Oil Adding in this section.
Recover the refrigerant from the A/C system via
the low-pressure connection in accordance with
the refrigerant center manufacturer's
instructions.
7. CAUTIONS:
The A/C system must be evacuated for

about 30 minutes before recharging, to
ensure that it operates correctly.
If moisture was able to enter an open

system over an extended period (several
hours), install a new suction accumulator and
increase the evacuation time to 2-3 hours.
Evacuate the A/C system according to the
refrigerant center manufacturer's instructions.
8. NOTE: If an air conditioning system that was
filled with refrigerant is being evacuated,
some refrigerant will still be in the refrigerant
oil in the compressor. This remaining
refrigerant may evaporate, causing a slight
increase in pressure during the leak test. The
system is leak-free, provided that this
pressure increase does not exceed 20 mbar
(2 kPa, 0.29 psi).
Perform the leak test.
1. For the leak test, close the hand valves on
the pressure gauge set, switch off the
refrigerant center vacuum pump and
observe the low pressure gauge.
2. Locate any leaks in the A/C refrigerant
circuit using a leak tester.
Electronic Leak Detection /
Fluorescent Dye Leak Detection in this
section.
9. Top up with refrigerant oil.
For additional information, refer to Refrigerant
Oil Adding in this section.
CAUTION: The air conditioning system must always be evacuated before charging.
10. NOTE: Depending on the type of refrigerant
center and the equipment (with or without
heated filling cylinder), the air conditioning
system is either charged with liquid via the
high-pressure connection or with gas through
the low-pressure connection.
NOTE: Charge quantity on sticker in engine

compartment.
Charging the A/C system (with liquid) via the
high-pressure connection.
1. Open the shut-off valve on the high-
pressure side.
2. Switch the refrigerant center to "Fill" mode
and fill with the prescribed quantity of
liquid refrigerant (R134a).
11. CAUTION: Only gaseous charging of the

air conditioning system is performed via the
low-pressure connection.
Charging the A/C system via the low-pressure
connection.
1. Open the shut-off valve on the low-
pressure side.
2. Switch the refrigerant center to "Fill" mode
and charge with gaseous refrigerant.
3. Top up with the remaining amount of
refrigerant whilst the air conditioning is
switched on. For this purpose, run the
engine at approx. 1200-1500 rpm. Switch
the air conditioning to maximum cooling
power and fresh air mode. Set the blower
to maximum speed. Fill with the remainder
of the prescribed fill capacity.
12. WARNING: Do not detach the high-

pressure hose when the air conditioning is
switched on.
Disconnect the refrigerant center.
1. Close the shut-off valves.
2. Switch off the refrigerant center.
3. Disconnect the refrigerant center lines
from the A/C system charging connections.
4. Attach the protective caps to the filling
valves.
13. Attach the right-hand wheel arch trim panel

Information - Refrigerant Oil Adding
Print
General Procedures
CAUTION: Collect the refrigerant oil in a clean measuring cylinder.

1. NOTE: This step only needs to be carried out
when replacing the A/C compressor.
NOTE: Rotate the compressor shaft at least 6
to 8 turns when draining the refrigerant oil.
Drain the refrigerant oil from the defective A/C
compressor and dispose of it.
2. CAUTION: If the refrigerant oil is not to

be reused within 15 minutes of draining it
from the new compressor, store it in a closed
and sealed container to prevent ingress of
moisture.
NOTE: The refrigerant oil from the new A/C
compressor needs to be drained because the
fill capacities at the factory are not always
the same.
NOTE: Rotate the compressor shaft at least 6
to 8 turns when draining the refrigerant oil.
Drain the refrigerant oil from the new A/C
compressor.
3. CAUTIONS:
The amount of refrigerant oil topped up

must not exceed the refrigerant oil fill
capacity.
If other A/C components are being

renewed in addition to the A/C compressor,
there is no need to top up with additional
refrigerant oil, apart from filling the
compressor.
Add the calculated quantity of new refrigerant oil.
See: Specifications (412-00 Heating, Ventilation,
Air-Conditioning - General information,
Specifications).

Information - Contaminated Refrigerant Transit/Tourneo Connect 2002.5 (06/2002-)
Handling
Print
General Procedures
CAUTION: Any R134a or R12 refrigerant which is contaminated with unsuitable

refrigerant should be extracted only by means of a suitable servicing unit designed for the
purpose of collecting and storing contaminated refrigerant, so that the spread to other
vehicles can be prevented.
1. Use refrigerant identification equipment to check
that there is contaminated refrigerant in the air
conditioning system.
2. Inform the customer about the additional cost to
repairing the system caused by the
contamination.
3. Extract the contaminated refrigerant.

Information - Air Distribution System Transit/Tourneo Connect 2002.5 (06/2002-)
Cleaning
Print
General Procedures
General Equipment
Spray gun with hose
Materials
Name Specification
Odour eliminating agent
(240 ml) (TOX Number
142040) All vehicles
1. WARNING: Avoid contact with eyes and

skin; wear gloves and respiratory protection.
Ensure that you perform this operation in a
well ventilated room. Keep all vehicle doors
and windows open for the duration of the
operation. Do not inhale vapors under any
circumstances. Do not smoke and avoid open
fire and unprotected light sources. Avoid
contact with eyes and skin; wear gloves and
respiratory protection. Ensure that you
perform this operation in a well ventilated
room. Keep all vehicle doors and windows
open for the duration of the operation. Do
not inhale vapors under any circumstances.
Do not smoke and avoid open fire and
unprotected light sources. Failure to observe
this instruction can lead to injuries.
NOTE: The odour eliminating agent can
remove deposits in the heater housing but
cannot prevent odours that are distributed by
the ventilation system, for example those
caused by damp carpets.
Precisely locate the musty or damp odour.
2. Disconnect the low pressure switch connector.
3. Turn on the ignition.
4. Open all ventilation nozzles.
5. Set the temperature control to maximum heating
power.
6. Set the blower motor control switch to the
highest setting.
7. Set the air distribution control to the fresh air
position.
8. Start the engine and let it warm up to operating
temperature.
9. To dry out the system, switch off the air
conditioning system and ventilate the vehicle for
approx. 15 minutes.
10. Switch off the engine.
Only Focus to MY 2004.75 and Galaxy

11. Remove the blower motor.
Only Ka, Fiesta 96 to MY 2002.25 and Puma

12. Remove the blower motor resistor
Only Fiesta from MY 2002.25, Focus C-Max and Focus

from MY 2004.75 with pollen filter
Only Fiesta from MY 2002.25, Focus C-Max and Focus

from MY 2004.75 without pollen filter
14. Remove the pollen filter housing cover.
All vehicles
15. Fill the spray gun with the odour eliminating
agent (240 ml).
16. WARNING: The maximum pressure of

13.5 bar must not be exceeded. Failure to
observe this instruction can lead to injuries.
Use the tyre inflator to apply pressure of 5.5 to
10 bar (operating pressure) to the spray gun.
17. Insert the hose of the spray gun as far as
possible into the opening created by removal of
the above component and point it in the direction
of the evaporator.
18. By moving the hose, spray the odour eliminating
agent over the entire surface of the evaporator.
19. Spray all of the odour eliminating agent into the
opening.
Allow the odour eliminating agent to take
effect for 10 minutes.
20. Install the components in reverse order.
21. Start the engine, switch off the air conditioning
system and ventilate the vehicle for approx. 15
minutes.
22. Open all ventilation nozzles.
23. Set the temperature control to maximum heating
power.
24. Set the blower motor control switch to the
highest setting.
25. Set the air distribution control to the fresh air
position.
26. Switch off the engine.
27. Connect the low pressure switch connector.
28. Ventilate the vehicle with the doors open for
another 30 minutes.

Information - Vacuum Leak Detection
Print
General Procedures
1. Drain the air conditioning (A/C) system.

and Charging in this section.

Air Distribution and Filtering - Air
Distribution and Filtering
Print
Air Distribution
Air from outside the vehicle enters below the windscreen through a pollen filter and leaves
again by forced air extraction above the tailgate or the rear doors.
Pollen filter
The pollen filter is located under the wind cowl grille on the right-hand side on LHD
vehicles, and on the left-hand side on RHD vehicles (as seen looking from the driver's
seat).
Protective screens to trap large particles are installed on the left- and right-hand sides of
the pollen filter.

1 - Protective screen
2 - Pollen filter

Air Distribution and Filtering - Air
Distribution and Filtering
Print
REFER to Section 412-00 Climate Control System - General Information.

Air Distribution and Filtering - Pollen
Filter
Print
Removal
1. NOTE: The pollen filter is situated on the
passenger side.
NOTE: Position the wipers in vertical
position.
Remove the hood rubber seal.
2. Remove the cowl panel on the passenger side.
3. Remove the water collection tray of the pollen

filter .
4. Remove the pollen filter retaining flap.

Installation
1. NOTE: Note the direction of flow of the pollen
filter.
Refit the components in reverse order.

Heating and Ventilation - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Tightening torques
Item Nm lb-ft lb-in

Passenger compartment-side nut for heat exchanger / evaporator housing 9 - 80
Engine compartment-side nut for heat exchanger / evaporator housing 7 - 62
Bolts, reinforcing element 20 15 -
Bolts, reinforcing element bracket 16 12 -
Bolt, steering column 17 13 -
Nut, steering column 16 12 -

Heating and Ventilation - Heating and
Ventilation
Print

Heating and Ventilation - Blower Motor Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1. Remove the footwell lower trim panel.
2. Remove the footwell vent air duct.
3. Disconnect the blower motor electrical

connector.
4. Remove the blower motor.
Installation

Heating and Ventilation - Heater Core—
Print

Special Tool(s)
Remover/Installer, Coolant Hose Clamp
303-397 (24-003)
Removal
Cooling.
2. NOTE: Seal off the coolant lines and the
heater core to prevent the entry of dirt.
Using the special tool, detach the coolant hoses
from the heater core.

4. Remove the center console. For additional
information, refer to Section 501-12 Instrument
Panel and Console.
5. Remove the rear footwell air guide.
1. Remove the bolt.
2. Pull out the air guide.
6. Remove the passenger side fascia/crash padding

lower trim.
7. Remove the driver side air guide.

8. Detach the driver side fascia/crash padding
lower trim from the fascia/crash padding.
9. Remove the driver side fascia/crash padding

lower trim.
Pull off the light switch connector.
11. Detach the accelerator pedal with bracket from

the bulkhead and lay it to one side.
12. Remove the right and left-hand reinforcing

element brackets (right-hand side shown).

13. Remove the right-hand air guide housing half.
14. Remove the left-hand air guide housing half.
15. Remove the heater core housing with heater

core.
16. Remove the heater core bolt.
17. Remove the heater core housing.

Installation
1. Install the components in the reverse order.

Heating and Ventilation - Heater Core—
Print

General Equipment
Hose clamp(s)
Removal
2. CAUTION: Make sure that all openings

are sealed.
General Equipment: Hose clamp(s)
3. Refer to: Floor Console - Vehicles Built From:

4.
5.

6.
7.

8. Torque: 9 Nm

All vehicles
9.
10.
11.

12.
13.

14.
Installation

2. Bleed the cooling system.
Refer to: Cooling System Draining, Filling and

Procedures).

Heating and Ventilation - Heater Core and
Evaporator Core Housing—Vehicles Built Transit/Tourneo Connect 2002.5 (06/2002-)
Up To: 04/2009
Print
Special Tool(s)
303-397 (24-003)
Disconnect Tool, Spring-Lock Coupling 5/8" (black)

412-081 (34-003)
Removal
For additional information, refer to: Air
and Charging (412-00 Climate Control System -
All vehicles
3. NOTE: Seal off the coolant line and the
4. Remove the wheel housing trim panel.
5. Remove the cover from the engine main wiring

harness connector.
Drill out the rivets.

6. Detach the main wiring harness connector from
the socket.
7. Remove the trim from the engine main wiring

harness connector.
8. Detach the engine wiring harness electrical

connector from the wheelhouse assembly.


11. Detach the charge air cooler outlet pipe from the
intake manifold.

1. Release the hose clip.
2. Remove the nuts.
Vehicles with booster heater

13. Detach the rear coolant hose from the fuel fired
booster heater using the special tool and lay it to
one side.


15. Remove the retaining clips of the spring-lock
couplings on the refrigerant lines.

16. NOTE: Seal off the refrigerant lines and the
A/C evaporator core to prevent entry of dirt.
Using the special tools, detach the refrigerant
lines from the A/C evaporator core.
All vehicles
17. Remove the audio unit.
For additional information, refer to: Audio Unit -
Vehicles Built Up To: 08/2006 (415-01A Audio
Unit, Removal and Installation) /
Audio Unit - Vehicles Built From: 08/2008 (415-
01A Audio Unit, Removal and Installation).
18. Remove the gearshift lever.
Lever (308-06 Manual Transmission/Transaxle
19. Remove the glove compartment.
20. Remove the lower dashboard trim on the

passenger side.
21. Disconnect the connector of the air flap actuator

motor.
22. Disconnect the blower motor resistor connector.

23. Disconnect the heater motor electrical connector.
24. Remove the right and left-hand side trim.

For additional information, refer to: Cowl Side
Trim Panel (501-05 Interior Trim and
Ornamentation, Removal and Installation).
25. Remove the left and right-hand A-pillar trim.
For additional information, refer to: A-Pillar Trim
Panel (501-05 Interior Trim and Ornamentation,
26. Detach the right-hand dashboard wiring harness
connector from the socket.
Remove the ground cable bolt.
27. Detach the lower dashboard trim on the driver's

side from the fascia/crash padding.
28. Remove the lower dashboard trim on the driver's

side.
Pull off the light switch connector.

29. Remove the audio unit remote control from the
steering column (if equipped).
30. Remove the audio unit remote control (if

equipped).
31. Remove the steering column lower trim.

2. Unscrew the bolts.
32. Disconnect the passive anti-theft system (PATS)

transceiver, windshield washer system switch
and airbag sliding contact connectors.
33. Disconnect the ignition switch and turn signal

switch connectors.

34. Disconnect the accelerator pedal electrical
connector.

equipped).
2. Stoplamp switch
36. Detach the wiring harness from the steering

column.
1. Release the retaining pin.
2. Detach the wiring harness.
37. Detach the steering column from the dashboard

crossmember.
38. Disconnect the left-hand dashboard wiring

harness connector from the socket.
Remove the ground cable bolt.

39. Separate the locking system connector.
40. Remove the shift cable bracket.
41. Disconnect the connector of the handbrake

warning lamp switch.
42. Disconnect the airbag module connector.
43. Remove the airbag module.

Unclip the wiring harness.

44. Detach the airbag module ground cable from the
floor panel.
45. Detach the adjusting mechanism of the air inlet

blend door from the heater core / evaporator
core housing.
46. Detach the adjusting mechanism of the

temperature flap from the heater core /
evaporator core housing.
47. Detach the airbag module wiring harness from

the dashboard crossmember bracket.
48. Remove the left and right-hand dashboard

crossmember brackets (right-hand side shown).

49. Remove the left and right-hand dashboard
covers (left-hand side shown).
50. Mark the position of the dashboard crossmember

relative to the A-pillars (left-hand side shown).
51. Remove the upper bolt of the dashboard

crossmember on the the left and right-hand side
(left-hand side shown).
52. Remove the dashboard upper bolts.
53. Remove the side bolt of the dashboard

crossmember on the the left and right-hand side
1. Remove the cover.
2. Remove the bolt.

54. Remove the lower bolt of the dashboard
crossmember on the left and right-hand side
55. Remove the dashboard together with the

dashboard crossmember.
56. Remove the right-hand engine compartment-side
nut for heater core / evaporator core housing.
57. Remove the left-hand engine compartment-side

nut for heater core / evaporator core housing.
58. Remove the right-hand passenger compartment-

side nut for heater core / evaporator core
housing.
59. Remove the left-hand passenger compartment-

side nut for heater core / evaporator core
housing.

60. Remove the heater core / evaporator core
housing.
Installation
WARNING: Screw new nuts and steering shaft bolts into the dashboard
crossmember. Failure to observe this instruction can lead to injuries.
NOTE: Install new refrigerant line O-rings.
NOTE: Coat the refrigerant line O-ring with clean refrigerant oil prior to installation.
1. Check the position of the dashboard
crossmember in relation to the A-pillars (left-
hand side shown).

Heating and Ventilation - Heater Core and Evaporator
Core Housing—Vehicles Built From: 04/2009
Print

Special Tool(s)
412-038
Disconnect Tool, Spring Lock Coupling (5/8" black)
General Equipment
4 mm drill bit
Blind rivet gun
Electric drill
Hose clamp(s)
Removal
WARNINGS:
The supplemental restraint system (SRS) is active for a certain length of time after the power supply has been
disconnected. Wait for a minimum of 3 minutes before disconnecting or removing any SRS components.
Make sure that the vehicle electrical system is fully depowered and no other power source is connected.
1. Refer to: Supplemental Restraint System (SRS) Health and Safety Precautions
(100-00 General Information, Description and Operation).
2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging
(412-00 Climate Control System - General Information, General Procedures).
5.
6. CAUTION: Make sure that all openings are sealed.

General Equipment: Hose clamp(s)
7.

8.
9. General Equipment: Electric drill

General Equipment: 4 mm drill bit
General Equipment: Blind rivet gun
10.
11.
12.

13. CAUTION: Make sure that
all openings are sealed.
Remove the Special Tool(s): 412-
038
14. Remove the driver door.

15. Remove the driver seat.
Refer to: Front Seat - Vehicles Built From: 04/2009 (501-10 Seating, Removal
and Installation).
16. On both sides.
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal
and Installation).
17.
18.

19.
20. Refer to: Gearshift Lever (308-06 Manual Transmission/Transaxle External

Controls, Removal and Installation).
21. Torque: 9 Nm
22. Torque: 8 Nm
23.

24. Torque: 25 Nm
25.
26.
27.

28. Torque: 25 Nm
29. On both sides.
30. On both sides.
31. Refer to: Audio Unit - Vehicles Built From: 04/2009 (415-01A Audio Unit,
Refer to: Audio Unit - Vehicles Built From: 04/2009, Vehicles With: Navigation
System (415-01A Audio Unit, Removal and Installation).
32.
33. Torque: 10 Nm
34. Torque: 10 Nm

35.
36. Torque: 28 Nm
37. Torque: 25 Nm
38.

Installation

2. Bleed the cooling system.
Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling,

Heating and Ventilation - Heater Core and
Evaporator Core Housing
Print
Disassembly
1. Detach the footwell vent hose.
3. Remove the right-hand air guide housing half.
4. Remove the left-hand air guide housing half.
5. Remove the heater core housing with heater

core.

6. Remove the heater core bolt.
7. Remove the heater core housing.
8. Separate the heater/blower housing parts.

1. Remove the two screws.
2. Release four retaining tangs.
9. Separate the blower/recirculated air housing

parts.
Release nine retaining tangs.
10. CAUTION: Cut through the foam seal at

the housing separation points, in order to
prevent damage to the foam seal.
Dismantle the recirculated air housing.

Release five retaining tangs.

Remove the air deflector.

Separate the heater core / evaporator core
housing.
Release 11 retaining tangs.
Assembly
1. CAUTIONS:
Cut foam seals can be reused; torn or

otherwise damaged foam seals must be
replaced.
Check that the guide pins are seated

correctly when assembling.
Replacement steel clips must be used if

the housing is not properly sealed after
assembly or the retaining tangs are broken.
Assemble the components in the reverse order.

Auxiliary Heating - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Tightening torques -

Nuts, booster heater to bulkhead 6 - 53
Band clamp, booster heater muffler 7 - 62
Bolts, bracket to booster heater 6 - 53
Nut, booster heater muffler 6 - 53
Booster heater glow plug 6 - 53

Auxiliary Heating - Auxiliary Heater Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Electric glowplug booster heater

1 - Battery
3 - Relay - glowplug booster heater II (R10)
4 - Glowplug 3
5 - Glowplug 2
6 - Glowplug 1
7 - Relay - glowplug booster heater I (R13)
8 - Relay - voltage supply, glowplug booster heater (R8, EEC Power)
The booster heater is for vehicles with a diesel engine.
The booster heater is mounted centrally on the bulkhead.
On vehicles intended for countries with a cold climate, a fuel operated booster heater is
installed, and this can also be ordered as an option.
The electrically operated glowplug booster heater is integral with the cooling system and is
switched on and off depending on certain pre-conditions.
The glowplugs are controlled through 3 relays by the PCM and are switched in three
different stages, depending on demand.
1st stage: glowplug 1 is activated
2nd stage: glowplugs 2 and 3 are activated
3rd stage: glowplugs 1, 2 and 3 are activated
The glowplugs are activated under the following conditions:

Cylinder head temperature below approx. 75 °C
Intake air temperature below 5 °C

The generator has enough power in reserve
Relay locations

1 - Relay - voltage supply, glowplug booster heater (R-8, EEC Power)
2 - Relay - glowplug booster heater I (R-13)
3 - Relay - glowplug booster heater II (R-10)
The relays are located in the fuse box in the engine compartment.
Fuel-fired additional heater

2 - Fuel supply line (to engine)
3 - Fuel supply line (to fuel filter)
4 - Fuel supply line to booster heater
5 - Metering pump
6 - Additional heater
-

7 Coolant inlet
8 - Coolant outlet
9 - Booster heater exhaust pipe
10 - Combustion air
11 - Exhaust silencer
Description of Operation
The fuel operated booster heater is for vehicles with a diesel engine in cold climates.
The booster heater is integral with the cooling system.
At the maximum level it provides up to 5 kW heating power to the coolant.
All start and control functions and the run-on functions to cool after switch off run
automatically.
Safety devices monitor the operation of the booster heater.
A fuel metering pump which is mounted on the booster heater provides it with fuel from the
supply line to the engine.
The combustion air is taken in from an area protected from water spray, in order to
guarantee operation of the booster heater in all weather conditions.
The booster heater has its own exhaust system which vents safely into the atmosphere.
The external temperature sensor prevents boost heating when the ambient temperature is
above 8 °C (no boost heating needed). The ambient temperature sensor is located at the
right, on the radiator bracket.
Coolant flow

1 - Vehicle engine
2 - Booster heater
3 - Heat exchanger
Coolant flows as follows: engine - EGR - booster heater - heat exchanger - engine (no EGR
in Turkey).
Switch on conditions
The following conditions must be satisfied before the unit will start:
12 V from generator (terminal 61) (generator voltage when starting must remain at more
than 11 V +/-0,5 V for longer than 5 seconds. The switch off signal is set at 8 V +/- 0,5 V
in order to avoid the unit switching on and off during operation.)
Terminal 15 (ignition is switched on)

Battery voltage (terminal 30) and ground (terminal 31) must be present at the control
unit of the booster heater
Coolant temperature below 75 °C
Ambient temperature below 8 °C
Operation sequence during first start (125 seconds)
First start and control start sequence

1 - Time in seconds
2 - Cycle frequency of fuel injection
3 - Blower motor voltage
4 - Glow plug voltage
Before the first start of the booster heater, the operation of the individual components is
tested.
This operational test consists of:

Control unit check
Flame sensor
Control sensor
Overheating sensor
Glow plug
Fuel pump
Blower motor
The booster heater will only start after the self test of the heating unit is successful.
Should a fault be detected, a fault notification will be output through the vehicle diagnosis.
The ceramic glowplug starts to heat the combustion chamber.
After a delay, the blower switches on. During the start procedure, the blower continuously
increases blowing power.
The fuel pump pumps fuel into the combustion chamber. The cycle frequency of the fuel
pump is also continuously increased during the start procedure.
The glowplug starts to vaporise the fuel, and creates the necessary temperature for the fuel

to ignite.
Once the booster heater is working, it runs continuously rising to maximum heating power.
After the flame sensor has detected the flame, the start process is complete, and the
glowplug switches off.
Second start (125 seconds)
If the first start is not successful, the heater commences a restart process. In doing this,
the glowplug voltage is increased, in order to obtain better starting conditions.
For the second start, the first start sequence is then repeated.
Unsuccessful second start
If the repeat start (second start) is not successful in igniting the heater, a fault code is
output from the heater (safety time exceeded).
A new attempt to start will only then occur after the engine has been switched off.
After 10 failed starts (first start, second start) one after the other, all further start attempts
are stopped by the control unit. This inhibit state can only be released by clearing the fault
memory.
Run-on mode (120 seconds)
After the coolant has reached a temperature of 85° C or the switch-on conditions are no
longer satisfied, the heater passes into run-on mode.
In run-on mode the combustion chamber is cooled and prepared for a new start.
The glowplug and blower motor are activated.
Temperature control of the booster heater

1 - Maximum power
2 - 50 % power
3 - Off
The control stages of the heater are determined by the coolant temperature.
The coolant temperature however depends on the amount of heat supplied by the engine
and by the booster heater.
Boost heat control depending on coolant temperature

up to 80 °C: 5 kW (max. power)
80 °C to 85 °C: 2.5 kW (50 % power)
over 85 °C: 0 kW (off)
75 °C: restart
Safety devices of the booster heater

After a failed start (unsuccessful first and second starts) the following fault notification
results: safety time exceeded.
If the flame extinguishes after flame recognition, the heater remains operationally ready, as
long as a restart is still allowed, if the second start is successful the fault code is cleared.
If no more repeat starts are allowed, the heater outputs the fault notification: Flame out.
If the temperature at the overheating sensor exceeds 125 °C the following fault notification
is output: Overheated.
If the voltage supply to the heater remains below 10.2 V for a time >40 seconds, a "Low
voltage shutdown" is notified.
A fault during self test causes the start process to interrupt and generates a fault
notification corresponding to the fault which occurred.

1 - Relay - voltage supply (R-8, EEC Power)
2 - Booster heater
4 - Ambient temperature switch
5 - PCM
6 - Ignition lock
7 - Central fuse box below instrument panel
8 - Relay, engine running, R24
9 - Fuse box - engine compartment
Parking heater
Description of Operation
A parking heater is optional, and only available with a diesel engine.

It takes over the function of the booster heater and mainly corresponds in its operation to
the fuel operated booster heater.

Additional components are the coolant pump and the mini-clock (control) In addition the
control unit has extra functions.
The parking heater is controlled through the mini-clock. The booster heater functions follow
automatically.
Start procedure: The coolant pump of the parking heater starts, and after a flush and pre-
glow process, combustion is initiated by the combustion blower, glowplug and fuel pump. If
the flame is stable, the glowplug is switched off.
The safety devices correspond to those of the fuel operated booster heater.
Like the booster heater, the parking heater is built into the cooling circuit.
Coolant flow

1 - Coolant pump
2 - Parking heater
3 - Vehicle heat exchanger
4 - Vehicle engine
First of all the parking heater warms the coolant for the vehicle engine.
After the engine has been heated by the coolant, the heat is passed to the vehicle interior,
depending on the blower level chosen.
Adjustment functions of the mini-clock

1 - Current time, preset time and main time
2 - Symbol for activated preset time
3 - Symbol for heating operation
4 - ON/OFF button, activate or deactivate preset time
-

5/7 Button for time adjustment, forwards / backwards
6 - Button to activate the adjustment mode
8 - Symbol for preset time 1, 2 or 3
Initial setup:
After connecting the current supply, all symbols will be shown flashing in the display.
The parking heater cannot be turned on in this state, the current time must first be
set:
Press button 6 - time flashes. Set time using buttons 5 and 7.
Press button 6 - current time is shown, colon symbol flashes.
Set current time:

Press button 6 for longer than 3 seconds, current time flashes,
Set time using buttons 5 and 7,
Press button 6 for less than 5 seconds - current time is shown, colon symbol flashes.
NOTE: If button 6 is not pressed after setting the current time, the system enters "Set
heating time" mode.
Set heating time:

Press button 6 for longer than 3 seconds, current time flashes,
Do not press any buttons, the mini-clock switches into "Set heating time" mode (symbol
for heating operation and heating time flash),
Adjust heating time (10 to 120 minutes) using buttons 5 and 7.
Press button 6, current time is shown, colon symbol flashes.
Set preset time

By pressing button 6 once, twice or three times, preset time 1, 2 or 3 is called up. Shown
in display e. g.: preset time 1.
Set preset time with buttons 5 and 7.
The preset time is activated or deactivated using button 4.
When preset time is activated, the symbol "ON" (2) is displayed.
When preset time is activated, the symbol 1, 2 or 3 is displayed.
Operating functions of the mini-clock
Switch on parking heater:

Press button 4. Heating time is . . . . . minutes. Shown in display: remaining heating time
and symbol 3 heating operation
Switch off parking heater:

Press button 4. The parking heater runs on for 3 minutes. Shown in display: current time.
Continuous operation:
Press button 7 and keep it depressed, then press button 4. The parking heater is switched
on until button 4 is pressed (switch off parking heater).
Activate/deactivate preset time:

Select preset time 1, 2 or 3 by pressing button 6.
The preset time is activated/deactivated using button 4.
When preset time is activated, the symbol ON is displayed.

When preset time is activated, the symbol 1, 2 or 3 is displayed.

1 - Coolant pump
2 - Parking heater
3 - Blower switch
4 - Blower motor
5 - Mini-clock (operating controls)
6 - PCM
7 - Ignition lock
8 - Central fuse box (below instrument panel)
9 - Engine running relay (R24)
10 - Blower motor relay
11 - Fuse box for parking heater
12 - Fuse box in the engine compartment
13 - Ignition relay (R1)
14 - Battery
15 - Ambient temperature switch

Auxiliary Heating - Fuel Fired Booster
Heater
Print

Refer to Wiring Diagrams Section 412-02B, for schematic and connector
information.
Special Tool(s)
Terminal Probe Kit
418-S035
General Equipment
Digital multimeter
Visual Inspection
Coolant level Fuses
Combustion air line Wiring harness
Exhaust gas pipe Connectors
Fuel line - booster heater
Fuel tank fill level
4. NOTE: Ensure that the fuel-fired booster heater is switched on during fault
diagnosis with WDS. If necessary, bridge the ambient temperature thermo switch.
4. If there is still cause for concern after the visual inspection, CARRY OUT fault
diagnosis of the fuel fired booster heater at the powertrain control module (PCM)
using the WDS tester and RECTIFY any displayed faults according to the fault
description. CHECK the operation of the system.
5. 5. If no fault is stored in the fault memory, PROCEED with the symptom chart
according to the fault symptom.

DTC index
DTC Description Action

B1317 Battery voltage too high, voltage greater CHECK battery,
than 16 V (excess voltage applied for REFER to: Battery (414-01 Battery, Mounting
more than 20 seconds) and Cables, Diagnosis and Testing).
CHECK charging system,

REFER to: Generator (414-02 Generator and
Regulator, Diagnosis and Testing).
B1318 Battery voltage too low, voltage less than CHECK battery,
10.2 V (undervoltage applied for more REFER to: Battery (414-01 Battery, Mounting
than 20 seconds) and Cables, Diagnosis and Testing).
CHECK charging system,
REFER to: Generator (414-02 Generator and
Regulator, Diagnosis and Testing).
If battery and charging system are OK:
- Vehicles with non-programmable fuel-fired
booster heater: GO to Pinpoint Test A.
- Vehicles with programmable fuel-fired
booster heater: GO to Pinpoint Test B.
B1342 Control module defective Renew control module
B2449 Glow plug circuit, short to ground GO to Pinpoint Test E.
B2450 Glow plug circuit, open circuit GO to Pinpoint Test E.
B2451 Auxiliary heater metering pump circuit, GO to Pinpoint Test D.
short to ground
B2452 Auxiliary heater metering pump circuit, GO to Pinpoint Test D.
open circuit
B2453 Combustion air blower motor circuit, short Check the combustion air blower motor
to ground according to the component check at the end
of this section.
B2454 Combustion air blower motor circuit, open Check the combustion air blower motor
circuit according to the component check at the end
of this section.
B2455 Combustion air blower motor speed Check the combustion air blower motor
outside the tolerance range according to the component check at the end
of this section.
B2456 Temperature sensor circuit, short to Check the temperature sensor according to
ground the component check at the end of this
section.
B2457 Temperature sensor circuit, open circuit Check the temperature sensor according to
the component check at the end of this
section.
B2458 Overheating sensor circuit, short to Check the overheating sensor according to
ground the component check at the end of this
section.
B2459 Overheating sensor circuit, open circuit Check the overheating sensor according to
the component check at the end of this
section.
B2460 Flame sensor circuit, short to ground Check the flame sensor according to the
component check at the end of this section.
B2461 Flame sensor circuit, open circuit Check the flame sensor according to the
B2462 Flame extinguished during operation, Check exhaust and combustion air pipes.
attempt to restart failed Check fuel line of fuel fired booster heater.
Check the additional heater metering pump
fuel quantity according to the component
check at the end of this section.
If the components are OK, check the flame
sensor according to the component check at
the end of this section.
B2463 Overheating sensor triggered due to Check the cooling system:
overheating - Check the cooling system for leaks.
- Check the cooling system for restrictions.
- Bleed the cooling system.

booster heater: Check the operation of the
fuel-fired booster heater (coolant pump)
If the cooling system is OK, check the
temperature sensor and the overheating
sensor according to the component check at
the end of this section.
B2464 Safety period exceeded Check exhaust and combustion air pipes.
B2465 Operation lock, too many unsuccessful Release the operation lock, delete the control
attempts at starting module fault memory using WDS for this
purpose.
B2466 Operation lock, permissible number of Release the operation lock, delete the control
overheating incidents exceeded module fault memory using WDS for this
purpose.
Check the cooling system:
- Check the cooling system for leaks.
- Check the cooling system for restrictions.
- Bleed the cooling system.
booster heater: Check the operation of the
fuel-fired booster heater (coolant pump)
B2467 Blower cooling time limit exceeded Check exhaust and combustion air pipes.
A temperature exceeding 70°C is Check the flame sensor according to the
measured by the flame sensor for longer component check at the end of this section.
than 240 seconds when the booster
heater is switched on.
Symptom Chart
Symptom Chart

Fuel fired booster heater * Fuse(s) * Vehicles with non-
inoperative * Circuit(s) programmable fuel-fired
* Ambient temperature booster heater: GO to
thermo switch Pinpoint Test A.
* Engine run relay * Vehicles with
* Central junction box programmable fuel-fired
* Fuel fired booster heater booster heater: GO to
* Parking heater controls Pinpoint Test B.
* Powertrain control module
(PCM)
Fuel-fired booster * Fuel fired booster heater * REFER to: (418-00 Module
heater/programmable fuel-fired not switched on Communications Network)
booster heater not communicating * Fuse(s) Communications
with the diagnostic tester * Circuit(s) Network - Vehicles
* Fuel fired booster Built Up To: 07/2006
heater /programmable (Diagnosis and
fuel fired booster heater Testing),
Communications
Network - Vehicles
Built From: 07/2006
(Diagnosis and
Testing).

Blower motor inoperative with * Fuse(s) * GO to Pinpoint Test C.
fuel-fired booster heater switched * Circuit(s)
on - vehicles with programmable * Blower relay, parking
fuel-fired booster heater heater
* Control module
Auxiliary heater metering pump * Circuit(s) * GO to Pinpoint Test D.
inoperative * Auxiliary heater metering
pump
Glow plug inoperative * Circuit(s) * GO to Pinpoint Test E.
* Glow plug
Fuel-fired booster heater (coolant * Circuit(s) * GO to Pinpoint Test F.
pump) inoperative - vehicles with * Fuel-fired booster heater -
programmable fuel-fired booster coolant pump
heater
Pinpoint Tests
PINPOINT TEST A : FUEL FIRED BOOSTER HEATER INOPERATIVE

NOTE: The fuel fired booster heater only works when the engine is running, the battery is
being charged by the generator, the ambient temperature is below 8°C and the coolant
temperature has not yet exceeded 75°C.
A1: CHECK FUSE F11
Is the fuse OK?
Yes
GO to A2.
No
REPAIR the short to ground using the Wiring
Diagrams.
2 Measure the voltage between fuse F11 (20 A) and
ground.
Yes
GO to A3.
No
system.
A3: CHECK FUSE F34
Is the fuse OK?
Yes
GO to A4.
No
Diagrams.

ground.
Yes
GO to A5.
No
system.
A5: CHECK VOLTAGE AT FUEL FIRED BOOSTER HEATER
2 Disconnect fuel fired booster heater C878.
3 Measure the voltage between the fuel fired booster
heater, connector C878, pin 1, circuit 30-RD18
(RD), wiring harness side and ground.

Yes
GO to A6.
No
LOCATE and REPAIR the break in circuit 30-RD18
(RD) between the fuel fired booster heater and
soldered connection F11 using the Wiring Diagrams.
A6: CHECK VOLTAGE AT FUEL FIRED BOOSTER HEATER
heater, connector C878, pin 4, circuit 15-RD18

Yes
GO to A7.
No
(GN/RD) between the fuel fired booster heater and
soldered connection S117 using the Wiring
A7: CHECK CONTROL VOLTAGE AT FUEL FIRED BOOSTER HEATER
1 Cool the ambient temperature thermo switch to a
temperature of 8°C or less using a suitable
medium.
3 Run the engine at idle speed.
NOTE: The charge warning indicator must no longer
illuminate.

heater, connector C878, pin 5, circuit 64S-RD18
(BU/WH), wiring harness side and ground.

Yes
GO to A8.
No
GO to A9.
A8: CHECK GROUND CONNECTION OF FUEL FIRED BOOSTER HEATER
2 Measure the resistance between the fuel fired
booster heater, connector C878, pin 2, circuit 31-
RD18 (BK), wiring harness side and ground.

Yes
CHECK the fuel fired booster heater and RENEW if
necessary. CHECK the operation of the system.
No
(BK) between the fuel fired booster heater and
A9: CHECK VOLTAGE AT AMBIENT TEMPERATURE THERMO SWITCH
2 Disconnect ambient temperature thermo switch
C875.
NOTE: The charge warning indicator must no longer
illuminate.
5 Measure the voltage between the ambient
temperature thermo switch, connector C875, pin 1,
circuit 64-RD18 (BU/WH), wiring harness side and
ground.

Yes
GO to A10.
No
GO to A11.

A10: CHECK FOR OPEN CIRCUIT BETWEEN THE AMBIENT TEMPERATURE THERMO
SWITCH AND THE FUEL FIRED BOOSTER HEATER.
2 Measure the resistance between the ambient
temperature thermo switch, connector C875, pin 2,
circuit 64S-RD18 (BU/WH), wiring harness side and
the fuel fired booster heater, connector C878, pin 5,
circuit 64S-RD18 (BU/WH), wiring harness side.

Yes
RENEW the ambient temperature thermo switch.
No
LOCATE and REPAIR the break in circuit 64S-RD18
(BU/WH) between the ambient temperature thermo
switch and the fuel fired booster heater using the
system.
A11: CHECK VOLTAGE AT ENGINE RUN RELAY
2 Disconnect engine run relay C1024 (CJB).
4 Measure the voltage between the engine run relay,
socket C1024, pin 3, wiring harness side and
ground.

Yes
GO to A12.
No
CHECK central junction box and RENEW if
A12: CHECK CONTROL VOLTAGE AT ENGINE RUN RELAY
ground.

Yes
GO to A13.

No
A13: CHECK FOR OPEN CIRCUIT BETWEEN THE ENGINE RUN RELAY AND THE
AMBIENT TEMPERATURE THERMO SWITCH
2 Measure the resistance between the engine run
relay, socket C1024, pin 5, wiring harness side and
the ambient temperature thermo switch, connector
C875, pin 1, circuit 64-RD18 (BU/WH), wiring
harness side.

Yes
GO to A15.
No
GO to A14.
A14: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE AMBIENT TEMPERATURE
THERMO SWITCH
2 Measure the resistance between the CJB, connector
C14, pin 6, circuit 64S-RD18 (BU/WH), wiring
harness side and the ambient temperature thermo
switch, connector C875, pin 1, circuit 64-RD18
(BU/WH), wiring harness side.

Yes
No
LOCATE and REPAIR the break in the circuit
between the CJB and the ambient temperature
thermo switch with the aid of the Wiring Diagrams.
A15: CHECK THE ENGINE RUN RELAY
1 Check the engine run relay according to the
Is the engine run relay OK?
Yes
Vehicles with a 1.8L (90 PS) diesel engine: GO to
A16.
A18.
No
RENEW the engine run relay. CHECK the operation
of the system.
A16: CHECK THE CIRCUIT BETWEEN THE ENGINE RUN RELAY AND THE POWERTRAIN
CONTROL MODULE (PCM) FOR OPEN CIRCUIT - VEHICLES WITH A 1.8L (90 PS)
DIESEL ENGINE

2 Measure the resistance between engine run relay,
socket C1024, pin 1, wiring harness side and PCM,
connector C414, pin 23, circuit 31S-PA19 (BK/GN),

Yes
CHECK the PCM and RENEW as necessary. CHECK
No
GO to A17.
A17: CHECK THE CIRCUIT BETWEEN THE CJB AND THE PCM FOR CONTINUITY.
C10, pin 3, circuit 31S-PA19 (BK/GN), wiring
harness side and the PCM, connector C414, pin 23,
circuit 31S-PA19 (BK/GN), wiring harness side.

Yes
No
CJB and the PCM with the aid of the Wiring
A18: CHECK THE CIRCUIT BETWEEN THE ENGINE RUN RELAY AND THE POWERTRAIN
DIESEL ENGINE

Yes
No
GO to A19.
A19: CHECK THE CIRCUIT BETWEEN THE CJB AND THE PCM FOR CONTINUITY.

C10, pin 3, circuit 31S-PA19 (BK/GN), wiring
harness side and the PCM, connector C415, pin 6,
circuit 31S-PA19 (BK/GN), wiring harness side.

Yes
No
PINPOINT TEST B : FUEL-FIRED BOOSTER HEATER INOPERATIVE -

VEHICLES WITH PROGRAMMABLE FUEL-FIRED BOOSTER HEATER
NOTE: The fuel fired booster heater is equipped with an integrated undervoltage
protection. This switches off the fuel fired booster heater when the supply voltage falls
below 10 V for longer than 20 seconds. Before performing further checks, ensure that
the vehicle battery is OK and that the charge state is sufficient.
NOTE: The fuel fired booster heater only works in booster heater mode if the engine is
running, the battery is being charged by the generator, the ambient temperature is
below 8°C and the coolant temperature has not yet exceeded 75°C.
B1: CHECK THE BOOSTER HEATER FUNCTION
NOTE: The charge warning indicator must no
longer illuminate.
3 Cool the ambient temperature thermo switch to a
temperature below 8° using a suitable medium.
Is the fuel fired booster heater working after the
startup phase?
Yes
GO to B6.
No
GO to B2.
B2: CHECK THE PARKING HEATER FUNCTION
2 Switch on the fuel-fired booster heater via the
parking heater controls.
Is the fuel fired booster heater working after the
startup phase?
Yes
GO to B15.
No
GO to B3.
B3: CHECK FUSE F11
Is the fuse OK?
Yes
GO to B4.

No
RENEW fuse F11 (20 A). If the fuse blows again,
LOCATE and REPAIR the short to ground using the
system.
B4: CHECK THE VOLTAGE AT FUSE F11
ground.
Yes
GO to B6.
No
system.
B5: CHECK THE VOLTAGE AT THE FUEL FIRED BOOSTER HEATER
1 Disconnect Connector C501 from the fuel-fired
booster heater.
heater, connector C501, pin 1, circuit C30-RD18

Yes
GO to B9.
No
LOCATE and RECTIFY the break in circuit 30-RD18
(RD) between the fuel fired additional heater and
fuse F11 with the aid of the Wiring Diagrams.
B6: CHECK FUSE FB
CHECK Fuse FB (auxiliary fuse box) (vehicles built
2
from 02/2004: fuse holder 4).
Is the fuse OK?
Yes
GO to B7.
No
Renew fuse FB (5 A). If the fuse blows again,
LOCATE and REPAIR the short to ground using the
system.
B7: CHECK THE VOLTAGE AT FUSE FB
1 Connect Fuse FB (auxiliary fuse box) (vehicles built
from 02/2004: fuse holder 4).
2 Measure the voltage between fuse FB (5 A) and
ground.

Yes
GO to B8.
No

REPAIR the voltage supply to fuse FB using the
system.
B8: CHECK CONTROL VOLTAGE AT FUEL-FIRED BOOSTER HEATER
2 Switch on the fuel-fired booster heater via the
parking heater controls.
heater, connector C501, pin 7, circuit 8-FC14
(WH/BK), wiring harness side and ground.

Yes
CHECK the fuel-fired booster heater using WDS and
RECTIFY the fault(s) displayed according to the
fault code table. CHECK the operation of the
system.If no fault is stored:GO to B10.
No
GO to B11.
B9: CHECK GROUND CONNECTION OF FUEL FIRED BOOSTER HEATER
1 Switch off the fuel-fired booster heater via the
parking heater control unit.
RD18A (BK), wiring harness side and ground.

Yes
CHECK the fuel-fired booster heater using WDS and
RECTIFY the fault(s) displayed according to the
fault code table. CHECK the operation of the
system.If no fault is stored:GO to B10.
No
LOCATE and RECTIFY the break in the circuit
between the fuel-fired additional heater and ground
connection G37 with the aid of the Wiring
B10: CHECK THE TEMPERATURE SENSOR
1 Check the temperature sensor according to the
Is the temperature sensor OK?

Yes
RENEW the control module. CHECK the operation of
the system.
No
RENEW the temperature sensor. CHECK the

B11: CHECK THE VOLTAGE AT THE PARKING HEATER CONTROL UNIT
1 Switch off the fuel-fired booster heater via the
parking heater control unit.
2 Disconnect Connector C505 from the parking
heater control unit.
3 Measure the voltage between the parking heater
control unit, connector C505, pin 1, circuit 30-FC7
Yes
GO to B12.
No
between the parking heater control unit and fuse
FB with the aid of the Wiring Diagrams. CHECK the
B12: CHECK THE GROUND CONNECTION OF THE PARKING HEATER CONTROLS
1 Measure the resistance between the parking heater
control unit, connector C505, pin 3, circuit 31-
FC7A (BK), wiring harness side and ground.
Yes
GO to B13.
No
between the parking heater control unit and
ground connection G63 with the aid of the Wiring
B13: CHECK FOR OPEN CIRCUIT BETWEEN THE PARKING HEATER CONTROLS AND
THE FUEL-FIRED BOOSTER HEATER
(WH/BK), wiring harness side and the fuel-fired
FC14 (WH/BK), wiring harness side.
Yes
GO to B14.
No
LOCATE and REPAIR the break in circuit 8-FC14
(WH/BK) between the parking heater control unit
and the fuel fired booster heater with the aid of the
system.
B14: CHECK FOR SHORT TO GROUND BETWEEN THE PARKING HEATER CONTROLS
AND THE FUEL-FIRED BOOSTER HEATER
(WH/BK), wiring harness side and ground.
Is a resistance of more than 10,000 ohms measured?

Yes
RENEW the parking heater controls. CHECK the
No
LOCATE and REPAIR the short to ground in circuit
8-FC14 (WH/BK) between the parking heater
control unit and the fuel fired booster heater with

B15: CHECK VOLTAGE AT AMBIENT TEMPERATURE THERMO SWITCH
2 Disconnect ambient temperature thermo switch
C875.
NOTE: The charge warning indicator must no
longer illuminate.
5 Measure the voltage between the ambient
temperature thermo switch, connector C875, pin
1, circuit 64-RD18 (BU/WH), wiring harness side
and ground.

Yes
GO to B16.
No
GO to B17.
B16: CHECK FOR OPEN CIRCUIT BETWEEN THE AMBIENT TEMPERATURE THERMO
SWITCH AND THE FUEL FIRED BOOSTER HEATER.
Measure the resistance between the ambient
2
temperature thermo switch, connector C875, pin
2, circuit 64S-RD18 (BU/WH), wiring harness side
and the fuel-fired booster heater, connector C501,
pin 6, circuit 64S-RD18 (BU/WH), wiring harness
side.
Yes
RENEW the ambient temperature thermo switch.
No
LOCATE and REPAIR the break in circuit 64S-RD18
(BU/WH) between the ambient temperature thermo
switch and the fuel fired booster heater using the
system.
B17: CHECK VOLTAGE AT ENGINE RUN RELAY
2 Disconnect engine run relay C1024 (CJB).
ground.

Yes

GO to B18.
No
B18: CHECK CONTROL VOLTAGE AT ENGINE RUN RELAY
ground.

Yes
GO to B19.
No
B19: CHECK FOR OPEN CIRCUIT BETWEEN THE ENGINE RUN RELAY AND THE
AMBIENT TEMPERATURE THERMO SWITCH
2 Measure the resistance between the engine run
relay, socket C1024, pin 5, wiring harness side and
the ambient temperature thermo switch, connector
C875, pin 1, circuit 64-RD18 (BU/WH), wiring
harness side.

Yes
GO to B21.
No
GO to B20.
B20: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE AMBIENT TEMPERATURE
THERMO SWITCH
2 Measure the resistance between the CJB,
connector C14, pin 6, circuit 64S-RD18 (BU/WH),
wiring harness side and the ambient temperature
thermo switch, connector C875, pin 1, circuit 64-
RD18 (BU/WH), wiring harness side.

Yes
No

between the CJB and the ambient temperature
thermo switch with the aid of the Wiring Diagrams.
B21: CHECK THE ENGINE RUN RELAY
1 Check the engine run relay according to the
Is the engine run relay OK?
Yes
B22.
B24.
No
RENEW the engine run relay. CHECK the operation
of the system.
B22: CHECK THE CIRCUIT BETWEEN THE ENGINE RUN RELAY AND THE POWERTRAIN
DIESEL ENGINE

Yes
No
GO to B23.
B23: CHECK THE CIRCUIT BETWEEN THE CJB AND THE PCM FOR CONTINUITY.
wiring harness side and the PCM, connector C414,
pin 23, circuit 31S-PA19 (BK/GN), wiring harness
side.

Yes
No
B24: CHECK THE CIRCUIT BETWEEN THE ENGINE RUN RELAY AND THE POWERTRAIN
DIESEL ENGINE


Yes
No
engine run relay and the PCM using the Wiring
B25: CHECK THE CIRCUIT BETWEEN THE CJB AND THE PCM FOR CONTINUITY.
wiring harness side and the PCM, connector C415,
pin 6, circuit 31S-PA19 (BK/GN), wiring harness
side.

Yes
No
PINPOINT TEST C : BLOWER MOTOR INOPERATIVE WHEN FUEL-FIRED

BOOSTER HEATER SWITCHED ON - VEHICLES WITH PROGRAMMABLE
FUEL-FIRED BOOSTER HEATER
NOTE: Before switching on the programmable fuel-fired booster heater the blower motor
needs to be switched to its lowest setting via the blower switch.
CONDITIONS
C1: TEST FUSE FA
2 CHECK Fuse FB (auxiliary fuse box) (vehicles built from 02/2004: fuse
holder 3).
Is the fuse OK?
Yes
GO to C2.
No
RENEW fuse FA (30 A). If the fuse blows again, LOCATE and RECTIFY the
short circuit using the Wiring Diagrams. CHECK the operation of the
system.

C2: TEST VOLTAGE AT FUSE FA
1 Connect Fuse FB (auxiliary fuse box) (vehicles built from 02/2004: fuse
holder 3).
2 Measure the voltage between fuse FA (30 A) and ground.
Yes
GO to C3.
No
REPAIR the voltage supply to fuse FA using the Wiring Diagrams. CHECK
C3: CHECK THE BLOWER MOTOR CIRCUIT
1 Disconnect Additional heater blower relay from socket C503.
2 Use a fused test lead (30 A) at the additional heater blower relay, socket
C503, to bridge pin 3 and pin 5, wiring harness side.
3 Select the lowest blower switch setting.
Does the blower motor run at the selected speed?
Yes
GO to C4.
No
LOCATE and RECTIFY the break in the circuit between the additional heater
blower relay and fuse FA with the aid of the Wiring Diagrams. CHECK the
C4: CHECK THE CONTROL VOLTAGE AT THE ADDITIONAL HEATER BLOWER RELAY
1 Switch on the fuel-fired booster heater via the parking heater controls.
NOTE: The control unit for the programmable fuel-fired booster heater
does not connect a control voltage until the coolant temperature exceeds
30°C.
2 Measure the voltage between the additional heater blower relay, socket
C503, pin 1, circuit 30S-FA23 (RD/BU), wiring harness side and ground.
Yes
GO to C8.
No
GO to C5.
C5: CHECK FOR OPEN CIRCUIT BETWEEN THE FUEL-FIRED BOOSTER HEATER AND
THE ADDITIONAL HEATER BLOWER RELAY
CAUTION: In order to prevent damage to the control module, always wait for the
run-on time of the fuel-fired booster heater to end before disconnecting.
1 Switch off the fuel-fired booster heater via the parking heater control unit.
2 Disconnect Connector C501 from the fuel-fired booster heater.
3 Measure the resistance between the fuel-fired booster heater, connector
C501, pin 3, circuit 30S-FA23 (RD/BU), wiring harness side and the
additional heater blower relay, socket C503, pin 1, circuit 30S-FA23
(RD/BU), wiring harness side.
Yes
GO to C6.
No
LOCATE and REPAIR the break in circuit 30S-FA23 (RD/BU) between the
fuel-fired booster heater and the additional heater blower relay with the aid
of the Wiring Diagrams. CHECK the operation of the system.
C6: CHECK THE CIRCUIT BETWEEN THE FUEL-FIRED BOOSTER HEATER AND THE
ADDITIONAL HEATER BLOWER RELAY FOR A SHORT CIRCUIT TO GROUND
C501, pin 3, circuit 30S-FA23 (RD/BU), wiring harness side and ground.

Yes
CHECK the fuel-fired booster heater using WDS and RECTIFY the fault(s)
displayed according to the fault code table. If no fault is stored: GO to C7.
No
LOCATE and REPAIR the short to ground in circuit 30S-FA23 (RD/BU)
between the fuel-fired booster heater and the additional heater blower
relay with the aid of the Wiring Diagrams. CHECK the operation of the
system.
C7: CHECK THE TEMPERATURE SENSOR
1 Check the temperature sensor according to the component check at the
end of this section.
Is the temperature sensor OK?
Yes
RENEW the control module. CHECK the operation of the system.
No
RENEW the temperature sensor. CHECK the operation of the system.
C8: CHECK THE GROUND CONNECTION OF THE ADDITIONAL HEATER BLOWER RELAY
1 Switch off the fuel-fired booster heater via the parking heater control unit.
2 Measure the resistance between the additional heater blower relay, socket
C503, pin 2, circuit 31-FA23 (BK), wiring harness side and ground.
Yes
RENEW the additional heater blower relay. CHECK the operation of the
system.
No
LOCATE and RECTIFY the break in the circuit between the additional heater
blower relay and ground connection G1 with the aid of the wiring diagrams.
PINPOINT TEST D : AUXILIARY HEATER METERING PUMP INOPERATIVE

CONDITIONS
D1: CHECK FOR OPEN CIRCUIT BETWEEN THE CONTROL MODULE AND THE
AUXILIARY HEATER METERING PUMP
2 Disconnect Connector C501 from the fuel-fired booster heater.
3 Disconnect Connector C502 from the additional heater metering pump.
C501, pin 4, circuit 30S-FC14 (RD/BK), wiring harness side and the
additional heater metering pump, socket C502, pin 2, circuit 30S-FC14
(RD/BK), wiring harness side.
Yes
GO to D2. RENEW the auxiliary heater metering pump. CHECK the
No
LOCATE and REPAIR the break in circuit 30S-FC14 (RD/BK) between the
fuel-fired booster heater and the additional heater metering pump. CHECK
D2: CHECK THE GROUND CONNECTION OF THE ADDITIONAL HEATER METERING
PUMP
1 Measure the resistance between the additional heater metering pump,
connector C502, pin 1, circuit 31-RD18B (BK), wiring harness side and
ground.

Yes
GO to D3.
No

LOCATE and REPAIR the break in the circuit between the additional heater
metering pump and soldered connection S121. CHECK the operation of the
system.
D3: CHECK THE CIRCUIT BETWEEN THE FUEL-FIRED BOOSTER HEATER AND THE
ADDITIONAL HEATER METERING PUMP FOR A SHORT CIRCUIT TO VOLTAGE.
Measure the voltage between the additional heater metering pump,
2
connector C502, pin 2, circuit 30S-FC14 (RD/BK), wiring harness side and
ground.
Is a voltage measured?
Yes
LOCATE and REPAIR the short to voltage in circuit 30S-FC14 (RD/BK)
between the fuel-fired booster heater and the additional heater metering
pump. CHECK the operation of the system.
No
GO to D4.
D4: CHECK THE CIRCUIT BETWEEN THE FUEL-FIRED BOOSTER HEATER AND THE
ADDITIONAL HEATER METERING PUMP FOR A SHORT CIRCUIT TO GROUND.
2 Measure the resistance between the additional heater metering pump,
connector C502, pin 2, circuit 30S-FC14 (RD/BK), wiring harness side and
ground.
Yes
RENEW the auxiliary heater metering pump. CHECK the operation of the
system.If the system is still inoperative, CHECK the wiring harness between
the additional heater metering pump and the control unit for damage and
REPAIR as necessary. If the wiring harness is OK, RENEW the control unit of
the additional heater.
No
LOCATE and REPAIR the short to ground in circuit 30S-FC14 (RD/BK)
between the fuel-fired booster heater and the additional heater metering
pump. CHECK the operation of the system.
PINPOINT TEST E : GLOW PLUG INOPERATIVE
CAUTION: Never apply 12 V to the glow plug. The glow plug is destroyed by voltages
exceeding 8 V.
E1: CHECK THE GLOW PLUG.
1 Disconnect Connector C1066 from control module.
2 Measure the resistance at the control module,
connector C1066, between pin 9 (WH) and pin 12
(BN), wiring harness side.
Is a resistance of less than 1 Ohms registered?

Yes
CHECK the wiring harness between the control
module and the glow plug for damage and REPAIR if
necessary. If the wiring harness is OK, RENEW the
glow plug. CHECK the operation of the system.
No
GO to E2.

E2: CHECK FOR OPEN CIRCUIT BETWEEN THE CONTROL MODULE AND THE GLOW
PLUG.
1 Disconnect Connectors C1071a and C1071b from the
glow plug.
2 Measure the resistance between the control module,
connector C1066, pin 9 (WH), wiring harness side
and the glow plug, connector C1071b (WH), wiring
harness side.

connector C1066, pin 12 (BN), wiring harness side
and the glow plug, connector C1071a (BN), wiring
harness side.
Is a resistance of less than 2 Ohms measured in both

cases?
Yes
RENEW the glow plug. CHECK the operation of the
system.
No
LOCATE and REPAIR the break in the relevant circuit
between the control module and the glow plug using
system.
PINPOINT TEST F : FUEL-FIRED BOOSTER HEATER (COOLANT PUMP)

INOPERATIVE - VEHICLES WITH PROGRAMMABLE FUEL-FIRED BOOSTER
HEATER
F1: CHECK THE CIRCUIT BETWEEN THE FUEL-FIRED BOOSTER HEATER (COOLANT
PUMP) AND THE CONTROL MODULE FOR SHORT CIRCUIT
1 Disconnect Connector C1066 from control module.
2 Disconnect Connector C1069 from the fuel-fired
booster heater (coolant pump).
3 Check the wiring harness between the control
module, connector C1066 and the fuel-fired booster
heater (coolant pump), connector C1069 for damage.
4 Measure the resistance at the control module,
connector C1066, between pin 10 (BN) and pin 11
(VT), wiring harness side.
Is the wiring harness undamaged and is a resistance

greater than 10,000 Ohms measured?

Yes
GO to F2.
No
LOCATE and REPAIR the short circuit or damage in
the circuit between the fuel-fired booster heater
(coolant pump) and the control module. CHECK the
F2: CHECK THE CIRCUIT BETWEEN THE FUEL-FIRED BOOSTER HEATER (COOLANT
PUMP) AND THE CONTROL MODULE FOR OPEN CIRCUIT
connector C1066, pin 10 (BN), wiring harness side
and the fuel-fired booster heater (coolant pump),
connector C1069 (BN), wiring harness side

connector C1066, pin 11 (VT), wiring harness side
and the fuel-fired booster heater (coolant pump),
connector C1069 (VT), wiring harness side

cases?
Yes
RENEW the fuel-fired booster heater (coolant pump).
No
LOCATE and REPAIR the break in the relevant circuit
between the fuel-fired booster heater (coolant pump)
and the control module. CHECK the operation of the
system.
Component Tests
Engine run relay

Measure the resistance at the relay, between pin 3 and pin 5, component side.
Is a resistance of more than 10 kOhms measured?
1. If yes, go to 2.
2. If no, RENEW the relay.

Using a fused test cable (1 A), connect pin 2 of the relay, component side, to the
battery positive terminal.
Using a test cable, connect pin 1 of the relay, component side, to the battery
negative terminal.
1. If yes, then the relay is OK.
Combustion air blower motor
CAUTION: Never apply 12 V to the combustion air blower motor. The combustion air
blower motor is destroyed by voltages exceeding 8 V.
1. 1. Combustion air blower motor speed not OK.
CHECK the combustion air blower fanwheel and motor for ease of movement and
soiling. Check for moisture, which can freeze at temperatures below 0° C. Ensure
correct routing of the wiring harness. ELIMINATE stiffness or blockage, RENEW the
combustion air blower motor if necessary.
2. 2. Combustion air blower motor, open/short circuit
CHECK and REPAIR the combustion air blower motor for damage, RENEW the
combustion air blower motor if necessary.
Measure the resistance between the control module, connector C1066, pin 13 (BK),
wiring harness side and the combustion air blower motor housing.
Measure the resistance between the control module, connector C1066, pin 14 (BN),
wiring harness side and the combustion air blower motor housing.
Is a resistance greater than 2,000 Ohms measured in both cases?
1. If yes, CHECK the combustion air blower fanwheel and motor for blockage. See above.
2. If no, RENEW the combustion air blower motor.
Temperature sensor

1. 1. CHECK both cables (BU) leading to the temperature sensor for damage and
RENEW the temperature sensor if necessary.
2. 2. Check the temperature sensor for a short to ground.
Measure the resistance between the control module, connector C1066, pin 3 (BU),
wiring harness side and the temperature sensor housing.
wiring harness side and the temperature sensor housing.
1. If yes, go on to 3.
2. If no, RENEW the temperature sensor.
3. 3. Check the temperature sensor:

Measure the resistance at the control module, connector C1066, between pin 3 and
Compare the resistance value with the following table.
Temperature Resistance value
0 °C 32.540 Ohm
10 °C 19.870 Ohm
20 °C 12.480 Ohm
30 °C 8.060 Ohm
40 °C 5.330Ohm
50 °C 3.600 Ohm
60 °C 2.480 Ohm
70 °C 1.750 Ohm
80 °C 1.250 Ohm
90 °C 910 Ohm
100 °C 670 Ohm
110 °C 500 Ohm
120 °C 380 Ohm
Does the resistance measured correspond to the required value?
1. If yes, the temperature sensor is OK.
2. If no, RENEW the temperature sensor.
Overheating sensor
1. 1. CHECK both cables (RD) leading to the overheating sensor for damage and RENEW
the overheating sensor if necessary.
2. 2. Check the overheating sensor for a short to ground.

Measure the resistance between the control module, connector C1066, pin 5 (RD),
wiring harness side and the overheating sensor housing.
Measure the resistance between the control module, connector C1066, pin 6 (RD),
wiring harness side and the overheating sensor housing.

2. If no, RENEW the overheating sensor.
3. 3. Check the overheating sensor:
0 °C 32.540 Ohm
10 °C 19.870 Ohm
20 °C 12.480 Ohm
30 °C 8.060 Ohm
40 °C 5.330Ohm
50 °C 3.600 Ohm
60 °C 2.480 Ohm
70 °C 1.750 Ohm
80 °C 1.250 Ohm
90 °C 910 Ohm
100 °C 670 Ohm
110 °C 500 Ohm
120 °C 380 Ohm
1. If yes, the overheating sensor is OK.
Flame sensor
1. 1. CHECK both cables leading to the flame sensor for damage and RENEW the flame
sensor if necessary.
2. 2. Check the flame sensor for short to ground.

wiring harness side and the flame sensor housing.
Measure the resistance between the control module, connector C1066, pin 2 (BN),
wiring harness side and the flame sensor housing.

3. 3. Check the flame sensor:
0 °C 1000 Ohm
10 °C 1022 Ohm
20 °C 1062 Ohm
30 °C 1097 Ohm
50 °C 1194 Ohm
80 °C 1309 Ohm
90 °C 1347 Ohm
100 °C 1385 Ohm
130 °C 1498 Ohm
150 °C 1573 Ohm
200 °C 1758 Ohm
250 °C 1941 Ohm
300 °C 2120 Ohm
350 °C 2297 Ohm
400 °C 2470 Ohm
1. If yes, the flame sensor is OK.
2. If no, RENEW the flame sensor.
Check the additional heater metering pump fuel quantity
NOTE: For the measurement, it must be ensured that the voltage at the booster heater is
between 11 V and 13 V during the measurement, as otherwise the measurement result
will be incorrect.
Preparations for measuring the fuel quantity
Disconnect the fuel line between the auxiliary heater metering pump and the heater.
Lengthen the fuel line if necessary. Insert the free end of the fuel line into a suitable
graduated vessel. Switch on the programmable fuel-fired booster heater via the parking
heater controls or for vehicles with non-programmable fuel-fired booster heater, start the
engine and run it at idle speed. (Note the switch-on conditions of the fuel-fired booster
heater
REFER to: Auxiliary Heater (412-02B Auxiliary Heating, Description and Operation).
) If necessary, bridge the ambient temperature thermo switch. Fuel delivery begins 45
seconds after the fuel-fired booster heater is switched on. If the fuel escapes from the fuel
line without air bubbles, switch off the fuel fired booster heater again and empty the
graduated vessel.
Measure the fuel quantity
Switch on the programmable fuel-fired booster heater via the parking heater controls or for
vehicles with non-programmable fuel-fired booster heater, start the engine and run it at

idle speed. (Note the switch-on conditions of the fuel-fired booster heater
REFER to: Auxiliary Heater (412-02B Auxiliary Heating, Description and Operation).
) Fuel delivery begins after 45 seconds.
NOTE: The end of the hose must be held at the height of the heater during the
measurement.
Fuel delivery ends automatically after approx. 90 seconds. Switch off the fuel fired booster
heater. The fuel quantity delivered should be between 7.8 cm³ and 9.0 cm³.
If the fuel quantity is outside this range check the additional heater fuel line and repair as
required. Check that the connections are correct. Where fuel lines are joined by a length of
hose, ensure that the ends of the fuel lines abut completely to prevent air bubbles from
forming.

1 - Correct line routing
2 - Incorrect line routing
If the booster heater fuel line is OK, renew the additional heater metering pump.

Auxiliary Heating - Electric Booster Heater Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Special Tool(s)
Terminal Probe Kit
418-S035

418-F224
General Equipment
Digital multimeter
Clip-on ammeter (DC)
Visual Inspection
Coolant level Fuses
Electric booster heater mounting Wiring harness
Connectors
the powertrain control module (PCM) and the charging system with WDS and
5. 5. For vehicles without any stored faults, PROCEED in accordance with the Symptom
Chart.

Symptom Chart
Symptom Chart

Electric booster heater inoperative / partly * Fuse(s) * GO to Pinpoint
inoperative * Circuit(s) Test A.

* Intake air temperature
signal
* Glow plug heating relay,
stage 1
stage 2
* Electric booster heater
(PCM)
System Check
PINPOINT TEST A : ELECTRIC BOOSTER HEATER INOPERATIVE / PARTLY

INOPERATIVE
NOTE: The electric booster heater only works when the engine is running, the battery is
A1: CHECK THE ELECTRIC BOOSTER HEATER
2 Measure the current in circuits 15-RD23 (GN/BK)
and 15-RD22 (GN/RD) at the electric booster
heater using the clip-on ammeter.
Is a current measured?
Yes
GO to A2.
No
GO to A3.
A2: CHECK 1ST STAGE OF ELECTRIC BOOSTER HEATER CIRCUIT
1 Measure the current in circuit 15-RD22 (GN/RD) at
the electric booster heater using the clip-on
ammeter.
Is a current of more than 10 A measured?

Yes
GO to A15.
No
GO to A6.
A3: CHECK THE ELECTRIC BOOSTER HEATER GLOW PLUG
2 Measure the resistance between the electric
booster heater, connector C965, circuit 15-RD22
(GN/RD), component side and electric booster
heater housing.

Is a resistance of less than 1.2 Ohm registered?
Yes
GO to A4.
No
RENEW the electric booster heater. CHECK the
A4: CHECK THE ELECTRIC BOOSTER HEATER GROUND CONNECTION
(BK), component side and ground.

Yes
GO to A5.
No
(BK) between the electric booster heater and
ground connection G57 using the Wiring Diagrams.
A5: CHECK THE SIGNAL FROM THE INTAKE AIR TEMPERATURE SENSOR
NOTE: The intake air temperature sensor is integrated in the mass air flow sensor
(engine management).
3 Check the intake air temperature signal using the
WDS.
Is the intake air temperature signal OK, i.e. is the
indicated temperature value plausible?
Yes
Check the powertrain control module (PCM) and
RENEW as necessary. CHECK the operation of the
system.
No
For further information, refer to REFER to Section
303-14 Electronic Engine Controls.
A6: CHECK FUSE F11
Is the fuse OK?

Yes
GO to A7.

No
Diagrams.
ground.
Yes
GO to A8.
No
system.
A8: CHECK VOLTAGE AT GLOW PLUG HEATING RELAY, STAGE 1
1 Disconnect glow plug heating relay, stage 1 C1013.
2 Measure the voltage between glow plug heating
relay, stage 1, socket C1013, pin 3, circuit 30-
RH24 (RD), wiring harness side and ground.

Yes
GO to A9.
No
LOCATE and REPAIR the break in circuit 30-RH24
(RD) between the glow plug heating relay, stage 1
and fuse F11 using the Wiring Diagrams. CHECK the
A9: CHECK CONTROL VOLTAGE AT GLOW PLUG HEATING RELAY, STAGE 1
RH23 (GN/RD), wiring harness side and ground.

Yes
GO to A10.
No
(GN/RD) between glow plug heating relay, stage 1,
and soldered connection S117 using the Wiring
A10: CHECK FOR OPEN CIRCUIT BETWEEN GLOW PLUG HEATING RELAY, STAGE 1,
AND THE ELECTRIC BOOSTER HEATER.

2 Measure the resistance between glow plug heating

Yes
GO to A12.
No
GO to A11.
(GN/RD), component side and ground.

Yes
and the electric booster heater using the Wiring
No
A12: CHECK GLOW PLUG HEATING RELAY, STAGE 1
1 Check glow plug heating relay 1, in accordance
with the component test at the end of this section.
Is the glow plug heating relay, stage 1 OK?
Yes
Vehicles with 104 pin EEC: GO to A13.
No
RENEW glow plug heating relay, stage 1. CHECK
A13: CHECK FOR OPEN CIRCUIT BETWEEN PCM AND GLOW PLUG HEATING RELAY,
STAGE 1 - VEHICLES WITH 104 PIN EEC
2 Measure resistance between glow plug heating
relay, stage 1, socket C1013, pin 2, circuit 31S-
RH23 (BK/OG), wiring harness side and PCM,
connector C415, pin 98, circuit 31S-RH23 (BK/OG),

Yes
No
LOCATE and REPAIR the break in circuit 31S-RH23
(BK/OG) between the PCM and the glow plug
heating relay, stage 1, using the Wiring Diagrams.

Yes
No
A15: CHECK FUSE F18
Is the fuse OK?
Yes
GO to A16.
No
Diagrams.
ground.
Yes

GO to A17.
No
system.

Yes
GO to A18.
No
RH25 (GN/BK), wiring harness side and ground.

Yes
GO to A19.
No
(GN/BK) between glow plug heating relay, stage 2,

Yes
GO to A22.
No
GO to A20.
1 Disconnect electric booster heater C966.
(GN/BK), component side and ground.

Yes
GO to A21.
No
1 Measure the resistance between electric booster
heater, connector C967, component side and
ground.

Yes
(GN/BK) between glow plug heating relay, stage 2
and the electric booster heater (or bridge at electric
booster heater) using the Wiring Diagrams. CHECK
No

Yes
No
RENEW glow plug heating relay, stage 2 CHECK the
RH25 (BK/GN), wiring harness side and PCM,
connector C415, pin 75, circuit 31S-RH25 (BK/GN),

Yes
No
(BK/GN) between the PCM and the glow plug

Yes
No
Component Tests
Glow plug heating relay, stage 1

1. If yes, go to 2.
negative terminal.
1. If yes, go to 2.

negative terminal.

Auxiliary Heating - Electric Booster Heater Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Special Tool(s)
Terminal Probe Kit
418-S035

418-F224
General Equipment
Digital multimeter
Clip-on ammeter (DC)
Visual Inspection
Coolant level Fuses
Electric booster heater mounting Wiring harness
Connectors
the powertrain control module (PCM) and the charging system with WDS and
5. 5. For vehicles without any stored faults, PROCEED in accordance with the Symptom
Chart.

Symptom Chart
Symptom Chart

Electric booster heater inoperative / partly * Fuse(s) * GO to Pinpoint
inoperative * Circuit(s) Test A.

* Intake air temperature
signal
stage 1
stage 2
* Electric booster heater
(PCM)
System Check
PINPOINT TEST A : ELECTRIC BOOSTER HEATER INOPERATIVE / PARTLY

INOPERATIVE
NOTE: The electric booster heater only works when the engine is running, the battery is
2 Measure the current in circuits 15-RD23 (GN/BK)
and 15-RD22 (GN/RD) at the electric booster
heater using the clip-on ammeter.
Is a current measured?
Yes
GO to A2.
No
GO to A3.
A2: CHECK 1ST STAGE OF ELECTRIC BOOSTER HEATER CIRCUIT
1 Measure the current in circuit 15-RD22 (GN/RD) at
the electric booster heater using the clip-on
ammeter.
Is a current of more than 10 A measured?

Yes
GO to A15.
No
GO to A6.
A3: CHECK THE ELECTRIC BOOSTER HEATER GLOW PLUG
(GN/RD), component side and electric booster
heater housing.

Yes
GO to A4.
No
A4: CHECK THE ELECTRIC BOOSTER HEATER GROUND CONNECTION
(BK), component side and ground.

Yes
GO to A5.
No
(BK) between the electric booster heater and
A5: CHECK THE SIGNAL FROM THE INTAKE AIR TEMPERATURE SENSOR
NOTE: The intake air temperature sensor is integrated in the mass air flow sensor
(engine management).
3 Check the intake air temperature signal using the
WDS.
Is the intake air temperature signal OK, i.e. is the
indicated temperature value plausible?
Yes
Check the powertrain control module (PCM) and
RENEW as necessary. CHECK the operation of the
system.
No
For further information, refer to REFER to Section
303-14 Electronic Engine Controls.
A6: CHECK FUSE F11
Is the fuse OK?

Yes
GO to A7.

No
Diagrams.
ground.
Yes
GO to A8.
No
system.

Yes
GO to A9.
No

Yes
GO to A10.
No


Yes
GO to A12.
No
GO to A11.
(GN/RD), component side and ground.

Yes
and the electric booster heater using the Wiring
No
Yes
No
RENEW glow plug heating relay, stage 1. CHECK

Yes
No

Yes
No
A15: CHECK FUSE F18
Is the fuse OK?
Yes
GO to A16.
No
Diagrams.
ground.
Yes

GO to A17.
No
system.

Yes
GO to A18.
No

Yes
GO to A19.
No
(GN/BK) between glow plug heating relay, stage 2,

Yes
GO to A22.
No
GO to A20.
(GN/BK), component side and ground.

Yes
GO to A21.
No
1 Measure the resistance between electric booster
heater, connector C967, component side and
ground.

Yes
(GN/BK) between glow plug heating relay, stage 2
and the electric booster heater (or bridge at electric
booster heater) using the Wiring Diagrams. CHECK
No

Yes
No
RENEW glow plug heating relay, stage 2 CHECK the

Yes
No

Yes
No
Component Tests

1. If yes, go to 2.
negative terminal.
1. If yes, go to 2.

negative terminal.

Auxiliary Heating - Booster Heater Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
303-397 (24-003)
Removal
Cooling.
intake manifold.

2. Remove the nuts.
5. CAUTION: Seal off the coolant hose and

the fuel fired booster heater to prevent the
entry of dirt.
Using the special tool, detach the front coolant
hose from the fuel fired booster heater.
6. NOTE: Seal off the coolant hose and the fuel

fired booster heater to prevent the entry of
dirt.
Using the special tool, detach the rear coolant
hose from the fuel fired booster heater.

7. CAUTION: Seal off the fuel line and the
fuel fired booster heater fuel pump to
prevent the entry of dirt.
Detach the fuel line from the fuel fired booster
heater fuel pump.
8. Pull off the fuel fired booster heater connector.
9. Unscrew the fuel fired booster heater upper nut.
10. Raise the vehicle. For additional information,

refer to Section 100-02 Jacking and Lifting.
11. Unscrew the fuel fired booster heater exhaust
system nut.
12. Remove the fuel fired booster heater exhaust

system.

13. Remove the fuel fired booster heater intake
hose.
14. NOTE: Seal off the coolant hoses and the

15. Unscrew the fuel fired booster heater left, lower

nut.
16. Unscrew the fuel fired booster heater right, lower

nut.
17. Guide the fuel fired booster heater downwards.

18. Remove the fuel fired booster heater with
bracket.
19. Pull off the fuel fired booster heater fuel pump
connector.
20. Detach the fuel hose from the fuel fired booster
heater.
21. Remove the fuel fired booster heater fuel pump

with bracket.
22. Remove the fuel fired booster heater.

Installation

Auxiliary Heating - Booster Heater Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Disassembly
Vehicles with non programmable fuel fired booster
heater
1. Remove the water cooling jacket cover.
2. Remove the combustion air blower motor cover.
Vehicles with programmable fuel fired booster heater

3. Remove the fuel metering pump cover.
4. Detach the auxiliary coolant flow pump from the

booster heater.
5. Remove the auxiliary coolant flow pump.


6. Disconnect the fuel metering pump electrical
connectors.
Pull back the wiring harness grommets.
7. CAUTION: Cap the fuel lines to prevent

dirt ingress.
Disconnect the fuel metering pump hose.
8. Remove the fuel metering pump.
All vehicles
10. Detach the overheat sensor and the temperature
sensor from the water cooling jacket.

11. Remove the fuel fired booster heater module
retaining bolts.
13. Remove the fuel fired booster heater module.

Disconnect the internal electrical
connector.

14. Disconnect the glow plug wire from the glow
plug.

15. Disconnect the cables from the fuel fired booster
heater electrical connector (glow plug shown

All vehicles
16. Disconnect the cables from the fuel fired booster
heater electrical connector (flame sensor shown
17. CAUTION: Use an open-ended wrench to

hold the pre-ignition chamber by the
hexagon to prevent damages of the pre-
ignition chamber.
Remove the glow plug.
18. Remove the flame sensor.

Remove the support.
19. Remove the pre-ignition chamber.

1. Turn the pre-ignition chamber clockwise.
2. Pull out the pre-ignition chamber.
1. Discard the O-ring seals.
20. Remove the combustion air blower motor.

Discard the seal.

21. Using a suitable screwdriver, remove the heat
exchanger.
Assembly
1. NOTE: Install new O-ring seals and gaskets.
NOTE: Coat the O-ring seals in coolant prior
to installation.

Air Conditioning - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
A/C compressor
Type
A/C compressor FVS 090
Orifice
Colour
Orifice Orange
Tightening torques
Item Nm lb-ft lb-in

Radiator crossmember 24 18 -
Dehydrator 7 - 62
Bolt, A/C compressor 24 18 -
Refrigerant line to dehydrator 8 - 71
Refrigerant line bracket to radiator crossmember 10 - 89
Bolt, refrigerant line to A/C compressor 20 15 -
Nut, refrigerant line to condenser 8 - 71
A/C charging connection 10 - 89
Orifice connection 8 - 71
Bolt, A/C compressor drive plate 13 10 -
High-pressure switch 10 - 89
Low pressure switch 2.5 - 23

Air Conditioning - Air Conditioning Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Refrigerant circuit

1 - Condenser
2 - Compressor
3 - Accumulator/dehydrator
4 - Clutch cycling switch
5 - Heater/air conditioning blower
6 - Evaporator
7 - Orifice tube valve with variable aperture
8 - High pressure switch (double pressure switch)
9 - Engine cooling fans
A - High pressure, liquid and warm
B - Low pressure, liquid and cold
C - Low pressure, gas and cold
D - High pressure, gas and hot
E - Cold air
F - Warm air
Installed locations

1 - Clutch cycling switch
2 - Orifice tube valve with variable aperture
3 - Evaporator
4 - High pressure charge valve
5 - High pressure switch (double pressure switch)
6 - Condenser
7 - Compressor
8 - Accumulator/dehydrator
Orifice tube valve with variable aperture

1 - Metering pin with different diameters
2 - Valve aperture
3 - Spring
4 - Aperture approx. 1.6 mm, e.g. when driving on highways and
motorways
5 - Aperture approx. 1.3 mm, e.g. when driving in town
6 - Aperture approx. 1.1 mm at idle
7 - Aperture approx. 1.4 mm
8 - Installation orientation
In contrast to other vehicles which have a fixed orifice tube, in this case a valve with a
variable aperture is installed.
Because of this valve with variable aperture, the air conditioning system uses less power.
Idle speed emissions are reduced.
Fuel consumption is reduced.
The pressure in the high pressure line pushes the metering pin against a spring with a force
which depends on the type of driving (idle, town or motorway/highway). The aperture of
the valve is increased or decreased by the different diameters of the metering pin and thus
matched to the driving situation.

Air Conditioning - Air Conditioning Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Air Conditioning - Air Conditioning (A/C)
Compressor
Print
Removal
1. Drain the air conditioning (A/C) system. For
Climate Control System - General Information.
3. Remove the drive belt cover.
4. Turn the drive belt tensioner counter-clockwise

and remove the drive belt.
5. CAUTION: Cap the refrigerant lines and

the A/C compressor to prevent dirt ingress.
Detach the refrigerant lines from the A/C
compressor.
6. Detach the A/C compressor clutch connector.
7. Remove the A/C compressor together with the

clutch and solenoid coil assembly.

8. Remove the A/C compressor drive plate.
9. NOTE: If necessary, remove a seized A/C

compressor pulley using a suitable remover.
Remove the A/C compressor pulley.
Remove the spacer washers.
Discard the pulley snap ring.
10. Remove the solenoid coil snap ring.
11. NOTE: Mark the installation position of the

A/C compressor clutch connector in relation
to the compressor housing.
Remove the solenoid coil.
Installation
1. CAUTION: Do not tilt the solenoid coil

when installing in the A/C compressor.

NOTE: Installation position of the A/C
compressor clutch connector in relation to
the compressor housing.
NOTE: Install a new A/C compressor pulley
snap ring.
NOTE: Install new refrigerant line O-rings.
NOTE: Coat the refrigerant line O-rings with
clean refrigerant oil before installation.
Install the components in the reverse order.
2. Check the A/C clutch air gap. For additional

Air Conditioning - Clutch and Clutch Field
Coil
Print

General Equipment
Two leg puller
Materials
Name Specification
M6 x 30 mm bolt
Washer
Removal
All vehicles
Drive.
2. Disconnect the air conditioning (A/C) compressor
clutch electrical connector.
CAUTION: Support the A/C compressor before removing the retaining bolts and
secure it to prevent load being placed on the refrigerant lines.
3. Detach the A/C compressor from the mounting
bracket.
Vehicles with 1.6L engine
CAUTION: Support the A/C compressor before removing the retaining bolts and
secure it to prevent load being placed on the refrigerant lines.
4. Detach the A/C compressor from the mounting
bracket.

All vehicles
5. Remove the A/C compressor drive plate.
6. Remove the A/C compressor pulley.

Remove the spacer shims.
7. NOTE: Mark the position of the A/C

compressor clutch electrical connector in
relation to the compressor housing.
Using a suitable two leg puller, remove the
clutch field coil.
Installation
All vehicles

NOTE: Do not skew the clutch field coil when installing it to the A/C compressor seat.
1. Using a suitable M6 x 30 mm bolt, a suitable
washer and the A/C compressor drive plate,
install the clutch field coil.
2. Remove the M6 x 30 mm bolt, washer and A/C

compressor drive plate.
Install the spacer shims.
3. NOTE: Install a new A/C compressor pulley
snap ring.
Install the A/C compressor pulley.
Install the snap ring.
4. Install the A/C compressor drive plate.
5. Check the A/C clutch air gap. For additional

Vehicles with 1.6L engine

6. Attach the A/C compressor to the A/C
compressor bracket.

All vehicles
7. Attach the A/C compressor to the A/C
compressor bracket.
8. Connect the A/C compressor clutch electrical

connector.

Drive.

Air Conditioning - Suction Accumulator Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Separator, refrigerant line 3/4" (white)
412-040 (34-002)
Materials
Name Specification
O-rings Green
Removal
CAUTION: Only renew the dehydrator if moisture has been allowed to enter the
unopened system for a long period of time (two to three hours).
1. Drain the air conditioning system.For additional
3. Remove the right-hand wheel arch trim panel
(shown with the wheel removed for clarity).
4. CAUTION: Close off the refrigerant lines

and the dehydrator to prevent
contamination.
Remove the dehydrator.
dehydrator using the special tool.
dehydrator.
3. Unscrew and remove the bolts and the nut
on the dehydrator.
Installation
1. NOTE: Install new refrigerant line O-ring
seals.
NOTE: Coat the O-rings for the refrigerant
lines with clean refrigerant oil prior to
installation.

Air Conditioning - Low-Pressure Cutoff
Switch
Print
Removal
1. Detach the power steering fluid expansion tank
from the wheelhouse panel and position it to one
side.
2. Disconnect the low-pressure cutoff switch

3. Start the engine and turn the air conditioning

(A/C) switch to the ON position.
4. NOTE: Make sure that the A/C compressor
runs during low-pressure cutoff switch
removal.
Connect a 20 A fuse rated jumper wire between
Pin 1 and Pin 4, harness side, of the low-
pressure cutoff switch electrical connector.
5. WARNING: Make sure that the low-

pressure cutoff switch valve closes
completely after removal of the low-pressure
cutoff switch to prevent loss of refrigerant.
personal injury.
Remove the low-pressure cutoff switch.
Installation
1. NOTE: Install new low-pressure cutoff switch
O-ring seals.
NOTE: Coat the low-pressure cutoff switch O-
ring seals with clean refrigerant oil prior to
installation.


Air Conditioning - Condenser Core Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
NOTE: The cooling system must not be drained.
For additional information, refer to: Air
and Charging (412-00 Climate Control System -
2. Detach the A/C charging connection holder from
the fender.

Operation).
4. Remove the lower radiator cover.
Discard the retaining clips.
5. Detach the refrigerant line bracket from the

radiator crossmember.

6. Detach the temperature sensor for the fuel fired
booster heater from the cooler traverse.
Unclip the wiring harness.
7. CAUTION: Seal off the refrigerant lines

and the condenser core to prevent the entry
of dirt.
Detach the lower refrigerant line from the
condenser core.
8. CAUTION: Seal off the refrigerant lines

and the condenser core to prevent the entry
of dirt.
Detach the upper refrigerant line from the
condenser core.
9. Remove the lower wheelhouse cover.
10. CAUTION: Support the cooler with a

transmission jack.
Remove the cooler traverse.

11. CAUTION: Support the cooler with a
transmission jack.
Remove the condenser core.
1. Push the condenser core to one side.
2. Pull out the condenser core downwards.
Installation
1. NOTE: Install new refrigerant line O-rings.
NOTE: Coat the refrigerant line O-rings with
clean refrigerant oil before installation.
NOTE: Install new lower radiator cover
retaining clips.


Air Conditioning - High-Pressure Cutoff
Switch
Print
Removal
Lifting.
2. Disconnect the high-pressure cutoff switch
3. NOTE: Make sure that the high-pressure

cutoff switch valve closes completely after
removal of the high-pressure cutoff switch to
prevent loss of refrigerant.
Remove the high-pressure cutoff switch.
Installation
1. NOTE: Install new high-pressure cutoff
switch O-ring seals.
NOTE: Coat the high-pressure cutoff switch
O-ring seals in clean refrigerant oil prior to
installation.

Air Conditioning - Evaporator Core Orifice Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
Remover/Installer, Fixed Orifice
412-034 (34-004)
Adapter for 412-034

412-034-01
Remover, Broken Orifice

412-035 (34-005)
Disconnect Tool, Spring-Lock Coupling 1/2" (blue)

412-027 (34-001)
Disconnect Tool, Spring-Lock Coupling 5/8" (black)

412-081 (34-003)
Removal
All vehicles
1. Drain the air conditioning (A/C) system. For
Climate Control System - General Information.
3. Remove the right-hand wheel arch trim panel
4. CAUTION: Seal off the refrigerant line to

prevent entry of dirt.
Separate the evaporator core to condenser core
refrigerant line.
5. Detach the refrigerant line from the wheel

housing.


intake manifold.

2. Remove the nuts.
Vehicles with booster heater

Cooling.
10. Detach the rear coolant hose from the fuel fired
booster heater using the special tool and lay it to
one side.


All vehicles
12. Remove the retaining clip of the refrigerant line
quick-fit connector.
13. NOTE: Seal off the refrigerant line and the

A/C evaporator core to prevent entry of dirt.
Using the special tool, detach the refrigerant line
from the A/C evaporator core.
14. CAUTION: Seal off the refrigerant line to

prevent entry of dirt.
Remove the evaporator core orifice refrigerant
line.
15. Hook the special tool into the evaporator core

orifice.
1. Insert the special tool together with the
adapter into the evaporator core orifice.
2. Engage the adapter in the evaporator core
orifice by means of a ¼ turn.
16. Remove the evaporator core orifice.

Turn the special tool, holding the adapter
at the same time.

17. NOTE: This step is only necessary if the
evaporator core orifice is faulty.
Remove faulty evaporator core orifice using
special tools.
Installation
1. NOTE: Install new refrigerant line O-rings.
NOTE: Coat the refrigerant line O-ring seals
with clean refrigerant oil prior to installation.

Air Conditioning - Evaporator Outlet Line Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Special Tool(s)
412-027
Disconnect Tool, Spring Lock Coupling (1/2" blue)
412-038
Materials
Name Specification
Compressor Oil - Air Conditioning WSH-M1C231-B / 6U7J-M1C231-AA
Removal
1. Carry out the air conditioning (A/C) system
recovery procedure.
Refer to: Air Conditioning (A/C) System

Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,

2.
3.
Vehicles with fuel fired heater

4. Carry out the cooling system drain procedure.
Refer to: Cooling System Draining, Filling and

Procedures).

are sealed.

6.
All Vehicles

are sealed.
8. Remove the right-hand front road wheel.

9.

are sealed.

Installation
1. Follow the disassembly procedure in reverse

order.
2. Coat the O-rings for the refrigerant line with
clean refrigerant oil.
Material: Compressor Oil - Air Conditioning

(WSH-M1C231-B / 6U7J-M1C231-AA)

Air Conditioning - Condenser to Evaporator Line Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Special Tool(s)
412-038
Materials
Name Specification
Removal

1. Carry out the air conditioning (A/C) system recovery procedure.
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging

2.
3.
Vehicles with fuel fired heater

4. Carry out the cooling system drain procedure.
Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling,

6.
All Vehicles

8. Remove the right-hand front road wheel.
Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
9.
10. CAUTION: Make sure that all

1. Torque: 8 Nm
Installation
1. Follow the disassembly procedure in reverse order.

2. Coat the O-rings for the refrigerant line with clean refrigerant oil.
Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-

AA)

Air Conditioning - Suction Accumulator to Condenser
Line
Print

Materials
Name Specification
Removal

1. Carry out the air conditioning (A/C) system recovery procedure.
Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging

Torque: 10 Nm
Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
4. CAUTION: Make sure that all

1. Torque: 8 Nm
2. Torque: 20 Nm
Installation
1. Follow the disassembly procedure in reverse order.

2. Coat the O-rings for the refrigerant line with clean refrigerant oil.
Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-

AA)

Control Components - Control
Components
Print

Control Components - Air Inlet Blend Door
Actuator
Print
Removal
1. Fully open the glove compartment.
2. Disconnect the air inlet blend door actuator
connector.
3. Remove the air inlet blend door actuator (heater

core / evaporator core housing removed for
clarity).
Installation
1. CAUTION: Ensure that the air inlet blend

door actuator shaft correctly engages in the
air inlet blend door.

Control Components - Climate Control
Assembly
Print
Removal
1. Remove the audio unit.For additional
information, refer to Section 415-01A Audio
Unit / 415-01B Information and Entertainment
System.
2. Unscrew and remove the upper bolts from the
fascia/crash padding console.
3. Remove the ashtray.
4. Unscrew and remove the lower bolts from the

5. Pull the fascia/crash padding console forwards

and disconnect the plug(s).
6. Detach the temperature flap actuation cables

and the air distribution flap from the heater/air
conditioning control unit.

7. Remove the heater/air conditioning control unit.
Installation
1. NOTE: To install the cables, turn the air
distribution control and the temperature
control counter-clockwise to the stop.

Control Components - Climate Control
Assembly—Vehicles Built From: 04/2009
Print
Removal

2.
Installation

Control Components - Temperature Blend
Door Control Cable—Vehicles Built From: Transit/Tourneo Connect 2002.5 (06/2002-)
04/2009
Print
Removal

2.
3.
4.
5.

Installation

Control Components - Air Distribution
Cable Control Assembly
Print
Removal
1. Remove the audio unit.For additional
System.
2. Unscrew and remove the upper bolts from the
3. Remove the ashtray.
4. Unscrew and remove the lower bolts from the

5. Pull the fascia/crash padding console forwards

and disconnect the plug(s).
6. Detach the temperature flap actuation cables

and the air distribution flap from the heater/air
conditioning control unit.

7. Detach the lower fascia/crash padding cover
from the fascia/crash padding.
8. Disconnect the headlamp switch electrical

connector.
9. Remove the actuation cable for the air

distribution flap.
10. Remove the actuation cable for the temperature

flap.
Installation
1. NOTE: To install the cables, turn the air
distribution control and the temperature
control counter-clockwise to the stop.


Control Components - Air Distribution
Cable Control Assembly—Vehicles Built Transit/Tourneo Connect 2002.5 (06/2002-)
From: 04/2009
Print
Removal

2.
3.
4.
5.

Installation

Control Components - Blower Motor
Resistor
Print
Removal
1. Fully open the glove compartment.
WARNING: Never perform operations on the blower motor resistor before the blower
motor resistor has cooled to ambient temperature. Failure to observe this instruction can
lead to injury.
2. Disconnect the blower motor resistor connector.
3. Remove the blower motor resistor.
Installation

Control Components - Blower Motor
Switch—Vehicles Built From: 04/2009
Print
Removal

2.
Installation

Control Components - Ambient Air
Temperature Sensor
Print
Removal

2.
3.
Installation

Instrument Cluster and Panel Illumination
- Instrument Cluster and Panel
Illumination—Vehicles Built Up To:
08/2006
Print
Electrical
Bulb (s)
Wiring harness
Electrical connectors
Instrument cluster
Switches
Chart.
Symptom Chart

The headlamp switch illumination * Fuse. * GO to Pinpoint Test A.
is inoperative * Circuit(s).
* Headlamp
switch.
The Instrument cluster * Circuit(s). * GO to Pinpoint Test B.
illumination is inoperative * Instrument
cluster.
The climate control illumination is * Circuit(s). * GO to Pinpoint Test C.
inoperative * Climate control
panel.
The audio system illumination is * Circuit(s). * GO to Pinpoint Test D.
inoperative * Audio unit.
The hazard lamps switch * Circuit(s). * GO to Pinpoint Test E.
illumination is inoperative * Hazard lamps
switch.
The passenger side window * Circuit(s). * GO to Pinpoint Test F.
control switch illumination is * Window control
inoperative switch.
The driver side window control * Window control * INSTALL a new drivers side window
switch illumination is inoperative switch. control switch. TEST the system for
normal operation.
The cigar lighter illumination is * Circuit(s). * GO to Pinpoint Test G.
inoperative * Cigar lighter
socket.
The parking aid switch * Circuit(s). * GO to Pinpoint Test H.
illumination is inoperative * Parking aid
switch.

Pinpoint Tests
PINPOINT TEST A : THE HEADLAMP SWITCH ILLUMINATION IS

INOPERATIVE
A1: CHECK THE HEADLAMP SWITCH ILLUMINATION GROUND CIRCUIT
2 Disconnect Headlamp switch C320.
3 Measure the resistance between the headlamp switch
C320 pin 10, circuit 31-LE29 (BK), harness side and
ground.

Yes
INSTALL a new headlamp switch. TEST the system
No
operation.
PINPOINT TEST B : THE INSTRUMENT CLUSTER ILLUMINATION IS

INOPERATIVE
B1: CHECK CIRCUIT 29S-GG14 (OG) FOR VOLTAGE
2 Disconnect Instrument cluster C809.
3 Place the headlamp switch in the headlamp ON
position.
4 Measure the voltage between the instrument cluster
C809 pin 3, circuit 29S-GG14 (OG), harness side and
ground.

Yes
GO to B2.
No
operation.
B2: CHECK CIRCUIT 91-GG14 (BK/OG) FOR OPEN
1 Place the headlamp switch in the OFF position.
2 Measure the resistance between the instrument
cluster C809 pin 2, circuit 91-GG14 (BK/OG),

Yes
INSTALL a new instrument cluster. TEST the system
No
operation.
PINPOINT TEST C : THE CLIMATE CONTROL ILLUMINATION IS

INOPERATIVE
C1: CHECK CIRCUIT 29S-LH27 (OG/GN) FOR VOLTAGE
2 Disconnect climate control C493.
position.
4 Measure the voltage between the climate control unit
C493 pin 2, circuit 29S-LH27 (OG/GN), harness side
and ground.

Yes
GO to C2.
No
operation.
C2: CHECK CIRCUIT 31-LH27 (BK) FOR OPEN
2 Measure the resistance between the climate control
unit C493 pin 1, circuit 31-LH27 (BK), harness side
and ground.

Yes
INSTALL a new climate control unit. TEST the system

No
operation.
PINPOINT TEST D : THE AUDIO SYSTEM ILLUMINATION IS INOPERATIVE

D1: CHECK CIRCUIT 29S-LK34 (OG/BK) FOR VOLTAGE
2 Disconnect Audio unit C443.
position.
4 Measure the voltage between the audio unit C443
pin 4, circuit 29S-LK34 (OG/BK), harness side and
ground.

Yes
GO to D2.
No
operation.
D2: CHECK CIRCUIT 91-MD34 (BK/YE) FOR OPEN
2 Measure the resistance between the audio C443 pin
2, circuit 91-MD34 (BK/YE), harness side and
ground.

Yes
INSTALL a new audio unit. TEST the system for
normal operation.
No
operation.
PINPOINT TEST E : THE HAZARD LAMPS SWITCH ILLUMINATION IS

INOPERATIVE
E1: CHECK CIRCUIT 29S-LH54 (OG/GN) FOR VOLTAGE
2 Disconnect Hazard lamps switch C458.
position.
4 Measure the voltage between the hazard lamps
switch C458 pin 3, circuit 29S-LH54 (OG/GN),


Yes
GO to E2.
No
operation.
E2: CHECK CIRCUIT 91-LG7 (BK/BU) FOR OPEN
2 Measure the resistance between the hazard lamps
switch C458 pin 8, circuit 91-LG7 (BK/BU), harness
side and ground.

Yes
INSTALL a new hazard lamps switch. TEST the
No
operation.
PINPOINT TEST F : THE PASSENGER SIDE WINDOW CONTROL SWITCH

ILLUMINATION IS INOPERATIVE
F1: CHECK CIRCUIT 31-LH31 (BK) FOR OPEN
2 Disconnect Passenger side window control switch
C489.
4 Measure the resistance between the passenger side
window control switch C489 pin 4, circuit 31-LH31
(BK), harness side and ground.

Yes
INSTALL a new passenger side window control
switch. TEST the system for normal operation.

No
operation.
PINPOINT TEST G : THE CIGAR LIGHTER ILLUMINATION IS INOPERATIVE

G1: CHECK CIRCUIT 29S-LH15 (OG) FOR VOLTAGE
2 Disconnect Cigar lighter C911.
position.
4 Measure the voltage between the cigar lighter C911
pin 1, circuit 29S-LK15 (OG), harness side and
ground.

Yes
INSTALL a new cigar lighter socket. TEST the
No
operation.
PINPOINT TEST H : THE PARKING AID SWITCH ILLUMINATION IS

INOPERATIVE
H1: CHECK CIRCUIT 29S-LH49 (OG/BK) FOR VOLTAGE
2 Disconnect Parking aid switch C620.
position.
4 Measure the voltage between the parking aid switch
C620 pin 3, circuit 29S-LH49 (OG/BK), harness side
and ground.

Yes
GO to H2.
No
operation.
H2: CHECK CIRCUIT 31-LH49 (BK) FOR OPEN
2 Measure the resistance between the parking aid
switch C620 pin 7, circuit 31-LH49 (BK), harness

side and ground.

Yes
INSTALL a new parking aid switch. TEST the system
No
operation.

Instrument Cluster and Panel Illumination
- Instrument Cluster and Panel
Illumination—Vehicles Built From:
08/2006
Print
Electrical
Bulb (s)
Fuses
Wiring harness
Light emitting diode(s) LED(s)
Bulbs
Instrument cluster
Switches
Audio unit
Climate control assembly
Chart.
Symptom Chart

The headlamp switch * Fuse. * GO to Pinpoint Test A.
illumination is inoperative * Circuit(s).
* Headlamp
switch.
The instrument cluster * Circuit(s). * GO to Pinpoint Test B.
illumination is inoperative * Instrument
cluster.
The climate control assembly * Circuit(s). * GO to Pinpoint Test C.
illumination is inoperative * Climate control
assembly.
The audio system illumination is * Circuit(s). * GO to Pinpoint Test D.
inoperative * Audio unit.
The hazard lamps switch * Circuit(s). * GO to Pinpoint Test E.
illumination is inoperative * Hazard lamps
switch.
The passenger side window * Circuit(s). * GO to Pinpoint Test F.
control switch illumination is * Window control
inoperative switch.
The driver side window control * Window control * INSTALL a new drivers side window
switch illumination is inoperative switch. control switch. TEST the system for
normal operation.
The cigar lighter illumination is * Circuit(s). * GO to Pinpoint Test G.

inoperative * Cigar lighter
socket.
Pinpoint Tests
PINPOINT TEST A : THE HEADLAMP SWITCH ILLUMINATION IS

INOPERATIVE
A1: CHECK THE HEADLAMP SWITCH ILLUMINATION GROUND CIRCUIT
2 Disconnect Headlamp Switch C320.
3 Measure the resistance between the headlamp switch
C320 pin 10, circuit 31-LE29 (BK), harness side and
ground.

Yes
INSTALL a new headlamp switch. TEST the system
No
operation.
PINPOINT TEST B : THE INSTRUMENT CLUSTER ILLUMINATION IS

INOPERATIVE
B1: CHECK CIRCUIT 29S-GG14 (OG) FOR VOLTAGE
2 Disconnect Instrument Cluster C809.
position.
4 Measure the voltage between the instrument cluster
C809 pin 24, circuit 29S-GG14 (OG), harness side
and ground.

Yes
GO to B2.
No
operation.
B2: CHECK CIRCUIT 91-GG14 (BK/OG) FOR OPEN

cluster C813 pin 2, circuit 91-GG14 (BK/OG), harness
side and ground.

Yes
INSTALL a new instrument cluster.
REFER to: Instrument Cluster (413-01 Instrument
Cluster, Removal and Installation).
No
operation.
PINPOINT TEST C : THE CLIMATE CONTROL ASSEMBLY ILLUMINATION IS

INOPERATIVE
C1: CHECK CIRCUIT 29S-LH27 (OG/GN) FOR VOLTAGE
2 Disconnect Climate Control Assembly C493.
position.
4 Measure the voltage between the climate control
assembly C493 pin 2, circuit 29S-LH27 (OG/GN),

Yes
GO to C2.
No
operation.
C2: CHECK CIRCUIT 31-LH27 (BK) FOR OPEN
2 Measure the resistance between the climate control
assembly C493 pin 1, circuit 31-LH27 (BK), harness
side and ground.

Yes

INSTALL a new climate control assembly.
REFER to: Climate Control Assembly (412-04 Control
Components, Removal and Installation).
No
operation.
PINPOINT TEST D : THE AUDIO UNIT ILLUMINATION IS INOPERATIVE

D1: CHECK CIRCUIT 29S-LK34 (OG/BK) FOR VOLTAGE
2 Disconnect Audio Unit C443.
position.
4 Measure the voltage between the audio unit C443 pin
14, circuit 29S-LK34 (OG/BK), harness side and
ground.

Yes
GO to D2.
No
operation.
D2: CHECK CIRCUITS 91-MD15 (BK/GN) AND 91-MD34 (BK/YE) FOR OPEN
2 Measure the resistance between the audio unit C443
pin 12, circuit 91-MD15 (BK/GN), harness side and
ground and between the audio unit C443 pin 11,
circuit 91-MD34 (BK/YE), harness side and ground.
Are the resistances less than 1 ohm?

Yes
INSTALL a new audio unit.
REFER to: Audio Unit - Vehicles Built From: 08/2008
(415-01A Audio Unit, Removal and Installation).
No
REPAIR circuit 91-MD15 (BK/GN) or circuit 91-MD34
(BK/YE). TEST the system for normal operation.
PINPOINT TEST E : THE HAZARD LAMPS SWITCH ILLUMINATION IS

INOPERATIVE
E1: CHECK CIRCUIT 29S-LH54 (OG/GN) FOR VOLTAGE

2 Disconnect Hazard Lamps Switch C458.
position.
4 Measure the voltage between the hazard lamps
switch C458 pin 3, circuit 29S-LH54 (OG/GN),

Yes
GO to E2.
No
operation.
E2: CHECK CIRCUIT 91-LG7 (BK/BU) FOR OPEN
2 Measure the resistance between the hazard lamps
switch C458 pin 8, circuit 91-LG7 (BK/BU), harness
side and ground.

Yes
INSTALL a new hazard lamps switch. TEST the
No
operation.
PINPOINT TEST F : THE PASSENGER SIDE WINDOW CONTROL SWITCH

ILLUMINATION IS INOPERATIVE
F1: CHECK CIRCUIT 31-LH31 (BK) FOR OPEN
2 Disconnect Passenger Side Window Control Switch
C489.
4 Measure the resistance between the passenger side
window control switch C489 pin 4, circuit 31-LH31

Yes
INSTALL a new passenger side window control
switch. TEST the system for normal operation.
No
operation.
PINPOINT TEST G : THE CIGAR LIGHTER ILLUMINATION IS INOPERATIVE

G1: CHECK CIRCUIT 29S-LH15 (OG) FOR VOLTAGE
2 Disconnect Cigar Lighter C911.
position.
4 Measure the voltage between the cigar lighter C911
pin 1, circuit 29S-LK15 (OG), harness side and
ground.

Yes
INSTALL a new cigar lighter socket. TEST the
No
operation.

Instrument Cluster - Instrument Cluster Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Overview

1 - Windshield wiper relay
2 - Rear window wiper relay
3 - Heated rear window and mirror heating relay
4 - Interior lighting relay
5 - Interior lighting relay
6 - Instrument cluster with timer functions
-

-
8 Battery ground (terminal 31)

9 - Ignition switch (terminal 15, terminal 75)
10 - Ground connection
11 - Parking brake sensor
12 - Lack of brake fluid sensor
13 - MK -25 Anti-lock Brake System (ABS) module
14 - High beam switch
15 - Windshield wiper switch
16 - Heated rear window switch
17 - Heated windshield switch
18 - Airbag central control module
19 - Hazard warning switch
20 - Turn signal switch
21 - Exterior light switch
23 - Internal tank module (tank display for fuel level)
24 - Oil pressure switch
25 - Sliding door contacts: Door contact switch for left-hand sliding door,
door contact switch for right-hand sliding door
26 - Driver's and passenger's door contacts: Door contact switch for
driver's door, door contact switch for passenger's door
27 - Door contact switch for tailgate or right rear door
28 - Central locking control module
SCP - SCP databus
Instrument cluster with timer functions
The instrument cluster communicates with the PCM via the SCP data bus. The
following data are transmitted to the instrument cluster via the SCP databus:
Engine speed (for the tachometer)
Generator failure (for the generator charging lamp)
Coolant temperature (for the coolant temperature display)
Fault in the engine management system (for Malfunction Indicator Light (MIL) and engine
control system) only on petrol engines
Pre-glow (for the pre-glow indicator on diesel vehicles only)
Vehicle speed (for the speedometer and odometer displays)
Fuel quantity (for the PCM)
The timer module is integrated into the instrument cluster. This module actuates various
time-controlled electrical consumers depending on the equipment level of the vehicle.
In addition, the integrated timer module also monitors systems which can give off a signal
in certain situations (warning tone and/or lamp display).
The instrument cluster is connected to the vehicle electrical system via two connectors.
The instrument cluster is lit by just two LEDs. The warning lights are also LEDs. Because of
the extremely long service life of LEDs, there is no need to renew them separately.

shown: Vehicles built up to 08/2004
1 - Engine management system warning indicator and exhaust gas
warning indicator (MIL), petrol engines only, yellow. On vehicles with
a diesel engine only the bulb test is carried out.
2 - Air bag warning indicator, yellow
3 - Left-hand turn signal indicator, green
4 - High beam indicator, blue
5 - Right-hand turn signal indicator, green
6 - ABS warning indicator, yellow
7 - Charge control lamp, red
8 - Oil pressure warning indicator, red
9 - Brake system warning indicator, red
10 - Traction Control System (TCS) warning indicator, yellow
11 - Passive anti-theft system (PATS) LED, red
12 - Glow plug indicator (diesel engines), yellow. Second function: if it
flashes while driving then it serves as a fault lamp, and provides the
driver with information about a fault in the engine management
system.

shown: Vehicles built from 08/2004
1 - Engine management system warning indicator (MIL), yellow
2 - Powertrain warning indicator, yellow
3 - Air bag warning indicator, yellow
4 - Brake pad wear indicator, yellow
5 - Glow plug indicator (diesel engines), yellow
6 - Left-hand turn signal indicator, green
7 - High beam indicator, blue
8 - Right-hand turn signal indicator, green
9 - ABS warning indicator, yellow
10 - Charge control lamp, red
11 - Oil pressure warning indicator, red
12 - Service indicator, yellow
13 - Brake system warning indicator, red
14 - TCS warning indicator, yellow
15 - Passive anti-theft system (PATS) LED, red
16 - Water in fuel warning indicator, yellow
Timer functions
Depending on the equipment level of the vehicle, the following functions are
controlled by the timer module of the instrument cluster.
Battery protection function
"Exterior lighting on" warning
Switching on the interior lighting when entering the vehicle
Switching off the interior lighting when getting out of the vehicle
Warning "airbag system fault" (warning tone)
Control of the rear window heating and rear view mirrors
Controls for the heated windshield

Control of the wash/wipe function on the windshield
Control of the wash/wipe function on the rear window
Modelling of the warning tones and signal tones, plus the management of their priorities
Battery protection function

1 - Battery protection relay
The battery protection function prevents the battery from being discharged by the vehicle
lighting or the warning tone generator when the engine is switched off.
30 minutes after switching off the engine the headlamps, the luggage compartment lamps,
the interior lamps and the warning tone generator are switched off.
The lighting is switched off by the battery protection relay. The relay is located in the
central fuse box underneath the instrument cluster.
The battery protection function and the 30-minute time counter are cancelled or reset
if:
the ignition is no longer OFF.
a door or the tailgate is opened.
the central locking control unit receives a signal to unlock the vehicle.
Interior lighting when entering the vehicle
The interior lighting is switched "ON" as a person enters the vehicle if the ignition is off and
a signal to unlock the vehicle is sent from the remote control or the lock cylinder is turned.
The interior lighting goes out again approx. 25 seconds after switching on the ignition, or
after receipt of a signal to lock the central locking (from the remote control or lock
cylinder).
Interior lighting when leaving the vehicle
The interior lighting is switched "ON" for getting out of the vehicle if all doors are closed
and the ignition is switched off.
The interior lighting goes out after 25 seconds or if one of the doors is opened a hand
width.
"Exterior lighting on" warning
An acoustic warning tone sounds if the exterior lighting is switched on, the ignition is
switched off and the driver's door is open.
The acoustic warning tone stops if the exterior lighting is switched off or the doors are
closed again.
Warning "airbag system fault" (warning tone)
This warning informs the driver about a fault in the airbag system if the warning lamp for
the fault in the airbag system has failed and the ignition is switched on.

"Interior lighting and exterior lighting on" warning

1 - Off
2 - Door-operated switch
3 - Continuous operation
4 - Reading lamp switch
The interior lighting controlled by the timer module includes (depending on the equipment
level of the vehicle) the overhead lamps and the luggage compartment lamps.
The interior lighting is activated by an opening signal from the remote control or by manual
opening via the lock cylinder.
The interior lighting is also switched on if a door is opened and switched off when all doors
are closed. A prerequisite for this function is that the interior lighting switch is in the "door
switch" position and not in the "continuous operation" or "Off" position.
The reading lamps in the interior lighting (optional) are switched on and off with separate
switches.
Control of the heated windshield
When the button for the windshield heating is pressed, the windshield is heated for approx.
4 minutes.
The requirement for this function is that the engine must be running. An LED in the switch
is lit while the windshield is being heated.
The windshield heating is switched via a relay in the fuse box in the engine compartment.
The windshield heating is switched off

after the 4-minute time period has elapsed,
by pressing the button again,
after the engine is switched off,
Engine speed below 400 rev/min

1 - Heated windshield relay
2 - LED, heated windshield warning lamp
3 - Button "heated windshield 2"
Control of the rear window heating
After pressing the button for the rear window heating, the rear window and the rear view
mirrors are heated for 10 minutes.
The requirement for this function is that the engine must be running.
An LED in the switch lights up while the rear window and the rear view mirrors are being
heated.
The rear window heating is switched via a relay in the central fuse box underneath the
instrument cluster.
The rear window heating and the heating for the rear view mirrors are switched off
after the 10-minute time period has elapsed,
by pressing the button again,
the engine is switched off.

1 - Rear heated window relay
2 - LED, rear heated window warning lamp
3 - Button "Heated rear window"
Control of the wash/wipe function on the windshield
The windshield wash/wipe function is only available with the ignition switched on.
4 different functions are available:

Off
Intermittent
Slow
Fast
The timer module of the instrument cluster has no influence on the "Slow" and "Fast"
functions.
With the "intermittent" function, the timer module controls the windshield wiper and
repeats the wipe cycle every 8 seconds.
The wiper returns to the park position when switched off.
Washer fluid is sprayed onto the windshield when the windshield washer button is pressed.
Two wipes are performed when the spraying is finished and after 100 milliseconds.
The relay for the windshield wipers is located in the central fuse box underneath the
instrument cluster.

1 - Windshield wiper relay
Control of the wash/wipe function on the rear window
The rear window wash/wipe function is only available with the ignition switched on.
The timer module has no influence on the wiper speed (slow) or the parking function of the
rear window wiper.
The delay time between the two wipe cycles is 10 seconds. The timer module switches the
wipe process using a relay (in the central fuse box underneath the instrument cluster).
When the washer button is pressed, washer fluid is sprayed onto the rear window. The
wiper is activated after a short delay (100 milliseconds).
If the washer function is no longer activated, then the wiper runs on continuously for four
seconds.

1 - Rear window wiper relay
Modelling of the warning tones and signal tones, plus the management of their priorities
The timer module generates the warning tones and signal tones and determines their
priorities. The following warning tones and signal tones are currently generated by
the timer module, listed in order of priority:
Airbag system fault, if the display in the instrument cluster has failed. Tone frequency
1000 Hz. The tone sounds 5 times at 5 second intervals and is repeated every 30
minutes.
Exterior lighting switched on, door ajar or open. Ignition off. Tone frequency 1500 Hz.
The tone continues to sound as long as the condition applies.
Hazard warning lights; when the hazard warning light switch is operated a clicking

tone sounds 70 to 110 times a minute until the hazard warning light switch is switched
off again.
Turn signal; when the turn signal switch is operated a clicking tone sounds 70 to 110
times a minute (or 140 to 250 times a minute if the bulb is faulty) as long as the turn
signal switch is switched on.

Instrument Cluster - Instrument Cluster—
Liquefied Petroleum Gas (LPG)
Print

1 - Malfunction Indicator Lamp (MIL)
2 - Powertrain warning lamp
3 - Air bag warning indicator
4 - Turn signal indicator
5 - High beam indicator
6 - Turn signal indicator
7 - Anti-lock Brake System (ABS) warning indicator
8 - Charge warning indicator
9 - Oil pressure warning indicator
10 - LPG select indicator
11 - Parking brake/Brake warning indicator
12 - Fuel gauge/LPG gauge
13 - Traction Control System (TCS)
14 - Speedometer
15 - Odometer
16 - Tachometer
17 - Temperature gauge
The LPG and petrol fuel systems share the same fuel gauge.
When LPG running is selected, the fuel gauge will move to the empty position and then
move back up the gauge until it settles to show the LPG fuel level. At the same time, the
LPG select indicator will flash until the vehicle is running on LPG when the light will remain
on.

When LPG running is deselected, the fuel gauge will move to the empty position and then
move back up the gauge until it settles to show the petrol fuel level. At the same time, the
LPG select light will extinguish when the vehicle is running on petrol.
All vehicles
The instrument cluster provides the driver with information and warning indicators on the
vehicle systems.
Vehicle options dictate the operational warning indicators, although the legends may be
fitted, not all will be illuminated.
The gauges and warning indicators may use the outputs from common sensors to carry out
their respective functions. This should always be considered when looking at any system
which may not be functioning correctly, for example:
The electronic speedometer receives its signal from the vehicle speed sensor (VSS)
mounted on the transaxle. Other systems which require input include, engine management,
anti-lock braking, speed control, trip computer.
Always consider and check associated systems for operation, as this may save time when
looking for a fault.
Instrument clusters should be repaired as an assembly and not dismantled for repair.

Print
General Equipment
The Ford approved diagnostic tool
Engine oil filter Fuse(s)
Engine oil level Wiring harness
Engine coolant temperature (ECT) sensor Electrical connector(s)
Engine coolant level Instrument cluster
Thermostat Light emitting diode(s) (LED)(s)
Collapsed or damaged fuel tank Alternative fuel control module (AFCM)
Door adjustment - Vehicles with LPG fuel system
Fuel level sensor - Vehicles with Liquified Powertrain control module (PCM)
Petroleum Gas (LPG) fuel system
Fuel level sensor gauge - Vehicles with
LPG fuel system
4. 4. If the cause is not visually evident, verify the symptom and enter the instrument
cluster Self-Diagnostic Mode.
Self-Diagnostic Mode
NOTE: The instrument cluster tripmeter reset button is located on the right-hand side of
the instrument cluster lens.
1. 1. To enter the instrument cluster Self-Diagnostic Mode simultaneously press and

hold the tripmeter reset button and turn the ignition switch to position II. It will
take between 5 and 8 seconds for the instrument cluster to enter the Self-
Diagnostic Mode.
2. 2. The tripmeter reset button must be released within 3 seconds of tESt being
displayed in the tripmeter LCD, or the Self-Diagnostic Mode will exit.
3. 3. The Self-Diagnostic Mode will enter the gauge sweep test.
4. 4. To navigate through or skip any of the instrument cluster Self-Diagnostic Mode

tests press the tripmeter RESET button. If the reset button is pressed and held for
more than 3 seconds between tests, the instrument cluster will exit the Self-
Diagnostic Mode.
5. 5. The Self-Diagnostic Mode is deactivated when the ignition switch is turned to the
OFF position.
6. 6. If the Self-Diagnostic Mode cannot be accessed, refer to the Symptom Chart or use

the Ford approved diagnostic tool to diagnose the instrument cluster.
Odometer Gauge/Indicator/Display
Test Display Tested Description
1. Gauge sweep GAGE Tachometer, speedometer, All gauges go through a full up
temperature and fuel and down pointer sweep
smoothness check, which takes
approximately 6 seconds.
2. Fill in all LCD All segments Odometer LCD and clock LCD Fills in the LCDs of the odometer
illuminated and clock.
3. Indicator LED lEdS Anti-lock brake system Illuminates all the LED warning
(s) (ABS) warning indicator indicators that are controlled by
Parking brake/brake the instrument cluster.
warning indicator
Charging system
warning indicator
Glow plug indicator
Low fuel level indicator
Malfunction indicator
Lamp (MIL)
4. ROM level r XXX or Instrument cluster read only Displays the instrument cluster
FAIL memory (ROM) ROM level and type.
5. Non-volatile EXXX or Instrument cluster non- Displays the instrument cluster
memory level FAIL volatile memory ROM level and type as stored in
the non-volatile memory.
6. Diagnostic dtc then DTCs To list the DTCs stored, press the
trouble code XXXX or RESET button. REFER to the
(DTC) nonE instrument cluster DTC index. A
new DTC code will be displayed
with each press of the reset
button.
7. Vehicle speed XXX.X Speedometer Displays the speed signal input in
m.p.h. m.p.h. 000.0 will be displayed in
odometer display if no signal
received.
8. Vehicle speed XXX.X Speedometer Displays the speed signal input in
km/h km/h. 000.0 will be displayed in
odometer display if no signal
received.
9. Not required XXX.0 - Not required.
10. Engine XXXX Tachometer Displays the tachometer input
speed signal (RPM). 0000 will be
displayed in odometer display if
no signal received.
11. Not required XXX.t - Not required.
12. Fuel volume FXXX Fuel sender system Displays the fuel volume signal
input. 000 - 009 Short circuit. 010
- 254 Normal range. 255 open
circuit.
13. Fuel volume LXXX Fuel sender system Displays the fuel volume signal
input as a percentage.
14. Not required XXX.f - Not required.
15. Engine XXX C ECT Displays the last engine coolant
coolant temperature signal input in 1/10
temperature degree C.
(ECT)
16. Not required XXX.C - Not required.

17. Battery bXX.X Vehicle charging system input Displays the charging voltage
charging voltage input to battery.
18. Anti-lock Ab-H or Ab- ABS status input Displays H for ABS input open
brake system L circuit or battery positive (LED
(ABS) failure ON), L for ABS input to ground
(LED OFF).
19. Electronic Eb-H or Eb-L EBD status Input Displays H for EBD input open
brake circuit or battery positive (LED
distribution ON), L for EBD input to ground
(EBD) failure (LED OFF).
20. Cluster IL-H or IL-L Cluster illumination input Displays H for illumination input
illumination battery positive (illumination ON),
L for illumination input open
circuit (illumination OFF).
21. Crank Cr-X Engine crank input Displays H with ignition in position
sensing II and L with ignition in position
III.
22. Not required A-HH - Not required.
23. Not required b-HH - Not required.
24. Not required C-HH - Not required.
25. Not required d-HH - Not required.
26. Battery 0XXX Battery voltage Displays battery voltage input.
voltage
27. Fuel sender 1XXX Fuel sender input
Displays the raw input from the
fuel level sender unit.
28. Intermittent 2L or 2H Intermittent front wiper Displays L for intermittent front
front wiper switch input wiper switch not pressed and H
for intermittent front wiper switch
pressed.
29. Drivers door 3H or 2L Drivers door courtesy switch Displays H for door closed and L
courtesy switch position input for door open.
30. Passenger 4H or 4L Passenger and rear door Displays H if both passenger and
and rear door courtesy switch position rear doors are closed and L if
courtesy switch inputs either passenger or rear door is
open.
31. Sliding door 5H or 5L Sliding door courtesy switch Displays H for door closed and L
courtesy switch position input for door open.
32. Intermittent 6L or 6H Intermittent rear wiper switch Displays L for intermittent rear
rear wiper position input wiper switch not pressed or not
installed and H for intermittent
rear wiper switch pressed.
33. Windscreen 7H or 7L Windscreen washer switch Displays H for windscreen washer
washer switch position input switch not pressed and L for
windscreen washer switch
pressed.
34. Not required P1XX - Not required.
NOTE: If the tripmeter reset button is pressed again, the self-diagnostic test will return to
gauge sweep test and continue to repeat the Self Diagnostic routine.
7. 7. If the concern is not evident refer to the Symptom Chart.
Symptom Chart

The fuel guage is inoperative or erratic. * Fuel pump and sender * GO to Pinpoint

unit/fuel level sensor. Test A.
* Circuit
* Instrument cluster
The water-in-fuel indicator is * Water-in-fuel indicator bulb. * GO to Pinpoint
inoperative/always on - diesel only. * Circuit. Test B.
* Water-in-fuel sensor.
* Instrument cluster.
* Fuse.
* Fuel filter requires draining.
Incorrect LPG fuel gauge indication - Vehicles * LPG fuel tank level float. * GO to Pinpoint
with LPG fuel system. * LPG fuel tank level indicator. Test C.
* AFCM.
* PCM.
PINPOINT TEST A : THE FUEL GAUGE IS INOPERATIVE OR ERRATIC
A1: CHECK CIRCUITS 8-GA7 (WH/RD) AND 9-GA7 (BN/RD) FOR OPEN CIRCUIT
2 Disconnect Fuel Level Sensor C732.
instrument cluster connector pins, harness side and
the fuel pump and sender unit/fuel level sensor
connector pins, harness side:
C809 pin 8, circuit 8-GA7 (WH/RD) and C732 pin 2,

circuit 8-GA7 (WH/RD).
C809 pin 15, circuit 9-GA7 (BN/RD), and C732 pin
4, circuit 9-GA7 (YE/VT).

Yes
GO to A2.
No
REPAIR circuit 8-GA7 (WH/RD) or 9-GA7 (BN/RD) as
A2: CHECK THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL
SENSOR
1 Remove the fuel pump and sender unit/fuel level
sensor.
REFER to: Fuel Level Sensor - 1.8L Duratorq-TDCi
(Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (310-
01A Fuel Tank and Lines, Removal and Installation) /
Fuel Pump - 75 PS/90 PS/110 PS, Vehicles Built
From: 08/2006 (303-04B Fuel Charging and Controls
2 Measure the resistance between the fuel level
sensor/fuel pump and sender unit pin 2, component
side and the fuel level sensor/fuel pump and sender
unit pin 4, component side while moving the float
arm lever from the empty to the full positions.
Is the resistance approximately 300 ohms +/- 3.5 ohms

at the empty position and approximately 10 ohms +/- 1
ohm at the full position?
Yes

REFER to the Ford approved diagnostic tool to
diagnose the instrument cluster.
No
MOVE the rigid wire lever from empty to full a
minimum of 10 times. CARRY OUT the resistance
check again. If the concern persists, INSTALL a new
fuel level sensor. TEST the system for normal
operation.
PINPOINT TEST B : THE WATER-IN-FUEL INDICATOR IS

INOPERATIVE/ALWAYS ON - DIESEL ONLY
B1: CHECK THE WATER-IN-FUEL WARNING LAMP
Does the water-in-fuel lamp illuminate?
Yes
CONFIRM there is no water in the fuel filter. If no
water is present INSTALL a new water-in-fuel sensor.
No
Vehicles built up to 06/2004GO to B2.
Vehicles built 06/2004 onwardsGO to B6.
B2: CHECK CIRCUIT 15-PE23 (GN/RD) FOR POWER
2 Disconnect Water-in-Fuel Sensor C724.
4 Measure the voltage between water-in-fuel sensor
C724 pin 2, circuit 15-PE23 (GN/RD), harness side
and ground.

Yes
GO to B3.
No
operation.
B3: CHECK THE WATER-IN-FUEL SENSOR
2 Install a 10 amp fused jumper wire between water-
in-fuel sensor C724 pin 3, circuit 15-PE23 (GN/RD),
harness side and water-in-fuel sensor C724 pin 1,
circuit 15S-PE23 (GN/RD), harness side.

Yes
GO to B4.
No

GO to B5.
B4: CHECK CIRCUITS 91-RN2 (BK/BU) AND 91-PE23 (BK/OG) FOR OPEN
2 Measure the resistance between water-in-fuel sensor
C724 pin 3, circuit 91-PE23 (BK/OG), harness side
and ground.

Yes
INSTALL a new water-in-fuel sensor. TEST the
No
operation.
B5: CHECK CIRCUIT 15S-PE23 (GN/RD) FOR OPEN
C724 pin 1, circuit 15S-PE23 (GN/RD), harness side
and instrument cluster C809 pin 17, circuit 15S-PE23
(GN/RD), harness side.

Yes
No
operation.
B6: CHECK CIRCUIT 91-PE23 (BK/OG) FOR POWER
2 Disconnect Water-in-Fuel Sensor C724.
4 Measure the voltage between water-in-fuel sensor
and ground.

Yes

GO to B8.
No
operation.
B7: CHECK CIRCUITS 91-RN2 (BK/BU) AND 91-PE23 (BK/OG) FOR OPEN
and ground.

Yes
GO to B8.
No
operation.
B8: CHECK THE WATER-IN-FUEL SENSOR
2 Install a jumper wire between water-in-fuel sensor
and water-in-fuel sensor C724 pin 1, circuit 91S-PE23
(BK/OG), harness side.

Yes
INSTALL a new water-in-fuel sensor. TEST the
No
GO to B9.
B9: CHECK CIRCUIT 91S-PE23 (BK/OG) FOR OPEN
C724 pin 1, circuit 91S-PE23 (BK/OG), harness side
and instrument cluster C813 pin 4, circuit 91S-PE23

Yes

No
operation.
PINPOINT TEST C : INCORRECT LPG FUEL GAUGE INDICATION - VEHICLES

WITH LPG FUEL SYSTEM
C1: CHECK THE LPG FUEL GAUGE FOR SWEEP
1 Disconnect LPG Fuel Tank C907.
3 Select LPG
Does the LPG fuel indicator in the instrument cluster
sweep to full?
Yes
GO to C2.
No
GO to C3.
C2: CHECK THE LPG FUEL GAUGE FOR RETURN
1 Install a 10 amp fused jumper wire between the LPG
fuel tank C907 pin 3, circuit 91-XL31 (BK/BU),
harness side and the LPG fuel tank C907 pin 1, circuit
8-GA6 (WH), harness side.
Does the LPG fuel indicator in the instrument cluster

return to empty?
Yes
GO to C5.
No
GO to C7.
C3: CHECK CIRCUIT 8-GA6 FOR POWER
1 Measure the voltage between the LPG fuel tank C907
pin 1, circuit 8-GA6 (WH), harness side and ground.
Is the voltage 5 volts?

Yes
GO to C4.
No
GO to C13.
C4: CHECK CIRCUIT 91-XL31 (BK/BU) FOR OPEN
1 Measure the resistance between the LPG fuel tank
C907 pin 3, circuit 91-XL31 (BK/BU), harness side
and ground.

Yes
GO to C5.
No
operation.
C5: CHECK THE LPG FUEL TANK GAUGE CIRCUIT
1 Measure the resistance between the LPG fuel tank
C907 pin 3, circuit 91-XL31 (BK/BU), component side
and the LPG fuel tank C907 pin 1, circuit 8-GA6
(WH), component side.
Is the resistance between 0-160 ohms?

Yes
GO to C6.
No
CHECK and REPAIR the circuit as necessary. TEST the
C6: CHECK THE FUEL LEVEL SENSOR GAUGE FOR CORRECT OPERATION
1 Remove the LPG fuel level sensor gauge.
NOTE: Place the magnet underneath the fuel level
sensor gauge.
2 Using a suitable magnet, check the fuel level sensor
gauge for movement by twisting the magnet
clockwise and counterclockwise.
Does the fuel level sensor gauge move freely?

Yes
INSTALL a new fuel level sensor.
REFER to: Fuel Level Sensor (310-01B Fuel Tank and
Lines - 1.8L Duratec-DOHC (85kW/115PS) - Zetec,
Installation).
No
INSTALL an new fuel level sensor gauge. TEST the
C7: CHECK CIRCUIT 8-GA6 (WH) FOR OPEN

3 Measure the resistance between the AFCM C405 pin
51, circuit 8-GA6 (WH), harness side and the LPG
fuel tank C907 pin 1, circuit 8-GA6 (WH), harness
side.

Yes
GO to C8.
No
operation.
C8: CHECK CIRCUIT 5-EG9C (BU/BK) AND CIRCUIT 5-EG8 (BU/WH) FOR OPEN
3 Measure the resistance between the PCM C415 pin
15, circuit 5-EG9C (BU/BK), harness side and the
instrument cluster C809 pin 26, circuit 5-EG8
(BU/WH), harness side.

Yes
GO to C9.
No
operation.
C9: CHECK CIRCUIT 4-EG9C (GY/OG) AND CIRCUIT 5-EG8 (GY/VT) FOR OPEN
1 Measure the resistance between the PCM C415 pin
16, circuit 4-EG9C (GY/OG), harness side and the
instrument cluster C809 pin 13, circuit 5-EG8
(GY/VT), harness side.

Yes
GO to C10.
No
operation.
C10: CHECK THE PCM FOR CORRECT OPERATION
1 Connect the Ford approved diagnostic tool to the
vehicle and select the SCOPE function.
2 Connect PCM C415.
3 Connect Instrument Cluster C809.
Is a pulse width modulated (PWM) signal indicated?

Yes
GO to C11.
No
GO to C12.
C11: CHECK THE CLUSTER FUNCTIONS
1 Observe the cluster for correct functionality.
Does the instrument cluster work correctly?
Yes
INSTALL a new PCM.
REFER to: Powertrain Control Module (PCM) - 1.8L
Duratorq-TDDi (55kW/75PS) - Lynx/1.8L Duratec-
DOHC (85kW/115PS) - Zetec, LHD FWD, Vehicles
Built Up To: 07/2006 (303-14 Electronic Engine
No
C12: CHECK THE CALIBRATION DATA OF THE AFCM
1 Using the Ford approved diagnostic tool check the
AFCM for the latest calibration information.
Is the latest calibration information installed?
Yes
INSTALL a new AFCM.
No
Reprogram the AFCM using the Ford approved
diagnostic tool. TEST the system for normal
operation.
C13: CHECK CIRCUIT 30-XL35 (RD) AND CIRCUIT 30-XL35A (RD) FOR POWER
1, circuit 30-XL35 (RD) harness side and ground and
the AFCM C405 pin 17, circuit 30-XL35A (RD),
Are both voltages greater than 10 volts?

Yes
GO to C14.
No
REPAIR the necessary circuit(s). TEST the system for
normal operation.
C14: CHECK CIRCUIT 15-LX35 (GN/WH) FOR SWITCHED POWER
2 Measure the resistance between C405 pin 18, circuit
15-LX35 (GN/WH) harness side and ground.

Yes
GO to C15.
No
operation.
C15: CHECK THE AFCM GROUND CIRCUIT FOR OPEN
37, circuit 91-XL35 (BK), harness side and ground
and the AFCM pin 38, circuit 91-XL35A (BK), harness
side and ground and the AFCM pin 39, circuit 91-
XL35B (BK), harness side and ground and the AFCM
pin 40, circuit 91-XL35C (BK), harness side and
ground and the AFCM pin 41, circuit 91-XL35D (BK),

Yes
GO to C12.
No
REPAIR the necessary circuit(s). TEST the system for
normal operation.
8. 8. REFER to the Ford approved diagnostic tool to continue diagnostics.
Configuration of Instrument Cluster

The instrument cluster is a programmable module, which must be configured by selecting
the Programmable Module Installation Routine on the Ford approved diagnostic tool.
The following features will need to be configured when a new instrument cluster is installed:
Malfunction Indicator Lamp (MIL) (if equipped).

Anti-lock Brake System (ABS) warning indicator.
Electronic brake distribution (EBD) indicator.

Print
NOTE: If a new instrument cluster is to be installed, connect WDS and upload the
instrument cluster configuration information using the programmable modules installation
routine, prior to commencing the removal of the instrument cluster.
2. Adjust the steering column to its maximum
extension and lowest position.
(s).

5 - Steering column upper shroud retaining clips
See Removal Detail
-

-
6 Instrument cluster bezel retaining screws
7 - Instrument cluster bezel and steering column upper shroud
8 - Instrument cluster retaining screws
9 - Instrument cluster electrical connectors
See Removal Detail
Removal Details
Item 5 : Steering column upper shroud retaining clips
1. Using a thin bladed screwdriver, release the

steering column upper shroud retaining clips.
Item 9 : Instrument cluster electrical connectors
CAUTION: Make sure the instrument cluster lens is protected by a clean soft cloth.
Failure to follow this instruction may result in damage to the instrument cluster lens.
1. To disconnect the instrument cluster electrical
connector:
1. Press the locking tang.
2. Move the release lever until fully engaged
in the open position.

Instrument Cluster - Instrument Cluster—
Print

General Equipment
Removal

Upload the instrument cluster configuration
information using the Programmable Modules
Installation Routine.

Record the odometer value from the original
instrument cluster. If the odometer value cannot
be obtained from the instrument cluster (display
failure), the customer should supply the
approximate odometer value.
3.
4.
5.

6.
Installation

Download the instrument cluster configuration
information to the newly installed instrument
cluster using the programmable modules
installation routine.

Horn - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Horn bracket retaining bolt 12 9 -

Horn - Horn Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Electrical
Fuse(s)
Wiring harness
Horn switch
Horn
Clockspring
Relay
Chart.
Symptom Chart
Symptom Chart

The horn is inoperative * Fuse(s). * GO to Pinpoint Test A.
* Circuit(s).
* Horn.
* Relay.
* Clockspring.
* Horn switch.
The horn is always on * Relay. * GO to Pinpoint Test B.
* Horn switch.
* Circuit(s).
* Clockspring.
Pinpoint Tests
PINPOINT TEST A : THE HORN IS INOPERATIVE

A1: CHECK POWER TO THE HORN
1 Disconnect Horn C982.
2 Measure the voltage between the horn C982 pin 1,
circuit 29S-GJ6 (OG/YE), harness side and ground
while pressing the horn switch.

Yes
GO to A2.
No
GO to A3.
A2: CHECK GROUND TO THE HORN
1 Measure the resistance between the horn C982 pin
2, circuit 31-GJ6 (BK), harness side and ground.

Yes
INSTALL a new horn. TEST the system for normal
operation.
No
REPAIR circuit 31-GJ6 (BK). TEST the system for
normal operation.
A3: CHECK POWER TO THE HORN RELAY
1 Disconnect Horn Relay C1014.
2 Measure the voltage between the horn relay C1014
pin 1, harness side and ground; and horn relay
C1014 pin 3, harness side and ground.

Yes
GO to A4.
No
INSTALL a new BJB. TEST the system for normal
operation.
A4: CHECK HORN SWITCH CIRCUIT FOR OPEN
1 Measure the resistance between the horn relay
C1014 pin 2, circuit 91S-GJ7 (BK/BU), harness side
and ground while pressing the horn switch.

Yes
GO to A5.
No
GO to A6.
A5: CHECK CIRCUIT 29S-GJ6 (OG/YE) FOR OPEN
1 Measure the resistance between the horn relay
C1014 pin 5, circuit 29S-GJ6 (OG/YE), harness side
and horn C982 pin 1, circuit 29S-GJ6 (OG/YE),
harness side.

Yes
INSTALL a new horn relay. TEST the system for
normal operation.
No
REPAIR the circuit . TEST the system for normal
operation.
A6: CHECK CIRCUIT 91S-GJ7 (BK/BU) FOR OPEN
WARNING: To deactivate the driver air bag, refer to the procedure in section 501-
20B for the correct air bag deactivation procedure. Failure to follow this instruction, may
1 Disconnect Clockspring C896.
2 Measure the resistance between the clockspring
C896 pin 6, circuit 91S-GJ7 (BK/BU), harness side
and horn relay C1014 pin 2, circuit 91S-GJ7
(BK/BU), harness side.

Yes
GO to A7.
No
operation.
A7: CHECK CIRCUIT 91-PG30 (BK/WH) FOR OPEN

C896 pin 7, circuit 91-PG30 (BK/WH), harness side
and ground.

Yes
GO to A8.
No
operation.
A8: CHECK THE HORN SWITCH
1 Remove the drivers air bag module. REFER to
Section 501-20A Safety Belt System / 501-20B
Supplemental Restraint System.
2 Measure the resistance between the horn switch
pin 1, component side and horn switch pin 2,
component side while pressing the horn switch.

Yes
INSTALL a new clockspring. REFER to Section 501-
20A Safety Belt System / 501-20B Supplemental
Restraint System. TEST the system for normal
operation.
No
INSTALL a new driver air bag module. REFER to
Supplemental Restraint System. TEST the system
PINPOINT TEST B : THE HORN IS ALWAYS ON

B1: CHECK CIRCUIT 29S-GJ7 (OG/YE) FOR SHORT TO BATTERY POSITIVE
1 Disconnect Horn Relay C1014.
Does the horn stop sounding with C1014 disconnected?
Yes
GO to B2.
No
operation.
B2: CHECK THE HORN SWITCH CIRCUIT FOR CONTINUITY
WARNING: To deactivate the driver air bag, refer to the procedure in section 501-
20B for the correct air bag deactivation procedure. Failure to follow this instruction, may
1 Disconnect Clockspring C896.

C896 pin 6, circuit 91S-GJ7 (BK/BU), component
side and clockspring C896 pin 7, circuit 91-PG30
(BK/WH), component side.
Is the resistance greater than 10,000 ohms?

Yes
GO to B3.
No
B3: CHECK HORN SWITCH CIRCUIT FOR SHORT TO GROUND
C896 pin 6, circuit 91S-GJ7 (BK/BU), component
side and ground.
Is the resistance greater than 10,000 ohms?

Yes
REPAIR circuit 91S-GJ7 (BK/BU). TEST the system
No

Horn - Horn Switch Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
NOTE: The horn switch and driver air bag module are one component and cannot be
serviced separately.
1. Remove the driver air bag module. For additional
information, refer to Section 501-20A Safety
Belt System / 501-20B Supplemental Restraint
System.

Warning Devices - Warning Devices Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Electrical
Instrument cluster

Warning Devices - Oil Change Indicator
Reset
Print
General Procedures
1. Turn the ignition key to position II without

cranking the engine.
2. Simultaneously press and hold the accelerator
pedal and the brake pedal for approximately 15
seconds until the oil change reminder indicator
starts to flash or the "Service Oil Reset
Complete" message appears in the information
and message center (if equipped).
3. Release the pedals.
4. Check that the oil change reminder indicator has
turned off or that there is no "Service Oil"
message in the information and message center
(if equipped). If the oil change reminder indicator
is still illuminated or the "Service Oil" message is
still displayed, turn the ignition key to position 0
and repeat the procedure from Step 1. If it has
turned off or the "Service Oil" message has
disappeared, proceed to Step 5.
5. Turn the ignition key to position 0 and leave it
there for at least 2 minutes so that the
powertrain control module (PCM) fully powers
down and updates the non-volatile memory
(NVM) in the PCM.
6. Turn the ignition key to position II without
cranking the engine and check that the oil
change reminder indicator is not illuminated or
that there is no "Service Oil" message displayed.
7. Turn the ignition key to position 0.

Parking Aid - Parking Aid Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Overview

1 - Parking aid control unit
2 - LED, parking aid switch
4 - Backup lamp switch
5 - Ignition lock
6 - Parking aid switch
7 - Ultrasonic sensors
Fitting locations

1 - Parking aid control unit, behind the instrument cluster. Located to the
left of the instrument cluster on LHD variants, to the right of the
instrument cluster on RHD variants. The speaker is located on the
parking aid control unit.
2 - Switch for turning off the parking aid, with LED
3 - Four ultrasonic sensors in the rear bumper
Function
The parking aid uses ultrasound to measure the distance from the vehicle to the nearest
obstacle.
The system consists of four ultrasonic sensors in the rear bumper, a control unit onto which
the speaker is positioned and a switch (with LED) for switching the system off.
The ultrasonic sensors emit ultrasonic sound waves which they then receive back after they
are reflected by the obstacle.
The ignition must be switched on and reverse gear must be engaged for this function to
work.
A speaker on the right-hand side (RHD) or left-hand side (LHD) (behind the instrument
cluster in each case) sounds an acoustic warning when reversing in front of obstacles.
The individual warning tones get closer and closer together as the vehicle approaches the

obstacle.
When the distance is reduced to approx. 25 cm a continuous warning tone sounds.
If the parking aid is switched off via the parking aid switch while reversing, then the system
is reactivated again after reverse gear is disengaged and then re-engaged.
Control unit
The control unit

controls the ultrasonic sensors and processes the echoes (sound waves) received from
the sensors,
controls the speaker positioned on the control unit,
monitors the system and stores any trouble codes,
controls the LED in the parking aid switch.
Speakers
The speaker emits an acoustic signal while reversing to indicate the distance to an obstacle.
Ultrasonic sensors
The ultrasonic sensor produces the ultrasound signal and receives the reflected echo
(signal).
All of the sensors are identical in form and electrical function.
The sensors are connected to the system by a 3-pole wiring harness connector.
Switch and indication of operation
The parking aid can be deactivated by pressing the switch while reversing.
The LED in the parking aid switch indicates the operation of the reversing aid. The LED is
controlled by the control unit.
The LED lights up:

during the system check after switching the ignition on for approx. 3 seconds.
continuously if a fault is found on the ultrasonic sensors or the speaker during the system
check.
if the parking aid is switched off.

1 - Ultrasonic sensor, right
2 - Ultrasonic sensor, right outer
3 - Ultrasonic sensor, left outer
4 - Ultrasonic sensor, left
5 - Rear bumper
6 - Speaker, located on the control unit
7 - Reverse gear switch
8 - DLC
9 - Control unit
10 - Parking aid switch with LED
11 - Central fuse box
12 - Ignition lock
13 - Fuse box - engine compartment
14 - Battery

Parking Aid - Parking Aid Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
On vehicles built up to 08/2006, the parking aid disabled indicator will illuminate for three
seconds when the ignition is turned to the RUN position. Pressing the parking aid disable
switch on the instrument panel will both disable the parking aid feature and illuminate the
parking aid disabled indicator. The system will default to enabled when the ignition switch is
turned to the RUN position.
The parking aid system will be disabled and the parking aid disable switch indicator remains
illuminated if a fault is detected in one of the four sensors, the parking aid speaker or the
parking aid module.
Vehicles built 08/2006 onward are not equipped with a parking aid disable switch.
Electrical
Fuse(s)
Wiring harness
Parking aid sensors
Parking aid disable switch (if equipped)
Light emitting diode (LED)
Parking aid speaker
Reversing lamp switch
Parking aid module
4. 4. If the cause is not visually evident, connect the Worldwide Diagnostic System (the
Ford diagnostic equipment) to the data link connector (DLC) and select the vehicle
system to be tested from the diagnostic menu.
5. 5. Retrieve the diagnostic trouble codes (DTC)s and refer to the DTC Index Chart.
6. 6. If no DTCs are retrieved or there is no communication with the module, proceed to

the Symptom Chart to continue diagnostics.
Symptom Chart

The parking aid is inoperative/does not operate * Fuse. * GO to Pinpoint Test
correctly * Circuit(s). A.
* Parking aid
module.

No communication with the parking aid module * DLC. * GO to Pinpoint Test
* Circuit(s). B.
* Parking aid
module.
Diagnostic Trouble Codes (DTC) Index

DTC Index
DTC Description Possible Source Action

C1699 Outer left sensor signal Parking aid Check the circuit 8-GN22 (WH/GN) for
circuit short to battery sensor signal short to battery. If the circuit is OK,
circuit. INSTALL a new parking aid module. TEST
Parking aid the system for normal operation.
module.
C1700 Outer left sensor signal Parking aid GO to Pinpoint Test C.
circuit open or short to sensor signal
ground circuit.
Parking aid
sensor.
Parking aid
module.
C1701 Concern with outer left Outer left INSTALL a new parking aid sensor. TEST
parking aid sensor parking aid the system for normal operation.
sensor.
C1702 Outer right sensor Parking aid CHECK the circuit 8-GN19 (WH) for short
signal circuit short to sensor signal to battery. If the circuit is OK, INSTALL a
battery circuit. new parking aid module. TEST the
Parking aid system for normal operation.
module.
C1703 Outer right sensor Parking aid GO to Pinpoint Test D.
signal circuit open or sensor signal
short to ground circuit.
Parking aid
sensor.
Parking aid
module.
C1704 Concern with outer Outer right INSTALL a new parking aid sensor. TEST
right parking aid sensor parking aid the system for normal operation.
sensor.
C1705 Inner left sensor signal Parking aid CHECK the circuit 8-GN21 (WH/BU) for
circuit short to battery sensor signal short to battery. If the circuit is OK,
circuit. INSTALL a new parking aid module. TEST
module.
C1706 Inner left sensor signal Parking aid GO to Pinpoint Test E.
circuit open or short to sensor signal
ground circuit.
Parking aid
sensor.
Parking aid
module.
C1707 Concern with inner left Inner left INSTALL a new parking aid sensor. TEST
sensor.
C1708 Inner right sensor Parking aid CHECK the circuit 8-GN20 (WH/RD) for
signal circuit short to sensor signal short to battery. If the circuit is OK,
battery circuit. INSTALL a new parking aid module. TEST
module.

C1709 Inner right sensor Parking aid GO to Pinpoint Test F.
signal circuit open or sensor signal
short to ground circuit.
Parking aid
sensor.
Parking aid
module.
C1710 Concern with inner right Inner right INSTALL a new parking aid sensor. TEST
sensor.
B1299 Sensor voltage supply Parking aid GO to Pinpoint Test G.
short to ground sensors voltage
supply circuits.
C1742 Parking aid speaker Parking aid GO to Pinpoint Test H.
circuit short to ground speaker circuit
(s).
Parking aid
speaker.
Parking aid
module.
C1743 Parking aid speaker Parking aid GO to Pinpoint Test I.
circuit short to battery speaker circuit
(s).
Parking aid
speaker.
Parking aid
module.
B2373 Parking aid disable Parking aid CHECK the circuit 15S-GN23 (GN/OG) for
switch LED circuit open disable switch open. If the circuit is OK, INSTALL a new
or short to battery circuit. parking aid module. TEST the system for
Parking aid normal operation.
module.
C1920 Parking aid disable Parking aid CHECK the circuit 15S-GN23 (GN/OG) for
switch LED circuit short disable switch short to battery. If the circuit is OK,
to ground circuit. INSTALL a new parking aid module. TEST
module.
C1748 Parking aid disable Parking aid GO to Pinpoint Test J.
switch short to ground disable switch
circuit.
Parking aid
disable switch.
Parking aid
module.
B1342 RAM Error Parking aid INSTALL a new parking aid module. TEST
module. the system for normal operation.
B2477 ROM/EEPROM Error Parking aid INSTALL a new parking aid module. TEST
module. the system for normal operation.
Pinpoint Tests
PINPOINT TEST A : THE PARKING AID IS INOPERATIVE/DOES NOT

OPERATE CORRECTLY
A1: CHECK FOR VOLTAGE TO THE PARKING AID MODULE
1 Disconnect Parking Aid Module C622.
2 Ignition switch in position I.
3 Measure the voltage between the parking aid module
C622 pin 1, circuit 15-GN10 (GN/YE), harness side

and ground.

Yes
GO to A2.
No
REPAIR the circuit 15-GN10 (GN/YE). TEST the
A2: CHECK THE PARKING AID MODULE GROUND CIRCUIT
module C622 pin 3, circuit 91-GN10 (BK/YE),
Is the resistance less than 1 Ohm?

Yes
GO to A3.
No
REPAIR the circuit 91-GN10 (BK/YE). TEST the
A3: CHECK THE REVERSE LAMP VOLTAGE INPUT
1 Select REVERSE.
C622 pin 9, circuit 15S-LG3B (GN/YE), harness side
and ground.

Yes
INSTALL a new parking aid module.
REFER to: Parking Aid Module (413-13 Parking Aid,
No
REPAIR the circuit 15S-GN11/15S-LG3B. TEST the
PINPOINT TEST B : NO COMMUNICATION WITH THE PARKING AID

MODULE
B1: CHECK THAT THE FORD DIAGNOSTIC EQUIPMENT IS COMMUNICATING THROUGH

THE DLC
1 Select an alternative system to check the DLC.
Is the Ford diagnostic equipment able to communicate
with the selected system?
Yes
GO to B2.
No
CHECK the DLC. For additional information, refer to
the Wiring Diagrams.
B2: CHECK THE CIRCUIT 8-EE13 FOR OPEN CIRCUIT
2 Measure the resistance between the DLC pin 7 and
the parking aid module C622 pin 5, circuit 8-EE13
(WH/RD), harness side.
Is the resistance less the 1 Ohm?

Yes
No
operation.
PINPOINT TEST C : DTC C1700 : REAR OUTER LEFT SENSOR SIGNAL

CIRCUIT OPEN OR SHORT TO GROUND
C1: CHECK CIRCUIT 8-GN22 (WH/GN) FOR OPEN CIRCUIT
2 Disconnect Parking Aid Sensor C607.
module C622 pin 11, circuit 8-GN22 (WH/GN),
harness side and the parking aid sensor C607 pin 2,
circuit 8-GN22 (WH/GN), harness side.

Yes
GO to C2.
No
operation.
C2: CHECK CIRCUIT 8-GN22 (WH/GN) FOR SHORT TO GROUND
module C622 pin 11, circuit 8-GN22 (WH/GN),

Is the resistance greater than 10,000 Ohms?
Yes
INSTALL a new parking aid sensor. If the concern
persists, INSTALL a new parking aid module.
No
REPAIR the short to ground. TEST the system for
normal operation.
PINPOINT TEST D : DTC C1703 : REAR OUTER RIGHT SENSOR SIGNAL

D1: CHECK CIRCUIT 8-GN19 (WH) FOR OPEN CIRCUIT
module C622 pin 24, circuit 8-GN19 (WH), harness
side and the parking aid sensor C604 pin 2, circuit 8-
GN19 (WH), harness side.

Yes
GO to D2.
No
operation.
D2: CHECK CIRCUIT 8-GN19 (WH) FOR SHORT TO GROUND
side and ground.

Yes

No
normal operation.
PINPOINT TEST E : DTC C1706 : REAR INNER LEFT SENSOR SIGNAL

E1: CHECK CIRCUIT 8-GN21 (WH/BU) FOR OPEN CIRCUIT
module C622 pin 10, circuit 8-GN21 (WH/BU),
circuit 8-GN21 (WH/BU), harness side.

Yes
GO to E2.
No
operation.
E2: CHECK CIRCUIT 8-GN21 (WH/BU) FOR SHORT TO GROUND
module C622 pin 10, circuit 8-GN21 (WH/BU),

Yes
No
normal operation.
PINPOINT TEST F : DTC C1709 : REAR INNER RIGHT SENSOR SIGNAL

F1: CHECK CIRCUIT 8-GN20 (WH/RD) FOR OPEN CIRCUIT
module C622 pin 23, circuit 8-GN20 (WH/RD),

circuit 8-GN20 (WH/RD), harness side.

Yes
GO to F2.
No
operation.
F2: CHECK CIRCUIT 8-GN20 (WH/RD) FOR SHORT TO GROUND
module C622 pin 23, circuit 8-GN20 (WH/RD),

Yes
No
normal operation.
PINPOINT TEST G : DTC B1299 : SENSOR VOLTAGE SUPPLY SHORT TO

GROUND
G1: CHECK THE CIRCUIT 7-GN2 (YE/RD) FOR SHORT TO GROUND
1 Disconnect Parking Aid sensors C604, C605, C606,
C607.
module C622 pin 15, circuit 7-GN2 (YE/RD), harness
side and ground.

Yes
GO to G2.
No

normal operation.
G2: CHECK EACH PARKING AID SENSOR FOR SHORT BETWEEN PINS 1 AND 3
1 Measure the resistance of each parking aid sensor
between pins 1 and 3 component side.

Yes
INSTALL a new parking aid sensor(s). TEST the
No
PINPOINT TEST H : DTC C1742: PARKING AID SPEAKER CIRCUIT SHORT

TO GROUND
H1: CHECK CIRCUIT 8-GN26 (WH) FOR SHORT TO GROUND
2 Disconnect Parking Aid Speaker C627.
side and the parking aid speaker C627 pin 1, circuit
8-GN26 (WH), harness side.

Yes
GO to H2.
No
operation.
H2: CHECK CIRCUIT 9-GN26 (BN) FOR SHORT TO GROUND
module C622 pin 17, circuit 9-GN26 (BN), harness
side and the parking aid speaker C627 pin 2, circuit
9-GN26 (BN), harness side.

Yes
INSTALL a new parking aid speaker. TEST the system

for normal operation. If the concern persists,
No
operation.
PINPOINT TEST I : DTC C174: PARKING AID SPEAKER CIRCUIT SHORT TO

BATTERY
I1: CHECK CIRCUIT 8-GN26 (WH) FOR SHORT TO BATTERY
2 Disconnect Parking Aid Speaker C627.
C622 pin 14, circuit 8-GN26 (WH), harness side and
ground.
Is a voltage present?
Yes
operation.
No
GO to I2.
I2: CHECK CIRCUIT 9-GN26 (BN) FOR SHORT TO BATTERY
C622 pin 17, circuit 9-GN26 (BN), harness side and
ground.
Is a voltage present?
Yes
operation.
No
INSTALL a new parking aid speaker. TEST the system
PINPOINT TEST J : DTC C1748 : PARKING AID DISABLE SWITCH SHORT

TO GROUND

J1: CHECK CIRCUIT 31S-GN12 (BK/OG) FOR SHORT TO GROUND
1 Disconnect Parking aid module C622.
2 Disconnect Parking aid disable switch C620.
module C622 pin 7, circuit 31S-GN12 (BK/OG)

Yes
INSTALL a new parking aid disable switch. TEST the
No
normal operation.

Parking Aid - Azimuth System Check Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Procedures
1. NOTE: The object used in this system check

can be fabricated from a 7.62 cm diameter
pipe, 99.06 cm in height.
NOTE: The following system check should be
carried out with the vehicle on a level
surface.
NOTE: The parking aid system will switch on
when the ignition is turned from position 0 to
position II.
Turn the ignition switch to position II.
2. Apply the parking brake.
3. Place the gear shift in reverse.
4. Verify the parking aid system detects the object
(7.62 cm diameter pipe 99.06 cm high) when
placed in the five specified locations (P1, P2, P3,
P4, P5).

Parking Aid - Elevation System Check Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Procedures
1. Ground reflection verification and sensor

coverage pattern.
2. The parking aid system must be checked to

assure that the system does not see signals from
ground reflections.
3. The following system check should be carried out
with the vehicle on a 4.8 metres wide by 3.00
metres deep smooth concrete surface, free of all
obstacles. The area should be free of noise from
fans and pneumatic tools.
4. Turn the ignition switch to position II.
5. Apply the parking brake.
6. Place the gear shift in reverse.
7. NOTE: No audible tones should be heard. If
audible alerts are heard, check to make sure
the bumper is properly installed and is not
tilted downward so the sensor is pointing
toward the ground.
Verify that no audible alerts are heard.

Parking Aid - Parking Aid Module Transit/Tourneo Connect 2002.5 (06/2002-)
Print

(s).


5 - Parking aid speaker electrical connector
6 - Parking aid module electrical connector
See Removal Detail
7 - Parking aid module retaining bolts
8 - Parking aid module
Removal Details
Item 6 : Parking aid module electrical connector
1. To disconnect the parking aid module electrical

connector:
1. Press the locking tang.
2. Detach the self locating electrical
connector.

Parking Aid - Parking Aid Module—
Print
Removal
1.
2.
3.
Installation

Charging System - General Information -
Charging System
Print
'Smart charge' generator control system

General
With conventional generators, a fixed target voltage is defined by the internal voltage
regulator, against which the system voltage is controlled.
On a generator with smart charge generator control, the voltage regulation functions
remain, the target voltage value is calculated in advance by the Powertrain Control Module
(PCM).
Because vehicle batteries can be better charged by a higher voltage when cold and by a
lower voltage when warm, it is advantageous to match the battery charging voltage to the
temperature of the battery. To do this, the PCM needs the vehicle battery electrolyte
temperature information.
Measuring the electrolyte temperature
The heat radiated by the vehicle engine must be taken into account when the electrolyte
temperature is considered.
In order to calculate the electrolyte temperature, the Intake Air Temperature (IAT) is
recorded. This is compared with the stored value which applied at the last time the engine
was switched off.
By comparing both temperatures, the PCM d calculates the vehicle battery electrolyte
temperature when the engine is running.
Layout of the "Smart Charge" current supply system

1 - Engine running relay
2 - Consumers
3 - Generator output, PCM input
4 - PCM output, generator input
-

-
5 Charge warning lamp in instrument cluster
6 - Intake air temperature signal
7 - Idle Air Control (IAC) valve, not diesel engines
The Smart Charge system needs no extra components compared with the conventional
regulator system.
The PCM simultaneously controls and monitors the power of the generator through two
electrical connections.
From the signal line "generator output, PCM input", the PCM receives the signal (pulse width
modulated) for the load on the generator. The signal is processed in the PCM , so that the
idle speed will be increased at high charging current. On petrol engines this is done through
the idle speed control valve, on diesel engines it is done directly through the PCM . The
generator output is also monitored through this signal line.
Via the signal line "PCM output, generator input" the generator voltage is regulated in
accordance with the PCM input signals, IAT and battery voltage.
The PCM controls the engine running relay. Through this relay, high current consumers (e.g.
the heated windshield) are only supplied with current when the generator is working.
The PCM actuates the charge warning lamp in the instrument cluster.
Starting the generator during engine starting
In the "smart charge current supply system", the generator is not activated during engine
starting. The generator is only switched on after the engine has started.
Switching on is done electronically by the PCM. The generator power is then increased
smoothly to the value required.
Increased idle speed
At idle with high generator load, the idle speed is increased in order to increase the
generator power.
The system can increase the idle speed in steps by up to 125 rev/min.
Diagnosis
There is a self-test facility for the Smart Charge System, stored in the PCM and which can
be diagnosed through WDS.
If a fault occurs in the system, the charge warning lamp is lit by the PCM.
if voltage regulation fails, the generator operates with a fixed charging voltage.
With fixed charging voltage the generator operates as usual and still delivers enough
current for the vehicle systems.
After the ignition is switched on, the PCM switches on the charge warning lamp to check
that it operates. After the engine starts, if the generator is producing enough electrical
power, the charge warning lamp is switched off again.

Charging System
Print

information.
General Equipment
Surface charge dissipation unit (SCD²)
Micro390 battery tester

WARNINGS:
Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also,
shield your eyes when working near batteries to protect against possible splashing of the
acid solution. In case of acid contact with skin or eyes, flush immediately with water for a
minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a
physician immediately. Failure to follow these instructions may result in personal injury.
Batteries normally produce explosive gases which can cause personal injury.
Therefore, do not allow flames, sparks or lighted substances to come near the battery.
When charging or working near a battery, always shield your face and protect your eyes.
Always provide ventilation. Failure to follow these instructions may result in personal
injury.
Accessory drive belt Fuse(s)
Generator Wiring harness
Generator decoupler (if equipped) Electrical connector(s)
Battery
Battery cables
Charging system warning indicator
4. 4. Check the operation of the charging system warning indicator lamp, located in the
instrument cluster. Normal operation is as follows:
Normal Charging System Voltages
Engine to Charging System

Ignition Switch I Generator B+ battery Warning Indicator
Position Circuit Circuit Battery ground Operation
Position 0 0V 10-12V 10-12V 0V OFF
Position II 0V 10-12V 10-12V 0V Illuminated
Position II with 13-15V 13-15V 13-15V 0V OFF
the engine
running

Chart.
Symptom Chart
Symptom Possible Action

Sources
The charging system warning * Accessory * CHECK the accessory drive belt condition,
indicator is on with the engine drive belt. REFER to: Accessory Drive (303-05
running (The charging system Accessory Drive, Diagnosis and Testing).
voltage does not increase) * Circuit. * CARRY OUT the generator tests, REFER to
* Generator. the Generator On-Vehicle Tests in
* Voltage Component Tests in this section.
regulator.
The charging system warning * Bulb. * INSTALL a new bulb.
indicator is off with the ignition * Ignition * CHECK the ignition switch.
switch in the RUN position and switch.
the engine off * Circuit. * CARRY OUT the generator tests, REFER to
* Generator. the Generator On-Vehicle Tests in
Component Tests in this section.
Radio interference * Circuit. * REFER to the WDS
* Generator.
The generator is noisy * Accessory * REFER to: Accessory Drive (303-05
drive belt. Accessory Drive, Diagnosis and Testing).
* Loose * TIGHTEN the generator mounting bolts.
generator
mounting
bolts.
* Generator. * INSTALL a new generator.
REFER to: Generator - 1.8L Duratorq-TDCi
Diesel, Vehicles Built From: 05/2003 (414-
02 Generator and Regulator, Removal and
Installation) /
Vehicles Built Up To: 05/2003 (414-02
Generator and Regulator, Removal and
Installation) /
Vehicles Built Up To: 05/2003 (414-02
Generator and Regulator, Removal and
Installation) /
/
/
in this section.
Vehicle electrical systems * Battery. * CARRY OUT the battery test, REFER to the
inoperative Battery Test in Component Tests in this
section.
The engine cranks slowly * Battery. * CARRY OUT the battery test, REFER to the
Battery Test in Component Tests in this
section.
* Battery cable * REFER to: Starting System - Vehicles Built
(s). From: 08/2006 (303-06 Starting System,
* Starter motor. Diagnosis and Testing).
Component Tests
Generator On-Vehicle Tests - No-Load Test

1. 1. Turn off all electrical loads and the ignition switch.
2. 2. Switch the multimeter to the voltage function.
3. 3. Connect the leads of the multimeter across the battery terminals.
4. 4. Read the voltage (base voltage).
5. 5. Start the engine.
6. 6. Run the engine at 1500 rpm with no electrical load.
7. 7. Read the voltage. The voltage should be in the range of 14.1 volts to 15.1 volts. If
the voltage increase is less than 2.5 volts above the base voltage, carry out the
Load Test. If the voltage increase is greater than 2.5 volts, REFER to the WDS.
Generator On-Vehicle Tests - Load Test
1. 1. With the engine running, turn on the air conditioning (if equipped), turn the blower
motor to high speed and the headlamps to high beam.
2. 2. Increase the engine speed to 2000 rpm. The voltage should increase a minimum of
0.5 volts above the base voltage. If the voltage does not increase as specified,
REFER to the WDS. If the voltage increases as specified, the charging system is
charging correctly. REFER to the Symptom Chart.
Battery Identification

1 - Cold crank amp (CCA) rating
2 - Reserve capacity (RC) rating (minutes)
3 - Battery voltage
4 - Ford Part number
5 - FINIS code
6 - EN number (European Norm)
7 - Battery type: Ca = Silver/Calcium; Sb = Lead/Antimony
8 - Amp hour rating
Battery Surface Charge Removal
Surface charge dissipation unit (SCD²)

1 - Connect black lead to battery - Connect red lead to battery +
2 - Red A indicator illuminates and green B indicator flashes
3 - Wait until green B indicator illuminates
4 - Disconnect from battery
5 - Max 18v
6 - -20°C to +55°C
7 - Red indicator (A)
8 - Green indicator (B)
CAUTION: Prior to testing any battery, the surface discharge must be dissipated. This
includes batteries that are returned disconnected from the vehicle. If the battery is
holding a surface charge, the battery tester will give false readings.
NOTE: The SCD² tool eliminates the need to dissipate the battery's surface charge via the
manual process of loading the battery via the operation of the vehicles electrical systems.
It also removes the variability in the process and makes sure that the actual dissipation of
the surface charge is qualified prior to testing.
1. 1. Connect the black lead to the battery negative terminal and the red lead to the
2. 2. The red indicator (A) illuminates and the green indicator (B) flashes.
3. 3. Wait until the green indicator (B) fully illuminates, then disconnect from the
battery.
Alternative Method To Dissipate The Battery Surface Charge
1. 1. Leave the battery to stand for a minimum of six hours without charging or
discharging or remove the surface charge through partial loading as follows:
Turn the ignition key to position II and switch on the headlamps (main beam),
heated windshield (if equipped), heated rear window (if equipped) and the heater

blower motor (position II). Leave the vehicle in this condition for a minimum of 60
seconds to dissipate the battery surface charge.
Turn the ignition key to position 0 and switch off the headlamps, heated windshield
(if equipped), heated rear window (if equipped) and the heater blower motor.
Leave the vehicle in this condition for a minimum of five minutes before testing
battery condition.
Battery Test
NOTE: Using the Micro390 Battery Tester: To fully determine battery condition once the
surface charge has been dissipated, the Micro390 battery tester must be used. For the
Micro390 battery tester to operate, it requires a minimum of 5.5 volts charge to be
present on the test battery. Therefore, if the Micro390 does not operate when connected
to a test battery, then a charge of less than 5.5 volts is present. In this instance, the
battery must be charged in line with the battery charging instructions prior to testing. In
the event of a conflict of results between the charge eye indicator and the battery tester,
the battery tester result must always be used. The charge eye indicator is for guidance
only.
1. 1. Connect the battery tester to the battery.
Connect the red clip to the battery positive (+) terminal and the black clip to the
battery negative (–) terminal.
2. NOTE: The label affixed to the top of batteries progressively from 06/1998 identifies
the battery CCA rating. Remove the battery if the label is obscured.
2. Use the ”Arrow” buttons on the battery tester to scroll to the battery’s labelled CCA
rating.

3. 3. Press the ”Test” button that corresponds to the correct battery temperature.
If the battery temperature is above zero degrees centigrade: press the ”sun”
button. If the battery temperature is below zero degrees centigrade: press the
”Ice-crystal” button.
4. 4. Carry out the action based upon the test result displayed and the following table.
1. Charge level bar graph.

2. Test result.
3. Battery voltage.
5. 5. Press the "information" button and carefully note the six-digit "Test Code" on the
job card for claim submission and audit purposes (graphic shows an example of the
code only).
Battery tester results and required actions
Tester Reading Action

GOOD BATTERY Return to service
GOOD RECHARGE Fully charge the battery and return to service*
CHARGE & RETEST Fully charge the battery and retest
REPLACE BATTERY or
BAD CELL BATTERY WARNING: Do not recharge the battery.
Make sure that the surface charge was removed. If so, disconnect the

battery from the vehicle and retest. If the result remains after surface
charge removal, install a new battery.
UNABLE TO TEST Disconnect the battery from the vehicle and retest.
*In addition, it is advisable to check the vehicle electrical system. Check that the generator
is functioning correctly and that all key-off loads (luggage compartment lamps, glove
compartment lamp and interior lamps) are not staying on.

Battery Charging
Print
General Procedures
General Equipment
Midtronics GR-590 Battery Management Center
Battery Charger
WARNINGS:
Always observe the battery charger equipment manufacturer’s instructions.
Do not jump/slave start using a battery charging system from another vehicle.
Do not overfill a battery as this can cause acid leakage that will result in damage to
the vehicle and possible personal injury.
CAUTIONS:
Do not rely on the generator to recharge a discharged battery. It would take in

excess of eight hours of continuous driving with no additional loads placed on the
charging system.
Make sure that the battery electrolyte reaches the indicated maximum mark.
Connect the battery charger cables to the battery before switching the battery
charger on.
Switch the battery charger off before disconnecting the battery charger cables from
the battery.
NOTE: Ford batteries generally require no maintenance however, in certain conditions, it
is possible for the electrolyte in a battery to fall below the minimum level.
NOTE: The use of the Midtronics GR-590 Battery Management Center, which has been
specifically designed for use on silver calcium type batteries is recommended. Once
connected to the battery, the battery charger detects the state of battery charge and
then applies the appropriate charge rate and duration. When the battery is fully charged,
the battery charger switches to stand-by, keeping the battery in a fully charged state
preventing excessive gassing and overcharging. The Midtronics GR-590 Battery
Management Center also incorporates a software program that has the capability to assist
in the recovery of deeply discharged (sulphated) batteries.
NOTE: Charging methods and types of battery chargers vary widely. Whichever method is
utilized it must be carried out carefully to avoid damage to the battery and possible
personal injury. Specific instructions accompanying each battery charger and must be
followed exactly. Safeguards provided by the equipment manufacturer should not be
disregarded by the operator.
NOTE: A battery which has been stored in a highly discharged state may be slow to
accept a charge at first. In such cases the initial charging rate may be so low that the
ammeter on some battery testers will not show any indication of charge for 5 to 10
minutes.
NOTE: Automatic battery chargers are also protected against reverse polarity connection
and require no adjustment or monitoring.
NOTE: Slow-charging will readily restore a battery to a full state of charge and, since the
charging current is relatively low, the possibility of overcharging a battery are minimized.
The charge rate used should be approximately equal to 5% of the reserve capacity of the
battery being charged (approximately three to six Amps depending on battery size). The
charging current should be adjusted 10 minutes after initial setting and again after 1 hour
before being left to charge the battery for between 8 and 12 hours.
NOTE: A constant voltage battery charger will charge a battery at a set maximum
voltage. The voltage used depends upon the design and condition of the battery charger

and the age and temperature of the battery. This type of battery charger initially charges
at a high rate of current that reduces as battery voltage is restored. When using a
constant voltage battery charger, the charging current should be recorded after five
minutes and the battery charger switched off when the charging current falls to one–third
of the recorded value, or after eight hours whichever occurs first.
NOTE: Multiple battery chargers are designed to charge a number of batteries,
simultaneously. Of the two different types of multiple battery chargers available, only
those that charge batteries in series should be used and it is important that batteries are
of the same or very similar ratings and voltages. Multiple battery chargers that charge
batteries in parallel are not recommended.
NOTE: The use of a fast (boost) battery charger is not recommended as it can cause
damage to a battery. Fast charging will only restore a battery to a state of charge that
will enable it to carry out it’s critical function of cranking the engine. Fast charging will not
restore a battery to a full state of charge and must therefore be followed by a period of
slow charging. Excessively fast charging can cause damage to a battery. For this reason,
charging times must be carefully controlled. Fast battery chargers vary widely in design
so it is very important to strictly adhere to the equipment manufacturer’s instructions. A
charge of 30 amps for up to 30 minutes is the most common fast charging application. If
the battery is very discharged and requires additional restoration, an additional charge of
20 amps for a period up to one and a half hours should be applied. Fast charging for a
period in excess of two hours significantly increases the risk of causing damage to the
battery.
NOTE: When connecting and disconnecting the battery from the vehicle, make sure that
the battery ground cable is disconnected first and connected last and that all electrical
items are switched off. Record the audio unit keycode and preset radio frequencies before
disconnecting the battery.
1. Remove the battery (Focus C-MAX 2003.75,
Focus 2004.75, S-MAX/Galaxy 2006.50, Mondeo
2007.50 only).
2. Disconnect the battery ground cable (All, except
the vehicles mentioned in the previous step).
3. NOTE: The maximum battery electrolyte
level is approximately 40 mm below the very
top of the battery casing. This corresponds
to a point just below the lower rim of the
battery casing.
Check that the battery electrolyte reaches the
indicated maximum level. Top up with
distilled/de-ionized water, as necessary.
4. Connect the positive red clamp from the battery

charger to the positive battery terminal.
5. Connect the negative black clamp from the
battery charger to the negative battery terminal.
6. Connect the AC power cable to the mains outlet
and switch on.
7. Follow the instructions supplied with the battery
charger to charge the battery.
8. To disconnect the battery charger, reverse the
connection procedure.

Battery, Mounting and Cables -
Specifications
Print
Battery Specifications
Ah Rating Model Battery Type Build date that Ca battery can be installed from
43 Focus Silver Calcium (Ca) All
50 Transit Silver Calcium (Ca) 08/1994
60 Transit Silver Calcium (Ca) 08/1994
70 Focus (diesel) Silver Calcium (Ca) All
70 Transit (diesel) Silver Calcium (Ca) 08/1994

Battery clamp nuts (to battery terminal) 5 - 44
Battery tray bolts 12 9 -
Battery hold - down clamp 12 9 -
Auxiliary connections on battery clamps 5 - 44
Ground cable to engine bolt 35 26 -
Generator electrical connector nut 8 - 71
Starter motor solenoid electrical connector 12 9 -

Battery, Mounting and Cables - Battery Transit/Tourneo Connect 2002.5 (06/2002-)
Print
REFER to: Charging System (414-00 Charging System - General Information, Diagnosis and
Testing).

Battery, Mounting and Cables - Battery
Disconnect and Connect
Print
General Procedures
Disconnect
WARNINGS:
Batteries normally produce explosive gases which may cause personal injury,
therefore do not allow flames, sparks or lighted substances to come near the battery.
When charging or working near the battery always shield your face and protect your
eyes. Always provide adequate ventilation. Failure to follow these instructions may result
in personal injury.
Batteries contain sulphuric acid, avoid contact with skin eyes or clothing. Shield your
eyes when working near the battery to protect against possible splashing of the acid
solution. In case of acid contact with the skin or eyes, flush immediately for a minimum
of 15 minutes and seek prompt medical attention. If swallowed, call a physician
Audio unit key code saving devices must not be used when working on supplemental
restraint or fuel systems. When using these devices the vehicle electrical system is still
live but with a reduced current flow. Failure to follow this instruction may result in
personal injury.
CAUTION: Make sure the engine is not running before disconnecting the battery
ground cable to avoid damage to the vehicle electrical system.
NOTE: Before disconnecting the battery make sure that no data is required from the
powertrain control module (PCM), as battery cable disconnection will erase any fault
codes and idle/drive values held in the keep alive memory (KAM). It is not necessary to
disconnect or remove electronic control modules.
NOTE: This procedure should be used to disconnect the battery while carrying out repairs
that refer to the battery being disconnected.
1. Obtain and record the audio unit keycode and
preset radio frequencies.
Connect
WARNINGS:
in personal injury.
Batteries contain sulphuric acid, avoid contact with skin eyes or clothing. Shield your
CAUTION: Make sure all electrical systems are switched OFF before connecting the
battery ground cable to avoid damage to the vehicle electrical system.
2. NOTE: This step is only required for vehicles

with 1.8L direct fuel injection.
NOTE: Do not press the accelerator pedal or
attempt to start the engine during the 30
second initialization period as this will cause
the initialization process to fail.
Turn the ignition key to position II for 30 seconds
to initialize the throttle body.
3. Enter the audio unit keycode and preset radio
frequencies.
4. Reset the clock to the correct time.
5. NOTE: When the battery has been
disconnected and connected, the stored idle
and drive values contained within the
powertrain control module (PCM) will have
been erased. The following steps must be
carried out to allow the PCM to relearn its
idle and drive values.
Start and run the engine at idle for three
minutes.
6. When the engine reaches normal operating
temperature, increase the engine speed to 1200
rpm and maintain for approximately two
minutes.
7. Drive the vehicle for approximately five
miles/eight kilometers of varied driving.

Battery, Mounting and Cables - Battery Transit/Tourneo Connect 2002.5 (06/2002-)
Print

(s).

1 - Battery positive terminal cover
2 - Battery positive terminal clamp
3 - Battery hold down clamp retaining bolt
4 - Battery hold down strap
5 - Battery hold down clamp
6 - Battery

CAUTION: If installing a new battery, only install the specified battery type.
For additional information, refer to: Specifications (414-01 Battery, Mounting and Cables,
Specifications).
Item 6 : Battery
CAUTION: Make sure the battery is positioned as close as possible to the left-hand
side front fender within the battery tray.

Tray
Print
1. Remove the battery.

For additional information, refer to Battery in this
section.
(s).

1 - Battery to starter motor solenoid cable retaining clips
2 - Engine wiring harness retaining clips
3 - Fuel injection supply wiring harness retaining clips
4 - Battery tray retaining bolts
5 - Battery tray

Cables—1.8L Duratec-DOHC Transit/Tourneo Connect 2002.5 (06/2002-)
Print
WARNINGS:
in personal injury.
Batteries contain sulphuric acid, avoid contact with skin, eyes or clothing. Shield your
personal injury.
ground cables to avoid damage to the vehicle electrical system.
(s).

1 - Auxiliary ground cable retaining nut
2 - Auxiliary ground cable
3 - Battery negative terminal clamp
5 - Auxiliary power cable retaining nut
6 - Auxiliary power cable
8 - Auxiliary power cable retaining clip
9 - Battery ground cable retaining bolt
11 - Battery hold down clamp
12 - Starter motor solenoid electrical connector
13 - Battery cable retaining clip

See Removal Detail
15 - Battery ground cable electrical connector
16 - Starter motor solenoid electrical connector retaining nut
17 - Starter motor electrical connector retaining nut
18 - Starter motor and starter motor solenoid electrical connector
20 - Battery cable to generator electrical connector
21 - Battery cable
frequencies.
minutes.
minutes.

Removal Details
Item 14 : Starter motor retaining bolt

Lifting.

Cables—1.8L Duratorq-TDCi (Lynx) Transit/Tourneo Connect 2002.5 (06/2002-)
Diesel/1.8L Duratorq-TDDi (Lynx) Diesel
Print
WARNINGS:
in personal injury.
Batteries contain sulphuric acid, avoid contact with skin, eyes or clothing. Shield your
personal injury.
ground cables to avoid damage to the vehicle electrical system.
(s).

1 - Auxiliary ground cable retaining nut
2 - Auxiliary ground cable
3 - Battery negative terminal clamp
5 - Auxiliary power cable retaining nut
6 - Auxiliary power cable
7 - Auxiliary power cable retaining clip
9 - Battery ground cable retaining bolt
11 - Battery hold down strap
12 - Starter motor solenoid electrical connector
13 - Battery cable retaining clips

See Removal Detail
15 - Battery ground cable electrical connector
16 - Battery cable retaining clip
17 - Starter motor solenoid electrical connector retaining nut
18 - Starter motor electrical connector retaining nut
20 - Battery cable
frequencies.

minutes.
minutes.
Removal Details
NOTE: Raise the vehicle.
NOTE: Lower the vehicle.

Generator and Regulator - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Torque Specifications - vehicles with diesel engine

Generator decoupler retaining bolts 12 9 -
Generator decoupler pulley bracket retaining bolts 25 18 -
Air conditioning (A/C) compressor retaining bolts 25 18 -

Engine roll restrictor retaining bolts 48 35 -
Front engine mounting to body retaining bolts 48 35 -

Generator and Regulator - Generator Transit/Tourneo Connect 2002.5 (06/2002-)
Print
REFER to Section 414-00 Charging System - General Information.

Generator and Regulator - Generator—
Zetec
Print
Special Tool(s)
310-040 (23-041)
WARNINGS:
in personal injury.
The fuel system remains pressurised for a long time after the ignition is switched off.
1. Depressurise the fuel system. For additional
Drive.
4. Remove the roll restrictor to crossmember
retaining bolt.

(s).

1 - Coolant expansion tank retaining bolt
2 - Coolant expansion tank retaining clip
3 - Coolant expansion tank
See Removal Detail
4 - Power steering reservoir
See Removal Detail
5 - Evaporative emission (EVAP) canister purge valve retaining bolts
6 - EVAP canister purge valve
See Removal Detail
7 - Fuel charging wiring harness electrical connector retaining bolt
8 - Fuel charging wiring harness electrical connector
See Removal Detail
9 - Engine ground cable to body retaining bolt
10 - Engine ground cable
See Removal Detail
12 - Fuel supply line to fuel injection supply manifold fuel supply pipe quick
release coupling
See Removal Detail
13 - Engine front mounting to body retaining bolts
14 - Engine assembly
See Removal Detail

15 - Generator electrical connector
16 - Battery to generator cable electrical connector retaining nut
17 - Battery to generator cable
18 - Generator upper retaining bolt
19 - Generator lower retaining bolt
See Removal Detail
20 - Generator
Removal Details
Item 3 : Coolant expansion tank
1. Secure the coolant expansion tank to one side.

Item 4 : Power steering reservoir
1. Detach the power steering reservoir and secure it

to one side.
Item 6 : EVAP canister purge valve
1. Secure the EVAP canister purge valve to one

side.
Item 8 : Fuel charging wiring harness electrical connector
1. Disconnect the fuel charging wiring harness

electrical connector and secure it to one side.

Information.
Item 12 : Fuel supply line to fuel injection supply manifold fuel supply pipe quick release
coupling
1. Disconnect the fuel supply line from the fuel

injection supply manifold fuel supply pipe. For
Item 14 : Engine assembly

Slide the engine forward.
Secure in position using an engine
mounting to body retaining bolt.
Item 19 : Generator lower retaining bolt
1. The generator lower retaining bolt can not be

removed at this stage.
Item 20 : Generator
1. Install the generator lower retaining bolt to the

generator. Do not tighten at this stage.
Item 14 : Engine assembly

Remove the engine mount to body
retaining bolt.
Slide the engine backwards.

1.8L Duratorq-TDCi (Lynx) Diesel/1.8L
Print
Removal
All vehicles
Operation).

All vehicles
4. Disconnect the generator electrical connectors.
5. Remove the generator decoupler retaining bolts.
6. Remove the generator decoupler.

Installation
All vehicles
1. NOTE: Do not tighten the generator retaining
bolts at this stage.
Install the generator and the generator retaining
bolts finger tight.
2. Install the generator decoupler and the generator

decoupler pulley bracket retaining bolts.
3. Tighten the generator retaining bolts (generator

decoupler shown removed for clarity).
4. Install the generator decoupler retaining bolts.

5. Connect the generator electrical connectors.

6. Install the A/C compressor and the A/C
compressor retaining bolts.
All vehicles

1.8L Duratorq-TDCi (Lynx) Diesel/1.8L
Built From: 05/2003
Print
Removal
All vehicles
Operation).

All vehicles
4. Disconnect the generator electrical connectors.

5. Remove the generator decoupler retaining bolts.
6. Remove the generator decoupler.


Installation
1. Install the generator and generator retaining
bolts.

2. NOTE: Do not tighten the generator retaining
bolts at this stage.
Install the generator and the generator retaining
bolts finger tight.
3. Install the generator decoupler and the generator

decoupler pulley bracket retaining bolts.
4. Tighten the generator retaining bolts (generator

decoupler shown removed for clarity).
5. Install the generator decoupler retaining bolts.
All vehicles
6. Connect the generator electrical connectors.

7. Install the A/C compressor and the A/C
compressor retaining bolts.
All vehicles


1.8L Duratorq-TDCi (Lynx) Diesel, Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1. Refer to: Accessory Drive Belt - 1.8L Duratorq-

Installation).
2.
2. if equipped
3.
Installation
1. Torque: 25 Nm
2.
2. if equipped
Torque: 8 Nm
3. Torque: 8 Nm

3. Refer to: Accessory Drive Belt - 1.8L Duratorq-
Installation).

Information and Entertainment System -
General Information - Specifications
Print
Item Specification
Cassette head cleaning fluid (from cassette head cleaner kit) Isopropyl alcohol

General Information - Audio System— Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.Refer to Wiring Diagrams Section 415-03, for schematic and
connector information.
General Equipment

NOTE: If the audio unit keycode is entered incorrectly 3 times, the audio unit will lock
out. The component can only be unlocked by the manufacturer.
Audio unit Fuse(s)
Antenna Wiring harness
Cassette player Electrical connector(s)
Foreign objects contacting speaker Audio unit
Trim poorly fitted/resonance Audio control switch (if equipped)
Audio control switch (if equipped)
4. 4. If the cause is not visually evident, verify the symptom and refer to the Self-
Diagnostic Mode.
Self-Diagnostic Mode - 2 Channel System

NOTE: The audio unit must be in radio mode before entering the Self-Diagnostic Mode.
1. 1. To enter the audio unit Self-Diagnostic Mode, switch the audio unit ON. Within four
seconds depress the preset buttons 3 and 6 together.
2. 2. Release the preset buttons 3 and 6 and the audio unit will enter the Self-Diagnostic
Mode.
3. 3. To exit the Self-Diagnostic Mode, switch the audio unit OFF.
Message Displayed Circuit Tested

1. 4CH LF for four channel system 2CH LF for two channel Left-hand front speaker circuit.
system.
2. 4CH RF for four channel system 2CH RF for two channel Right-hand front speaker
system. circuit.
3. 4CH LR for four channel system. Left-hand rear speaker circuit.
4. 4CH RR for four channel system. Right-hand rear speaker

circuit.
4. 4. If the cause is not evident after the Self-Diagnostic Mode, connect the WDS to the
data link connector (DLC).
5. 5. Retrieve the Diagnostic Trouble Code (DTC)s and refer to the DTC Index Chart.
Self-Diagnostic Mode - 4 Channel System

NOTE: The audio unit must be in radio mode before entering the Self-Diagnostic Mode.
1. 1. To enter the audio unit Self-Diagnostic Mode, switch the audio unit ON. Within four
seconds depress the preset button 4 and TA together.
2. 2. Release the preset button 4 and TA and the audio unit will enter the Self-
Diagnostic Mode.
3. 3. To exit the Self-Diagnostic Mode, switch the audio unit OFF.
Message Displayed Circuit Tested

1. 4CH LF for four channel system 2CH LF for two channel Left-hand front speaker circuit.
system.
2. 4CH RF for four channel system 2CH RF for two channel Right-hand front speaker
system. circuit.
3. 4CH LR for four channel system. Left-hand rear speaker circuit.
4. 4CH RR for four channel system. Right-hand rear speaker
circuit.
5. FM frequency received. Antenna cable.
4. 4. If the cause is not evident after the Self-Diagnostic Mode, connect the WDS to the
data link connector (DLC).
5. 5. Retrieve the Diagnostic Trouble Code (DTC)s and refer to the DTC Index Chart.
Diagnostic Trouble Code (DTC) Index Chart
DTC Description/Condition Possible Source Action

B1342 Audio unit internal failure Audio unit INSTALL a new audio unit.
REFER to: Audio Unit - Vehicles Built
From: 08/2008 (415-01A Audio Unit,
B2401 Tape player failure Audio unit INSTALL a new audio unit.
B2403 CD player internal failure Audio unit INSTALL a new audio unit.
B2404 Audio control switch Audio control GO to Pinpoint Test E.
circuit failure switch
B2406 CD player internal failure Audio unit INSTALL a new audio unit.

B2408 Speaker line short circuit Speaker(s) GO to Pinpoint Test D.
B2409 AM receiving signal error Antenna cable GO to Pinpoint Test B.
B2410 FM receiving signal error Antenna cable GO to Pinpoint Test B.
B2477 Module configuration Audio unit and REFER to the WDS.
failure central junction
box (CJB)
P1628 Module ignition supply CJB REFER to the WDS.
input
1. 1. If the cause is still evident, refer to the Symptom Chart.
Symptom Chart
Symptom Possible Action

Sources
The audio unit is inoperative/does not * Fuse(s). * GO to Pinpoint Test A.
operate correctly * Circuit.
* Audio unit.
The display is blank - radio and cassette * Audio unit. * INSTALL a new audio unit.
player operate
Poor reception * Antenna. * GO to Pinpoint Test B.
* Antenna
cable.
* Audio unit.
Poor quality/distorted sound from one or * Speaker(s). * GO to Pinpoint Test C.
more speakers (not all speakers) * Circuit.
* Audio unit.
No sound from all speakers * Audio unit. * INSTALL a new audio unit, TEST
No sound from one or more of the * Speaker(s). * GO to Pinpoint Test D.
speakers (not all speakers) * Circuit.
* Audio unit.
The auxiliary audio control is * Circuit. * GO to Pinpoint Test E.
inoperative/does not operate correctly. * Audio control
switch.
* Audio unit.
Pinpoint Tests
PINPOINT TEST A : THE AUDIO UNIT IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
A1: CHECK FOR VOLTAGE TO AUDIO UNIT
3 Measure the voltage between the audio unit C443 pin
15, circuit 29-MD15 (OG/BK), harness side and
ground, and between the audio unit C443 pin 16,
circuit 75-MD15 (YE/GN), harness side and ground.

Yes

GO to A2.
No
REPAIR circuit 29-MD15 (OG/BK) or circuit 75-MD15
(YE/GN). TEST the system for normal operation.
A2: CHECK THE AUDIO UNIT GROUND CIRCUITS FOR OPEN
pin 12, circuit 91-MD15 (BK/GN), harness side and
ground, and between the audio unit C443 pin 11,
circuit 91-MD34 (BK/YE), harness side and ground.

Yes
No
REPAIR circuit 91-MD15 (BK/GN) or 91-MD34
(BK/YE). TEST the system for normal operation.
PINPOINT TEST B : POOR RECEPTION

B1: CHECK THE ANTENNA CABLE SHIELD
2 Disconnect the antenna cable from the audio unit.
3 Measure the resistance between the antenna cable
ground connector (shield), and ground.

Yes
GO to B2.
No
CLEAN and TIGHTEN the antenna base connection
to the body. If the concern persists, INSTALL a new
antenna cable.
REFER to: Antenna Cable - Vehicles Built Up To:
04/2009 (415-02 Antenna, Removal and
Installation).
B2: CHECK THE ANTENNA CENTER CONDUCTOR FOR OPEN
1 Remove the antenna mast.
2 Measure the resistance of the center conductor
between the ends of the antenna cable.

Yes
GO to B3.
No
INSTALL a new antenna cable.
Installation).
B3: CHECK ANTENNA CABLE FOR SHORT
1 Measure the resistance between the antenna center
conductor and the antenna ground (shield).
Is the resistance greater than 10,000 ohms (open

circuit)?
Yes
CLEAN and TIGHTEN the ground connections at the
base of the antenna and battery negative cable to
the body. If concern the persists, INSTALL a new
audio unit.
REFER to: Audio Unit - Vehicles Built From:
08/2008 (415-01A Audio Unit, Removal and
Installation).
No
INSTALL a new antenna cable.
Installation).
TEST the system for normal operation. If the
concern persists, INSTALL a new audio unit.
Installation).
PINPOINT TEST C : POOR QUALITY/DISTORTED SOUND FROM ONE OR

MORE SPEAKERS (NOT ALL SPEAKERS)
C1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.
2 Measure the resistance between the inoperative

speaker pin 1 and pin 2, component side.
Is the resistance approximately 4.0 ohms?

Yes
GO to C2.
No
INSTALL a new speaker. TEST the system for
normal operation.
C2: CHECK SPEAKER INPUT FOR SHORT TO GROUND
speaker connector pin 1, harness side and ground.

circuit)?
Yes
GO to C3.
No
REPAIR speaker input circuit. TEST the system for
normal operation.
C3: CHECK SPEAKER RETURN FOR SHORT TO GROUND
speaker connector pin 2, harness side and ground.

circuit)?
Yes
SUBSTITUTE a known good speaker. TEST the
system for normal operation. If the concern
persists, INSTALL a new audio unit.
Installation).
No
REPAIR speaker return circuit. TEST the system for
normal operation.

PINPOINT TEST D : NO SOUND FROM ONE OR MORE OF THE SPEAKERS
(NOT ALL SPEAKERS)
D1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.
speaker pin 1 and pin 2, component side.
Is the resistance approximately 4.0 ohms?

Yes
GO to D2.
No
INSTALL a new speaker(s). TEST the system for
normal operation.
D2: CHECK THE INOPERATIVE SPEAKER(S) CONNECTOR PIN 1 CIRCUIT
2 Measure the resistance between the following audio
unit C442 pins, harness side and the inoperative
speaker(s) connector pin 1, harness side:
(Left front speaker) C937, pin 1 (WH) to C442 pin

3 (WH/BK).
(Right front speaker) C938, pin 1 (WH) to C442

pin 2 (WH/RD).
(Left rear speaker) C939, pin 1 (WH/VT) to C442

pin 4 (WH/VT).
(Right rear speaker) C940, pin 1 (WH) to C442

pin 1 (WH).
Yes
GO to D3.
No
REPAIR the circuit in question. TEST the system for
normal operation.
D3: CHECK THE INOPERATIVE SPEAKER(S) CONNECTOR PIN 2 CIRCUIT
1 Measure the resistance between the following audio

unit C442 pins, harness side and the inoperative

speaker(s) connector pin 2, harness side:
(Left front speaker) C937, pin 2 (GY) to C442 pin

7 (GY/BK).
(Right front speaker) C938, pin 2 (GY) to C442

pin 6 (GY/RD).
(Left rear speaker) C939, pin 2 (GY/WH) to C442

pin 8 (GY/WH).
(Right rear speaker) C940, pin 2 (GY) to C442 pin

5 (GY).
Yes
GO to D4.
No
normal operation.
D4: CHECK THE INOPERATIVE SPEAKER(S) CIRCUIT FOR SHORT TO GROUND
inoperative speaker(s) connector pin 2, harness
side and ground:
(Left front speaker) C937, pin 2 (GY) to ground.
(Right front speaker) C938, pin 2 (GY) to ground.
(Left rear speaker) C939, pin 2 (GY/WH) to

ground.
(Right rear speaker) C940, pin 2 (GY) to ground.

circuit)?
Yes
SUBSTITUTE a known good speaker. TEST the
system for normal operation. If the concern
persists, INSTALL a new audio unit.
No
normal operation.
PINPOINT TEST E : THE AUDIO CONTROL SWITCH IS INOPERATIVE/DOES

NOT OPERATE CORRECTLY
E1: CHECK THE AUDIO UNIT OPERATES CORRECTLY WITHOUT USING THE AUDIO
CONTROL SWITCH
1 Operate the audio unit without the audio control
switch.
Does the audio unit operate correctly without using the
remote control?
Yes
GO to E2.
No

E2: CHECK THE CIRCUIT 8-MD26 FOR OPEN
2 Disconnect Audio Control Switch C437.
pin 6, circuit 8-MD26 (WH/BK) harness side and the
audio control switch C437 pin 1, circuit 8-MD26
(WH/BK) harness side.

Yes
GO to E3.
No
operation.
E3: CHECK CIRCUIT 9-MD26 FOR OPEN
pin 8, circuit 9-MD26 (BN/YE) harness side and the
audio control switch C437 pin 2, circuit 9-MD26
(BN/YE) harness side.

Yes
INSTALL a new audio control switch. TEST the system
No
operation.

Audio Unit - Audio System Transit/Tourneo Connect 2002.5 (06/2002-)
Print
REFER to Section 415-00 Information and Entertainment System - General Information.

Audio Unit - Audio Unit—Vehicles Built Up
To: 08/2006
Print
General Equipment
Audio unit removal tools
Removal
1. NOTE: Make sure the audio unit key code is
available before disconnecting the audio unit
electrical connectors and note the audio unit
station presets.
Using the audio unit removal tools, remove the
audio unit.
1. Insert the audio unit removal tools.
2. Pull the audio unit removal tools gently
outwards.
3. Detach the audio unit.
4. Disconnect the electrical connectors.
5. Disconnect the antenna cable(s).
2. Remove the audio unit removal tools.
Installation
1. CAUTION: The audio unit wiring harness

must not become trapped when installing the
audio unit.
NOTE: The audio unit rear support must
engage with the audio unit support bracket.

Audio Unit - Audio Unit—Vehicles Built From: 08/2008 Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Audio unit removal tools (GV3301)
Removal
NOTE: Make sure any media is ejected from the unit.
1. General Equipment: Ford diagnostic equipment
2. General Equipment: Audio unit removal tools (GV3301)
3. If a new audio unit is to be
installed, connect the diagnostic
tool and upload the audio unit
configuration information using the
Programmable Module Installation
Routine, prior to commencing the
removal of the audio unit.
General Equipment: Ford diagnostic

equipment
4. CAUTION: Take care not to

damage the wiring harnesses.
General Equipment: Audio unit
removal tools (GV3301)
5. Remove the audio unit removal

tools from the audio unit.
6.
Installation
1. NOTE: New units must be configured using the Programmable Module

Installation Routine in the diagnostic tool.
To Install, reverse the removal procedure.

Audio Unit - Audio Unit—Vehicles Built
From: 04/2009
Print

General Equipment
Removal
NOTE: Make sure that any media is ejected from the unit.
Connect the diagnostic tool and upload the audio
unit configuration information using the
Programmable Modules Installation Routine, prior
to commencing the removal of the audio unit.

2.
3.

4.
Installation
1. NOTE: New units must be configured using

the Programmable Module Installation
Routine in the diagnostic tool.

Audio Unit - Audio Unit—Vehicles Built From: 04/2009,
Vehicles With: Navigation System
Print

General Equipment
Audio unit removal tools (GV3301)
Removal
NOTE: Make sure that any media is ejected from the unit.
1. NOTE: This step is only necessary when installing a new component.
Connect the diagnostic tool and upload the audio unit configuration information
using the Programmable Modules Installation Routine, prior to commencing the
removal of the audio unit.

2.
3. General Equipment: Audio unit

removal tools (GV3301)
Installation
1. NOTE: New units must be configured using the Programmable Module

Installation Routine in the diagnostic tool.

Navigation System Antenna—Vehicles Built Transit/Tourneo Connect 2002.5 (06/2002-)
From: 04/2009
Print
General Equipment
4 mm drill bit
Blind rivet gun
Electric drill
Removal
WARNINGS:
The supplemental restraint system (SRS) is active for a certain length of time after the
power supply has been disconnected. Wait for a minimum of 3 minutes before
disconnecting or removing any SRS components.
Make sure that the vehicle electrical system is fully depowered and no other power
source is connected.
1. Refer to: Supplemental Restraint System (SRS)
Health and Safety Precautions (100-00 General
2. Refer to: Battery Disconnect and Connect (414-01
Battery, Mounting and Cables, General
Procedures).
4.


6.
7.

Refer to: Front Seat - Vehicles Built From: 04/2009

(501-10 Seating, Removal and Installation).
10. On both sides.
Refer to: A-Pillar Trim Panel (501-05 Interior Trim

and Ornamentation, Removal and Installation).
11.
12.

13.
14. Refer to: Gearshift Lever (308-06 Manual

Transmission/Transaxle External Controls, Removal
and Installation).
15. Torque: 9 Nm
16. Torque: 8 Nm
17.

18. Torque: 25 Nm
19.
20.

21.
22. Torque: 25 Nm
23. On
both
sides.

24. On both sides.
25. Refer to: Audio Unit - Vehicles Built From: 08/2008

Refer to: Audio Unit - Vehicles Built From:
04/2009, Vehicles With: Navigation System (415-
26.
27. Torque: 10 Nm

28. Torque: 10 Nm
29.
30. Torque:
28 Nm
31. Torque:
25 Nm

32.
Installation

Antenna - Antenna Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Antenna - Antenna Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1.
Vehicles with overhead console

2. Refer to: Front Headliner - Short Wheelbase Kombi (501-05 Interior Trim and
3. Torque: 10 Nm
All vehicles
4. Torque: 3 Nm

Installation

Antenna - Antenna Cable—Vehicles Built
Up To: 04/2009
Print
1. Remove the headliner. For additional

information, refer to Section 501-05 Interior
Trim and Ornamentation.
(s).
NOTE: Instrument panel removed for clarity.

1 - Glove compartment retaining screws
2 - Glove compartment
3 - Antenna cable to heater core housing retaining clip
4 - Antenna cable to instrument panel bulkhead retaining clips
5 - Antenna cable to A-pillar retaining clips
6 - Antenna base and antenna
See Removal Detail
-

-
7 Antenna cable to windscreen header rail retaining clips
8 - Audio unit
See Removal Detail
9 - Antenna cable
See Removal Detail
Removal Details
Item 6 : Antenna base and antenna
1. Disconnect the antenna cable electrical

connector.
Item 8 : Audio unit
1. Remove the audio unit. For additional

System.
Item 9 : Antenna cable
NOTE: Make a note of the routing of the antenna cable.
Item 9 : Antenna cable
NOTE: The antenna cable must be installed to the same routing as when removed.

Antenna - Antenna Cable—Vehicles Built
From: 04/2009
Print

General Equipment
4 mm drill bit
Blind rivet gun
Electric drill
Removal
WARNINGS:
The supplemental restraint system (SRS) is active for a certain length of time after the
power supply has been disconnected. Wait for a minimum of 3 minutes before
disconnecting or removing any SRS components.
Make sure that the vehicle electrical system is fully depowered and no other power
source is connected.
1. Refer to: Supplemental Restraint System (SRS)
Health and Safety Precautions (100-00 General
2. Refer to: Battery Disconnect and Connect (414-01
Battery, Mounting and Cables, General
Procedures).
4.


6.
7.

Refer to: Front Seat - Vehicles Built From: 04/2009

(501-10 Seating, Removal and Installation).
10. On both sides.
Refer to: A-Pillar Trim Panel (501-05 Interior Trim

11.
12.

13.
14. Refer to: Gearshift Lever (308-06 Manual

Transmission/Transaxle External Controls, Removal
and Installation).
15. Torque: 9 Nm
16. Torque: 8 Nm
17.

18. Torque: 25 Nm
19.
20.

21.
22. Torque: 25 Nm
23. On
both
sides.

24. On both sides.
25. Refer to: Audio Unit - Vehicles Built From: 08/2008

04/2009, Vehicles With: Navigation System (415-
26.
27. Torque: 10 Nm

28. Torque: 10 Nm
29.
30. Torque:
28 Nm
31. Torque:
25 Nm

32. Refer to: Headliner - Van (501-05 Interior Trim
Refer to: Front Headliner - Short Wheelbase Kombi
(501-05 Interior Trim and Ornamentation, Removal
and Installation).
Refer to: Front Headliner - Long Wheelbase Kombi
(501-05 Interior Trim and Ornamentation, Removal
and Installation).

33. Torque:
10 Nm
All vehicles
34. Torque: 3 Nm

Installation

Speakers - Speakers Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Exterior Lighting - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Headlamp alignment
Item X value
Headlamp X = 12 cm/10 m = 0 degrees 41 minutes = 1.2%
Fog lamp X = 22 cm/10 m = 1 degree 16 minutes = 2.2%
Tightening torques
Parts Nm lb.ft lb.in

Bolt, headlamp 5 - 44

Exterior Lighting - Exterior Lighting Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Front lighting
Front headlamps

1 - Turn indicator bulb retainer (bayonet fixing)
2 - Headlamp levelling system servo motor
3 - Cover
4 - Turn indicator bulb, coloured yellow (bayonet fixing)
5 - Side lamp bulb, push-fit
6 - Holder for side lamp bulb, glass based push fit
7 - H4 halogen bulb
The headlamps form a unit with the front turn signal lamps and the side lights.
They are made entirely of plastic and can only be replaced as a unit.
The servo motor for the headlamp levelling system cannot be exchanged.
The main headlamp is retained with three bolts.
The bulbs can be replaced without removing the headlamp.
The reflectors are free shape reflectors. The free shape technology allows the full reflector
to be utilised.
In this technology, every point of the freely calculated reflector is allocated to lighting a
particular part of the road in front of the vehicle. As a result it is possible to optimise the
light distribution through the form of the reflector alone.
The plastic cover is only there for protection.
Conventional H4 bulbs are used in the main headlamps.
The turn signal lamps are equipped with 21W bulbs. The turn signal lamps are coloured

yellow.
5W glass base bulbs are used for the side lights.

1 - 3 retaining bolts
2 - Side-to-side adjustment
3 - Height adjustment
Fog lights

1 - Bulb
2 - Bulb holder
3 - Wiring harness connector
H11 halogen bulbs with a power rating of 55W are used.
The fog lights are mounted in the lower part of the front bumper.
To change the bulbs, grasp behind the bumper, unlatch the wiring harness connector and
disconnect it.
The bulb holder can now be turned anti-clockwise and pulled out.
Side turn signal lamp

1 - Opening in fender
2 - Bulb holder
3 - 5W bulb
4 - Cover, yellow
To change the bulb, the whole lamp unit must be turned clockwise and pulled out.
Separate the lamp housing and the bulb holder by turning the lamp housing anti-clockwise
and pulling out the bulb holder.
Rear lighting
Rear lights

1 - Twin filament bulbs, reversing light 5W, brake light 21W
2 - Turn signal light, 21W
3 - Reversing light, 21W
4 - Rear fog light, 21W
5 - Bulb holder, rear view
6 - Securing nuts
As well as the rear lamps, the rear lamp clusters incorporate all rearward facing lights with
exception of the license plate lamp and the additional high-mounted stoplamp.
The relevant rear lamp must be removed to change the bulbs. To do this, remove the two
retaining nuts on the D-pillar, take out the rear lamp and unclip the bulb holder.

Third stop light

1 - Retaining nut
2 - Lamp housing
3 - 16W bulb
On models with a tailgate, the high mounted third stop lamp is mounted in the middle
above the tailgate.
To change a bulb, the brake light unit must be removed. To do this, remove the nuts on the
inside.
Number plate lamp

1 - 10W bulb
2 - Cover
To change the bulb, unclip and open the cover.

Exterior Lighting - Stoplamps Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Special Tool(s)
Terminal Probe Kit
29-011 A

NOTE: If the powertrain control module (PCM) is changed, the new one must be
programmed. For this purpose, the vehicle-specific data is read out of the module to be
replaced using WDS and is transferred to the new module.
REFER to: Module Configuration (418-01 Module Configuration, General Procedures).
NOTE: If the anti-lock braking system/traction control system module is changed, the
new one must be reinitialized. For this purpose, the vehicle-specific data is read out of the
module to be replaced using WDS and is transferred to the new module. REFER to:
Anti-Lock Control (206-09A Anti-Lock Control, Diagnosis and Testing),
Anti-Lock Control - Traction Control (206-09B Anti-Lock Control - Traction Control,
NOTE: Before reading out the vehicle-specific data, remake all the electrical connections
which were separated in the vehicle, so that communication between the module and
WDS is ensured.
2. 2. Visually inspect for obvious signs of electrical or mechanical damage.
Visual Inspection
Stop lamp switch adjustment Fuse
Bulb(s)
Wiring harness
3. 3. Resolve any obvious causes or concerns found during the visual inspection before
carrying out any further tests.
4. 4. If the concern is not visually evident, refer to the Symptom Chart.
Symptom Chart
Symptom Chart

Stoplamps inoperative * Fuse * GO to Pinpoint
* Circuit(s) Test A.
* Stoplamp switch
* Central junction box (CJB)
One or more stoplamps not * Circuit(s) * GO to Pinpoint
working * Left/right-hand rear lamp assembly Test B.
* High mounted stoplamp

Stoplamps permanently * Circuit(s) * GO to Pinpoint
illuminated * Stoplamp switch Test C.
* ABS control module
* ABS control module/traction control
system
* Trailer switch interface (SI) module
* Powertrain control module (PCM)
Pinpoint Tests
PINPOINT TEST A : STOPLAMPS INOPERATIVE
A1: CHECK FUSE F42 (15 A) (CJB).
2 CHECK Fuse F42 (15 A) (CJB).
Is the fuse OK?
Yes
GO to A2.
No
RENEW fuse F42 (15 A) (CJB) and CHECK the
LOCATE and RECTIFY the short circuit using the
system.
A2: CHECK THE VOLTAGE SUPPLY TO FUSE F42 (15 A) (CJB) FOR OPEN CIRCUIT
1 Connect Fuse F42 (15 A) (CJB).
Measure the voltage between F42 (15 A) (CJB) and
3
ground.
Is battery voltage measured?
Yes
GO to A3.
No
LOCATE AND RECTIFY the break in the voltage
supply of fuse F42 (15 A) (CJB) using the Wiring
Diagrams. If necessary RENEW the CJB. CHECK the
A3: CHECK VOLTAGE SUPPLY TO THE STOP LAMP SWITCH FOR OPEN CIRCUIT
2 Disconnect stoplamp switch from connector C444.
4 Vehicles built up to 08/2005
5 Measure the voltage between the stoplamp switch,
connector C444, pin 3, circuit 15-LG23 (GN/WH),
6 Vehicles built from 08/2005

7 Measure the voltage between the stoplamp switch,
connector C444, pin 2, circuit 15-LG23 (GN/WH),

Yes
GO to A4.
No
between fuse F42 (CJB) and the stoplamp switch
using the Wiring Diagrams. If necessary RENEW the
CJB. CHECK the operation of the system.
A4: CHECK THE STOPLAMP SWITCH
3 Using a fused bridging cable (15 A) at the brake
light switch, connect between connector C444, pin
3, circuit 15-LG23 (GN/WH) and pin 1, circuit 15S-
LG14(A)/(B) (GN/RD), 15S-CF58 (GN/OG), 15S-
RN2A (GN/BU), wiring harness side.
4 Vehicles built from 08/2005 to 08/2006


7 Connect a fused jumper wire (15 A) to the stop
lamp switch, connector C444, between pin 2,
circuit 15-LG23 (GN/WH) and pin 1, circuit 15S-
LG14 (GN/RD)/15S-LG5 (GN/RD), wiring harness
side.

9 CHECK the stop lamps.
Do the stoplamps light up?

Yes
RENEW the stoplamp switch. CHECK the operation
of the system.
No
between the stop lamp switch and soldered
PINPOINT TEST B : ONE OR MORE STOPLAMPS INOPERATIVE

B1: DETERMINE THE FAULT CONDITION


side.

10 Determine the fault conditions.
Is the high mounted stoplamp inoperative?
Yes
GO to B2.
No
- Left-hand stoplamp inoperative: GO to B3.
- Right-hand stoplamp inoperative: GO to B4.

B2: CHECK THE VOLTAGE SUPPLY OF THE ADDITIONAL HIGH-MOUNTED STOPLAMP
FOR OPEN CIRCUIT
NOTE: The fused jumper lead used in the previous step is still connected to the stop
lamp switch.
2 Disconnect High-mounted stoplamp from connector
C107.
4 Measure the voltage between the high-mounted
stoplamp, connector C107, pin 1, circuit 15S-LG6
(H) (GN/YE), wiring harness side and ground.

Yes
LOCATE and RECTIFY the break in circuit 31-LG6
(BK) between the high-mounted stoplamp and
Diagrams. If necessary RENEW the high-mounted
stoplamp. CHECK the operation of the system.
No
between soldered connection S212 and the high-
mounted stoplamp using the Wiring Diagrams.
B3: CHECK THE VOLTAGE SUPPLY TO THE LEFT-HAND REAR LAMP ASSEMBLY
(STOPLAMP) FOR OPEN CIRCUIT
lamp switch.
2 Disconnect Left-hand rear lamp assembly from
connector.
Vehicles without trailer socket: C474
Vehicles with trailer socket: C474a

4 Measure voltage between left-hand rear lamp
assembly:
Vehicles without trailer socket: Connector C474,

pin 6, circuit 15S-LG14 (GN/RD), wiring harness
side and ground.
Vehicles with trailer socket: Connector C474a, pin

6, circuit (BK/RD), wiring harness side and
ground.

Yes
between the left-hand rear lamp assembly and

If necessary, RENEW the rear lamp assembly.
No
between soldered connection S212 and the left-
hand rear lamp assembly using the Wiring
B4: CHECK THE VOLTAGE SUPPLY TO THE RIGHT-HAND REAR LAMP ASSEMBLY (STOP
LAMP)
lamp switch.
2 Disconnect Right-hand rear lamp assembly from
connector.

4 Measure voltage between right-hand rear lamp
assembly:

pin 6, circuit 15S-LG21 (GN/BK), wiring harness
side and ground.

6, circuit (GN), wiring harness side and ground.

Yes
between the right-hand rear lamp assembly and
If necessary, RENEW the rear lamp assembly.
No
between soldered connection S212 and the right-
PINPOINT TEST C : STOPLAMPS PERMANENTLY ILLUMINATED

CONDITIONS
C1: CHECK THE STOPLAMP SWITCH
Do the stoplamps illuminate continuously?
Yes
GO to C2.
No
RENEW the stoplamp switch. CHECK the operation of the system.
C2: DETERMINE MODEL VERSION

2 Connect Stoplamp switch to connector C444.
3 Determine the model version.
Does the vehicle have a trailer socket?
Yes
GO to C3.
No
GO to C4.
C3: EXCLUDE THE TRAILER SWITCH INTERFACE (SI) MODULE AS CAUSE FOR THE
SHORT TO BATTERY VOLTAGE
NOTE: Fuse holder 1 is located near the trailer switch interface (SI) module.
1 Disconnect Fuse FC (10 A) (fuse holder 1).
Yes
GO to C4.
No
RENEW the trailer switch interface (SI) module. CHECK the operation of
the system.
2 Connect Fuse FC (10 A) (fuse holder 1).
Does the vehicle have ABS/traction control?
Yes
GO to C5.
No
GO to C6.
C5: ELIMINATE THE ABS CONTROL MODULE/TRACTION CONTROL SYSTEM AS CAUSE
FOR THE SHORT TO BATTERY VOLTAGE
1 Disconnect Fuse F13 (30 A) (BJB).
3 Disconnect Fuse F36 (7.5 A) (CJB).
Yes
- Vehicles built up to 08/2006 GO to C6.
- Vehicles built from 08/2006 GO to C9.
No
RENEW the anti-lock braking system/traction control system module.
2 Connect Fuse F13 (30 A) (BJB).
4 Connect Fuse F36 (7.5 A) (CJB).
Does the vehicle have a diesel engine?
Yes
GO to C7.
No
Vehicles with petrol and LPG engines: GO to C8.
C7: RULE OUT THE POWERTRAIN CONTROL MODULE (PCM) AS POSSIBLE CAUSE FOR
A SHORT TO BATTERY VOLTAGE

1 Disconnect powertrain control module (PCM) from connector.
Vehicles with 1.8L Duratorq-TDCi engine: C414
Vehicles with 1.8L Duratorq-TDDi engine: C415

Yes
LOCATE and RECTIFY the short to battery voltage in the circuits connected
to soldered connection S212 using the Wiring Diagrams. CHECK the
No
INSTALL a new PCM. CHECK the operation of the system.
Yes
No
2 Disconnect Powertrain control module (PCM) from connector C417.
3 Disconnect Powertrain control module (PCM) from connector C419.
Yes
No

Exterior Lighting - Parking, Rear and
License Plate Lamps
Print

information.
Special Tool(s)
Terminal probe kit
29-011 A
General Equipment
Worldwide Diagnostic System (Ford diagnostic
equipment)

NOTE: The central timer module (CTM) is part of the instrument cluster.
which were separated in the vehicle, so that communication between the module and
WDS is ensured.
2. 2. Visually inspect for obvious signs of electrical damage:
NOTE: Ensure correct locking of wiring harness connector.

Electrical
Fuse(s)
Bulb(s)
Wiring harness
4. 4. If the concern is not visually evident, PERFORM a fault diagnosis on the central
timer module (CTM) with Ford diagnostic equipment and RECTIFY any displayed
faults in accordance with the displayed fault description. CHECK operation of
system.
5. 5. On a vehicle without stored fault(s), continue according to the Symptom Chart and
the corresponding symptom.
6. 6. After checking or rectifying the fault(s) and finishing the work, READ OUT the fault
memory in the central timer module (CTM) and DELETE any saved faults. After
performing a road test and CHECKING the system, READ OUT the fault memories
again.
Ford Diagnostic Equipment Trouble Code Table - Central Timer Module (CTM)
Ford diagnostic equipment Trouble Code Table - Central Timer Module (CTM)

B1312 Short circuit at the input of the instrument lighting circuits (short to GO to Pinpoint
battery positive) Test C.
Symptom Chart
Symptom Chart

Front side lamps, rear lamps and license * Fuse(s) * GO to Pinpoint Test A.
plate lamps are inoperative * Circuit(s)
* Headlight
switch
* Central
junction box
(CJB)
Parking lamps, rear lamps and license * Fuse * REFER to: Daytime Running
plate lamps are inoperative when * Circuit(s) Lamps (DRL) (417-04 Daytime
daytime running lights (DRL) are * Headlight Running Lamps (DRL), Diagnosis
switched on. switch and Testing).
One or more parking, rear or license * Fuse(s) * GO to Pinpoint Test B.
lamp(s) is/are inoperative * Circuit(s)
* Headlamp
* Rear lamp
assembly
* License plate
lamps
* Headlight
switch
* Central
junction box
(CJB)
Parking lamps, rear lamps and license * Circuit(s) * GO to Pinpoint Test C.
plate lamps lit continuously * Headlight
switch
* Central
junction box
(CJB)
* Cigarette
lighter
* Heater Control
Module
* Radio
* Instrument
cluster
Pinpoint Tests
NOTE: Perform all measurements using a digital multimeter.
PINPOINT TEST A : PARKING LAMPS, REAR LAMPS AND LICENSE PLATE
LAMPS ARE INOPERATIVE.
A1: CHECK FUSE F30/F132 (10 A) (CJB)
1 Disconnect Fuse.
Vehicles built up to 08/2006: F30 (10 A) (CJB)
Vehicles built from 08/2006: F132 (10 A) (CJB)

2 CHECK Fuse.


Is the fuse OK?
Yes
GO to A2.
No
RENEW fuse F30/F132 (10 A) (CJB) and CHECK the
LOCATE and RECTIFY the short using the Wiring
A2: CHECK THE VOLTAGE SUPPLY TO FUSE F30/F132 (10 A) (CJB) FOR OPEN
CIRCUIT
1 Connect Fuse.

2 Measure the voltage between fuse:

and ground.

and ground.
Yes
GO to A3.
No
CHECK CJB and if necessary RENEW. CHECK
operation of system.
A3: CHECK THE VOLTAGE SUPPLY TO THE LIGHT SWITCH FOR OPEN CIRCUIT
1 Disconnect Headlight switch from connector C320.
2 Measure the voltage between the headlight switch,
connector C320, pin 11, circuit 29-LE29 (OG/BK),

Yes
RENEW headlight switch. CHECK operation of
system.
No
between fuse F30/F132 (CJB) and the headlight
switch using the Wiring Diagrams. If necessary
RENEW the CJB. CHECK operation of system.
PINPOINT TEST B : ONE OR MORE PARKING LAMP(S), REAR LAMP(S) OR

LICENSE PLATE LAMP(S) IS/ARE INOPERATIVE.
B1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS

1 SWITCH ON side light.
2 CHECK the parking, rear and license plate lamps.
Is a parking lamp, rear lamp or license plate lamp on
the right-hand side inoperative?
Yes
- Parking lamp and rear lamp inoperative on the
right-hand side: GO to B2.
- Right-hand parking lamp inoperative: GO to B4.
- Right-hand rear lamp inoperative: GO to B8.
- Right-hand license plate lamp is inoperative: GO
to B14.
- Both license plate lamps (all other lamps OK): GO
to B17.
- All parking and rear lamps are inoperative (license
plate lamps OK): GO to B20.
No
- Parking lamp and rear lamp inoperative on the
left-hand side: GO to B3.
- Left-hand parking lamp inoperative: GO to B6.
- Left-hand rear lamp inoperative: GO to B11.
- Left-hand license plate lamp is inoperative: GO to
B16.
B2: CHECK FUSE F57/F56 (7.5 A) (CJB).
2 Disconnect Fuse.
Vehicles built up to 08/2006: F57 (7.5 A) (CJB)
Vehicles built from 08/2006: F56 (7.5 A) (CJB)

3 CHECK Fuse.

Is the fuse OK?
Yes
CHECK CJB and if necessary RENEW. CHECK the
No
RENEW fuse F57/F56 (7.5 A) (CJB) and CHECK the
2 Disconnect Fuse.

3 CHECK Fuse.
Is the fuse OK?

Yes

CHECK CJB and if necessary RENEW. CHECK the
No
B4: CHECK GROUND SUPPLY OF RIGHT-HAND HEADLAMP FOR OPEN CIRCUIT
2 Disconnect Right-hand headlamp from connector
C834.
3 Measure the resistance between right-hand
headlamp, connector C834, pin 4, circuit 31-LE30
(BK), wiring harness side and ground.

Yes
GO to B5.
No
between the right-hand headlamp and soldered
B5: CHECK THE VOLTAGE SUPPLY OF THE RIGHT-HAND HEADLAMP (PARKING LAMP)
FOR OPEN CIRCUIT
2 Measure voltage between right-hand headlamp,
connector C834, pin 3, circuit 29S-LF16 (OG/GN),

Yes
CHECK and if necessary RENEW the headlamp.
No
between fuse F57/F56 (CJB) and the right-hand
headlamp using the Wiring Diagrams. CHECK
B6: CHECK GROUND SUPPLY OF LEFT-HAND HEADLAMP FOR OPEN CIRCUIT
2 Disconnect Left-hand headlamp from connector
C835.
3 Measure the resistance between left-hand

Yes
GO to B7.
No
between the left-hand headlamp and soldered
B7: CHECK THE VOLTAGE SUPPLY OF THE LEFT-HAND HEADLAMP (PARKING LAMP)
FOR OPEN CIRCUIT
2 Measure voltage between left-hand headlamp,
connector C835, pin 3, circuit 29S-LF7 (OG/BU),

Yes
No
between fuse F58/F55 (CJB) and the left headlamp
the system.
B8: CHECK RIGHT-HAND REAR LAMP ASSEMBLY
2 SWITCH ON right-hand turn signal.
3 Check rear right-hand turn signal.
Does the right-hand rear turn signal work?
Yes
GO to B10.
No
GO to B9.
B9: CHECK GROUND CONNECTION TO RIGHT-HAND REAR LAMP ASSEMBLY FOR OPEN
CIRCUIT
connector.

3 SWITCH OFF the right-hand turn indicator.
4 Measure resistance between right-hand rear lamp
assembly:

pin 5, circuit 31-LF24 (BK), wiring harness side
and ground.


Yes
CHECK and if necessary RENEW the right-hand rear
lamp assembly. CHECK operation of system.
No
B10: CHECK THE VOLTAGE SUPPLY TO THE RIGHT-HAND REAR LAMP ASSEMBLY
(REAR LAMP) FOR OPEN CIRCUIT
connector.

4 Measure voltage between right-hand rear lamp
assembly:
Vehicles without trailer socket: connector C475,

pin 2, circuit 29S-LF20 (OG), wiring harness side
and ground.

2, circuit (OG), wiring harness side and ground.

Yes
No
between fuse F57/F56 (CJB) and the right-hand
rear lamp assembly using the Wiring Diagrams.
CHECK operation of system.
B11: CHECK LEFT-HAND REAR LAMP ASSEMBLY
2 SWITCH ON the left-hand turn signal
3 Check left-hand rear turn signal.
Is the left-hand rear turn signal operative?
Yes
GO to B13.

No
GO to B12.
B12: CHECK GROUND CONNECTION TO LEFT-HAND REAR LAMP ASSEMBLY FOR OPEN
CIRCUIT
connector.

3 SWITCH OFF the left-hand turn indicator.
4 Measure the resistance between left-hand rear
lamp assembly:

and ground.

5, circuit (BN), wiring harness side and ground.

Yes
CHECK and if necessary RENEW the left-hand rear
No
B13: CHECK THE VOLTAGE SUPPLY TO THE LEFT-HAND REAR LAMP ASSEMBLY (REAR
LAMP) FOR OPEN CIRCUIT
connector.

4 Measure voltage between left-hand rear lamp
assembly:
Vehicles without trailer socket: connector C474,

pin 2, circuit 29S-LF11 (OG/WH), wiring harness
side and ground.
Vehicles with trailer socket: connector C474a, pin

2, circuit (OG/WH), wiring harness side and
ground.
Yes
lamp assembly. CHECK the operation of the system.
No

between fuse F58/F55 (CJB) and the left-hand rear
lamp assembly using the Wiring Diagrams. CHECK
B14: CHECK THE VOLTAGE SUPPLY TO THE RIGHT-HAND LICENCE PLATE LAMP FOR
OPEN CIRCUIT
2 Disconnect Right-hand license plate lamp from
connector C496.
4 Measure the voltage at the right-hand license plate
lamp, connector C496, between pin 2, circuit 29S-
LF22 (OG/BK) and pin 1, circuit 31-LF22 (BK),

Yes
CHECK and if necessary RENEW the license plate
lamp. CHECK the operation of the system.
No
GO to B15.
B15: CHECK GROUND SUPPLY OF RIGHT-HAND LICENSE PLATE LAMP FOR OPEN
CIRCUIT
1 SWITCH OFF side light.
2 Measure resistance between right-hand license
lamp, connector C496, pin 1, circuit 31-LF22 (BK),

Yes
LOCATE and REPAIR the break in circuit 29S-LF22
(OG/BK), between the left-hand license plate lamp
and the right-hand license plate lamp using the
system.
No
between the right-hand license plate lamp and
B16: CHECK GROUND SUPPLY OF LEFT-HAND LICENSE PLATE LAMP FOR OPEN
CIRCUIT
1 Disconnect Left-hand license plate lamp from
connector C495.
2 Measure resistance between left-hand license lamp,
connector C495, pin 1, circuit 31-LF21 (BK), wiring

Yes
CHECK and if necessary RENEW license plate lamp.
No
between the left-hand licence plate lamp and
B17: CHECK FUSE F62/F57 (7.5 A) (CJB)
2 Disconnect Fuse.

3 CHECK Fuse.

Is the fuse OK?
Yes
GO to B18.
No
B18: CHECK THE VOLTAGE SUPPLY TO FUSE F62/F57 (7.5 A) (CJB) FOR OPEN
CIRCUIT
1 Connect Fuse.


and ground.

and ground.
Yes
LOCATE and RECTIFY the break in circuit 29S-LF21

(H) (OG/BK) between fuse F62/F57 (CJB) and the
left-hand license plate lamp using the Wiring
Diagrams. If necessary RENEW the CJB. CHECK
No
GO to B19.
B19: CHECK HEADLIGHT SWITCH
2 Connect a fused jumper wire (10 A) to the
headlight switch, connector C320, between pin 11,
circuit 29-LE29 (OG/BK) and pin 16, circuit 29S-LF5
(OG/BU), wiring harness side.
3 Measure the voltage between fuse F62/F57 (7.5 A)

(CJB) and ground.
Yes
RENEW headlight switch. CHECK the operation of
the system.
No
(OG/BU), between the headlamp switch and fuse
F62/F57 (CJB) using the Wiring Diagrams. If
necessary RENEW the CJB. CHECK operation of
system.
B20: CHECK HEADLIGHT SWITCH
2 Connect a fused jumper wire (10 A) to the
headlight switch, connector C320, between pin 11,
circuit 29-LE29 (OG/BK) and pin 13, circuit 29S-LF1
(OG/YE), wiring harness side.
3 Check parking lamps and rear lamps.

Do the parking lamps and rear lamps illuminate?
Yes
RENEW headlight switch. CHECK operation of
system.
No
(OG/YE) between the headlight switch and fuses
F57/F56 and F58/F55 (CJB) using the Wiring
PINPOINT TEST C : PARKING LAMPS, REAR LAMPS AND LICENSE PLATE

LAMPS LIT CONTINUOUSLY

C1: CHECK SUPPLY CIRCUIT OF RIGHT-HAND PARKING LAMPS AND REAR LAMPS FOR
SHORT CIRCUIT TO BATTERY VOLTAGE
2 Disconnect Fuse.

CHECK the right-hand parking lamps and rear
4
lamps.
Are the right-hand parking lamp/rear lamp lit
continuously?
Yes
LOCATE and RECTIFY the short to battery voltage in
the circuits connected to fuse F57/F56 (7.5 A)
(CJB), output side, using the Wiring Diagrams. If
necessary RENEW the CJB. (vehicles with trailer
hitch, check trailer socket and RENEW it if
necessary). CHECK operation of system.
No
GO to C2.
C2: CHECK SUPPLY CIRCUIT OF THE LEFT-HAND PARKING LAMPS AND REAR LAMPS
FOR SHORT CIRCUIT TO BATTERY VOLTAGE
2 Disconnect Fuse.

4 Check left-hand parking lamps and rear lamps.
Are the left-hand parking lamp/rear lamp lit
continuously?
Yes
necessary RENEW the CJB. (vehicles with trailer
hitch, check trailer socket and RENEW it if
necessary). CHECK the operation of the system.
No
GO to C3.
C3: CHECK THE SUPPLY CIRCUIT OF THE LICENSE PLATE LAMPS FOR A SHORT TO
BATTERY VOLTAGE
2 Disconnect Fuse.

3 Connect Fuse.

4 Connect Fuse.

6 CHECK the license plate lamps.
Are the license plate lamps permanently on?
Yes
necessary RENEW the CJB. CHECK the operation of
the system.
No
GO to C4.
C4: CHECK THE POWER SUPPLY CIRCUITS OF THE FUSES FOR A SHORT TO BATTERY
VOLTAGE
2 Connect Fuse.

5 CHECK the parking, rear and license plate lamps.
Are the license plate lamps permanently on?
Yes
the circuit between the headlight switch and fuse
F62/F57 (7.5 A) (CJB) using the Wiring Diagrams. If
necessary RENEW the CJB. CHECK the operation of
the system.
No
- Parking and rear lamps illuminate continuously,
vehicles built up to 08/2006: LOCATE and RECTIFY
the short to battery voltage in the circuit between
the headlight switch and fuses F57/F58 (7.5 A)
(CJB) using the Wiring Diagrams. If necessary
RENEW the CJB. CHECK operation of system.
- Parking and rear lamps illuminate continuously,
vehicles built from 08/2006: LOCATE and RECTIFY
the short to battery voltage in the circuit between
the headlight switch and fuses F55/F56 (7.5 A)
RENEW the CJB. CHECK the operation of the
system.
- All lamps are off: GO to C5.
C5: CHECK THE INSTRUMENT LIGHTING SUPPLY CIRCUIT FOR A SHORT TO BATTERY
VOLTAGE
1 Measure voltage between headlamp switch,
connector C320, pin 9, circuit 29S-DA2 (OG/BU),

Yes
GO to C7.
No
- Vehicles with daytime running lights: GO to C6.
- Vehicles without daytime running lights: RENEW
headlight switch. CHECK the operation of the
system
C6: CHECK THE SUPPLY CIRCUIT FOR THE DAYTIME RUNNING LAMPS (DIPPED
BEAM) FOR A SHORT TO BATTERY VOLTAGE
2 Measure voltage between headlight switch,
connector C320, pin 15, circuit 15S-LE29 (GN/BK),

Yes
REFER to: Daytime Running Lamps (DRL) (417-04
Daytime Running Lamps (DRL), Diagnosis and
Testing).
No
the system.
C7: NARROW DOWN THE CONDITIONS UNDER WHICH THE FAULT OCCURS
NOTE: Ignition should be switched off when carrying out the measurement.

Yes
GO to C8.
No
GO to C9.

C8: ELIMINATE THE CIGARETTE LIGHTER AS CAUSE FOR THE SHORT TO BATTERY
VOLTAGE
1 Disconnect Fuse.


Yes
the circuits connected to soldered connection S5
using the Wiring Diagrams. CHECK operation of
system.
No
RENEW cigarette lighter. CHECK operation of
system.
C9: ELIMINATE THE HEATER CONTROL MODULE AS CAUSE FOR THE SHORT TO
BATTERY VOLTAGE
2 Disconnect Fuse.

3 Disconnect Fuse.


Yes
GO to C10.
No
RENEW heater control module. CHECK operation of
system.
C10: ELIMINATE THE RADIO AS CAUSE FOR THE SHORT TO BATTERY VOLTAGE

2 Connect Fuse.

3 Connect Fuse.

4 Disconnect Fuse.

5 Disconnect Fuse.


Yes
GO to C11.
No
RENEW radio. CHECK operation of system.
C11: ELIMINATE THE INSTRUMENT CLUSTER AS CAUSE FOR THE SHORT TO BATTERY
VOLTAGE
2 Connect Fuse.

3 Disconnect Fuse.

4 Disconnect Fuse.
Vehicles built up to 08/2006: F20 (10 A) (BJB)


Yes
the system.
No
RENEW instrument cluster. CHECK the operation of
the system

Exterior Lighting - Fog Lamps Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Special Tool(s)
Terminal probe kit
29-011 A
Electrical
Fuse(s)
Bulb(s)
Wiring harness
Symptom Chart
Symptom Chart

Fog lamps inoperative * Fuse * GO to Pinpoint
* Headlight switch
* Rear fog lamp cut-off relay
* Cut-off relay, rear fog
lamp/parking aid
* Trailer socket
Individual fog lamp inoperative * Circuit(s) * GO to Pinpoint
* Fog lamp Test B.
* Left/right-hand rear lamp
assembly
Rear fog lamps or front fog lamps * Circuit(s) * GO to Pinpoint
illuminate continuously * Headlight switch Test C.
Pinpoint Test
PINPOINT TEST A : FOG LAMPS INOPERATIVE
A1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
NOTE: Ensure that no adapters are connected to the trailer socket.
Ignition switch in position II.

1
2 Switch on DIPPED BEAM.
3 SWITCH ON the front and rear fog lamps.
4 CHECK fog lamps.
Are all of the fog lamps on the vehicle not working?
Yes
GO to A2.
No
- Front fog lamps inoperative: GO to A9.
- Rear fog lamps inoperative (only vehicles with
front fog lamps): GO to A5.
A2: CHECK FUSE F28 (20 A) (BJB).
2 CHECK Fuse F28 (20 A) (BJB).
Is the fuse OK?
Yes
GO to A3.
No
RENEW fuse F28 (20 A) (BJB) and CHECK the
A3: CHECK THE VOLTAGE SUPPLY TO FUSE F28 (20 A) (BJB) FOR OPEN CIRCUIT
CHECK the voltage between F28 (20 A) (BJB) and
3
ground.
Yes
GO to A4.
No
- Vehicles built before 08/2006: LOCATE and
RECTIFY the break in circuit 15-DC28 (GN/BU),
between ignition relay 1 (without front fog lamps)
or ignition relay 2 (with front fog lamps) and fuse
F28 (BJB), using the Wiring Diagrams. CHECK the
- Vehicles built from 08/2006: LOCATE and RECTIFY
the break in circuit 15-DC28 (GN/BU) between
soldered connection S105 and fuse F28 (20 A)
(BJB) using the Wiring Diagrams. CHECK the
A4: CHECK THE VOLTAGE SUPPLY TO THE HEADLIGHT SWITCH FOR OPEN CIRCUIT
4 Measure the voltage between the headlamp switch,
connector C320, pin 7, circuit 15-LD16 (GN/RD),

Yes
- Vehicles with front fog lamps: INSTALL A NEW
headlight switch. CHECK the operation of the
system.
- Vehicles without front fog lamps: GO to A5.
No
between fuse F28 (BJB) and the headlight switch
the system.
A5: CHECK THE HEADLIGHT SWITCH
2 Using a fused bridging cable (20 A) at the headlight
switch, connect between connector C320, pin 7,
circuit 15-LD16 (GN/RD) and pin 2, circuit 15S-LD6
(GN/YE), wiring harness side.

4 Check the rear fog lamps.
Do the rear fog lamps illuminate?
Yes
INSTALL A NEW headlight switch. CHECK the
No
- Vehicles without trailer socket: Vehicles built up to
02/2004: LOCATE and RECTIFY the break in circuit
15S-LD6 (GN/YE) between the headlight switch and
intermediate connector C61b, pin 16 using the
system.
- Vehicles without trailer socket: Vehicles built from
02/2004 to 8/2006: LOCATE and RECTIFY the break
in circuit 15S-LD6 (GN/YE) between the headlight
switch and intermediate connector C54, pin 10
the system.
08/2008: LOCATE and RECTIFY the break in circuit
15S-LD6 (GN/YE) between the headlight switch and
intermediate connector C61, pin 1 using the Wiring
- Vehicles with trailer socket: GO to A6.
A6: CHECK THE VOLTAGE SUPPLY TO THE REAR FOG LAMP CUT-OFF RELAY FOR OPEN
CIRCUIT
NOTE: The fused jumper lead used in the previous test step is still connected to the
headlamp switch.
2 Disconnect Corresponding component.
- Vehicles without parking aid: Rear fog lamp cut-

off relay from socket C1103

Vehicles with parking aid: Rear fog lamp/parking
aid cut-off relay from socket C1110
4 Measure the voltage between:
- Vehicles without parking aid: rear fog lamp cut-

off relay, socket C1103, circuit (RD/WH), wiring
Vehicles with parking aid: rear fog lamp/parking

aid cut-off relay, socket C1110, circuit (RD/WH),

Yes
GO to A7.
No
LOCATE and RECTIFY the break in circuit (RD/WH)
between the headlight switch and the cut-off relay
the system.
A7: CHECK THE GROUND CONNECTION OF THE REAR FOG LAMP CUT-OFF RELAY FOR
OPEN CIRCUIT
2 Measure the resistance between:

off relay, socket C1103, circuit (BN), wiring

aid cut-off relay, socket C1110, circuit (BN),

Yes
GO to A8.
No
between the cut-off relay and soldered connection
S1001 using the Wiring Diagrams. CHECK the
A8: CHECK CIRCUIT (RD/YE) BETWEEN THE REAR FOG LAMP CUT-OFF RELAY AND
TRAILER SOCKET FOR SHORT TO GROUND

off relay, socket C1103, circuit (RD/YE), wiring

aid cut-off relay, socket C1110, circuit (RD/YE),

Yes
RENEW the cut-off relay CHECK the operation of the
system.

No
circuit between the cut-off relay and the trailer
socket using the Wiring Diagrams. CHECK the
operation of the system. If necessary RENEW the
trailer socket. CHECK the operation of the system.
3 Using a fused bridging cable (20 A) at the headlight
switch, connect between connector C320, pin 7,
circuit 15-LD16 (GN/RD) and pin 3, circuit 15S-LD1

5 CHECK the front fog lamps.
Do the front fog lamps illuminate?
Yes
No
LOCATE and RECTIFY the break in circuit 15S-LD1
(GN/YE) between the headlight switch and soldered
PINPOINT TEST B : INDIVIDUAL FOG LAMP INOPERATIVE

2 Switch on DIPPED BEAM.
3 SWITCH ON the front and rear fog lamps.
4 CHECK fog lamps.
Is a single fog lamp inoperative?
Yes
- Left front fog lamp inoperative: GO to B2.
- Right front fog lamp inoperative: GO to B4.
No
- Left rear fog lamp inoperative: GO to B6.
- Right rear fog lamp inoperative: GO to B8.
B2: CHECK THE VOLTAGE SUPPLY OF THE LEFT-HAND FRONT FOG LAMP FOR OPEN
CIRCUIT
2 Disconnect left-hand front fog lamp from connector
C302.
4 Switch on the front fog lamps.
6 Measure the voltage between left-hand front fog
lamp, connector C302, pin 2, circuit 15S-LD11
(GN/WH), wiring harness side and ground.

8 Measure the voltage between left-hand front fog

Yes
GO to B3.
No
between soldered connection S110 and the left-
hand front fog lamp using the Wiring Diagrams.
B3: CHECK GROUND CONNECTION OF LEFT-HAND FRONT FOG LAMP FOR OPEN
CIRCUIT
3 Measure the resistance between left-hand front fog
lamp, connector C302, pin 1, circuit 31-LD11 (BK),

5 Measure the resistance between the left-hand front
fog lamp, connector C302, pin 2, circuit 31-LD11

Yes

CHECK left front fog lamp and RENEW if necessary.
No
between the left-hand front fog lamp and soldered
connection S121 using the Wiring Diagrams.
B4: CHECK VOLTAGE SUPPLY OF RIGHT-HAND FRONT FOG LAMP FOR OPEN CIRCUIT
2 Disconnect right-hand front fog lamp from
connector C304.
4 Switch on the front fog lamps.
6 Measure the voltage between right-hand front fog

8 Measure the voltage between right-hand front fog

Yes
GO to B5.
No
hand front fog lamp using the Wiring Diagrams.
B5: CHECK GROUND CONNECTION OF RIGHT-HAND FRONT FOG LAMP FOR OPEN
CIRCUIT
3 Measure the resistance between right-hand front

5 Measure the resistance between right-hand front

Yes
CHECK the right-hand front foglamp and RENEW it
as necessary. CHECK the operation of the system.
No
between the right-hand front fog lamp and soldered
connection S109 using the Wiring Diagrams.
B6: CHECK THE VOLTAGE SUPPLY TO THE LEFT-HAND REAR LAMP ASSEMBLY (REAR
FOG LAMP) FOR OPEN CIRCUIT
2 Disconnect left-hand rear lamp assembly.
Vehicles without trailer socket: from connector

C474
Vehicles with trailer socket: from connector

C474a
4 SWITCH ON the rear fog lamps.
5 Measure the voltage between left-hand rear lamp
assembly:

pin 1, circuit 15S-LD6 (GN/YE), wiring harness
side and ground.
Vehicles with trailer socket: Connector C474a,

pin 1, circuit (VT/YE), wiring harness side and
ground.
Yes
GO to B7.
No
- Vehicles without trailer socket: Vehicles built up

to 02/2004: LOCATE and RECTIFY the break in the
circuit between intermediate connector C61b, pin
16 and the left-hand rear lamp assembly using the
system.
02/2004 to 08/2006: LOCATE and RECTIFY the
break in the circuit between intermediate connector
C54, pin 10 and the left-hand rear lamp assembly
the system.
08/2006: LOCATE and RECTIFY the break in the
circuit between intermediate connector C61, pin 1
and the left-hand rear lamp assembly using the
system.
- Vehicles with trailer socket: LOCATE and RECTIFY
the break in the circuit between the cut-off relay
and the left-hand rear lamp assembly using the
system.
B7: CHECK THE GROUND CONNECTION AT THE LEFT-HAND REAR LAMP ASSEMBLY
FOR OPEN CIRCUIT
2 Measure the resistance between the left-hand rear
lamp assembly:

and ground.

pin 5, circuit (BN), wiring harness side and
ground.
Yes
lamp assembly. CHECK the operation of the
system.
No
- Vehicles without trailer socket: LOCATE and
RECTIFY the break in the circuit between the left-
hand rear fog lamp and ground connection G46
the system.
the break in the circuit between the left-hand rear
fog lamp and soldered connection S1001 using the
system.
B8: CHECK THE VOLTAGE SUPPLY TO THE RIGHT-HAND REAR LAMP ASSEMBLY (REAR
FOG LAMP) FOR OPEN CIRCUIT
2 Disconnect right-hand rear lamp assembly.
Vehicles without trailer socket: from connector

C475

Vehicles with trailer socket: from connector
C475a
4 SWITCH ON the rear fog lamps.
5 Measure the voltage between the right-hand rear
lamp assembly:

pin 1, circuit 15S-LD12 (GN/YE), wiring harness
side and ground.

pin 1, circuit (VT/YE), wiring harness side and
ground.
Yes
GO to B9.
No
- Vehicles without trailer socket: Vehicles built up
to 02/2004: LOCATE and RECTIFY the break in the
circuit between intermediate connector C61b, pin
16 and the right-hand rear lamp assembly using
system.
02/2004 to 08/2006: LOCATE and RECTIFY the
break in the circuit between intermediate connector
C54, pin 10 and the right-hand rear lamp assembly
the system.
08/2006: LOCATE and RECTIFY the break in the
circuit between intermediate connector C61, pin 1
and the right-hand rear lamp assembly using the
system.
the break in the circuit between the cut-off relay
and the right-hand rear lamp assembly using the
system.
B9: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP ASSEMBLY
FOR OPEN CIRCUIT
2 Measure the resistance between the right-hand
rear lamp assembly:

and ground.

pin 5, circuit (GN), wiring harness side and
ground.

Yes
lamp assembly. CHECK the operation of the

system.
No
PINPOINT TEST C : REAR FOG LAMPS OR FRONT FOG LAMPS ILLUMINATE

CONTINUOUSLY
C1: CHECK THE HEADLIGHT SWITCH
4 CHECK the front and rear fog lamps.
Are the front or rear fog lamps permanently on?
Yes
- Front fog lamp permanently lit: LOCATE and
RECTIFY the short to battery voltage in the circuits
connected to soldered connection S110 using the
system.
- Rear fog lamps permanently on: Vehicles without
trailer socket: LOCATE and RECTIFY the short to
battery voltage in the circuits connected to the
headlamp switch, connector C320, pin 2 using the
system.
- Rear fog lamps permanently on: Vehicles with
trailer socket: GO to C2.
No
C2: NARROW DOWN THE CAUSE OF THE SHORT TO BATTERY VOLTAGE
- Vehicles without parking aid: Rear fog lamp cut-

off relay from socket C1103

4 Measure the voltage between:

off relay, socket C1103, circuit (RD/WH), wiring

aid cut-off relay, socket C1110, circuit (RD/WH),

Yes
the circuits connected to the headlamp switch,

connector C320, pin 2 using the Wiring Diagrams.
No
LOCATE and RECTIFY short to battery voltage in the
circuits (VT/YE), connected to the cut-off relay with
the aid of the wiring diagrams. CHECK the

Exterior Lighting - Headlamps Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Special Tool(s)
Terminal probe kit
29-011 A
General Equipment

NOTE: If the instrument cluster is changed, the new one must be reinitialised. For this
purpose, the vehicle-specific data is read out of the module to be replaced using WDS and
is transferred to the new module.
REFER to: Central Timer Module (CTM) (419-10 Multifunction Electronic Modules,
in the vehicle, so that communication between the module and WDS is ensured.
2. 2. Visually inspect for obvious signs of electrical (or mechanical) damage.

Electrical
Fuse(s)
Bulb(s)
Wiring harness
4. 4. If the cause of the concern cannot be determined with a visual inspection, proceed
to the Symptom Chart.
WDS Trouble Code Table - Central Timer Module (CTM)

WDS Trouble Code Table - Central Timer Module (CTM)

B1312 Short circuit in dipped beam control circuit (short to battery GO to Pinpoint Test
positive) F.
Symptom Chart
Symptom Chart

Headlamps inoperative (dipped beam and * Fuse(s) * GO to Pinpoint

main beam) * Circuit(s) Test A.
* Central junction box
(CJB)
Dipped beams inoperative (both sides) * Fuse(s) * GO to Pinpoint
* Circuit(s) Test B.
* Dipped beam relay
* Headlight switch
* Battery junction box
(BJB).
Main beams inoperative (both sides) * Circuit(s) * GO to Pinpoint
* Main beam relay Test C.
* Turn signal switch
Dipped beam on one side not working (main * Fuse * GO to Pinpoint
beam OK) * Circuit(s) Test D.
* Headlamp
Main beam on one side not working (dipped * Fuse * GO to Pinpoint
beam OK) * Circuit(s) Test E.
* Headlamps
The headlamps are on continuously * Circuit(s) * GO to Pinpoint
* Dipped beam relay Test F.
* Main beam relay
* Headlight switch
The headlamp flasher is inoperative * Circuit(s) * GO to Pinpoint
* Turn signal switch Test G.
Pinpoint Test
PINPOINT TEST A : HEADLAMPS INOPERATIVE (DIPPED BEAM AND MAIN
BEAM)
2 SWITCH ON dipped beam.
3 SWITCH ON main beam.
4 CHECK the headlamp.
Are both headlamps inoperative?
Yes
GO to A2.
No
- Left-hand headlamp inoperative: GO to A5.
- Right-hand headlamp inoperative: GO to A6.
A2: CHECK FUSE F37/F58 (7.5 A) (CJB).
2 Disconnect Fuse.
Vehicles before 08/2006: F37 (7.5 A) (CJB)
Vehicles from 08/2006: F58 (7.5 A) (CJB)

3 CHECK Fuse.
Is the fuse OK?

Yes
GO to A3.
No
- Vehicles before 08/2006: RENEW fuse F37 (7,5 A)
and CHECK the operation of the system. If the fuse
blows again, LOCATE and RECTIFY the short to
ground using the Wiring Diagrams. CHECK the
- Vehicles from 08/2006: RENEW fuse F58 (7,5 A)
and CHECK the operation of the system. If the fuse
ground using the Wiring Diagrams. CHECK the
operation of the system
A3: CHECK THE VOLTAGE SUPPLY TO FUSE F37/F58 (7.5 A) (CJB)
1 Connect Fuse.

Vehicles before 08/2006: F37 (7.5 A) (CJB) and

ground.
Vehicles from 08/2006: F58 (7.5 A) (CJB) and

ground.
Yes
- Vehicles without daytime running lights: GO to
A4.
- Vehicles with daytime running lights: LOCATE and
REPAIR break in circuit 91-DA3 (BK/OG) between
soldered connection S118 and ground G37 with the
aid of the Wiring Diagrams. CHECK the operation of
the system.
No
- Vehicles before 08/2006: LOCATE AND RECTIFY
the break in the voltage supply of fuse F37 (7.5 A)
CHECK and RENEW the CJB. CHECK the operation
of the system.
- Vehicles from 08/2006: LOCATE AND RECTIFY the
break in the voltage supply of fuse F58 (7.5 A)
CHECK and RENEW the CJB. CHECK the operation
of the system
A4: TEST COMMON VOLTAGE SUPPLY TO RELAYS (LOAD CIRCUIT)
2 Disconnect main beam relay from socket C1005.
4 Measure the voltage between the main beam relay,
socket C1005, pin 3, circuit 30-LE13 (RD), BJB side
and ground.

Yes
LOCATE and REPAIR break in circuit 91-DA3
(BK/OG) between soldered connection S118 and
Diagrams. CHECK the operation of the system
No
LOCATE and RECTIFY the break in the circuit(s)
between the battery and soldered connection S102
the system
A5: CHECK THE GROUND CONNECTION OF LEFT-HAND HEADLAMP
C835.
3 Measure the resistance between left-hand

Yes
CHECK the operation of the system
No
LOCATE and RECTIFY break in circuit(s) between
headlamp and ground connection G37 with the aid
of the wiring diagrams. CHECK the operation of the
system
A6: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
C834.

Yes
No
LOCATE and RECTIFY break in circuit(s) between
headlamp and ground connection G56 with the aid
system
PINPOINT TEST B : DIPPED BEAMS INOPERATIVE (BOTH SIDES)

B1: CHECK THE VOLTAGE SUPPLY OF THE DIPPED BEAM RELAY
2 Disconnect dipped beam relay from socket C1006.
4 Measure the voltage between the dipped beam
relay, socket C1006, pin 3, circuit 30-LE20(A)
(RD), BJB side and ground.

Yes
GO to B4.
No
- Vehicles without daytime running lights: LOCATE
and RECTIFY the break in the circuit 30-LE20 (RD)
between soldered connection S102 and the dipped
beam relay using the Wiring Diagrams. CHECK the
- Vehicles with daytime running lights: GO to B2.
B2: CHECK FUSE F22 (20 A) (BJB).
Is the fuse OK?
Yes
GO to B3.
No
RENEW fuse F22 (20 A) (BJB) CHECK the operation
of the system If the fuse blows again, LOCATE and
RECTIFY the short to ground using the Wiring
B3: CHECK THE VOLTAGE SUPPLY TO FUSE F22 (20 A) (BJB) FOR OPEN CIRCUIT
3 Measure voltage between fuse F22 (20 A) (BJB)
and ground.
Yes
LOCATE and RECTIFY the break in circuit 30-LE20A
(RD) between fuse F22 (20 A) (CJB) and the dipped

beam relay using the Wiring Diagrams. CHECK the
No
supply of fuse F22 (20 A) (BJB) using the Wiring
Diagrams. If necessary CHECK and RENEW the BJB.
B4: CHECK CONTROL CIRCUIT OF DIPPED BEAM RELAY FOR OPEN CIRCUIT
2 Measure the voltage between the dipped beam
relay, socket C1006, pin 1, circuit 15S-LE19
(GN/BU), BJB side and ground.

Yes
GO to B5.
No
GO to B7.
B5: CHECK THE GROUND CONNECTION OF THE DIPPED BEAM RELAY FOR OPEN
CIRCUIT
2 Measure the resistance between the dipped beam
relay, socket C1006, pin 2, circuit 91-LE19
(BK/BU), BJB side and ground.

Yes
- Vehicles without daytime running lights: RENEW
the dipped beam relay. CHECK the operation of the
system
- Vehicles with daytime running lights: GO to B6.
No
between the dipped beam relay and soldered
connection S118 using the wiring diagrams. CHECK
B6: CHECK THE POWER CIRCUIT OF THE DIPPED BEAM RELAY FOR OPEN CIRCUIT
1 Connect a fused bridging cable (30 A) to the dipped
beam relay, socket C1006 between pin 3, circuit
30-LE20A (RD) and pin 5, circuit 15S-LE20
(GN/RD), BJB side.
2 CHECK the dipped beam.

Is the dipped beam on?
Yes
RENEW the dipped beam relay. CHECK the
No
LOCATE and RECTIFY the break in the circuit 15S-
LE20 (GN/RD) between soldered connection S120
and the dipped beam relay using the Wiring
B7: CHECK THE VOLTAGE SUPPLY OF THE HEADLIGHT SWITCH
connector C320, pin 8, circuit 15-LE29 (GN/BK),

Yes
GO to B8.
No
RECTIFY the break in the circuit between fuse F37
(20A) (CJB) and the headlamp switch using the
system.
the break in the circuit between fuse F58 (20A)
(CJB) and the headlamp switch using the Wiring
B8: CHECK THE HEADLIGHT SWITCH
2 Connect Dipped beam relay to socket C1006.
3 Using a fused bridging cable (7.5 A) at the
headlight switch, connect between connector C320,
pin 8, circuit 15-LE29 (GN/BK) and pin 6, circuit
15S-LE14 (GN/RD), wiring harness side.

Is the dipped beam on?
Yes
No
GO to B9.

B9: CHECK CIRCUIT 15S-LE14 (GN/RD) FOR OPEN CIRCUIT
2 Connect Headlight switch with connector C320.
3 Disconnect Turn signal switch from connector
C459.
6 Measure the voltage between turn signal switch,
connector C459, pin 8, circuit 15S-LE14 (GN/RD),

Yes
GO to B10.
No
between the headlight switch and the turn signal
switch using the Wiring Diagrams. CHECK the
B10: CHECK CIRCUIT 15S-LE19 (GN/BU) FOR OPEN CIRCUIT
2 Disconnect Dipped beam relay from socket C1006.
3 Measure resistance between the turn signal switch,
connector C459, pin 9, circuit 15S-LE19 (GN/BU),
wiring harness side and the dipped beam relay,
socket C1006, pin 1, circuit 15S-LE19 (GN/BU),

Yes
RENEW the turn signal switch. CHECK the operation
of the system.
No
between the turn signal switch and the dipped
beam relay using the wiring diagrams. CHECK the
PINPOINT TEST C : MAIN BEAMS INOPERATIVE (BOTH SIDES)

C1: CHECK THE VOLTAGE SUPPLY TO THE MAIN BEAM RELAY FOR OPEN CIRCUIT
2 Disconnect Main beam relay from socket C1005.
socket C1005, pin 3, circuit 30-LE13 (RD), BJB side

and ground.

Yes
GO to C2.
No
LOCATE and RECTIFY the break in the circuit 30-
LE13 (RD) between soldered connection S102 and
the main beam relay using the Wiring Diagrams.
C2: CHECK THE CONTROL VOLTAGE AT THE MAIN BEAM RELAY
socket C1005, pin 1, circuit 15S-LE12 (GN/YE), BJB
side and ground.

Yes
GO to C3.
No
GO to C4.
C3: CHECK THE GROUND CONNECTION OF THE MAIN BEAM RELAY
2 Measure the resistance between the main beam
relay, socket C1005, pin 2, circuit 91-LE12
(BK/YE), BJB side and ground.

Yes
RENEW the main beam relay. CHECK the operation
of the system
No
between the main beam relay and soldered
the operation of the system
C4: CHECK THE VOLTAGE SUPPLY TO THE TURN SIGNAL SWITCH FOR OPEN CIRCUIT
C459.

4 Measure the voltage between the turn signal
switch, connector C459, pin 6, circuit 15-LE14

Yes
GO to C5.
No
RECTIFY break in the circuit between fuse F37
(CJB) and the turn signal switch with the aid of the
wiring diagrams. CHECK the operation of the
system
RECTIFY break in the circuit between fuse F58
(CJB) and the turn signal switch with the aid of the
wiring diagrams. CHECK the operation of the
system
C5: CHECK THE TURN SIGNAL SWITCH
2 Connect Main beam relay to socket C1005.
3 Connect a fused bridging cable (7.5 A) at the turn
signal switch, connector C459, between pin 6,
circuit 15-LE14 (GN/RD), wiring harness side and
pin 7, circuit 15S-LE12 (GN/YE), wiring harness
side.

5 CHECK the main beam.
Are the main beam headlamps lit up?
Yes
of the system
No
between the turn signal switch and the main beam
relay using the wiring diagrams. CHECK the
PINPOINT TEST D : DIPPED BEAM ON ONE SIDE INOPERATIVE (MAIN

BEAM OK)
D1: DETERMINE WHICH OF THE DIPPED BEAMS IS INOPERATIVE
3 DETERMINE which dipped beam lamp is inoperative

Is the left-hand dipped beam inoperative?
Yes
GO to D2.
No
Right-hand dipped beam inoperative: GO to D5.
D2: CHECK FUSE F16 (BJB)
Is the fuse OK?
Yes
GO to D3.
No
D3: CHECK THE VOLTAGE SUPPLY TO FUSE F16 (10 A) (BJB)
Measure voltage between fuse F16 (10 A) (BJB)
4
and ground.
Yes
GO to D4.
No
and RECTIFY the break in circuit 15S-DC16 (GN/BU)
between the dipped beam relay and fuse F16 (10 A)
RECTIFY the break in circuit 15S-DC16A (GN/BU)
between the soldered connection S120 and fuse F16
(10 A) (BJB) using the Wiring Diagrams. CHECK the
D4: TEST THE VOLTAGE SUPPLY TO THE LEFT-HAND HEADLAMP (DIPPED BEAM)
C835.
5 Measure the voltage between left-hand headlamp,
connector C835, pin 7, circuit 15S-LE16 (GN/OG),

Yes

No
between fuse F16 (10 A) (BJB) and the left-hand
headlight with the aid of the wiring diagrams.
D5: CHECK FUSE F17 (10 A) (BJB).
2 Disconnect fuse F17 (10 A) (BJB).
3 CHECK fuse F17 (10 A) (BJB).
Is the fuse OK?
Yes
GO to D6.
No
D6: CHECK THE VOLTAGE SUPPLY TO FUSE F17 (10 A) (BJB)
1 Connect fuse F17 (10 A) (BJB).
Measure the voltage between fuse F17 (BJB) and
4
ground.
Yes
GO to D7.
No
and RECTIFY the break in circuit 15S-DC17 (GN/BU)
between the dipped beam relay and fuse F17 (10 A)
RECTIFY the break in circuit 15S-DC17A (GN/BU)
between soldered connection S120 and fuse F17
(10 A) (BJB) using the Wiring Diagrams. CHECK the
D7: TEST THE VOLTAGE SUPPLY TO THE RIGHT-HAND HEADLAMP (DIPPED BEAM)
C834.
5 Measure the voltage between the right-hand
headlamp, connector C834, pin 7, circuit 15S-LE23

Yes

No
between fuse F17 (10 A) (BJB) and the right-hand
headlamp with the aid of the wiring diagrams.
PINPOINT TEST E : MAIN BEAM ON ONE SIDE INOPERATIVE (DIPPED

BEAM OK)
E1: DETERMINE WHICH MAIN BEAM IS INOPERATIVE
3 DETERMINE WHICH MAIN BEAM IS INOPERATIVE
Is the left-hand main beam inoperative?
Yes
GO to E2.
No
Right-hand high beam is inoperative: GO to E5.
E2: CHECK FUSE F15 (10 A) (BJB).
Is the fuse OK?
Yes
GO to E3.
No
E3: CHECK THE VOLTAGE SUPPLY TO FUSE F15 (10 A) (BJB)
4
and ground.
Yes
GO to E4.
No
LOCATE and RECTIFY the break in circuit 15S-DC15
(GN/BU) between the main beam relay and fuse
F15 (10 A) (BJB) using the Wiring Diagrams. CHECK
E4: TEST THE VOLTAGE SUPPLY TO THE LEFT-HAND HEADLAMP (MAIN BEAM)
C835.

Yes
No
LOCATE and RECTIFY break in circuit between fuse
F15 (BJB) and headlight with the aid of the wiring
diagrams. CHECK the operation of the system
E5: CHECK FUSE F25 (10 A) (BJB).
Is the fuse OK?
Yes
GO to E6.
No
RENEW fuse F25 (10 A). CHECK the operation of the
system If the fuse blows again, LOCATE and
E6: CHECK THE VOLTAGE SUPPLY TO FUSE F25 (10 A) (BJB)
4
and ground.
Yes
GO to E7.
No
(GN/BU) between the main beam relay and fuse
F25 (10 A) (BJB) using the Wiring Diagrams. CHECK
E7: TEST THE VOLTAGE SUPPLY TO THE RIGHT-HAND HEADLAMP (MAIN BEAM)
C834.
5 Measure the voltage between right-hand headlamp,
connector C834, pin 6, circuit 15S-LE22 (GN/OG),

Yes
No
between fuse F25 (10 A) (BJB) and the headlamp
using the wiring diagrams. CHECK the operation of
the system.
PINPOINT TEST F : THE HEADLAMPS ARE ON CONTINUOUSLY

F1: DETERMINE THE CAUSE OF THE FAULT
NOTE: Only switch on the ignition on vehicles without daytime running lamps.
2 SWITCH OFF the dipped beam.
3 SWITCH OFF main beam.
4 CHECK the headlamp.
Are the main beam headlamps permanently on?
Yes
GO to F8.
No
Dipped beam permanently on: GO to F2.
F2: CHECK POWER SUPPLY CIRCUIT FOR SHORT TO BATTERY VOLTAGE
Is one of the dipped beam headlamps on?
Yes
- Left-hand dipped beam lit: LOCATE and RECTIFY
the short to battery voltage in circuit 15S-LE16
(GN/OG) between fuse F16 (10 A) (BJB) and the
left-hand headlamp using the Wiring Diagrams.
CHECK the operation of the system. If necessary
CHECK and RENEW the BJB. CHECK the operation
of the system.
- Right-hand dipped beam lit: LOCATE and RECTIFY
the short to battery voltage in circuit 15S-LE23
(GN/WH) between fuse F17 (10 A) (BJB) and the
right-hand headlamp using the Wiring Diagrams.
CHECK the operation of the system If necessary
CHECK and RENEW the BJB. CHECK the operation
of the system
No
GO to F3.

F3: CHECK FOR A SHORT TO BATTERY VOLTAGE IN THE COMMON SUPPLY CIRCUIT
4 Disconnect Dipped beam relay from socket C1006.
5 Disconnect For vehicles with daytime running
lights: Daytime running lamp relay from socket
C1012.
Is the undiminished dipped beam permanently on?
Yes
and RECTIFY the short to battery voltage in circuits
15S-DC16 (GN/BU) and 15S-DC17 (GN/BU) which
are connected to the dipped beam relay, socket
C1006, pin 5 using the Wiring Diagrams. CHECK the
operation of the system If necessary CHECK and
RENEW the BJB. CHECK the operation of the system
RECTIFY short to battery voltage in the circuits
connected to soldered connection S120 with the aid
system If necessary CHECK and RENEW the BJB.
CHECK the operation of the system If the concern
persists:
Testing).
No
GO to F4.
F4: CHECK THE CONTROL CIRCUIT OF THE DIPPED BEAM RELAY FOR SHORT TO
BATTERY VOLTAGE
1 Measure the voltage between dipped beam relay,
socket C1006, pin 1, circuit 15S-LE19 (GN/BU),

Yes
GO to F5.
No
RENEW the dipped beam relay. CHECK the
F5: RULE OUT THE LIGHT SWITCH AS A POSSIBLE CAUSE OF THE FAULT
2 Connect Dipped beam relay with socket C1006.
Yes

GO to F6.
No
F6: CHECK CIRCUIT 15S-LE19 (GN/BU) FOR SHORT TO BATTERY VOLTAGE
C459.
Yes
circuit 15S-LE19 (GN/BU) between the turn signal
switch and the dipped beam relay with the aid of
system
No
GO to F7.
F7: EXCLUDE THE TURN SIGNAL SWITCH AS THE CAUSE OF THE FAULT
1 Measure the voltage between turn signal switch,
connector C459, pin 8, circuit 15S-LE14 (GN/RD),

Yes
the circuit(s) between the turn signal switch and
the headlamp switch using the Wiring Diagrams.
No
CHECK and if necessary RENEW the turn signal
switch. CHECK the operation of the system If the
concern persists (vehicles with daytime running
lamps):
Testing).
F8: CHECK POWER SUPPLY CIRCUIT FOR SHORT TO BATTERY VOLTAGE
Is one of the main beam headlamps on?

Yes
- Left-hand main beam permanently lit: LOCATE
and RECTIFY the short to battery voltage in circuit
15S-LE15 (GN/BK) between fuse F15 (10 A) (BJB)
and the left-hand headlamp using the Wiring
Diagrams. CHECK the operation of the system If

necessary CHECK and RENEW the BJB. CHECK the
- Right-hand high beam permanently lit: GO to F12.
No
GO to F9.
F9: CHECK FOR A SHORT TO BATTERY VOLTAGE IN THE COMMON SUPPLY CIRCUIT
4 Disconnect Main beam relay from socket C1005.
Yes
circuits 15S-DC15 (GN/BU) and 15S-DC25 (GN/BU)
which are connected to the main beam relay,
socket C1005, pin 5 using the Wiring Diagrams.
No
GO to F10.
F10: CHECK THE CONTROL CIRCUIT OF THE MAIN BEAM RELAY FOR A SHORT TO
BATTERY VOLTAGE
socket C1005, pin 1, circuit 15S-LE12 (GN/YE), BJB
side and ground.

Yes
GO to F11.
No
RENEW the main beam relay. CHECK the operation
of the system.
F11: RULE OUT THE TURN SIGNAL SWITCH AS THE CAUSE OF THE FAULT
2 Connect Main beam relay with socket C1005.
C459.
Yes
LOCATE and RECTIFY the short circuit in circuit
15S-LE12 (GN/YE) between the turn signal switch
and the main beam relay with the aid of the Wiring
Diagrams. CHECK the operation of the system. If
necessary CHECK and RENEW the BJB. CHECK the
No
of the system

F12: EXCLUDE THE INSTRUMENT CLUSTER AS CAUSE OF THE SHORT CIRCUIT
2 Disconnect Vehicles built before 08/2006: Fuse F20
(10 A) (BJB).
(7.5 A) (CJB).
(7.5 A) (CJB).
5 Disconnect Vehicles built from 08/2006: Fuse F37
(7.5 A) (CJB).
6 Disconnect Vehicles built from 08/2006: Fuse F59
(7.5 A) (CJB).
7 Disconnect fuse F48 (7.5 A) (CJB).
Yes
the circuits connected to fuse F25 (10 A) (BJB),
output side, using the Wiring Diagrams. CHECK the
operation of the system If necessary CHECK and
RENEW the BJB. CHECK the operation of the system
No
cluster. CHECK the operation of the system
PINPOINT TEST G : HEADLAMP FLASHER INOPERATIVE (DIPPED BEAM

OK)
G1: DETERMINE THE CAUSE OF THE FAULT
Are the main beam headlamps lit up?
Yes
GO to G2.
No
GO to Pinpoint Test C.
G2: CHECK THE VOLTAGE SUPPLY OF THE TURN SIGNAL SWITCH
C459.
4 Measure the voltage between the turn signal

Yes

of the system
No
RECTIFY the break in circuit 15-LE14 (GN/RD)
between fuse F37 (7.5 A) (CJB) and the turn signal
switch using the wiring diagrams. CHECK the
the break in circuit 15-LE14 (GN/RD) between fuse
F58 (7.5 A) (CJB) and the turn signal switch using
the wiring diagrams. CHECK the operation of the
system

Exterior Lighting - Headlamp Leveling Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Special Tool(s)
Terminal probe kit
29-011 A
2. 2. Visually inspect for obvious signs of electrical (or mechanical) damage.
Electrical
Fuse
Headlight switch
Wiring harness
Symptom Chart
Symptom Chart

Headlamp levelling system * Fuse * GO to Pinpoint
inoperative/malfunctioning * Circuit(s) Test A.
* Headlight switch
* Headlamp positioning
motor
Pinpoint Tests
PINPOINT TEST A : HEADLAMP LEVELLING SYSTEM
INOPERATIVE/MALFUNCTIONING
3 OPERATE the headlamp levelling.
4 CHECK the headlamps.
Does the headlamp levelling not work on both of the
headlamps?
Yes
GO to A8.

No
- The headlamp, left-hand side is unadjustable: GO
to A2.
- The right-hand headlamp cannot be adjusted: GO
to A5.
A2: CHECK THE PARKING LAMP IN THE LEFT-HAND HEADLAMP
2 CHECK left-hand parking lamp.
Is the parking lamp on?
Yes
GO to A3.
No
REFER to: Parking, Rear and License Plate Lamps
(417-01 Exterior Lighting, Diagnosis and Testing).
A3: CHECK THE CONTROL CIRCUIT OF THE LEFT-HAND HEADLAMP LEVELLING
SYSTEM
C835.
6 CHANGE the SETTING of the headlamp leveling
system during the measurement (UP/DOWN).
connector C835, pin 2, circuit 64-LE45 (BU), wiring
Does the registered voltage vary proportionally with

the adjustment of the variable resistor?
Yes
GO to A4.
No
between the headlamp and soldered connection
S106 using the wiring diagrams. CHECK the
A4: CHECK THE CIRCUITS TO THE LEFT-HAND HEADLAMP POSITIONING MOTOR
3 Measure the resistance between the left-hand
headlamp, connector C835, pins 2, 3 and 4,
component side and the corresponding pins on the
headlamp positioning motor, connector C840,

Is a resistance of less than 2 Ohms measured in all of
the cases?
Yes
CHECK and if necessary RENEW the headlamp
positioning motor. CHECK the operation of the
system.
No
LOCATE and REPAIR the break in the affected
circuits using the wiring diagrams. CHECK the
A5: CHECK THE PARKING LAMP IN THE RIGHT-HAND HEADLAMP
2 CHECK right-hand parking lamp.
Is the parking lamp on?
Yes
GO to A6.
No
A6: CHECK THE CONTROL CIRCUIT OF THE RIGHT-HAND HEADLAMP LEVELLING
SYSTEM
C834.
6 Measure the voltage between right-hand
(BU/RD), wiring harness side and ground.

Yes
GO to A7.
No
S106 using the wiring diagrams. CHECK the
A7: CHECK THE CIRCUITS TO THE RIGHT-HAND HEADLAMP POSITIONING MOTOR
headlamp, connector C834, pins 2, 3 and 4,
component side and the corresponding pins on the
headlamp positioning motor, connector C841,

the cases?
Yes
CHECK and if necessary RENEW the headlamp
positioning motor. CHECK the operation of the
system.
No
LOCATE and REPAIR the break in the affected
circuits using the wiring diagrams. CHECK the
2 CHECK Fuse.
Vehicles built before 08/2006: F37 (7.5 A) (CJB)

Is the fuse OK.?
Yes
GO to A9.
No
- Vehicles built before 08/2006: RENEW fuse F37
(7.5 A) (CJB) and CHECK the operation of the
system. If the fuse blows again, LOCATE and
RECTIFY short using the Wiring Diagrams. CHECK
- Vehicles built from 08/2006: RENEW fuse F58
RECTIFY short using the Wiring Diagrams. CHECK
A9: CHECK THE VOLTAGE SUPPLY TO FUSE F37/F58 (7.5 A) (CJB) FOR OPEN CIRCUIT
1 Connect Fuse.


and ground.

and ground.

Yes

GO to A10.
No
- Vehicles built before 08/2006: LOCATE AND
RECTIFY the break in the voltage supply of fuse
F37 (7.5 A) (CJB) using the Wiring Diagrams.
- Vehicles built from 08/2006: LOCATE AND
F58 (7.5 A) (CJB) using the Wiring Diagrams.
A10: CHECK THE VOLTAGE SUPPLY TO THE LIGHT SWITCH FOR OPEN CIRCUIT

Yes
GO to A11.
No
(7.5 A) (CJB) and the headlamp switch using the
system.
- Vehicles built from 08/2006: LOCATE and
system.
A11: EXCLUDE THE HEADLAMP AS THE CAUSE OF THE CONCERN
3 Connect Headlight switch to connector C320.
C835.
C834.

Yes
GO to A12.
No
- No voltage is displayed: GO to A13.
- Battery voltage is displayed: GO to A15.
A12: EXCLUDE THE HEADLAMP AS THE CAUSE OF THE CONCERN
3 Connect Right-hand headlamp to connector C834.

Yes
CHECK and if necessary INSTALL A NEW left-hand
headlamp. CHECK the operation of the system.
No
CHECK and if necessary INSTALL A NEW right-hand
headlamp. CHECK the operation of the system.
A13: CHECK COMMON CONTROL CIRCUIT FOR OPEN CIRCUIT
3 Measure resistance between headlamp switch,
harness side and headlamp, left, connector C835,
pin 2, circuit 64-LE45 (BU), wiring harness side.

Yes
GO to A14.
No
LOCATE and RECTIFY the break in the circuit 64-
LE1 (BU), between the headlamp switch and
A14: CHECK CONTROL CIRCUIT FOR SHORT TO GROUND
1 Measure the resistance between the headlamp
switch, connector C320, pin 1, circuit 64-LE1 (BU),

Yes
No
LOCATE and RECTIFY short to ground in the circuits
connected to soldered connection S106 with the aid
system.
A15: CHECK CONTROL CIRCUIT FOR SHORT TO BATTERY VOLTAGE
4 Measure the voltage between the headlamp switch,

Yes
LOCATE and RECTIFY short to battery voltage in
with the aid of the wiring diagrams. CHECK the
No
GO to A16.
A16: CHECK THE GROUND CONNECTION OF THE HEADLIGHT SWITCH FOR OPEN
CIRCUIT
2 Measure the resistance between the headlamp

Yes
No
between the headlight switch and soldered
connection S6 using the wiring diagrams. CHECK

Exterior Lighting - Turn Signal and Hazard
Lamps
Print

information.
Special Tool(s)
Terminal probe kit
29-011 A
Inspection and Testing


Electrical
Fuse(s)
Bulb(s)
Wiring harness
4. 4. If the cause of the concern cannot be found by visual inspection, continue with the
symptom chart.
Symptom Chart
Troubleshooting Table

Turn indicators inoperative * Fuse(s) * GO to Pinpoint Test A.
* Circuit(s)
* Hazard warning
lamp switch
Turn signal lamps illuminate or flash * Fuse(s) * GO to Pinpoint Test B.
continuously * Circuit(s)
* Hazard warning

lamp switch
Hazard warning lamps inoperative * Circuit(s) * GO to Pinpoint Test C.
* Hazard warning
lamp switch
One or more turn indicators are * Circuit(s) * GO to Pinpoint Test D.
inoperative or lit all the time * Hazard warning
lamp switch
* Front turn signal
lamp
* Turn signal side
repeater lamp
* Rear lamp
assembly
The turn indicators on one side flash * Hazard warning * GO to Pinpoint Test E.
continuously lamp switch
* Central security
module
Turn indicators operate correctly, but turn * Circuit(s) * GO to Pinpoint Test F.
indicator warning lamp does not work * Diode
Turn signal lamps operate correctly, but * flasher relay * RENEW the flasher relay.
without acoustic signal CHECK operation of system.
System Check
PINPOINT TEST A : TURN INDICATORS INOPERATIVE
2 Disconnect Fuse.

3 CHECK Fuse.

Is the fuse OK?
Yes
GO to A2.
No
(7.5 A). CHECK the operation of the system. If the
fuse blows again, LOCATE and RECTIFY the short to
ground using the Wiring Diagrams. CHECK
(7.5 A). CHECK system operates correctly If the
ground using the Wiring Diagrams. CHECK system
operates correctly
A2: CHECK THE VOLTAGE SUPPLY TO FUSE F48/F44 (7.5 A) (CJB)
1 Connect Fuse.

and ground.

and ground.

and ground.

and ground.
Yes
GO to A3.
No
F48 (7.5 A) (CJB) using the Wiring Diagrams. If
system.
F44 (7.5 A) (CJB) using the Wiring Diagrams. If
system.
A3: CHECK FUSE F61/F30 (15 A) (CJB).
2 Disconnect Fuse.
Vehicles built before 08/2006: F61 (15 A) (CJB)

3 CHECK Fuse.

Is the fuse OK?
Yes
GO to A4.
No
(15 A). CHECK system operates correctly If the
ground using the Wiring Diagrams. CHECK
- Vehicles built from 08/2006: RENEW fuse F30 (15
A). CHECK system operates correctly If the fuse
operates correctly
A4: CHECK THE VOLTAGE SUPPLY TO FUSE F61/F30 (15 A) (CJB)
1 Connect Fuse.


and ground.

and ground.
Yes
GO to A5.
No
F61 (15 A) (CJB) using the Wiring Diagrams.
CHECK system operates correctly CHECK and
INSTALL A NEW CJB if necessary. CHECK operation
of system.
CHECK operation of system. CHECK and INSTALL A
NEW CJB if necessary. CHECK operation of system.
A5: CHECK VOLTAGE SUPPLY TO FLASHER RELAY FOR OPEN CIRCUIT
2 Disconnect flasher relay from socket C457.
4 Measure the voltage between the flasher relay,
socket C457, pin 2, circuit 15-LG25(A) (GN/BU),
socket side and ground.

Yes
GO to A6.
No
RECTIFY the break in the circuit(s) between fuse
F48 (7.5 A) (CJB) and the turn signal relay using
the wiring diagrams. CHECK operation of system.
CHECK and INSTALL A NEW CJB if necessary.
CHECK system operates correctly
the wiring diagrams. CHECK system operates
correctly CHECK and INSTALL A NEW CJB if
necessary. CHECK system operates correctly
A6: CHECK VOLTAGE SUPPLY TO FLASHER RELAY FOR OPEN CIRCUIT
1 Measure the voltage between the turn signal relay,
socket C457, pin 3, circuit 29-LG26 (OG), socket
side and ground.

Yes
GO to A7.
No
F61 (15 A) (CJB) and the turn signal relay using
A7: CHECK GROUND SUPPLY TO FLASHER RELAY FOR OPEN CIRCUIT
2 Measure the resistance between the turn signal
relay, socket C457, pin 5, circuit 91-LG25 (BK/BU),
socket side and ground.

Yes
GO to A8.
No
between the turn signal relay and ground
connection G41 with the aid of the wiring diagrams.
A8: CHECK CIRCUIT 15-LG27 (GN/BK) FOR OPEN CIRCUIT
C459.
3 Measure resistance between turn signal relay,
socket C457, pin 1, circuit 15-LG27 (GN/BK),
wiring harness side and the turn signal switch,
connector C459, pin 2, circuit 15-LG27 (GN/BK),

Yes
GO to A9.
No
between the turn signal relay and the turn signal
switch using the wiring diagrams. CHECK operation
of system.
A9: RULE OUT THE TURN SIGNAL RELAY AS THE CAUSE OF THE FAULT
2 Connect Turn signal relay to socket C457.
3 Use a fused jumper lead (15 A) at the turn signal
switch, connector C459, to connect between pin 2,
circuit 15-LG27 (GN/BK), wiring harness side and
pin 1, circuit 49S-LG1 (BU), wiring harness side.

5 CHECK the turn signal lamps.
Are the left-hand turn signal lamps flashing?
Yes
RENEW the turn signal switch. CHECK system
operates correctly
No
RENEW the flasher relay. CHECK system operates
correctly
PINPOINT TEST B : TURN SIGNAL LAMPS ILLUMINATE OR FLASH

CONTINUOUSLY
B1: DETERMINE THE FAULT CONDITION
2 CHECK the turn signal lamps after each operation
of the switch.
3 SWITCH ON the hazard warning lamp switch.
4 SWITCH OFF the hazard warning lamp switch.
Are all turn signal lamps lit continuously with the

hazard warning lamps switch in the off position?
Yes
- Vehicles with petrol engine: GO to B2.
- Vehicles with diesel engine, built from 08/2004:
GO to B2.
- Vehicles with diesel engine, with anti-theft

warning system/central locking module, with trailer
socket, built before 08/2004: GO to B3.
- Vehicles with diesel engine, with anti-theft
warning system/central locking module, without
trailer socket, built before 08/2004: CHECK the
anti-theft warning system/central locking module
using WDS, RENEW if necessary. CHECK operation
of system.
No
- Turn signal lamps illuminate continuously when
the hazard warning lights switch is switched on: GO
to B5.
- Turn signal lamps flash continuously when the
hazard warning lights switch is in the off position:
GO to B4.
B2: EXCLUDE THE INSTRUMENT CLUSTER AS THE CAUSE OF THE FAULT
2 Disconnect Fuse.
Vehicles built before 08/2006: F20 (10 A) (BJB)

3 Disconnect Fuse.

4 Disconnect Fuse.

Are the turn signal lamps lit up permanently?
Yes
- vehicles with anti-theft warning system/central
locking module, with trailer socket: GO to B3.
- vehicles without anti-theft warning system/central
locking module, with trailer socket: RENEW the
trailer switch interface (SI) module. CHECK
- Vehicles with anti-theft warning system/central
locking module, without trailer socket: CHECK the
anti-theft warning system/central locking module
using WDS, RENEW if necessary. CHECK operation
of system.
No
CHECK the instrument cluster using WDS, RENEW if
B3: EXCLUDE THE ANTI-THEFT WARNING SYSTEM/CENTRAL LOCKING MODULE AS
THE CAUSE OF THE FAULT
2 Connect Fuse.

3 Connect Fuse.

4 Connect Fuse.

5 Disconnect Fuse.

6 Disconnect Fuse.

7 Disconnect fuse F63 (20 A) (CJB).
Are the turn signal lamps lit up permanently?
Yes
RENEW the trailer switch interface (SI) module.
No
CHECK the anti-theft warning system/central
locking module using WDS, RENEW if necessary.
B4: CHECK THE HAZARD WARNING LIGHT SWITCH
2 Disconnect Hazard warning light switch from
connector C458.
Are the turn signal lamps flashing continuously?
Yes
CHECK operation of system. If the concern persists,
CHECK and if necessary RENEW the turn signal
switch. CHECK operation of system.
No
RENEW the hazard warning light switch. CHECK
system operates correctly
2 Disconnect Fuse.

3 CHECK Fuse.

Is the fuse OK?
Yes
GO to B6.
No
operates correctly
operates correctly
B6: CHECK THE VOLTAGE SUPPLY TO FUSE F48/F44 (7.5 A) (CJB)
1 Connect Fuse.


and ground.

and ground.
Yes
GO to B7.
No
- LOCATE AND RECTIFY the break in the voltage
supply of fuse F48 (7.5 A) (CJB) using the Wiring
B7: CHECK FUSE F61/F30 (15 A) (CJB).
2 Disconnect Fuse.

3 CHECK Fuse.

Is the fuse OK?
Yes
GO to B8.
No
(15 A) (CJB). CHECK system operates correctly If
the fuse blows again, LOCATE and RECTIFY the
short to ground using the Wiring Diagrams. CHECK
A) (CJB). CHECK system operates correctly If the
operates correctly
B8: CHECK THE VOLTAGE SUPPLY TO FUSE F61/F30 (15 A) (CJB)
1 Connect Fuse.


and ground.

and ground.
Yes
GO to B9.
No
CHECK the operation of the system. CHECK and
INSTALL A NEW CJB if necessary. CHECK system
operates correctly
CHECK operation of system. CHECK and INSTALL A
NEW CJB if necessary. CHECK operation of system.
B9: CHECK VOLTAGE SUPPLY TO FLASHER RELAY FOR OPEN CIRCUIT

Yes
GO to B10.
No
CHECK and INSTALL A NEW CJB if necessary.
necessary. CHECK operation of system.
B10: CHECK VOLTAGE SUPPLY TO FLASHER RELAY FOR OPEN CIRCUIT
connector C457, pin 3, circuit 29-LG26 (OG),
Does meter display battery voltage?

Yes
GO to B11.
No
the wiring diagrams. CHECK the operation of the
system. CHECK and INSTALL A NEW CJB if
B11: CHECK GROUND CONNECTION OF FLASHER RELAY FOR OPEN CIRCUIT
2 Measure the resistance between the flasher relay,
connector C457, pin 5, circuit 91-LG25 (BK/BU),

Yes
GO to B12.
No

B12: CHECK CIRCUIT 49-LG8 (BU/WH) FOR SHORT TO BATTERY VOLTAGE
2 Measure the voltage between the turn signal lamp
relay, connector C457, pin 4, circuit 49-LG8

Yes
GO to B13.
No
RENEW the flasher relay. CHECK operation of
system.
B13: EXCLUDE THE HAZARD WARNING SWITCH AS THE CAUSE OF THE FAULT
connector C458.

Yes
LOCATE and RECTIFY the short to battery voltage
in the circuit between the turn signal relay and the
hazard warning switch using the wiring diagrams.
No
PINPOINT TEST C : HAZARD WARNING LAMPS INOPERATIVE

C1: CHECK THE HAZARD WARNING LIGHT SWITCH
connector C458.
3 Use a fused jumper lead (7.5 A) at the hazard
warning switch, connector C458, to connect
between pin 6, circuit 49-LG8 (BU/WH) and pin 5,
circuit 49S-LG3 (BU) wiring harness side.

Are the left-hand turn signal lamps flashing?
Yes
No
GO to C2.
C2: CHECK CIRCUIT 49-LG8 (BU/WH) FOR OPEN CIRCUIT
3 Measure the resistance between the turn signal
relay, socket C457, pin 4, circuit 49-LG8 (BU/WH),
wiring harness side and the hazard warning light
switch, connector C458, pin 6, circuit 49-LG8
(BU/WH), wiring harness side.

Yes
RENEW the flasher relay. CHECK operation of
system.
No
between the turn signal relay and the hazard
warning light switch using the wiring diagrams.
PINPOINT TEST D : ONE OR MORE TURN INDICATORS ARE INOPERATIVE

OR LIT ALL THE TIME
D1: DETERMINE THE FAULT CONDITION
of the switch.
3 SWITCH ON the turn signal switch.
4 SWITCH OFF the turn signal switch.
Are the turn signals lit continuously on one side?
Yes
- Turn signal lamps lit continuously when the turn
signal switch is not actuated: GO to D3.
- Turn signal lamps lit continuously when the turn
signal switch is actuated: GO to D25.
No

GO to D2.
of the switch.
2 SWITCH ON the left-hand turn signal lamps.
3 TURN ON the turn signal right-hand side.
Are only the front and side repeater turn signal lamps
on the left–hand side inoperative?
Yes
GO to D10.
No
- Front and side turn signal lamp inoperative on the
right-hand side, vehicles built from 08/2006:
LOCATE and RECTIFY the break in the shared
voltage supply between soldered connection S4 and
Diagrams. CHECK system operates correctly
- Side turn signal lamp inoperative on the left-hand
side: GO to D11.
- Side turn signal lamp inoperative on the right-
hand side: GO to D12.
- Left-hand front turn signal lamp inoperative: GO
to D13.
- Right-hand front turn signal lamp inoperative: GO
to D14.
- Left-hand rear turn signal lamp inoperative: GO
to D15.
- Right-hand rear turn signal lamp inoperative: GO
to D18.
- All turn signal lamps inoperative on the left-hand
side when the turn signal switch is operated: GO to
D21.
- All turn signal lamps inoperative on the left-hand
side when the hazard light switch is operated: GO
to D22.
- All turn signal lamps inoperative on the right-
hand side when the turn signal switch is operated:
GO to D23.
- All turn signal lamps inoperative on the right-
hand side when the hazard light switch is operated:
GO to D24.
D3: EXCLUDE THE TURN SIGNAL SWITCH AS THE CAUSE OF THE FAULT
C459.
Yes
GO to D4.
No
of the system.
D4: EXCLUDE THE HAZARD WARNING LAMP SWITCH AS THE CAUSE OF THE FAULT
connector C458.

Yes
- Vehicles with petrol engine: GO to D5.
- Vehicles with diesel engine, built from 08/2004:
GO to D5.
- vehicles with a diesel engine, with anti-theft
warning system/central locking module: GO to D6.
- vehicles with a diesel engine, without anti-theft
warning system/central locking module, with trailer
socket: GO to D8.
- Vehicles with diesel engine, without anti-theft
warning system/central locking module, without
trailer socket: GO to D7.
No
D5: EXCLUDE THE INSTRUMENT CLUSTER AS THE CAUSE OF THE FAULT
2 Disconnect Fuse.

3 Disconnect Fuse.

4 Disconnect Fuse.

Yes
- vehicles with anti-theft warning system/central
locking module: GO to D6.
locking module, with trailer socket: GO to D8.
locking module, without trailer socket: GO to D7.
No
D6: EXCLUDE THE ANTI-THEFT WARNING SYSTEM/CENTRAL LOCKING MODULE AS
THE CAUSE OF THE FAULT
2 Connect Fuse.

3 Connect Fuse.


4 Connect Fuse.

5 Disconnect Fuse.

6 Disconnect Fuse.

7 Disconnect fuse F63 (20 A) (CJB).
Yes
- Vehicles with trailer socket: GO to D8.
- Vehicles without trailer socket: GO to D7.
No
Are the turn signal lamps permanently lit on the left-
hand side?
Yes
with the aid of the wiring diagrams. CHECK
No
with the aid of the wiring diagrams. CHECK
D8: ELIMINATE THE TRAILER SWITCH INTERFACE (SI) MODULE AS CAUSE OF THE
FAULT.
2 Connect Fuse.

3 Connect Fuse.

4 Connect fuse F63 (20 A) (CJB).
5 Disconnect Fuse FC (10 A).
Yes
GO to D9.
No
CHECK the trailer switch interface (SI) module,
RENEW as necessary. CHECK operation of system.
D9: NARROW DOWN THE CAUSE OF THE FAULT
2 Disconnect Trailer switch interface (SI) module
from connector C1102.
Is the rear left-hand turn signal permanently lit?
Yes
the circuits connected to the left-hand rear lamp
cluster, connector C474(a), pin 3 with the aid of
correctly
No
- Rear right-hand turn indicator permanently lit:
the circuits connected to the right-hand rear lamp
cluster, connector C475(a), pin 3 with the aid of
- All turn signal lamps on the left-hand side
permanently lit: LOCATE and RECTIFY short to
battery voltage in the circuits connected to
soldered connection S3 with the aid of the wiring
diagrams. CHECK operation of system.
All turn signal lamps on the right-hand side
permanently lit: LOCATE and RECTIFY short to
battery voltage in the circuits connected to
soldered connection S4 with the aid of the wiring
diagrams. CHECK system operates correctly
D10: CHECK COMMON GROUND CONNECTION OF FRONT LEFT-HAND TURN SIGNAL
LAMPS FOR OPEN CIRCUIT
2 SWITCH ON the windshield wiper.
Does the windshield wiper operate?
Yes
LOCATE and RECTIFY the open circuit in the shared
voltage supply to the left-hand front turn signal
lamps in the circuit(s) between soldered connection
S3 and soldered connection S104 with the aid of
the Wiring Diagrams. CHECK operation of system.
No
LOCATE and REPAIR the open circuit in the shared
voltage supply to the left-hand front turn signal
lamps in circuit 31-DA3 (BK) between soldered
connection S121 and ground connection G37 with
the aid of the Wiring Diagrams. CHECK operation of
system.
D11: CHECK GROUND CONNECTION OF THE LEFT-HAND TURN SIGNAL SIDE

REPEATER LAMP FOR OPEN CIRCUIT
2 Disconnect Front left-hand turn signal side
repeater lamp from connector C753.
3 Measure the resistance between left-hand turn
signal side repeater lamp, connector C753, pin 1,
circuit 31-LG13 (BK), wiring harness side and
ground.

Yes
LOCATE and REPAIR the break in circuit 49S-LG13
(BU/RD) between soldered connection S104 and
the side turn signal lamp with the aid of the wiring
diagrams. CHECK operation of system. If the
concern persists, CHECK and if necessary RENEW
the left-hand side repeater lamp. CHECK operation
of system.
No
between the side turn signal lamp and soldered
connection S121 with the aid of the wiring
D12: CHECK GROUND CONNECTION OF THE RIGHT-HAND TURN SIGNAL SIDE
REPEATER LAMP FOR OPEN CIRCUIT
2 Disconnect Front right-hand turn signal side
repeater lamp from connector C754.
indicator side repeater lamp, connector C754, pin
1:
1.8L Duratorq-TDCi (Kent) diesel, built from

02/2004: circuit 91-LG20 (BK/OG), wiring
All other models: circuit 31-LG20 (BK), wiring


Yes
REPAIR break in circuit 49S-LG20 (BU/WH),
between solder point S4 and side repeater lamp,
using the wiring diagrams. CHECK operation of
system. If the concern persists, CHECK and if
necessary RENEW the left-hand side repeater lamp.
- Vehicles built from 08/2006: LOCATE and REPAIR
the break in circuit 49S-LG20 (BU/WH) between
soldered connection S131 and the side turn signal
lamp with the aid of the wiring diagrams. CHECK
system operates correctly If the concern persists,
CHECK and if necessary RENEW the left-hand side

repeater lamp. CHECK system operates correctly
No
RECTIFY the break in the circuit(s) between the
turn signal side lamp and ground connection G24
system.
RECTIFY the break in the circuit(s) between the
turn signal side lamp and ground connection G22
system.
D13: CHECK GROUND CONNECTION OF THE LEFT-HAND HEADLAMP (TURN SIGNAL)
FOR OPEN CIRCUIT
C835.
3 Measure the resistance between the left-hand
headlamp, connector C835, pin 5, circuit 31-LG11

Yes
LOCATE and REPAIR break in circuit 49S-LG11
(BU/OG), between solder point S104 and
headlamp, using the wiring diagrams. CHECK
operation of system. If the concern persists, CHECK
and if necessary RENEW the headlamp. CHECK
No
S121 using the wiring diagrams. CHECK operation
of system.
D14: CHECK THE GROUND SUPPLY OF THE RIGHT-HAND HEADLAMP (TURN SIGNAL
LAMP) FOR OPEN CIRCUIT
C834.
headlamp, connector C834, pin 5, circuit 31-LG18

Yes

REPAIR break in circuit 49S-LG18 (BU), between
solder point S4 and headlamp, using the wiring
diagrams. CHECK operation of system. If the
concern persists, CHECK and if necessary RENEW
the headlamp. CHECK system operates correctly
- Vehicles built from 08/2006: LOCATE and REPAIR
the break in circuit 49S-LG18A (BU) between
soldered connection S131 and the headlamp with
the aid of the wiring diagrams. CHECK system
operates correctly If the concern persists, CHECK
and if necessary RENEW the headlamp. CHECK
No
S109 using the wiring diagrams. CHECK operation
of system.
D15: CHECK GROUND CONNECTION OF THE LEFT-HAND REAR LAMP CLUSTER (TURN
SIGNAL) FOR OPEN CIRCUIT
2 Disconnect left-hand rear lamp assembly from
connector:.

3 Measure resistance between left-hand rear lamp
assembly:

and ground.

pin 5, circuit (BN), wiring harness side and
ground.
Yes
REPAIR break in circuit 49S-LG12 (BU), between
solder point S3 and left-hand rear lamp cluster,
system. If the concern persists, CHECK and if
necessary RENEW the left-hand rear lamp cluster.
No
between the left-hand rear lamp cluster and ground
connection G46 using the Wiring Diagrams. CHECK
D16: CHECK VOLTAGE SUPPLY OF THE LEFT-HAND REAR LAMP CLUSTER (TURN
2 Disconnect Trailer switch interface (SI) from
connector C1102.
4 SWITCH ON the left-hand turn signal switch.

Measure voltage between trailer switch interface
5
(SI), connector C1102, circuit (GY/WH), wiring
Is fluctuating battery voltage measured?
Yes
GO to D17.
No
LOCATE and REPAIR the break in the circuit(s)
between soldered connection S3 and trailer switch
interface (SI) using the Wiring Diagrams. CHECK
D17: CHECK VOLTAGE SUPPLY OF THE LEFT-HAND REAR LAMP CLUSTER (TURN
2 Connect Left-hand rear lamp cluster with connector
C474a.
3 Use a fused bridging cable (5 A) at the trailer
module switch interface (SI), connector C1102, to
bridge between circuit (GY/WH) and circuit (WH),
5 SWITCH ON the left-hand turn signal switch.
Does the left-hand rear turn signal flash?
Yes
INSTALL A NEW trailer module switch interface
(SI). CHECK operation of system.
No
between the trailer module switch interface (SI)
and the left-hand rear lamp cluster using the
Wiring Diagrams. CHECK operation of system. If
the concern persists, CHECK and if necessary
RENEW the left-hand rear lamp cluster. CHECK
D18: CHECK GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP CLUSTER
(TURN SIGNAL) FOR OPEN CIRCUIT
connector:.

rear lamp assembly:

and ground.
Vehicles with trailer socket: Connector C475, pin


Yes

REPAIR break in circuit 49S-LG19 (BU/RD),
between solder point S4 and right-hand rear lamp
cluster, using the wiring diagrams. CHECK
operation of system. If the concern persists, CHECK
and if necessary RENEW the right-hand rear lamp
cluster. CHECK operation of system.
No
between the right-hand rear lamp cluster and
D19: CHECK VOLTAGE SUPPLY OF THE RIGHT-HAND REAR LAMP CLUSTER (TURN
2 Disconnect Trailer switch interface (SI) from
connector C1102.
4 Switch on RIGHT-HAND TURN SIGNAL.
Measure voltage between trailer switch interface
5
(SI), connector C1102, circuit (GN/RD), wiring
Yes
GO to D20.
No
LOCATE and REPAIR the break in the circuit(s)
between soldered connection S4 and trailer switch
interface (SI) using the Wiring Diagrams. CHECK
D20: CHECK VOLTAGE SUPPLY OF THE RIGHT-HAND REAR LAMP CLUSTER (TURN
2 Connect Right-hand rear lamp cluster to connector
C475a.
module switch interface (SI), connector C1102, to
bridge between circuit (GN/RD) and circuit
5 SWITCH ON the right-hand turn signal switch.
Does the rear right-hand turn signal flash?
Yes
INSTALL A NEW trailer module switch interface
(SI). CHECK operation of system.
No
and the right-hand rear lamp cluster using the
Wiring Diagrams. CHECK operation of system. If
the concern persists, CHECK and if necessary
RENEW the right-hand rear lamp cluster. CHECK
D21: RULE OUT THE TURN SIGNAL SWITCH AS THE CAUSE OF THE FAULT (LEFT-
HAND SIDE)
Disconnect Turn signal switch from connector

2 C459.
3 Use a fused jumper lead (15 A) at the turn signal
circuit 15-LG27 (GN/BK) and pin 1, circuit 49S-LG1
(BU) wiring harness side.

Do the turn signal lamps flash on the left-hand side?
Yes
operates correctly
No
between the turn signal switch and soldered
D22: RULE OUT THE HAZARD WARNING LIGHTS SWITCH AS THE CAUSE OF THE
FAULT (LEFT-HAND SIDE)
connector C458.
warning switch, connector C458, to connect
circuit 49S-LG3 (BU) wiring harness side.

Do the turn signal lamps flash on the left-hand side?
Yes
No
between the hazard warning lights switch and
soldered connection S3 using the Wiring Diagrams.
D23: RULE OUT THE TURN SIGNAL SWITCH AS THE CAUSE OF THE FAULT (RIGHT-
HAND SIDE)
C459.
3 Use a fused jumper lead (7.5 A) at the turn signal
circuit 15-LG27 (GN/BK) and pin 3, circuit 49S-LG2
(BU/RD) wiring harness side.

Do the turn signal lamps flash on the right-hand side?
Yes
operates correctly
No
between the turn signal switch and soldered
D24: RULE OUT THE HAZARD WARNING LIGHTS SWITCH AS THE CAUSE OF THE
FAULT (RIGHT-HAND SIDE)
connector C458.
warning lights switch, connector C458, to connect
circuit 49S-LG4 (BU/RD) wiring harness side.

Do the turn signal lamps flash on the right-hand side?
Yes
No
between the hazard warning lights switch and
D25: CHECK FUSE F48/F44 (7.5A) (CJB).
2 Disconnect Fuse.

3 CHECK Fuse.

Is the fuse OK?

Yes
GO to D26.
No
(7.5 A) (CJB). CHECK system operates correctly If
(7.5 A) (CJB). CHECK system operates correctly If
D26: CHECK THE VOLTAGE SUPPLY TO FUSE F48/F44 (7.5 A) (CJB)
1 Connect Fuse.


and ground.

and ground.
Yes
GO to D27.
No
D27: CHECK FUSE F61/F30 (15 A) (CJB).
2 Disconnect Fuse.

3 CHECK Fuse.

Is the fuse OK?
Yes
GO to D28.
No

(15 A) (CJB). CHECK system operates correctly If
A) (CJB). CHECK system operates correctly If the
operates correctly
D28: CHECK THE VOLTAGE SUPPLY TO FUSE F61/F30 (15 A) (CJB)
1 Connect Fuse.


and ground.

and ground.
Yes
GO to D29.
No
operates correctly
operates correctly
D29: CHECK VOLTAGE SUPPLY TO FLASHER RELAY FOR OPEN CIRCUIT

Yes
GO to D30.

No
D30: CHECK VOLTAGE SUPPLY TO FLASHER RELAY FOR OPEN CIRCUIT
connector C457, pin 3, circuit 29-LG26 (OG),

Yes
GO to D31.
No
D31: CHECK GROUND CONNECTION OF FLASHER RELAY FOR OPEN CIRCUIT
2 Measure the resistance between the flasher relay,
connector C457, pin 5, circuit 91-LG25 (BK/BU),

Yes
GO to D32.
No

D32: EXCLUDE THE TURN SIGNAL SWITCH AS THE CAUSE OF THE FAULT
C459.
(GN/BK), wiring harness side and ground.

Yes
in the circuit between the turn signal relay and the
turn signal switch switch with the aid of the Wiring
No
operates correctly
PINPOINT TEST E : THE TURN INDICATORS ON ONE SIDE FLASH

CONTINUOUSLY
CONDITIONS
E1: EXCLUDE THE TURN SIGNAL SWITCH AS THE CAUSE OF THE FAULT
2 Disconnect Turn signal switch from connector C459.
Do the turn signals flash continuously on one side?
Yes
- vehicles with anti-theft warning system/central locking module: GO to
E2.
- vehicles without anti-theft warning system/central locking module:
RENEW the hazard warning light switch. CHECK operation of system.
No
RENEW the turn signal switch. CHECK operation of system.
E2: EXCLUDE THE HAZARD WARNING LAMP SWITCH AS THE CAUSE OF THE FAULT
2 Disconnect Hazard warning light switch from connector C458.
Yes
CHECK the anti-theft warning system/central locking module using WDS,
RENEW if necessary. CHECK operation of system.
No
RENEW the hazard warning light switch. CHECK operation of system.
PINPOINT TEST F : TURN INDICATORS OPERATE CORRECTLY, BUT TURN

INDICATOR WARNING LAMP DOES NOT WORK

F1: DETERMINE THE FAULT CONDITION
NOTE: On vehicles with a diesel engine, decoupling diodes are installed in the control
circuits of the turn signal warning lamps.
2 Switch on LEFT-HAND TURN SIGNAL.
4 CHECK the turn signal warning lamp after each
operation of the switch.
Is the turn signal warning lamp inoperative?
Yes
- turn signal warning lamp inoperative for left-turn
signal, vehicles with petrol engine: GO to F2.
- turn signal warning lamp inoperative for left-turn
signal, vehicles with diesel engine: LOCATE and
REPAIR the break in the circuit(s) between soldered
connection S3 and soldered connection S7 using the
Wiring Diagrams. CHECK operation of system.
No
- turn signal warning lamp inoperative for right-turn
signal, vehicles with petrol engine: GO to F3.
- turn signal warning lamp inoperative for right-turn
signal, vehicles with diesel engine: LOCATE and
REPAIR the break in the circuit(s) between soldered
connection S4 and soldered connection S7 using the
- turn signal warning lamp inoperative for both
sides, vehicles with petrol engine: GO to F5.
- Turn signal warning lamp inoperative for both
sides, vehicles with diesel engine, vehicles built
before 02/2004: GO to F4.
F2: CHECK LEFT-HAND TURN SIGNAL WARNING LAMP CONTROL CIRCUIT FOR OPEN
CIRCUIT
2 Disconnect Instrument cluster from connector
C809.
5 Vehicles built before 08/2006: Measure the voltage
between the instrument cluster, connector C809,
pin 23, circuit 49S-LG15 (BU/BK), wiring harness
side and ground.
6 Vehicles built from 08/2006: Measure the voltage

pin 2, circuit 49S-LG15 (BU/BK), wiring harness
side and ground.

Yes
No
between soldered connection S3 and the instrument
cluster using the Wiring Diagrams. CHECK operation
of system.
F3: CHECK RIGHT-HAND TURN SIGNAL WARNING LAMP CONTROL CIRCUIT FOR
OPEN CIRCUIT
C809.
5 Vehicles built before 08/2006: Measure the voltage
pin 17, circuit 49S-LG22 (BU/YE), wiring harness
side and ground.
6 Vehicles built from 08/2006: Measure the voltage

pin 3, circuit 49S-LG22 (BU/YE), wiring harness side
and ground.

Yes
No
of system.
F4: CHECK TURN INDICATOR WARNING LAMP COMMON CONTROL CIRCUIT FOR
OPEN CIRCUIT

C809.
5 Measure the voltage between the instrument
cluster, connector C809, pin 23, circuit 49S-LG7
(BU/RD), wiring harness side and ground.

Yes
GO to F5.
No
of system.
F5: CHECK GROUND CONNECTION OF INSTRUMENT CLUSTER FOR OPEN CIRCUIT
2 Disconnect Instrument cluster from connector.
Vehicles built before 08/2006: C809
Vehicles built from 08/2006: C813

cluster, connector:
Vehicles built before 08/2006: C809, pin 2, circuit

91-GG14 (BK/OG), wiring harness side and
ground.
Vehicles built from 08/2006: C813, pin 2, circuit

91-GG14 (BK/OG), wiring harness side and
ground.
Yes
No
LOCATE and RECTIFY break in circuit between
instrument cluster and ground connection G41 with
the aid of the wiring diagrams. CHECK operation of
system.

Exterior Lighting - Reversing Lamps Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Special Tool(s)
Terminal probe kit
29-011 A
General Equipment


Electrical
Fuse(s)
Bulb(s)
Wiring harness
4. 4. If the concern persists after the visual inspection, PERFORM a fault diagnosis on
the central timer module (CTM) using WDS and RESOLVE the fault(s) displayed
according to the fault description. CHECK the operation of the system.
5. 5. On a vehicle without stored fault(s), continue according to the Symptom Chart and
the corresponding symptom.
6. 6. After checking or rectifying the fault(s) and finishing the work, READ OUT the fault
memory in the central timer module (CTM) and DELETE any saved faults. After
performing a road test and CHECKING the system, READ OUT the fault memories
again.
WDS DTC table, central timer module (CTM)

WDS DTC table, central timer module (CTM)

B291B Circuit of reversing lamp switch faulty (open circuit) GO to Pinpoint Test D.
Symptom Chart
Symptom Chart

Back-up lamp inoperative * Fuse * GO to Pinpoint
* Reversing lamp switch
* Central junction box (CJB)
Individual back-up lamp inoperative * Circuit(s) * GO to Pinpoint
* Left/right-hand rear lamp Test B.
assembly
Reversing lamps permanently lit * Circuit(s) * GO to Pinpoint
* Reversing lamp switch Test C.
* Parking aid module
Circuit of reversing lamp switch faulty * Circuit(s) * GO to Pinpoint
(open circuit) * Instrument cluster Test D.
Pinpoint Tests
PINPOINT TEST A : BACK-UP LAMP INOPERATIVE
A1: CHECK FUSE F53/41 (10 A) (CJB)
2 Disconnect Fuse.

3 CHECK Fuse.

Is the fuse OK?
Yes
GO to A2.
No
RENEW fuse F53/41 (10 A) (CJB) and CHECK the
A2: CHECK THE VOLTAGE SUPPLY TO FUSE F53/41 (10A) (CJB) FOR OPEN CIRCUIT
1 Connect Fuse.


and ground.

and ground.
Yes
GO to A3.
No
supply of fuse F53/41 (10 A) (CJB) using the Wiring
A3: CHECK VOLTAGE SUPPLY TO THE REVERSING LAMP SWITCH FOR OPEN CIRCUIT
2 Disconnect Reversing lamp switch from connector.
Vehicles built before 08/2006 with 1.8L Duratorq-

TDCi (Kent) diesel engine: C862
All other vehicles: C863

4 Measure the voltage between reversing lamp
switch:

TDCi (Kent) diesel engine: Connector C862, pin
2, circuit 15-LG28 (GN/WH), wiring harness side
and ground.
All other vehicles: Connector C863, pin 2, circuit

15-LG28(B) (GN/WH), wiring harness side and
ground.
Yes
GO to A4.
No
between fuse F53/41 (CJB) and the reversing lamp
A4: CHECK REVERSING LAMP SWITCH
2 Fused bridging cable (10A) at the reversing lamp

switch:

TDCi (Kent) diesel engine: connector C862,
bridge between pin 2, circuit 15-LG28 (GN/WH)
and pin 1, circuit 15S-LG3 (GN/YE), wiring

harness side.
All other vehicles: Connector C863, connect

between pin 2, circuit 15-LG28(B) (GN/WH) and
pin 1, circuit 15S-LG3 (GN/YE), wiring harness
side.
4 Check the back-up lamps.
Are the back-up lamps on?
Yes
INSTALL A NEW reversing lamp switch. CHECK the
No
LOCATE and RECTIFY the break in circuit 15S-LG3
(GN/YE) between the reversing lamp switch and
PINPOINT TEST B : INDIVIDUAL BACK-UP LAMP INOPERATIVE

B1: DETERMINE INOPERATIVE REVERSING LAMP
2 Engage reverse gear.
3 CHECK the backup lamps.
Is the left-hand back-up lamp inoperative?
Yes
GO to B2.
No
Right-hand reversing lamp inoperative: GO to B4.
B2: CHECK VOLTAGE SUPPLY TO LEFT-HAND REAR LAMP ASSEMBLY FOR OPEN
CIRCUIT
NOTE: Reverse gear is still engaged.
connector.

4 Measure the voltage between left-hand rear lamp
assembly:

pin 4, circuit 15S-LG9 (GN/BK), wiring harness
side and ground.


Yes
GO to B3.
No
between soldered connection S92 and the left-hand
rear lamp assembly using the Wiring Diagrams.

B3: CHECK GROUND CONNECTION TO LEFT-HAND REAR LAMP ASSEMBLY FOR OPEN
CIRCUIT
2 Measure the resistance between the left-hand rear
lamp assembly:

and ground.

5, circuit (BN), wiring harness side and ground.

Yes
No
B4: CHECK VOLTAGE SUPPLY TO RIGHT-HAND REAR LAMP ASSEMBLY FOR OPEN
CIRCUIT
NOTE: Reverse gear is still engaged.
connector.

4 Measure the voltage between the right-hand rear
lamp assembly:

pin 4, circuit 15S-LG16 (GN/OG), wiring harness
side and ground.
Vehicles with 7 pin trailer socket: Connector

C475a, pin 4, circuit (GN), wiring harness side
and ground.
Vehicles with 13 pin trailer socket: Connector

C475a, pin 4, circuit (VT/OG), wiring harness side
and ground.
Yes
GO to B5.
No
B5: CHECK THE GROUND CONNECTION TO THE RIGHT-HAND REAR LAMP ASSEMBLY

FOR OPEN CIRCUIT
rear lamp assembly:

and ground.


Yes
No
PINPOINT TEST C : REVERSING LAMPS PERMANENTLY LIT

CONDITIONS
C1: CHECK REVERSING LAMP SWITCH
2 Disconnect Reversing lamp switch from connector.
Vehicles built before 08/2006 with 1.8L Duratorq-TDCi (Kent) diesel

engine: C862
All other vehicles: C863

Do the reversing lamps illuminate continuously?
Yes
- Vehicles built before 08/2006, without parking aid: LOCATE and RECTIFY
the short to battery voltage in the circuits connected to soldered connection
S92 using the Wiring Diagrams. (vehicles with trailer hitch, check trailer
socket and RENEW it if necessary). CHECK the operation of the system.
- With parking aid: GO to C2.
No
INSTALL A NEW reversing lamp switch. CHECK the operation of the system.
C2: ELIMINATE THE PARKING AID MODULE AS CAUSE FOR THE SHORT TO BATTERY
VOLTAGE
2 Disconnect Fuse.


Yes

- Vehicles built before 08/2006: LOCATE and RECTIFY the short to battery
voltage in the circuits connected to soldered connection S92 using the
Wiring Diagrams. Vehicles with trailer coupling, check trailer socket and
RENEW if necessary. CHECK the operation of the system.
- Vehicles built from 08/2006: GO to C3.
No
INSTALL a new parking aid module. CHECK the operation of the system.
C3: ELIMINATE THE INSTRUMENT CLUSTER AS CAUSE FOR THE SHORT TO BATTERY
VOLTAGE
3 Disconnect fuse F48 (7.5 A) (CJB).
Yes
to soldered connection S92 using the Wiring Diagrams. Vehicles with trailer
coupling, check trailer socket and RENEW if necessary. CHECK the
No
INSTALL a new instrument cluster. CHECK the operation of the system.
PINPOINT TEST D : CIRCUIT OF REVERSING LAMP SWITCH FAULTY (OPEN

CIRCUIT)
D1: NARROW DOWN THE CAUSE OF THE FAULT
Are the back-up lamps on?
Yes
GO to D2.
No
D2: CHECK INSTRUMENT CLUSTER
2 Disconnect Instrument cluster from connector C809.
4 Measure the voltage between the instrument cluster,
connector C809, pin 26, circuit 15S-GG11 (GN/BU),

Yes
INSTALL a new instrument cluster. CHECK the
No

cluster using the Wiring Diagrams. CHECK the

Exterior Lighting - Trailer Lamps Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
Special Tool(s)
Terminal Probe Kit
29-011A
Visual Inspection
Electrical
Fuse(s)
Bulb(s)
Connectors
Trailer socket
Trailer lamps
Wiring harness
Symptom Chart
Symptom Chart

Trailer lamps inoperative * Fuse(s) * GO to Pinpoint Test
* Circuit(s) in vehicle A.
* Circuit(s) in trailer
* Trailer socket
* Trailer switch interface (SI)
module
* Rear fog lamp cut-off relay
One individual trailer lamp * Circuit(s) in vehicle * GO to Pinpoint Test
inoperative * Circuit(s) in trailer B.
module
Trailer lamps illuminate * Circuit(s) in vehicle * GO to Pinpoint Test
continuously * Circuit(s) in trailer C.
* Trailer socket
module
System Checks

PINPOINT TEST A : TRAILER LAMPS INOPERATIVE
A1: DETERMINE WHICH LAMPS ON THE TRAILER ARE INOPERATIVE
2 SWITCH ON in turn the side lights, stop lamps,
rear fog lamps and left- and right-hand turn signal
lamps. Engage REVERSE GEAR.
3 Check the trailer lamps.
Are all lamps on the trailer inoperative?
Yes
GO to A2.
No
- Stop lamps and turn signal lamps inoperative: GO
to A3.
- Only stop lamps inoperative: GO to A7.
- Only reversing lamp(s) inoperative: GO to A10.
- Only rear fog lamp(s) inoperative: GO to A11.
- Only the turn signal lamps inoperative (both
sides): RENEW the trailer switch interface (SI)
module. CHECK the operation of the system.
A2: CHECK GROUND CONNECTION OF TRAILER SOCKET FOR OPEN CIRCUIT
7 pin trailer socket: Connector C1109, pin 3,

circuit (BN/WH) and ground.
13 pin trailer socket: connector C1104, pin 3,

circuit (BN/WH) and ground and between pin 13,
circuit (BN) and ground.

Yes
Continue fault finding on the trailer. CHECK the
No
between the trailer socket and ground G47 AND
G46 (13 pin trailer socket) using the Wiring
A3: CHECK FUSE FC (10 A) (FUSE HOLDER 1)
NOTE: Fuse holder 1 is located near the trailer module switch interface (SI).
3 CHECK Fuse FC (10 A) (fuse holder 1).

Is the fuse OK?
Yes
GO to A4.
No
RENEW fuse FC (10 A). CHECK the operation of the
RECTIFY the short circuit to ground using the
Wiring Diagrams.
A4: CHECK THE VOLTAGE SUPPLY TO FUSE FC (10 A) (FUSE HOLDER 1) FOR OPEN
CIRCUIT
1 Connect Fuse FC (10 A) (fuse holder 1).
Measure the voltage between fuse FC (10 A) and
3
ground.
Yes
GO to A5.
No
LOCATE and RECTIFY the break in the voltage
supply of fuse FC (fuse holder 1) using the wiring
diagrams. CHECK the operation of the system.
A5: CHECK THE POWER SUPPLY TO THE TRAILER SWITCH INTERFACE (SI) MODULE
FOR OPEN CIRCUIT
2 Disconnect trailer switch interface (SI) module
4 Measure the voltage between the trailer switch
interface (SI) module, connector C1102, circuit
Yes
GO to A6.
No
LOCATE and RECTIFY break in circuit between fuse
FC (fuse holder 1) and trailer module switch
interface (SI) using the wiring diagrams. CHECK
A6: CHECK THE GROUND SUPPLY TO THE TRAILER SWITCH INTERFACE (SI) MODULE
FOR OPEN CIRCUIT
Measure the resistance between the trailer switch
2
(BN), wiring harness side and ground.
Yes
No
A7: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE STOP LAMPS
SWITCHED ON
2 Disconnect stop lamp switch from connector C444.

3


side.

10 Measure the voltage between the trailer socket:
7 pin socket: connector C1109, pin 6, circuit (VT)

and ground.
13 pin socket: connector C1104, pin 6, circuit

(VT) and ground.

Yes
Continue fault finding on the trailer.
No
GO to A8.
A8: CHECK THE VOLTAGE AT THE TRAILER MODULE SWITCH INTERFACE (SI) WITH
THE BRAKE LIGHTS ON
NOTE: The jumper lead used in the previous step is still connected.
Measure the voltage between the trailer switch
4
(BK/RD) and ground.
Yes
GO to A9.
No
between soldered connection S1000 and the trailer
module switch interface (SI) using the Wiring
A9: CHECK THE TRAILER SWITCH INTERFACE (SI) MODULE
NOTE: The jumper lead used in the previous step is still connected.
switch interface (SI) module, to bridge between
connector C1102, circuit (BK/RD), and circuit (VT),

and ground.

(VT) and ground.

Yes
No
LOCATE and RECTIFY the break in the circuit (VT)

and the trailer socket using the Wiring Diagrams.
A10: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE REVERSING LAMPS
SWITCHED ON
2 Engage REVERSE GEAR.
3 Measure the voltage between the trailer socket
C1104, pin 8, circuit (VT/OG) and ground.

Yes
No
A11: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE REAR FOG LAMPS
SWITCHED ON
2 Switch on the REAR FOG LAMP.

(RD/YE) and ground.

(RD/YE) and ground.

Yes
No
GO to A12.
A12: CHECK THE GROUND CONNECTION OF THE REAR FOG LAMP CUT-OFF RELAY FOR
OPEN CIRCUIT

- Vehicles without parking aid: Rear fog lamp
cut-off relay from socket C1103


off relay, socket C1103, circuit (BN), wiring

aid cut-off relay, socket C1110, circuit (BN),

Yes
GO to A13.
No
between the cut-off relay and soldered connection
S1001 using the Wiring Diagrams. CHECK the
A13: CHECK THE REAR FOG LAMP CUT-OFF RELAY
1 Fused bridging cable (20A) at:

off relay, connected between socket C1103,
circuit (RD/WH), and circuit (RD/YE), wiring
harness side.
Vehicles with parking aid: rear fog lamp cut-off

relay/parking aid, connected between socket
C1110, circuit (RD/WH), and circuit (RD/YE),
3 Switch on the REAR FOG LAMP.

(RD/YE) and ground.

(RD/YE) and ground.

Yes
RENEW the cut-off relay. CHECK the operation of
the system.
No
between the cut-off relay and the trailer socket
using the wiring diagrams. CHECK the operation of
the system.
PINPOINT TEST B : ONE INDIVIDUAL TRAILER LAMP INOPERATIVE

B1: DETERMINE WHICH LAMP IS INOPERATIVE
Is one of the rear lamps on the trailer inoperative?
Yes
- Left-hand trailer rear lamp inoperative: GO to B2.
- Right-hand trailer rear lamp inoperative: GO to
B3.
No
- Trailer stop lamps inoperative: GO to Pinpoint
Test A.
- Trailer reversing lamp(s) inoperative: GO to
Pinpoint Test A.
- Trailer rear fog lamp(s) inoperative: GO to
Pinpoint Test A.
- Left-hand trailer turn signal lamp inoperative: GO
to B4.
- Right-hand trailer turn signal lamp inoperative:
GO to B6.
B2: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE SIDE LIGHTS
SWITCHED ON
1 Switch on SIDE LIGHTS.
7 pin socket: Connector C1109, pin 7, circuit

(OG/WH) and ground.
13 pin socket: Connector C1104, pin 7, circuit

(OG/WH) and ground.

Yes
No
B3: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE SIDE LIGHTS
SWITCHED ON
1 Switch on SIDE LIGHTS.

(OG) and ground.

(OG) and ground.

Yes
No

B4: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE LEFT-HAND TURN
SIGNAL SWITCHED ON
2 Switch on the LEFT-HAND TURN SIGNAL.

(BU) and ground.

(BU) and ground.
Does the voltage alternate between 0 V and battery

voltage?
Yes
No
GO to B5.
B5: CHECK THE CIRCUIT BETWEEN THE TRAILER SWITCH INTERFACE (SI) MODULE
AND THE TRAILER SOCKET FOR OPEN CIRCUIT
3 Measure the resistance between the trailer switch
(BU), wiring harness side and the trailer socket.

(BU).

(BU).

Yes
No

B6: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE RIGHT-HAND TURN
SIGNAL SWITCHED ON

(BU/RD) and ground.

(BU/RD) and ground.
Does the voltage alternate between 0 V and battery

voltage?
Yes
No
GO to B7.
B7: CHECK THE CIRCUIT BETWEEN THE TRAILER SWITCH INTERFACE (SI) MODULE
AND THE TRAILER SOCKET FOR OPEN CIRCUIT
3 Measure the resistance between the trailer switch
(BU/RD), wiring harness side and the trailer socket:

(BU/RD).

(BU/RD).
Yes
No
PINPOINT TEST C : TRAILER LAMPS ILLUMINATE CONTINUOUSLY

C1: CHECK THE FAULT SYMPTOMS
Is/are the rear fog lamp(s) on the trailer permanently
on?
Yes
GO to C2.
No
- Trailer rear lamps illuminate continuously:
- Trailer reversing lamp permanently on:
REFER to: Reversing Lamps (417-01 Exterior
Lighting, Diagnosis and Testing).
- Trailer stop lamps illuminate continuously: GO to
C3.
- Trailer left-hand turn signal lamp illuminates
continuously: GO to C5.
- Trailer right-hand turn signal lamp illuminates
continuously: GO to C7.
- Trailer stop lamps and flashers illuminate
continuously: RENEW the trailer switch interface
(SI) module. CHECK the operation of the system.
C2: CHECK FOR SHORT TO BATTERY VOLTAGE AT THE TRAILER SOCKET (REAR FOG
LAMP)

(RD/YE) and ground.

(RD/YE) and ground.

Yes
in the circuit between the cut-off relay and the
trailer socket using the wiring diagrams. CHECK the
operation of the system. If necessary RENEW the
trailer socket. CHECK the operation of the system.
No
C3: CHECK FOR SHORT TO BATTERY VOLTAGE AT THE TRAILER SOCKET (STOP
LAMPS)


and ground.

(VT) and ground.

Yes
GO to C4.
No

and ground.

(VT) and ground.

Yes

in the circuit between the trailer switch interface
(SI) module and the trailer socket using the Wiring
Diagrams. If necessary RENEW the trailer socket.
No
C5: CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE (LEFT-HAND TURN
SIGNAL LAMP)

(BU) and ground.

(BU) and ground.

Yes
GO to C6.
No

(BU) and ground.

(BU) and ground.

Yes
No
C7: CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE (RIGHT-HAND
TURN SIGNAL LAMP)

(BU/RD) and ground.

(BU/RD) and ground.

Yes
GO to C8.
No


(BU/RD) and ground.

(BU/RD) and ground.

Yes
No

Exterior Lighting - Headlamp Masking Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Procedures
All vehicles
NOTE: The templates are different for LHD and RHD vehicles. The templates are different
for the left and right-hand headlamps.
1. Print out the corresponding templates at the end
of this operation.
2. Measure dimension X on the printout of the
template.
3. Calculate the enlargement/reduction factor Y for
the photocopier using the following formula:
Y=Z÷X×100.
X = measurement on the printout of the
template in mm
Y = enlargement/reduction factor in %
Z = original dimension in mm = 25
4. Enlarge/reduce the printout with a photocopier
by the calculated percentage.
Compare dimension X on the photocopy
with the original dimension.
5. Cut out the prepared template for the headlamp.
6. Cut out the hatched areas.
Left-hand drive vehicle

7. NOTE: Right headlamp only.
Align the template on the lens of the headlamp.
1. Alignment edge on the headlamp lens
2. Reference point
3. Template
8. NOTE: Left headlamp only.

2. Reference point
3. Template
Right-hand drive vehicle

9. NOTE: Right headlamp only.
2. Reference point
3. Template

10. NOTE: Left headlamp only.
1. Alignment edges on the headlamp lens
2. Reference point
3. Template
All vehicles
11. CAUTION: Do not scratch the lamp

surface.
Copy the outline of the template with a suitable
pen onto the headlamp lens.
12. Remove the template.
13. NOTE: Make sure not to go past the marked
area.
Mask the marked area with opaque black
adhesive tape.
14. Repeat operations 11 to 13 for the other
headlamp.
15. Template for LHD vehicles, right-hand headlamp
2. Reference point

16. Template for LHD vehicles, left-hand headlamp
2. Reference point

17. Template for RHD vehicles, right-hand headlamp
2. Reference point

18. Template for RHD vehicles, left-hand headlamp
2. Reference point

Exterior Lighting - Headlamp Adjustment Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Procedures
General Equipment
Beam setting equipment
1. Stand the vehicle on a level surface.
2. Make sure that the tire pressures are to
specification and that the vehicle is not
abnormally laden.
3. Switch on the dipped beam.
4. Repeatedly operate the headlamp levelling switch
through its range, then set it to "0".
5. Set up the measuring screen of the beam setting
device to the correct headlamp setting value.
6. Adjust the headlamps so that the boundary line
touches the horizontal line.
7. NOTE: A stray portion of the dipped beam

may cross the 15 degree line.
Adjust the dipped beam so that the rising line of
the light/dark boundary lies in the intersection
point of the horizontal line and the 15 degree
line.

Exterior Lighting - Front Fog Lamp
Adjustment
Print
General Procedures
General Equipment
Beam setting equipment
1. Stand the vehicle on a level surface.
2. Make sure that the tire pressures are to
specification and that the vehicle is not
abnormally laden.
3. Switch on front fog lamps.
4. Set up the measuring screen of the beam setting
device to the correct setting value for the front
fog lamps.
5. Adjust the front fog lamps so that the boundary
line touches the horizontal line.

Exterior Lighting - Headlamp Assembly—
Print

1. Remove the intercooler air scoop.
All vehicles
2. Remove the radiator grille.
(s).

1 - Lower headlamp bolts
See Removal Detail
2 - Upper headlamp bolts
See Removal Detail
-

-
3 Headlamp
See Removal Detail
4 - Headlamp connector
See Removal Detail
5. Headlamp Adjustment
For additional information, refer to 417-01 in this
section.
Removal Details
Item 1 : Lower headlamp bolts
1. NOTE: Raise the vehicle.For additional

information, refer to Section 100-02 Jacking
and Lifting.
Unscrew and remove the lower headlamp bolts.
Item 2 : Upper headlamp bolts

Item 4 : Headlamp connector
1. Disconnect the headlamp connector.

Exterior Lighting - Headlamp Switch Transit/Tourneo Connect 2002.5 (06/2002-)
Print
(s).

1 - Bolts, lower fascia/crash padding cover
2 - Lower fascia/crash padding cover
3 - Connector, headlamp switch
See Removal Detail

4 - Bolts, headlamp switch
5 - Headlamp switch.
Removal Details
Item 3 : Connector, headlamp switch
1. Disconnect the headlamp switch connector.

Exterior Lighting - Headlamp Switch—
Print
Removal
1.
Installation

Exterior Lighting - Front Fog Lamp Transit/Tourneo Connect 2002.5 (06/2002-)
Print
(s).

1 - Connector, fog lamp
2 - Bolt, fog lamp
3 - Fog lamp

Exterior Lighting - Headlamp Assembly—
Print
Removal
1. Refer to: Front Bumper Cover - Vehicles Built

From: 04/2009 (501-19 Bumpers, Removal and
Installation).
2.
3.
Installation
1.
2. Refer to: Headlamp Adjustment (417-01
Exterior Lighting, General Procedures).

Interior Lighting - Interior Lighting—
Print

information.
Electrical
Fuse(s)
Bulb(s)
Switch(es)
Relay(s)
Wiring harness
Instrument cluster
Chart.
Symptom Chart
Symptom Chart

The interior lamps are inoperative * Circuit(s). * GO to Pinpoint Test A.
* Battery saver
relay.
* Interior lamp.
* CJB.
* Instrument
cluster.
The interior center lamp is inoperative * Circuit(s). * GO to Pinpoint Test B.
* Interior center
lamp.
The interior rear lamp is inoperative * Circuit(s). * GO to Pinpoint Test C.
* Interior rear
lamp.
The interior lamps do not turn on with * Door ajar switch * REFER to the Ford approved
one door open (es). diagnostic tool..
* Instrument
cluster.
* Circuit(s). * GO to Pinpoint Test D.
* Interior front
lamp.
* Interior lamp
relay.
* CJB.
* Instrument

cluster.
The battery saver does not operate * Instrument * REFER to the Ford approved
correctly cluster. diagnostic tool..
Pinpoint Test
PINPOINT TEST A : THE INTERIOR LAMPS ARE INOPERATIVE

A1: CHECK CIRCUIT 29-LC7B (OG/BU) FOR VOLTAGE
1 Disconnect Interior lamp C899.
2 Measure the voltage between the interior front
lamp C899 pin 1, circuit 29-LC7B (OG/BU), harness
side and ground.

Yes
INSTALL a new interior front lamp. TEST the system
No
GO to A2.
A2: CHECK CIRCUIT 29-LC7B (OG/BU) FOR OPEN
1 Disconnect CJB C14.
2 Measure the resistance between the interior front
side and CJB C14 pin 7, circuit 29-LC7 (OG/BU),
harness side.

Yes
GO to A3.
No
operation.
A3: BATTERY SAVER RELAY COMPONENT TEST
1 Disconnect Battery saver relay K115.
2 CARRY OUT a relay component test. REFER to the
wiring diagrams in this section.
Is the relay OK?
Yes
GO to A4.
No
INSTALL a new battery saver relay. TEST the
A4: CHECK FOR VOLTAGE TO THE BATTERY SAVER RELAY
1 Measure the voltage between the CJB C1023 pin 1,
component side and ground and between the CJB
C1023 pin 3, component side and ground.

Yes
GO to A5.
No
INSTALL a new CJB. TEST the system for normal
operation.
A5: CHECK THE CJB C1023 PIN 5 CIRUIT FOR AN OPEN
1 Measure the resistance between the CJB C1023 pin
5, component side and CJB C14 pin 7, component
side.

Yes
GO to A6.
No
operation.
A6: CHECK THE CJB C1023 PIN 2 CIRUIT FOR AN OPEN
2 Measure the resistance between the CJB C1023 pin
2, component side and CJB C13 pin 3, component
side.

Yes
GO to A7.
No
operation.
A7: CHECK CIRCUIT 31S-LC22 FOR OPEN
2 Measure the resistance between the CJB C13 pin 3,
circuit 31S-LC22 (BK/OG), harness side and
instrument cluster C809 pin 5, circuit 31S-LC22

Yes
No
operation.
PINPOINT TEST B : THE INTERIOR CENTER LAMP IS INOPERATIVE

B1: CHECK CIRCUIT 29-LB25A (OG/BU) FOR VOLTAGE
1 Disconnect Interior center lamp C820.
2 Measure the voltage between the interior center
lamp C820 pin 2, circuit 29-LB25A (OG/BU), harness
side and ground.

Yes
GO to B2.
No
operation.
B2: CHECK CIRCUIT 31S-LB25A (BK/BU) FOR OPEN
1 Disconnect Interior center lamp C819.
2 Disconnect Interior front lamp C892.
3 Measure the resistance between the interior center
lamp C819 pin 1, circuit 31S-LB25A (BK/BU),
harness side and interior front lamp C892 pin 1,
circuit 31S-LB25A (BK/BU), harness side.

Yes
INSTALL a new interior center lamp. TEST the system
No
operation.

PINPOINT TEST C : THE INTERIOR REAR LAMP IS INOPERATIVE
C1: CHECK CIRCUIT 29-LB25B (OG/BU) FOR VOLTAGE
1 Disconnect Interior rear lamp C822.
2 Measure the voltage between the interior rear lamp
C822 pin 2, circuit 29-LB25B (OG/BU), harness side
and ground.

Yes
GO to C2.
No
operation.
C2: CHECK CIRCUIT 31S-LB25B (BK/BU) FOR OPEN
1 Disconnect Interior rear lamp C821.
3 Measure the resistance between the interior rear
lamp C821 pin 1, circuit 31S-LB25B (BK/BU),
harness side and interior front lamp C892 pin 1,
circuit 31S-LB25B (BK/BU), harness side.

Yes
INSTALL a new interior rear lamp. TEST the system
No
operation.
PINPOINT TEST D : THE INTERIOR LAMPS DO NOT TURN ON WITH ONE

DOOR OPEN
D1: CHECK CIRCUIT 31S-LC7 FOR GROUND
2 Open the drivers side door.
lamp C890 pin 1, circuit 31S-LC7 (BK/BU), harness
side and ground.

Yes
INSTALL a new interior front lamp. TEST the system
No
GO to D2.
D2: CHECK CIRCUIT 31S-LC7 FOR OPEN
side and CJB C14 pin 9, circuit 31S-LC7 (BK/BU)
harness side.

Yes
GO to D3.
No
operation.
D3: CHECK CIRCUIT 31-DA1 FOR OPEN
circuit 31-DA1 (BK) harness side and ground.

Yes
GO to D4.
No
operation.
D4: INTERIOR LAMP RELAY COMPONENT TEST
1 Disconnect Interior lamp relay K142.
2 CARRY OUT a relay component test. REFER to the
wiring diagrams in this section.
Is the relay OK?
Yes
GO to D5.
No
INSTALL a new interior lamp relay. TEST the
D5: CHECK CIRCUIT 31S-LC18 (BK/BU) FOR OPEN
cluster C813 pin 19, circuit 31S-LC18 (BK/BU),
harness side and CJB C10 pin 9, circuit 31S-LC18
(BK/BU), harness side.

Yes
concern persists, install a new CJB. TEST the
No
operation.

Interior Lighting - Interior Lighting—
Print

information.
General Equipment
Electrical
Fuse(s)
Bulb(s)
Switch(es)
Relay(s)
Wiring harness
Instrument cluster
Lamp(s)
Chart.
Symptom Chart

The interior lamps are inoperative * Circuit(s). * GO to Pinpoint Test
* Battery saver relay. A.
* Interior lamp.
* CJB.
The centre interior lamp is inoperative * Circuit(s). * GO to Pinpoint Test
* Centre interior B.
lamp.
The rear interior lamp is inoperative * Circuit(s). * GO to Pinpoint Test
* Rear interior lamp. C.
The interior lamps do not turn on with one door * Door ajar switch * REFER to the WDS.
open (es).
* Circuit(s). * GO to Pinpoint Test
* Front interior lamp. D.
* Interior lamp relay.
* CJB.
The battery saver does not operate correctly * Instrument cluster. * REFER to the WDS.
Pinpoint Test

PINPOINT TEST A : THE INTERIOR LAMPS ARE INOPERATIVE
A1: CHECK CIRCUIT 29-LC7B (OG/BU) FOR VOLTAGE
1 Disconnect Interior Lamp C899.
2 Measure the voltage between the front interior
side and ground.

Yes
INSTALL a new front interior lamp. TEST the system
No
GO to A2.
A2: CHECK CIRCUIT 29-LC7B (OG/BU) FOR OPEN CIRCUIT
CAUTION: Take care not to damage the CJB electrical connector when back-probing
the pin.
1 Measure the resistance between the front interior
side and the CJB C14 pin 9, circuit 29-LC7 (OG/BU),
harness side.

Yes
GO to A3.
No
operation.
A3: CJB INPUT AND TIMER FUNCTION TESTS
1 Using the WDS, carry out a CJB test.
Does the CJB pass the WDS test?
Yes
GO to A4.
No
operation.
A4: CHECK CIRCUIT 31S-LC22 FOR OPEN CIRCUIT
the pin.
circuit 31S-LC22 (BK/OG), harness side and the
instrument cluster C809 pin 9, circuit 31S-LC22

Yes
concern persists, INSTALL a new CJB. TEST the
No
operation.
PINPOINT TEST B : THE CENTRE INTERIOR LAMP IS INOPERATIVE

B1: CHECK CIRCUIT 29-LB25A (OG/BU) FOR VOLTAGE
1 Disconnect Centre Interior Lamp C820.
2 Measure the voltage between the centre interior
lamp C820 pin 2, circuit 29-LB25A (OG/BU), harness
side and ground.

Yes
GO to B2.
No
operation.
B2: CHECK CIRCUIT 31S-LB25A (BK/BU) FOR OPEN CIRCUIT
1 Disconnect Centre Interior Lamp C819.
2 Disconnect Front Interior Lamp C892.
3 Measure the resistance between the centre interior
lamp C819 pin 1, circuit 31S-LB25A (BK/BU),
harness side and the front interior lamp C892 pin 1,
circuit 31S-LB25A (BK/BU), harness side.

Yes
INSTALL a new centre interior lamp. TEST the system

No
operation.
PINPOINT TEST C : THE INTERIOR REAR LAMP IS INOPERATIVE

C1: CHECK CIRCUIT 29-LB25B (OG/BU) FOR VOLTAGE
1 Disconnect Rear Interior Lamp C822.
2 Measure the voltage between the rear interior lamp
C822 pin 2, circuit 29-LB25B (OG/BU), harness side
and ground.

Yes
GO to C2.
No
operation.
C2: CHECK CIRCUIT 31S-LB25B (BK/BU) FOR OPEN CIRCUIT
1 Disconnect Rear Interior Lamp C821.
3 Measure the resistance between the rear interior
lamp C821 pin 1, circuit 31S-LB25B (BK/BU),
harness side and the front interior lamp C892 pin 1,
circuit 31S-LB25B (BK/BU), harness side.

Yes
INSTALL a new rear interior lamp. TEST the system
No
operation.
PINPOINT TEST D : THE INTERIOR LAMPS DO NOT TURN ON WITH ONE

DOOR OPEN
D1: CHECK CIRCUIT 31S-LC7 FOR GROUND
2 Open the driver side door.
side and ground.

Yes
INSTALL a new front interior lamp. TEST the system
No
GO to D2.
D2: CHECK CIRCUIT 31S-LC7 FOR OPEN CIRCUIT
the pin.
side and the CJB C14 pin 5, circuit 31S-LC7
(BK/BU) harness side.

Yes
GO to D3.
No
operation.
D3: CHECK CIRCUIT 31-DA1 FOR OPEN CIRCUIT
the pin.
circuit 31-DA1 (BK) harness side and ground.

Yes
GO to D4.
No
operation.
D4: CJB INPUT AND TIMER FUNCTION TESTS
1 Using the WDS, carry out a CJB test.

Does the CJB pass the WDS test?
Yes
GO to D5.
No
operation.
D5: CHECK CIRCUIT 31S-LC18 (BK/BU) FOR OPEN CIRCUIT
the pin.
cluster C809 pin 12, circuit 31S-LC18 (BK/BU),
harness side and the CJB C11 pin 11, circuit 31S-
LC18 (BK/BU), harness side.

Yes
operation.
No
operation.

Daytime Running Lamps (DRL) - Daytime
Running Lamps (DRL)
Print
information.
Special Tool(s)
Terminal probe kit
29-011 A
Electrical
Fuse(s)
Bulb(s)
Switch(es)
Wiring harness
Symptom Chart
Symptom Chart

Daytime running lamps (DRL) inoperative * Fuse * GO to
* Circuit(s) Pinpoint Test
* Daytime running A.
lamp relay
* Headlight switch
Parking lamps, rear lamps and license plate lamps are * Fuse * GO to
inoperative when daytime running lights (DRL) are * Circuit(s) Pinpoint Test
switched on * Headlight switch B.
* Battery junction
box (BJB)
The daytime running lamps are on with the ignition * Circuit(s) * GO to
switched off * Daytime running Pinpoint Test
lamp relay C.
* Ignition switch.
* Headlight switch
* Central junction
box (CJB)
Pinpoint Test
NOTE: Perform all measurements using a digital multimeter.

PINPOINT TEST A : DAYTIME RUNNING LAMPS (DRL) INOPERATIVE
A1: CHECK THE DIPPED BEAM
3 CHECK the low beams.
Does the dipped beam come on at full power?
Yes
GO to A2.
No
REFER to: Headlamps (417-01 Exterior Lighting,
A2: DETERMINE THE CONDITION UNDER WHICH THE FAULT OCCURS
2 SWITCH OFF dipped beam.
3 Check the daytime running lamps (dipped beam).
4 CHECK the daytime running lamps (parking lamps,
rear lamps and license plate lamps.
Are the daytime running lamps completely inoperative?
Yes
GO to A3.
No
- Only the reduced dipped beam is inoperative:
LOCATE and RECTIFY the break in circuit 15S-LE8
(GN/RD) between the daytime running lamp relay,
socket C1012 and soldered connection S120 with
- Parking lamps, rear lamps and license plate lamps
are inoperative: GO to Pinpoint Test B.
A3: CHECK FUSE F22 (20 A) (BJB).
Is the fuse OK?
Yes
GO to A4.
No
LOCATE and RECTIFY the short to ground using the
system
A4: CHECK THE VOLTAGE SUPPLY TO FUSE F22 (20 A) (BJB) FOR OPEN CIRCUIT
3
and ground.
Yes
GO to A5.
No
supply of fuse F22 (20 A) (BJB) using the Wiring

2 CHECK Fuse.

Is the fuse OK?
Yes
GO to A6.
No
- Vehicles built from 08/2006: RENEW fuse F58 (7.5
A) (CJB) and CHECK the operation of the system. If
A6: CHECK THE VOLTAGE SUPPLY TO FUSE F37/F58 (7.5 A) (CJB) FOR OPEN CIRCUIT
1 Connect Fuse.


and ground.

and ground.
Yes
GO to A7.
No
RECTIFY the break in the voltage supply of fuse F37
(7.5 A) (CJB) using the Wiring Diagrams. CHECK
RECTIFY the break in the voltage supply of fuse F58
(7.5 A) (CJB) using the Wiring Diagrams. CHECK
A7: CHECK THE VOLTAGE SUPPLY TO DAYTIME RUNNING LAMP RELAY (LOAD
CIRCUIT)
2 Disconnect Daytime running lamp relay from socket
C1012.
4 Measure voltage between daytime running lamp
relay, socket C1012, pin 3, circuit 30-LE7 (RD), BJB
side and ground.

Yes
GO to A8.
No
between fuse F22 (20 A) (BJB) and the daytime
running lamp relay using the Wiring Diagrams.
A8: CHECK VOLTAGE SUPPLY TO DAYTIME RUNNING LAMP RELAY (CONTROL
CIRCUIT)
relay, socket C1012, pin 1, circuit 15S-LE6
(GN/YE), BJB side and ground.

Yes
GO to A9.
No
GO to A10.
A9: CHECK GROUND CONNECTION OF DAYTIME RUNNING LAMP RELAY
2 Measure resistance between daytime running lamp
relay, socket C1012, pin 2, circuit 91-LE6 (BK/YE),
BJB side and ground.
Is a resistance of less than 2 ohms registered?

Yes
RENEW daytime running lamp relay. CHECK the
No
LOCATE and RECTIFY break in circuit between
daytime running lamp relay and soldered
A10: CHECK THE CONTROL CIRCUIT OF THE DAYTIME RUNNING LAMP RELAY


Yes
GO to A11.
No
the break in the circuit between fuse F58 (7.5 A)
(CJB) and the headlamp switch using the Wiring
2 Connect DRL relay to socket C1012.
3 Connect a fused jumper wire (7.5 A) to the
headlight switch, connector C320, pin 4, circuit
15S-LE6 (GN/YE) and pin 8, circuit 15-LE29
(GN/BK), wiring harness side.

5 Check the daytime running lamps.
Are the daytime running lamps on?
Yes
the system
No
LOCATE and RECTIFY break in circuit 15S-LE6
(GN/YE) between headlight switch and daytime
running lamp relay using the Wiring Diagrams.
PINPOINT TEST B : PARKING LAMPS, REAR LAMPS AND LICENSE PLATE

LAMPS ARE INOPERATIVE WHEN DAYTIME RUNNING LIGHTS (DRL) ARE
SWITCHED ON
B1: DETERMINE THE CAUSE OF THE FAULT
2 Switch on PARKING LIGHT.
3 CHECK parking lamps.
Are the parking lamps on?
Yes

GO to B2.
No
B2: CHECK FUSE F19 (10 A) (BJB).
Is the fuse OK?
Yes
GO to B3.
No
LOCATE and RECTIFY the short to ground using the
system.
B3: CHECK THE VOLTAGE SUPPLY TO FUSE F19 (10 A) (BJB)
Measure voltage between fuse F19 (10A) (BJB) and
3
ground.
Yes
GO to B4.
No
(GN/BU) between the daytime running lamp relay
and fuse F19 (10 A) (BJB) using the Wiring
B4: CHECK VOLTAGE SUPPLY TO HEADLIGHT SWITCH (DAYTIME RUNNING
LAMPS/PARKING LAMP)

Yes
the system.
No
between fuse F19 (10 A) (BJB) and the headlamp
PINPOINT TEST C : THE DAYTIME RUNNING LAMPS ARE ON WITH THE

IGNITION SWITCHED OFF

C1: DETERMINE THE CAUSE OF THE FAULT
2 Disconnect Daytime running lamp relay from socket
C1012.
3 CHECK the daytime running lamps.
Are the daytime running lamps permanently on?
Yes
GO to C7.
No
GO to C2.
C2: CHECK CONTROL CIRCUIT OF DAYTIME RUNNING LAMP RELAY FOR SHORT TO
BATTERY VOLTAGE
relay, socket C1012, pin 1, circuit 15S-LE6 (GN/YE)
and pin 2, circuit 91-LE6 (BK/YE), BJB side.

Yes
GO to C3.
No
RENEW daytime running lamp relay. CHECK the
C3: NARROW DOWN THE LOCATION OF THE SHORT TO BATTERY VOLTAGE
1 Connect DRL relay to socket C1012.
2 Disconnect Fuse.

Yes
GO to C5.
No
GO to C4.
C4: CHECK THE IGNITION SWITCH
1 Connect Fuse.

2 Disconnect Ignition switch from connector C456.
Yes
RECTIFY short to battery voltage in circuit between
ignition switch and fuse F37 (7.5 A) (CJB) using the
Wiring Diagrams. If necessary RENEW the CJB.

short to battery voltage in circuit between ignition
switch and fuse F58 (7.5 A) (CJB) using the Wiring
No
RENEW the ignition switch. CHECK the operation of
the system.
Yes
the circuit(s) between the headlamp switch and the
daytime running lamp relay with the aid of the
system.
No
GO to C6.
C6: CHECK CIRCUIT AT HEADLAMP SWITCH FOR SHORT TO BATTERY VOLTAGE

Yes
the circuit(s) connected to the headlamp switch,
C320, pin 8 using the Wiring Diagrams. If necessary
RENEW the CJB. CHECK the operation of the system
No
the system
Are the daytime running lamps (dipped beam)
permanently on?
Yes
GO to C8.
No
Parking lamps, rear lamps and license lamps
permanently on: GO to C9.
Are the daytime running lamps (dipped beam) lit

continuously on one side?
Yes
- Left-hand daytime running lamps (dipped beam).

between fuse F16 (10 A) (BJB) and the left-hand
operation of system. If the concern is still present:
- Right-hand daytime running lamps (dipped beam).
between fuse F17 (10 A) (BJB) and the right-hand
operation of system. If the concern is still present:
No
- No daytime running lamps on: LOCATE and
RECTIFY the short to battery voltage in the circuits
connected to the daytime running lamp relay,
connector C1012, pin 5 with the aid of the Wiring
Diagrams. CHECK the operation of the system If the
concern is still present:
- Parking lamps, rear lamps and license lamps
permanently on: GO to C9.
Are the daytime running lamps (dipped beam)
permanently on?
Yes
the circuit between fuse F19 (10 A) (BJB) and the
headlamp switch with the aid of the Wiring
No
- Daytime running lamps (license plate lamps)
permanently lit: GO to C10.
- Daytime running lamps (parking lamps / rear
lamps) permanently lit: GO to C11.
- None of the daytime running lamps permanently
on: RENEW the light switch. CHECK the operation of
the system
1 Disconnect Fuse.

Are the daytime running lamps (license plate lamps)

permanently on?
Yes
RECTIFY the short to battery voltage in the circuit
(s) between fuse F82 (7.5 A) (CJB) and the license

plate lamps with the aid of the wiring diagrams.
the short to battery voltage in the circuit(s)
between fuse F57 (7.5 A) (CJB) and the license
plate lamps with the aid of the wiring diagrams.
No
(s) between fuse F82 (7.5 A) (CJB) and the
headlamp switch with the aid of the wiring
between fuse F57 (7.5 A) (CJB) and the headlamp
switch with the aid of the wiring diagrams. CHECK
1 Disconnect Fuse.

2 Disconnect Fuse.

Are the left-hand daytime running lamps (parking

lamps / rear lamps) permanently on?
Yes
(s) between fuse F58 (7.5 A) (CJB) and the parking
lamps / rear lamps with the aid of the wiring
between fuse F55 (7.5 A) (CJB) and the parking
lamps / rear lamps with the aid of the wiring
No
- Right-hand daytime running lamps (parking
lamps / rear lamps) permanently on, vehicles built
before 08/2006: LOCATE and RECTIFY the short to
battery voltage in the circuit(s) between fuse F57
(7.5 A) (CJB) and the headlamp switch with the aid
system
- Right-hand daytime running lamps (parking
lamps / rear lamps) permanently on, vehicles built
from 08/2006: LOCATE and RECTIFY the short to
battery voltage in the circuit(s) between fuse F56
(7.5 A) (CJB) and the headlamp switch with the aid
system
- No daytime running lamps (parking lamps / rear

lamps) permanently on, vehicles built before
08/2006: LOCATE and RECTIFY the short to battery
voltage in the circuits between headlight switch and
fuses F57/F58 (7.5 A) (CJB) using the Wiring
- No daytime running lamps (parking lamps / rear
lamps) permanently on, vehicles built from
08/2006: LOCATE and RECTIFY the short to battery
voltage in the circuits between headlight switch and
fuses F55/F56 (7.5 A) (CJB) using the Wiring

Module Communications Network -
Communications Network
Print
General
In a communications network (data bus system), various modules of different systems are
connected to one another via one or several lines.
The sole purpose of the data bus system is the transmission of data between the connected
modules themselves, as well as between the connected modules and the Worldwide
Diagnostic System (WDS).
In a data bus system, complete data blocks are transmitted instead of single on/off pulses.
In addition to the actual information, these data blocks also contain data regarding the
address of the module to be addressed, the size of the data block and information for
monitoring the content of each individual data block.
Data bus systems offer various advantages:

Simplified data transmission between the modules due to a standardized protocol
Fewer sensors and connectors
Improved diagnostic options
Lower costs
The WDS is connected to the various bus systems and to the power supply via the standard
16-pin (DLC)Data Link Connector. The signal for the module programming is also
transmitted via the DLC.
If, in a data bus system, there is a break in one or both lines or a short to ground or short
to voltage is present, then communication between the modules and with the WDS is faulty
or is no longer possible at all.
In order to be able to establish communication with one another, the modules of the
individual systems must use the same language. This language is called a protocol.
At present, Ford uses four different data bus systems. Depending upon model and
equipment level, all four data bus systems may be used. Each of these data bus systems
has its own protocol.
Data bus systems:

Standard Corporate Protocol (SCP) bus. This consists of two twisted wires. It is used for
communication between the Powertrain Control Module (PCM) and the WDS via the DLC.
Depending upon engine version and year of manufacture, a third wire (ACP bus) is used
for programming the PCM. This bus is only used in conjunction with the SCP bus.
International Organization for Standardization ISO 9141 bus. This consists of a single
wire and is used exclusively for communication between the modules and the WDS. The
fault memories of the various modules are read out via the ISO 9141 bus.
The Local Interconnect Network (LIN) bus is a standard especially for the cost-efficient
communication between intelligent sensors and actuators in motor vehicles. Local
Interconnect Network (LIN) is used in every situation where the band width and
versatility of CAN is not needed. The LIN specification comprises the LIN protocol, a
standard format for describing a complete LIN and the interface between a LIN and the
application. A LIN comprises a LIN master and one or several LIN slaves. The LINnetwork
utilizes the master/slave principle for the purpose of bus access control. This has the
significant advantage that few resources (CPU performance, ROM, RAM) are required for
bus management in the slave module. The master is implemented in a control module or
a gateway which has the necessary resources. All communication is initiated by the
master. Consequently, a message always consists of a header, which is generated by the
master, and a response from the slave. The data transfer rate is in the region of up to 20

Kbit/s. The LIN master knows the time sequence of all data which are to be transmitted.
These data are transmitted by the corresponding LIN slaves (e.g. ultrasonic sensors)
when requested to do so by the LIN master. LIN is a single-wire bus, i.e. the data is
transferred in the cable via one wire. Usually the same cable is also used to provide the
supply voltage. The ground connection of the supply voltage also acts as the ground
connection of the data transmission. No terminating resistors are used in the LIN.
Controller Area Network (CAN) bus. This consists of two twisted wires and operates
serially (data is transmitted sequentially). It is used for communication between the
modules themselves and between the modules and the WDS. The modules are connected
to the data bus in parallel. New modules can be incorporated easily, without modifying
the other wiring or modules. The transmitted data is received by every module connected
to the Controller Area Network (CAN). As each data packet has an identifier (label), in
which the priority of the message is determined as well as the content identification, each
module can detect whether or not the data is relevant for its own information processing.
This enables several modules to be addressed with a particular data packet and supplied
with data simultaneously. For this purpose, it is ensured that important data (for example
from the Anti-lock Brake System (ABS)) is transmitted first. The other modules are only
able to submit their data to the data bus after the high-priority messages have been
received.
In order to guarantee a high degree of error protection, two 120 Ohm terminating resistors
are installed in the CAN. These are integrated in the first module connected to the CAN and
in the last module connected to the CAN respectively and are used for suppression as well
as the elimination of voltage peaks. In order to ensure correct functioning of the data bus
system, the modules must always be connected with an integral terminating resistor.
The advantages of the CAN bus are:

Minimization of wiring requirements.
High degree of error protection (fault / fail-proof).
Robustness.
Good extendibility.
Prioritization of messages.
Inexpensive.
Automatic repetition of faulty messages.
Independent system monitoring and the ability to automatically disconnect faulty
modules from the data bus.
In vehicles built from MY 2003.75, an additional second CAN is used depending upon
vehicle model. The only significant difference is a lower transmission rate and at present it
is mainly used for the convenience electronics. In order to be able to differentiate between
individual CAN systems, the CAN with the high transmission rate is designated as high-
speed (HS) CAN and the CAN with the lower transmission rate as mid-speed (MS) CAN. As
in all CAN systems, two 120 Ohm terminating resistors are also installed in the MS CAN in
order to increase the error protection. In order to enable communication between the
modules on the HS CAN and the modules on the MS CAN, one module is connected to both
data bus systems. The connection of both data bus systems is designated as a gateway. In
this gateway, the received data is converted to the transmission rate required for the
relevant data bus and is transmitted. This ensures an optimal distribution of information
between both data bus systems.
Network components
ISO 9141 bus

1 - DLC
2 - ISO 9141 bus
3 - Restraints Control Module (RCM)
4 - Parking aid module
5 - Door lock module
6 - Fuel fired booster heater
7 - Electronic stability program module
The modules connected to the ISO 9141 bus depend upon the equipment level of the
vehicle. The ISO 9141 bus is used solely for reading out the fault memories of the modules
connected to the data bus.
The ISO 9141 bus connects the various modules to the WDS via the DLC.
CAN - vehicles built from 07/2006
Depending upon equipment level, two data bus systems are used in the Transit/Tourneo
Connect built from MY 2007.
The number of modules connected to the two data bus systems depends upon the
equipment level of the vehicle.

1 - High-speed CAN bus
2 - Mid-speed CAN bus
3 - DLC
-

4 Audio module
5 - Electronic instrument cluster
6 - Anti-lock brake system module
8 - Terminating resistors
Due to the increased number of modules and the resulting ever-increasing data
transmission, a second CAN bus (mid-speed CAN bus (MS CAN)) is used in the
Transit/Tourneo Connect built from MY 2007. This operates at a lower speed and is mainly
used for communication relating to the convenience electronics.
A gateway is used in order to enable data exchange between the HS CAN bus and the MS
CAN bus. The gateway serves as interface between the two CAN data bus systems and is
installed in the electronic instrument cluster.
The modules connected to the two CAN data bus systems depend upon the equipment level
of the vehicle.
One 120 Ohm terminating resistor of the HS CAN bus is installed in the PCM and in the
electronic instrument cluster respectively.
One 120 Ohm terminating resistor of the MS CAN bus is installed in the audio module and
one in the electronic instrument cluster respectively.
These terminating resistors are used for suppression of the data bus system. In order to be
able to ensure correct functioning of the data bus system, the modules must always be
connected with an integral terminating resistor.
SCP bus - vehicles built up to 07/2006

1 - DLC
2 - SCP bus
3 - Electronic instrument cluster
5 - ACP bus

The SCP bus connects only the PCM and the electronic instrument cluster to the DLC. It is
only responsible for communication between the PCM, electronic instrument cluster and
WDS.

Communications Network—Vehicles Built Transit/Tourneo Connect 2002.5 (06/2002-)
Up To: 07/2006
Print

information.
Special Tool(s)
Terminal Probe Kit
418-S035
General Equipment
Digital Multimeter
1. 1. CHECK the concern.
Visual Inspection
Electrical
Fuses
Wiring harness
(if possible) before proceeding to the next step. CHECK the operation of the system.
4. 4. If the concern persists after the visual inspection, PERFORM a fault diagnosis with
WDS and RECTIFY any displayed faults in accordance with the displayed fault
description. CHECK operation of system.
5. 5. For vehicles with no stored fault(s), PROCEED in accordance with the symptom
chart according to the fault symptom.

must be DELETED. READ OUT the fault memory of all modules again after a road
test.
Symptom Chart
Symptom Chart
Safety restraint control module (RCM) not * Fuse(s) * GO to
communicating with the diagnostic unit * Circuit(s) Pinpoint Test
* Restraints control A.
module (RCM).
ABS module not communicating with the diagnostic * Fuse(s) * GO to

unit * Circuit(s) Pinpoint Test
* ABS module. B.
Powertrain control module (PCM) not * Fuse(s) * GO to
communicating with the diagnostic unit * Circuit(s) Pinpoint Test
* Powertrain control C.
module (PCM).
Fuel-fired additional heater not communicating with * Fuse(s) * GO to
the diagnostic unit * Circuit(s) Pinpoint Test
* Fuel-fired booster D.
heater.
Parking aid module not communicating with the * Fuse(s) * GO to
diagnostic unit * Circuit(s) Pinpoint Test
* Parking aid module. E.
Door locking module not communicating with the * Fuse(s) * GO to
diagnostic unit * Circuit(s) Pinpoint Test
* Door locking module. F.
Instrument cluster or central timer module (CTM) * Fuse(s) * GO to
not communicating with the diagnostic unit * Circuit(s) Pinpoint Test
* Instrument cluster or G.
CTM.
No communications possible via the ISO 9141 bus * Fuse(s) * GO to
* Circuitry. Pinpoint Test
* ABS module. H.
* Fuel-fired booster
heater.
* Parking aid module.
* Door locking module.
* Safety restraint control
module (RCM)
No communications possible via the SCP bus * Fuse(s) * GO to
* Circuitry. Pinpoint Test
* Instrument cluster I.
* PCM
System tests
PINPOINT TEST A : SAFETY RESTRAINT CONTROL MODULE (RCM) NOT

COMMUNICATING WITH THE DIAGNOSTIC UNIT
WARNINGS:
The stored voltage must be discharged in order to prevent unintentional deployment

of the airbag/belt pretensioner. After disconnecting the battery, wait at least 1 minute
before starting work on the safety restraint system (SRS). Failure to observe this
instruction can lead to injury.
Do not program any keycodes while working on the safety restraint system in order
to prevent the risk of accidental deployment of safety restraint system components.
Failure to observe this instruction can lead to injury.
Never use terminal probes to test any connectors of the airbag systems or of any
other safety restraint systems. Failure to observe this instruction can lead to injury.
A1: CHECK FUSE F10
Is the fuse OK?

Yes
GO to A2.

No
INSTALL A NEW fuse F10 (10 A). CHECK operation
of system. If the fuse blows again, LOCATE and
2
ground.
Yes
GO to A3.
No
A3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)
1 Measure the voltage between the DLC, connector
C200, pin 16, circuit 30-RA1 (RD), wiring harness
side and ground.

Yes
GO to A4.
No
between the DLC and fuse F10 using the Wiring
Diagrams. CHECK operation of system.
A4: CHECK THE GROUND CONNECTION OF THE DLC (PIN 4)
1 Measure the resistance between the DLC,
connector C200, pin 4, circuit 31-RA1 (BK), wiring

Yes
GO to A5.
No
between the DLC and ground connection G14 with
the aid of the Wiring Diagrams. CHECK system
operates correctly
A5: CHECK THE GROUND CONNECTION OF THE DLC (PIN 5)
connector C200, pin 5, circuit 91-RA1 (BK/OG),

Yes
GO to A6.
No
operates correctly
A6: CHECK FUSE F63
Is the fuse OK?
Yes
GO to A7.
No
Install a new fuse F63 (20 A). CHECK system
operates correctly If the fuse blows again, LOCATE
and REPAIR the short using the Wiring Diagrams.
ground.
Yes
GO to A8.
No
of the Wiring Diagrams. CHECK operation of
system.
A8: CHECK FUSE F38
Is the fuse OK?
Yes
GO to A9.
No
INSTALL A NEW fuse F38 (7.5 A). CHECK system
3 Measure the voltage between fuse F38 (7.5 A)
and ground.
Yes
GO to A10.
No

A10: CHECK THE VOLTAGE AT THE RCM
NOTE: After connecting the battery, initialize the power window motors.
2 Disconnect Battery ground cable.
3 Disconnect connector C451 from RCM.
5 Connect Battery ground cable.
6 Measure the voltage between the RCM, connector
C451, pin 5, circuit 29-AA17 (OG/WH), wiring

Yes
GO to A12.
No
GO to A11.
A11: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE RCM
connector C13, pin 4, circuit 29-AA17 (OG/WH),
wiring harness side and the RCM, connector C451,
pin 5, circuit 29-AA17 (OG/WH), wiring harness
side.

Yes
No
LOCATE and REPAIR the open circuit in 29-AA17
(OG/WH) between the RCM and the CJB using the
A12: CHECK THE VOLTAGE AT THE RCM
2 Measure the voltage between RCM, connector
C424, pin 8, circuit 15-JA10 (GN/OG), wiring

Yes
GO to A14.

No
GO to A13.
A13: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE RCM
connector C15, pin 8, circuit 15-JA10 (GN/OG),
pin 8, circuit 15-JA10 (GN/OG), wiring harness
side.

Yes
No
LOCATE and REPAIR the open circuit in 15-JA10
(GN/OG) between the RCM and the CJB using the
Wiring Diagrams. CHECK system operates
correctly
A14: CHECK THE GROUND CONNECTION OF THE RCM
2 Measure the resistance between the RCM,
connector C424, pin 9, circuit 91-JA10 (BK/RD),

Yes
GO to A15.
No
LOCATE and RECTIFY the break in circuit 91-JA10
(BK/RD) between the RCM and ground connection
G59 with the aid of the Wiring Diagrams. CHECK
A15: CHECK FOR OPEN CIRCUIT BETWEEN THE RCM AND THE DLC
CAUTION: The following measurement may only be performed using the WDS digital
multimeter. Failure to observe this instruction can lead to damage.
connector C424, pin 7, circuit 8-EE7 (WH/RD),
wiring harness side and the DLC, connector C200,
pin 7, circuit 8-EE10 (WH/BK), wiring harness
side.

Yes
GO to Pinpoint Test H.
No
LOCATE and RECTIFY the break in circuit 8-EE7
(WH/RD) between the RCM and soldered
connection S10 with the aid of the Wiring
PINPOINT TEST B : ABS MODULE NOT COMMUNICATING WITH THE

DIAGNOSTIC UNIT
3 Select the safety restraint control module (RCM)
with the diagnostic tester.
Is it possible to establish communication with the safety
restraint control module (RCM)?
Yes
GO to B2.
No
B2: CHECK FUSE F23
Is the fuse OK?
Yes
GO to B3.
No
INSTALL a new fuse F23 (20 A). CHECK operation of
ground.
Yes
GO to B4.
No
B4: CHECK FUSE F13
1 CHECK Fuse F13 (BJB).
Is the fuse OK?
Yes
GO to B5.
No
1 Connect Fuse F13 (BJB).
ground.

Yes

GO to B6.
No
B6: CHECK FUSE F36
Is the fuse OK?
Yes
GO to B7.
No
RENEW fuse F36 (7.5 A). CHECK operation of
Measure the voltage between fuse F36 (7.5 A) and
3
ground.
Yes
GO to B8.
No
B8: CHECK THE VOLTAGE AT THE ABS MODULE
2 Disconnect Connector C830 of the ABS module.
3 Measure voltage between the ABS module,
connector C830, pin 32, circuit 30-CF6A (RD),

Yes
GO to B9.
No
between the ABS module and fuse F23 using the
wiring diagrams. CHECK operation of system.
1 Measure voltage between the ABS module,

Yes
GO to B10.

No
between the ABS module and fuse F13 using the
Measure the voltage between the ABS module,
2
connector C830, pin 4, circuit 15-CF6A (GN/YE),
Yes
GO to B12.
No
GO to B11.
B11: CHECK CIRCUIT BETWEEN THE ABS MODULE AND CJB FOR OPEN CIRCUIT
Measure the resistance between the CJB, connector
3
C10, pin 2, circuit 15-CF6 (GN/YE), wiring harness
side and the ABS module, connector C830, pin 4,
circuit 15-CF6A (GN/YE), wiring harness side.
Yes
No
between the ABS module and CJB using the wiring
B12: CHECK THE GROUND CONNECTION OF THE ABS MODULE
2 Measure the resistance between the ABS module,
connector C830, pin 16, circuit 91-CF6 (BK/YE),


cases?
Yes
GO to B13.
No
- If a resistance of more than 2 Ohms is measured
in one of the measurements:LOCATE and REPAIR

the break in the relevant circuit between the ABS
module and soldered connection S141 using the
- If a resistance greater than 2 Ohms is measured
in both cases:LOCATE and REPAIR the open in
circuit between solder point S141 and ground G55,
by using the wiring diagrams. CHECK operation of
system.
B13: CHECK THE CIRCUIT BETWEEN THE ABS MODULE AND THE DATA LINK
CONNECTOR (DLC) FOR OPEN CIRCUIT
connector C830, pin 2, circuit 8-EE6A (WH), wiring
harness side and the DLC, connector C200, pin 7,
circuit 8-EE10 (WH/BK), wiring harness side.

Yes
CHECK the ABS module and if necessary INSTALL a
new one. CHECK operation of system.
No
between the ABS module and solder point S10
system.
PINPOINT TEST C : POWERTRAIN CONTROL MODULE (PCM) NOT

C1: CHECK FUSE F10
Is the fuse OK?
Yes
GO to C2.
No
2
ground.
Yes
GO to C3.
No
C3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)

side and ground.

Yes
GO to C4.
No
C4: CHECK THE GROUND CONNECTION OF THE DLC (PIN 4)

Yes
GO to C5.
No
system.
C5: CHECK THE GROUND CONNECTION OF THE DLC (PIN 5)

Yes
- Vehicles with common rail fuel injection
system:GO to C10.
- Vehicles without common rail fuel injection
system:GO to C6.
No
system.

C6: CHECK FUSE F20
Is the fuse OK?
Yes
GO to C7.
No
Install a new fuse F20 (10 A). CHECK operation of
C7: TEST THE VOLTAGE AT FUSE F20
ground.
Yes
- Vehicles with diesel engine:GO to C10.
- All except vehicles with diesel engines:GO to C8.
No
system.
C8: CHECK FUSE F18
Is the fuse OK?
Yes
GO to C9.
No
RENEW fuse F18 (10 A). CHECK operation of
ground.
Yes
GO to C12.
No
GO to C10.
C10: CHECK FUSE F9
Is the fuse OK?
Yes
GO to C11.
No
RENEW fuse F9 (20 A). CHECK operation of system.
If the fuse blows again, LOCATE and REPAIR the
short using the Wiring Diagrams.
ground.

Yes

system:GO to C17.
- Vehicles with direct injection:GO to C14.
No
C12: CHECK THE VOLTAGE AT THE PCM (PIN 1)
3 Measure the voltage between the PCM, connector
C416, pin 1, circuit 30-RE8 (RD), wiring harness
side and ground.

Yes
GO to C13.
No
LOCATE and RECTIFY the break in circuit 30-RE8
(RD) between PCM and fuse F20 with the aid of the
C13: CHECK THE VOLTAGE AT THE PCM (PIN 37 + PIN 57)
2 Measure the voltage between PCM, connector
C416, pin 37, circuit 15-RE8M (GN/YE), wiring
Measure the voltage between PCM, connector

3
C416, pin 57, circuit 15-RE8N (GN/YE), wiring
Is battery voltage measured in both cases?
Yes
GO to C28.
No
- If battery voltage is not measured during one
measurement:LOCATE and RECTIFY the break in
the corresponding circuit between the PCM and
solder point S54 with the aid of the Wiring
- If battery voltage is not measured during both of
the measurements:LOCATE and RECTIFY the break
in the corresponding circuit between the voltage
supply relay and solder point S54 with the aid of

C415, pin 8, circuit 15-RE17 (GN/BU), wiring

Yes
GO to C15.
No
between the PCM and the ignition switch using the
C415, pin 55, circuit 30-RE8 (RD), wiring harness
side and ground.
Yes
GO to C16.
No
between the PCM and fuse F20 using the Wiring
C16: CHECK THE VOLTAGE AT THE PCM
2 Use a fused test lead (1 A) at the PCM, connector
C415, pin 96 to bridge circuit 31S-RH10 (BK/OG),

C415, pin 97, circuit 15-RE8A (GN/YE), wiring

Yes
GO to C31.
No
GO to C19.

C414, pin 37, circuit 15-RE17A (GN/BU), wiring

Yes
GO to C18.
No
between the PCM and the ignition switch using the
C18: CHECK THE VOLTAGE AT THE PCM
C414, pin 9 to bridge circuit 31S-RH10A (BK/OG),

C414, pin 3, circuit 15-RE8G (GN/YE), wiring
C414, pin 4, circuit 15-RE8H (GN/YE), wiring

C414, pin 5, circuit 15-RE8J (GN/YE), wiring

Yes
GO to C34.
No
- Battery voltage not measured in one/two

cases:LOCATE and RECTIFY the break in the
corresponding circuit between the PCM and solder
point S54 with the aid of the Wiring Diagrams.
- If battery voltage is not measured during all of the
measurements:GO to C19.
C19: CHECK THE VOLTAGE AT THE POWER SUPPLY RELAY
1 Disconnect voltage supply relay from socket
C1008.
2 Measure the voltage between the power supply
relay, socket C1008, pin 3, circuit 30-RH10 (RD),

Yes
- Vehicles with diesel engine:GO to C23.
No
(RD) between the power supply relay and fuse F9
system.
relay, socket C1008, pin 1, circuit 15-RH9
(GN/BU), wiring harness side and ground.

Yes
GO to C21.
No
between the power supply relay and the ignition
C21: CHECK THE GROUND CONNECTION OF THE ENGINE MANAGEMENT RELAY
2 Measure the resistance between the power supply
relay, socket C1008, pin 2, circuit 91-DA4 (BK/GN),

Yes
GO to C22.
No
between the power supply relay and ground
connection G37 with the aid of the Wiring
C22: CHECK FOR OPEN CIRCUIT BETWEEN THE POWER SUPPLY RELAY AND THE PCM
2 Measure the resistance between power supply
(GN/RD) wiring harness side and PCM, connector
C416, pin 37, circuit 15RE8M (BK/OG), wiring
harness side.

Yes
RENEW the power supply relay. CHECK operation of
system.
No
engine management relay and the PCM using the

Yes
system:GO to C26.
- Vehicles with direct injection:GO to C24.
No
system.
relay, socket C1008, pin 2, circuit 31S-RH10
(BK/OG), wiring harness side and the PCM,

Yes
GO to C25.
No
(BK/OG) between the power supply relay and the
PCM using the Wiring Diagrams. CHECK operation
of system.
C415, pin 97, circuit 15-RE8A (GN/YE), wiring
harness side.

Yes
system.
No
(BK/OG), wiring harness side and the PCM,
connector C414, pin 9, circuit 31S-RH10A (BK/OG),

Yes
GO to C27.
No

C414, pin 4, circuit 15-RE8H (GN/YE), wiring
harness side.

Yes
system.
No
between the voltage supply relay and solder point
S54 with the aid of the Wiring Diagrams. CHECK
C28: CHECK THE GROUND CONNECTION OF THE PCM
connector C416, pin 16, circuit 91-RE8M (BK/YE),

connector C416, pin 40, circuit 91-RE8N (BK/YE),

connector C416, pin 60, circuit 91-RE8P (BK/YE),
the cases?
Yes
GO to C29.
No
in one or two of the measurements:LOCATE and
REPAIR the break in the relevant circuit between
the PCM and soldered connection S53 using the
- Is a resistance of more than 2 Ohms measured in
all of the measurements?LOCATE and RECTIFY the
break in the circuit between solder point S53 and

C29: CHECK THE GROUND CONNECTION OF THE PCM (PIN 20)
connector C416, pin 20, circuit 31-RE8B (BK),

Yes
GO to C30.
No
RE8B (BK) between the PCM and ground connection
C30: CHECK FOR OPEN CIRCUIT BETWEEN THE PCM AND THE DLC (SCP BUS)
CAUTION: The measurements below may only be performed using the WDS digital
connector C416, pin 19, circuit 4-EG9 (vehicles
built from 02/2004: 4-EG9C) (GY/OG), wiring
harness side and DLC, connector C200, pin 2,
circuit 4-EG7 (GY/RD), wiring harness side.

built from 02/2004: 5-EG9C) (BU/BK), wiring
circuit 5-EG7 (BU/RD), wiring harness side.

cases?
Yes
GO to Pinpoint Test I.
No
LOCATE and REPAIR the break in the relevant
circuit between the PCM and the DLC using the
connector C415, pin 76, circuit 91-RE8E (BK/YE),

connector C415, pin 77, circuit 91-RE8 (BK/YE),
connector C415, pin 103, circuit 91-RE8C (BK/YE),

the cases?
Yes
GO to C32.
No
in one or two of the measurements:LOCATE and
C32: CHECK THE GROUND CONNECTION OF THE PCM (PIN 25)
connector C415, pin 25, circuit 31-RE8 (BK), wiring

Yes
GO to C33.
No
RE8 (BK) between the PCM and ground connection

connector C415, pin 16, circuit 4-EG9 (GY/OG),
pin 2, circuit 4-EG7 (GY/RD), wiring harness side.

connector C415, pin 15, circuit 5-EG9 (BU/BK),
pin 10, circuit 5-EG7 (BU/RD), wiring harness side.

cases?
Yes
No
connector C414, pin 1, circuit 91-RE8G (BK/YE),

connector C414, pin 2, circuit 91-RE8H (BK/YE),
connector C414, pin 28, circuit 91-RE8J (BK/YE),
connector C414, pin 66, circuit 91-RE8K (BK/YE),
connector C414, pin 88, circuit 91-RE8L (BK/YE),
the cases?
Yes
GO to C35.

No
in one or more of the measurements:LOCATE and
connector C414, pin 55, circuit 4-EG9B (GY/OG),

connector C414, pin 74, circuit 5-EG9B (BU/BK),

cases?
Yes
No
PINPOINT TEST D : FUEL-FIRED ADDITIONAL HEATER NOT

NOTE: Ensure that the fuel-fired booster heater is switched on during fault diagnosis with
WDS. If necessary, bridge the ambient temperature thermo switch.
D1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS

Yes
GO to D2.
No
D2: CHECK FUSE F11
Is the fuse OK?
Yes
GO to D3.
No
D3: CHECK THE VOLTAGE AT FUSE F11
ground.
Yes
GO to D4.
No
of the Wiring Diagrams. CHECK system operates
correctly
D4: CHECK FUSE F34
Is the fuse OK?
Yes
GO to D5.
No
Install a new fuse F34 (7.5 A). CHECK system
3
ground.
Yes
GO to D6.
No
correctly
D6: CHECK THE VOLTAGE AT THE FUEL FIRED ADDITIONAL HEATER
2 Disconnect Connector C878 of the fuel fired
additional heater.
3 Measure the voltage between the fuel fired
additional heater, connector C878, pin 1, circuit 30-
RD18 (RD), wiring harness side and ground.

Yes
GO to D7.
No
D7: CHECK THE VOLTAGE AT THE FUEL FIRED ADDITIONAL HEATER
RD18 (GN/RD), wiring harness side and ground.

Yes
GO to D8.
No
(GN/RD) between the fuel fired additional heater
D8: CHECK GROUND CONNECTION OF FUEL FIRED BOOSTER HEATER

Yes
GO to D9.
No
(BK) between the fuel fired additional heater and

D9: CHECK THE CIRCUIT BETWEEN THE FUEL-FIRED ADDITIONAL HEATER AND THE
DATA LINK CONNECTOR (DLC) FOR OPEN CIRCUIT
1 Measure the resistance between the fuel-fired
EE11 (WH/VT), wiring harness side and the DLC,
connector C200, pin 7, circuit 8-EE10 (WH/BK),

Yes
CHECK and if necessary RENEW the fuel-fired
additional heater. CHECK operation of system.
No
(WH/VT) between the fuel-fired additional heater
PINPOINT TEST E : PARKING AID MODULE NOT COMMUNICATING WITH

THE DIAGNOSTIC UNIT
E1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
Yes
GO to E2.
No
E2: CHECK FUSE F48
Is the fuse OK?
Yes
GO to E3.
No
INSTALL a new fuse F48 (7.5 A). CHECK operation
E3: CHECK THE VOLTAGE AT FUSE F48
ground.

Yes
GO to E4.
No

E4: CHECK THE VOLTAGE AT THE PARKING AID MODULE
2 Disconnect Connector C622 of the parking aid
module.
4 Measure the voltage between the parking aid
module, connector C622, pin 1, circuit 15-GN10

Yes
GO to E6.
No
GO to E5.
E5: CHECK CIRCUIT BETWEEN THE PARKING AID MODULE AND CJB FOR OPEN
CIRCUIT
C15, pin 3, circuit 15-DA6 (GN/WH), wiring harness
side and the parking aid module, connector C622,
pin 1, circuit 15-GN10 (GN/YE), wiring harness side.

Yes
No
between the parking aid module and CJB using the
E6: CHECK THE GROUND CONNECTION OF THE PARKING AID MODULE
(BK/YE), wiring harness side and ground.

Yes
GO to E7.

No
LOCATE and RECTIFY the break in circuit 91-GN10
(BK/YE) between the parking aid module and
E7: CHECK THE CIRCUIT BETWEEN THE PARKING AID MODULE AND THE DATA LINK
module, connector C622, pin 5, circuit 8-EE13
(WH/RD), wiring harness side and the DLC,

Yes
CHECK the parking aid module if necessary INSTALL
a new one. CHECK operation of system.
No
(WH/RD) between the parking aid module and
PINPOINT TEST F : DOOR LOCKING MODULE NOT COMMUNICATING WITH

THE DIAGNOSTIC UNIT
F1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
Yes
GO to F2.
No
GO to Pinpoint Test H.
F2: CHECK FUSE F63
Is the fuse OK?
Yes
GO to F3.
No
F3: TEST THE VOLTAGE AT FUSE F63

ground.
Yes
GO to F4.
No
F4: CHECK FUSE F61
Is the fuse OK?
Yes
GO to F5.
No
F5: CHECK THE VOLTAGE AT FUSE F61
ground.
Yes
GO to F6.
No
F6: CHECK FUSE F48
Is the fuse OK?
Yes
GO to F7.
No
3
ground.
Yes
GO to F8.
No
F8: CHECK THE VOLTAGE AT THE DOOR LOCKING MODULE
2 Disconnect connector C451 from door locking
module.
3 Measure the voltage between the door locking
module, connector C451, pin 5, circuit 29-AA17
(OG/WH), wiring harness side and ground.

Yes
GO to F10.
No
GO to F9.
F9: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE DOOR LOCKING MODULE
2
harness side and the door locking module,
Yes
No
(OG/WH) between the door locking module and the
CJB using the Wiring Diagrams. CHECK operation of
system.
module, connector C451, pin 2, circuit 29-AA17A
Yes
GO to F12.
No
GO to F11.
2
C14, pin 10, circuit 29-AA17A (OG/WH), wiring
connector C451, pin 2, circuit 29-AA17A (OG/WH),
Yes
No
LOCATE and REPAIR the open circuit in 29-AA17A
system.

module.

Yes
GO to F14.
No
GO to F13.
side and the door locking module, connector C452,
pin 7, circuit 15-AA17 (GN/WH), wiring harness
side.

Yes
No
between the door lock module and the CJB using
F14: CHECK THE GROUND CONNECTION OF THE DOOR LOCKING MODULE
2 Measure the resistance between the door locking

Yes
GO to F15.
No
between the door lock module and ground
connection G15 with the aid of the Wiring Diagrams.

F15: CHECK THE CIRCUIT BETWEEN THE DOOR LOCKING MODULE AND THE DATA
LINK CONNECTOR (DLC) FOR OPEN CIRCUIT
(WH/GN), wiring harness side and the DLC,

Yes
CHECK and if necessary RENEW the door locking
module. CHECK operation of system.
No
(WH/GN) between the door locking module and
PINPOINT TEST G : INSTRUMENT CLUSTER NOT COMMUNICATING WITH

THE DIAGNOSTIC UNIT
G1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
3 Select the powertrain control module (PCM) with
the diagnostic tester.
Is it possible to establish communication with the PCM?
Yes
GO to G2.
No
G2: CHECK FUSE F20
Is the fuse OK?
Yes
GO to G3.
No
G3: TEST THE VOLTAGE AT FUSE F20
ground.

Yes
GO to G4.
No

system.
G4: CHECK FUSE F40
Is the fuse OK?
Yes
GO to G5.
No
Install a new fuse F40 (7.5 A). CHECK operation of
G5: TEST THE VOLTAGE AT FUSE F40
ground.
Yes
GO to G6.
No
system.
G6: CHECK FUSE F48
Is the fuse OK?
Yes
GO to G7.
No
G7: CHECK THE VOLTAGE AT FUSE F48
3
ground.
Yes
GO to G8.
No
G8: CHECK THE VOLTAGE AT THE INSTRUMENT CLUSTER
2 Disconnect connector C809 of instrument cluster.
cluster, connector C809, pin 14, circuit 30-GG14

Yes
GO to G9.
No
LOCATE and RECTIFY the break in circuit 30-GG14
(RD) between the instrument cluster and fuse F20
with the aid of the Wiring Diagrams. CHECK
(YE/BU), wiring harness side and ground.

Yes
GO to G11.
No
GO to G10.
G10: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE INSTRUMENT CLUSTER
C15, pin 15, circuit 75-GG14 (YE/BU), wiring
harness side and instrument cluster, connector
C809, Pin 10, circuit 75-GG14 (YE/BU), wiring
harness side.

Yes
No
(YE/BU) between the instrument cluster and CJB


Yes
GO to G13.
No
GO to G12.
G12: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE INSTRUMENT CLUSTER
C15, pin 10, circuit 15-GG14 (GN/RD), wiring
C809, Pin 16, circuit 15-GG14 (GN/RD), wiring
harness side.

Yes
No
(GN/RD) between the instrument cluster and CJB
G13: CHECK THE GROUND CONNECTION OF THE INSTRUMENT CLUSTER
(BK/OG), wiring harness side and ground.

Yes
GO to G14.
No
LOCATE and REPAIR the open in circuit between
instrument cluster and ground G41, by using the
G14: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DATA LINK

cluster, connector C809, pin 13, circuit 4-EG8
(GY/VT), wiring harness side and the DLC,
connector C200, pin 2, circuit 4-EG7 (GY/RD),

Yes
GO to G15.
No
between the instrument cluster and the DLC using
G15: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DATA LINK
cluster, connector C809, pin 26, circuit 5-EG8
(BU/WH), wiring harness side and the DLC,
connector C200, pin 10, circuit 5-EG7 (BU/RD),

Yes
No
between the instrument cluster and the DLC using
PINPOINT TEST H : NO COMMUNICATIONS POSSIBLE VIA THE ISO 9141

BUS
H1: CHECK FUSE F10
Is the fuse OK?

Yes
GO to H2.

No
H2: CHECK THE VOLTAGE AT FUSE F10
ground.
Yes
GO to H3.
No
H3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)
side and ground.

Yes
GO to H4.
No
H4: CHECK THE GROUND CONNECTION OF THE DLC

Yes
GO to H5.
No
the aid of the Wiring Diagrams. CHECK operation
of system.
H5: CHECK THE GROUND CONNECTION OF THE DLC

Yes
GO to H6.
No
LOCATE and REPAIR the break in circuit 91-RA1
(BK/OG) between the DLC and ground connection
G41 using the Wiring Diagrams. CHECK operation
of system.
H6: PERFORM NETWORK TEST
NOTE: The number of modules connected to the ISO 9141 bus depends on the vehicle
equipment level. Therefore not every vehicle will have all the modules mentioned below.
2 Disconnect a listed component, then perform the
following test step:
ABS module C830
Parking aid module C622
Fuel-fired booster heater 878
Door locking module C451

3 Select the vehicle with the diagnostic tester.
Is it possible to establish communication with the
Yes
The component disconnected last is the cause of
the concern, CHECK component and if necessary
RENEW. CHECK operation of system.
No
- If not all the listed components are
disconnected:Key in the OFF position.
DISCONNECT the next component (go to test step
3).
- If all the listed components are disconnected:GO
to H7.
H7: CHECK FOR OPEN CIRCUIT BETWEEN THE SAFETY RESTRAINT CONTROL MODULE
(RCM) AND THE DATA LINK CONNECTOR (DLC)
WARNINGS:


2 Disconnect Connector C424 from restraints control
module (RCM).
4 Measure the resistance between the restraints
control module (RCM), connector C424, pin 7,
circuit 8-EE7 (WH/RD), wiring harness side and the
DLC, connector C200, pin 7, circuit 8-EE10
(WH/BK), wiring harness side.

Yes
GO to H8.
No
LOCATE and REPAIR the break in circuit 8-EE10
(WH/BK) between the DLC and soldered connection
S10 using the Wiring Diagrams. CHECK operation
of system.
H8: TEST THE ISO 9141 BUS FOR A SHORT TO VOLTAGE
C200, pin 7, circuit 8-EE10 (WH/BK), wiring
Is a voltage registered?
Yes
LOCATE and RECTIFY the short to voltage supply in
No
GO to H9.
H9: CHECK THE ISO 9141 BUS FOR A SHORT TO GROUND

Yes
CHECK and if necessary RENEW the restraint
control module (RCM). CHECK system operates
correctly
No
circuits connected to soldered connection S10 with
operates correctly
PINPOINT TEST I : NO COMMUNICATIONS POSSIBLE VIA THE SCP BUS
I1: CHECK FUSE F10
Is the fuse OK?
Yes
GO to I2.
No
I2: CHECK THE VOLTAGE AT FUSE F10
ground.
Yes
GO to I3.
No
I3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)
side and ground.

Yes
GO to I4.
No
I4: CHECK THE GROUND CONNECTION OF THE DLC

Yes
GO to I5.
No
system.
I5: CHECK THE GROUND CONNECTION OF THE DLC

Yes
GO to I6.
No
system.
I6: PERFORM NETWORK TEST
2 Disconnect connector C809 from the instrument
cluster, then perform the following test step:

Yes
No
- All except vehicles with diesel engines:GO to I7.
- Vehicles with direct injection:GO to I8.

system:GO to I9.
I7: CHECK FOR OPEN CIRCUIT BETWEEN THE PCM AND THE DLC (SCP BUS)
built from 02/2004: 4-EG9C) (GY/OG), wiring
circuit 4-EG7 (GY/RD), wiring harness side.

built from 02/2004: 5-EG9C) (BU/BK), wiring
circuit 5-EG7 (BU/RD), wiring harness side.

cases?
Yes
GO to I10.
No
Break in the corresponding circuit between DLC and
connector C61a (vehicles built from 02/2004: C63),
LOCATE AND REPAIR THE FAULT with the aid of the
connector C415, pin 16, circuit 4-EG9 (GY/OG),

connector C415, pin 15, circuit 5-EG9 (BU/BK),

cases?

Yes
GO to I10.
No
connector C414, pin 55, circuit 4-EG9B (GY/OG),

connector C414, pin 74, circuit 5-EG9B (BU/BK),

cases?
Yes
GO to I10.
No
I10: CHECK SCP BUS FOR A SHORT CIRCUIT
connector C200, pin 10, circuit 5-EG7 (BU/RD) and
pin 2, circuit 4-EG7 (GY/RD), wiring harness side
and ground.

Yes
GO to I11.
No
LOCATE and REPAIR the short in the SCP bus by
system.
I11: CHECK CIRCUIT FOR SHORT TO VOLTAGE BETWEEN THE PCM AND THE DLC (SCP

BUS)
C200, pin 10, circuit 5-EG7 (BU/RD), wiring

C200, pin 2, circuit 4-EG7 (GY/RD) and ground.
Yes
LOCATE and REPAIR the short to voltage supply in
the relevant circuit between the PCM and the DLC
system.
No
GO to I12.
I12: CHECK CIRCUIT FOR SHORT TO GROUND BETWEEN THE PCM AND THE DLC (SCP
BUS)
connector C200, pin 10, circuit 5-EG7 (BU/RD),

connector C200, pin 2, circuit 4-EG7 (GY/RD) and
ground.

Yes
CHECK the PCM and RENEW if necessary. CHECK

No
LOCATE and REPAIR the short to ground in the
relevant circuit between the PCM and the DLC using

Communications Network—Vehicles Built Transit/Tourneo Connect 2002.5 (06/2002-)
From: 07/2006
Print

information.
Special Tool(s)
Terminal Probe Kit
418-S035
General Equipment
Digital Multimeter
Visual Inspection
Electrical
Fuses
Wiring harness
4. 4. If the concern persists after the visual inspection, PERFORM a fault diagnosis with
WDS and RECTIFY any displayed faults in accordance with the displayed fault
description. CHECK operation of system.
5. 5. For vehicles with no stored fault(s), PROCEED in accordance with the symptom
chart according to the fault symptom.

must be DELETED. READ OUT the fault memory of all modules again after a road
test.
Symptom Chart
Symptom Chart
Restraints control module (RCM) not * Fuse(s) * GO to Pinpoint
communicating with the diagnostic tester. * Circuit(s) Test B.
* Restraints control
module (RCM).
ABS module not communicating with the * Fuse(s) * GO to Pinpoint

diagnostic unit * Circuit(s) Test C.
* ABS module.
ESP module not communicating with the * Fuse(s) * GO to Pinpoint
diagnostic tester * Circuit(s) Test D.
* ESP module
Audio module not communicating with the * Fuse(s) * GO to Pinpoint
diagnostic unit * Circuit(s) Test A.
* Audio module.
Powertrain control module (PCM) not * Fuse(s) * GO to Pinpoint
communicating with the diagnostic tester * Circuit(s) Test E.
* Powertrain control
module (PCM).
Fuel-fired booster heater not communicating with * Fuse(s) * GO to Pinpoint
the diagnostic tester. * Circuit(s) Test F.
heater.
Parking aid module not communicating with the * Fuse(s) * GO to Pinpoint
diagnostic unit * Circuit(s) Test G.
Door locking module not communicating with the * Fuse(s) * GO to Pinpoint
diagnostic unit * Circuit(s) Test H.
Instrument cluster not communicating with the * Fuse(s) * GO to Pinpoint
diagnostic unit * Circuit(s) Test I.
No communications possible via the ISO 9141 bus * Fuse(s) * GO to Pinpoint
* Circuitry. Test J.
* ESP module
heater.
* Restraints control
module (RCM).
No communications possible via the HS CAN bus. * Fuse(s) * GO to Pinpoint
* Circuitry. Test L.
* ABS module.
* PCM
No communications possible via the MS CAN bus. * Fuse(s) * GO to Pinpoint
* Circuitry. Test K.
* Audio module.
System tests
PINPOINT TEST A : AUDIO MODULE NOT COMMUNICATING WITH THE

DIAGNOSTIC UNIT
3 Select the instrument cluster with the diagnostic
tester.
instrument cluster?
Yes
GO to A2.
No

GO to Pinpoint Test K.
A2: CHECK FUSE F51
Is the fuse OK?
Yes
GO to A3.
No
INSTALL NEW fuse F51 (15 A). CHECK operation of
ground.
Yes
GO to A4.
No
GO to A6.
A4: CHECK FUSE F37
Is the fuse OK?
Yes
GO to A5.
No
INSTALL NEW fuse F37 (7.5 A). CHECK operation of
ground.
Yes
GO to A9.
No
A6: CHECK FUSE F3
Is the fuse OK?
Yes
GO to A7.
No
ground.

Yes
GO to A8.
No
REPAIR the voltage supply to fuse F3 with the aid of

A8: CHECK THE VOLTAGE AT THE CJB
Measure the voltage between the CJB, connector
2
C16, pin 10, circuit 30-DA2 (RD), wiring harness
side and ground.
Yes
No
LOCATE and REPAIR the break in circuit 30-DA2
(RD) between the CJB and fuse F3 using the Wiring
A9: CHECK THE VOLTAGE AT THE AUDIO MODULE
2 Disconnect Connector C443 from the audio module.
3 Measure the voltage between the audio module,
connector C443, pin 15, circuit 29-MD15 (OG/BK),

Yes
GO to A11.
No
GO to A10.
A10: CHECK THE CIRCUIT BETWEEN THE CJB AND THE AUDIO MODULE FOR OPEN
CIRCUIT
2
C17, pin 14, circuit 29-MD15 (OG/BK), wiring
harness side and the audio module, connector
C443, pin 15, circuit 29-MD15 (OG/BK), wiring
harness side.
Yes
No
LOCATE and REPAIR the break in circuit 29-MD15
(OG/BK) between the audio module and the CJB
system.
A11: CHECK THE VOLTAGE AT THE AUDIO MODULE
2 Measure the voltage between the audio module,
connector C443, pin 16, circuit 75-MD15 (YE/GN),

Yes
GO to A13.
No
GO to A12.
A12: CHECK THE CIRCUIT BETWEEN THE CJB AND THE AUDIO MODULE FOR OPEN
CIRCUIT
3
C11, pin 2, circuit 75-MD15 (YE/GN), wiring
harness side and the audio module, connector
C443, pin 16, circuit 75-MD15 (YE/GN), wiring
harness side.
Yes
No
LOCATE and REPAIR the break in circuit 75-MD15
(YE/GN) between the audio module and the CJB
system.
A13: CHECK THE GROUND CONNECTION OF THE AUDIO MODULE
Measure the resistance between the audio module,
2
connector C443, pin 11, circuit 91-MD34 (BK/YE),
Yes
GO to A14.
No
between the audio module and ground connection
G63 with the aid of the wiring diagrams. CHECK
A14: CHECK THE GROUND CONNECTION OF THE AUDIO MODULE
1 Measure the resistance between the audio module,
connector C443, pin 12, circuit 91-MD15 (BK/YE),
Yes
GO to A15.
No
between the audio module and ground connection
G63 with the aid of the wiring diagrams. CHECK

A15: CHECK FOR OPEN CIRCUIT BETWEEN THE AUDIO MODULE AND THE DATA LINK
CONNECTOR (DLC)
connector C443, pin 9, circuit 4-EC13 (GY/VT),
pin 3, circuit 4-EC13 (GY/VT), wiring harness side.
Yes
GO to A16.
No
between the audio module and the DLC using the
A16: CHECK FOR OPEN CIRCUIT BETWEEN THE AUDIO MODULE AND THE DATA LINK
CONNECTOR (DLC)
connector C443, pin 9, circuit 5-EC13 (BU/WH),
pin 11, circuit 5-EC13 (BU/WH), wiring harness
side.
Yes
CHECK and if necessary RENEW the audio module.
No
PINPOINT TEST B : SAFETY RESTRAINT CONTROL MODULE (RCM) NOT

WARNINGS:

B1: CHECK FUSE F62
Is the fuse OK?
Yes
GO to B2.
No
INSTALL NEW fuse F62 (7.5 A). CHECK operation

3 Measure the voltage between fuse F62 (7.5 A)
and ground.
Yes
GO to B3.
No
system.
B3: CHECK THE VOLTAGE AT THE RCM
6 Measure the voltage between RCM, connector
C424, pin 8, circuit 15-JA10 (GN/OG), wiring

Yes
GO to B5.
No
GO to B4.
B4: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE RCM
connector C11, pin 13, circuit 15-JA10 (GN/OG),
pin 8, circuit 15-JA10 (GN/OG), wiring harness
side.

Yes
No
LOCATE and REPAIR the open circuit in 15-JA10
(GN/OG) between the RCM and the CJB using the
Wiring Diagrams. CHECK system operates

correctly
B5: CHECK THE GROUND CONNECTION OF THE RCM
connector C424, pin 9, circuit 91-JA10 (BK/RD),

Yes
GO to B6.
No
LOCATE and RECTIFY the break in circuit 91-JA10
(BK/RD) between the RCM and ground connection
B6: CHECK FOR OPEN CIRCUIT BETWEEN THE RCM AND THE DLC
connector C424, pin 7, circuit 8-EE7 (WH/RD),
pin 7, circuit 8-EE10 (WH/BK), wiring harness
side.

Yes
GO to Pinpoint Test J.
No
RCM and the DLC using the Wiring Diagrams.
PINPOINT TEST C : ABS MODULE NOT COMMUNICATING WITH THE

DIAGNOSTIC UNIT
CONDITIONS
C1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
3 Select the powertrain control module (PCM) with the diagnostic tester.
Yes
GO to C2.
No
GO to Pinpoint Test L.
C2: CHECK FUSE F23

Is the fuse OK?
Yes
GO to C3.
No
INSTALL a new fuse F23 (20 A). CHECK operation of system. If the fuse
blows again, LOCATE and REPAIR the short using the Wiring Diagrams.
2 Measure the voltage between fuse F23 (20 A) and ground.
Yes
GO to C4.
No
REPAIR the voltage supply to fuse F23 using the Wiring Diagrams. CHECK
C4: CHECK FUSE F13
Is the fuse OK?
Yes
GO to C5.
No
INSTALL a new fuse F13 (30 A). CHECK operation of system. If the fuse
2 Measure the voltage between fuse F13 (30 A) and ground.
Yes
GO to C6.
No
C6: CHECK FUSE F61
Is the fuse OK?
Yes
GO to C7.
No
INSTALL NEW fuse F61 (7.5 A). CHECK operation of system. If the fuse
3 Measure the voltage between fuse F61 (7.5 A) and ground.
Yes
GO to C8.
No
C8: CHECK THE VOLTAGE AT THE ABS MODULE
2 Disconnect Connector C831 from ABS module.
3 Measure the voltage between the ABS module, connector C831, pin 1,
circuit 30-CF6B (RD), wiring harness side and ground.

Yes
GO to C9.
No
LOCATE and REPAIR the break in the circuit between the ABS module and
fuse F23 using the wiring diagrams. CHECK operation of system.
circuit 30-CF13B (RD), wiring harness side and ground.
Yes
GO to C10.
No
fuse F13 using the wiring diagrams. CHECK operation of system.
circuit 15-CF6B (GN/YE), wiring harness side and ground.
Yes
GO to C12.
No
GO to C11.
C11: CHECK CIRCUIT BETWEEN THE ABS MODULE AND CJB FOR OPEN CIRCUIT
Measure the resistance between the CJB, connector C11, pin 14, circuit
3
15-CF6 (GN/YE), wiring harness side and the ABS module, connector
C831, pin 20, circuit 15-CF6B (GN/YE), wiring harness side.
Yes
CHECK the CJB and RENEW as necessary. CHECK operation of system.
No
CJB using the wiring diagrams. CHECK operation of system.
C12: CHECK THE GROUND CONNECTION OF THE ABS MODULE
Measure the resistance between the ABS module, connector C831, pin 26,
2
circuit 91-CF13A (BK/YE), wiring harness side and ground.
Yes
GO to C13.
No
LOCATE and REPAIR the break in the relevant circuit between the ABS
module and ground connection G55 using the Wiring Diagrams. CHECK
C13: CHECK THE CIRCUIT BETWEEN THE ABS MODULE AND THE DATA LINK
1 Measure the resistance between the ABS module, connector C831, pin 23,
circuit 4-EC7B (GY/RD), wiring harness side and the DLC, connector C200,
pin 6, circuit 4-EC7 (GY/RD), wiring harness side.
Yes
GO to C14.

No
the DLC using the Wiring Diagrams. CHECK operation of system.
C14: CHECK THE CIRCUIT BETWEEN THE ABS MODULE AND THE DATA LINK
1 Measure the resistance between the ABS module, connector C831, pin 21,
circuit 5-EC7B (BU/RD), wiring harness side and the DLC, connector C200,
pin 14, circuit 5-EC7 (BU/RD), wiring harness side.
Yes
CHECK the ABS module and if necessary INSTALL a new one. CHECK
No
the DLC using the Wiring Diagrams. CHECK operation of system.
PINPOINT TEST D : ESP MODULE NOT COMMUNICATING WITH THE

DIAGNOSTIC TESTER
D1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
Yes
GO to D2.
No
D2: CHECK FUSE F23
Is the fuse OK?
Yes
GO to D3.
No
ground.
Yes
GO to D4.
No
D4: CHECK FUSE F13
Is the fuse OK?

Yes
GO to D5.

No
ground.
Yes
GO to D6.
No
D6: CHECK FUSE F61
Is the fuse OK?
Yes
GO to D7.
No
3
ground.
Yes
GO to D8.
No
D8: CHECK THE VOLTAGE AT THE ESP MODULE
2 Disconnect Connector C830 from electronic stability
program module.
3 Measure the voltage between the electronic
stability program module, connector C830, pin 32,
circuit 30-CF6A (RD), wiring harness side and
ground.

Yes
GO to D9.
No
between the ESP module and fuse F23 with the aid
of the wiring diagrams. CHECK operation of system.
1 Measure the voltage between the ESP module,


Yes
GO to D10.
No
between the ESP module and fuse F13 with the aid
of the wiring diagrams. CHECK operation of system.
Measure the voltage between the electronic
2
stability program module, connector C830, pin 4,
circuit 15-CF6A (GN/YE), wiring harness side and
ground.
Yes
GO to D12.
No
GO to D11.
D11: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE ESP MODULE
3
C11, pin 14, circuit 15-CF6 (GN/YE), wiring harness
side and the ESP module, connector C830, pin 4,
circuit 15-CF6A (GN/YE), wiring harness side.
Yes
No
between the electronic stability program module
and the CJB using the Wiring Diagrams. CHECK
D12: CHECK THE GROUND CONNECTION OF THE ELECTRONIC STABILITY PROGRAM
MODULE
2 Measure the resistance between the ESP module,


cases?
Yes
GO to D13.
No
in one of the measurements:LOCATE and REPAIR
the break in the relevant circuit between the ESP
module and soldered connection S141 using the
- If a resistance greater than 2 Ohms is measured
in both cases:LOCATE and REPAIR the open in
circuit between solder point S141 and ground G55,
by using the wiring diagrams. CHECK operation of
system.
D13: CHECK FOR OPEN CIRCUIT BETWEEN THE ELECTRONIC STABILITY PROGRAM
MODULE AND THE DATA LINK CONNECTOR (DLC)
connector C830, pin 2, circuit 8-EE6A (WH), wiring
harness side and the DLC, connector C200, pin 7,
circuit 8-EE10 (WH/BK), wiring harness side.

Yes
CHECK and if necessary RENEW the electronic
stability program module. CHECK operation of
system.
No
between the electronic stability program module
and the DLC using the Wiring Diagrams. CHECK
PINPOINT TEST E : POWERTRAIN CONTROL MODULE (PCM) NOT

E1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
3 Select the electronic instrument cluster with the

diagnostic tester.
Is it possible to establish communications with the
electronic instrument cluster?
Yes
GO to E2.
No
GO to Pinpoint Test L.
E2: CHECK FUSE F20
Is the fuse OK?
Yes
GO to E3.
No
INSTALL NEW fuse F20 (1 A). CHECK operation of
E3: TEST THE VOLTAGE AT FUSE F20
ground.
Yes
GO to E4.
No
system.
E4: CHECK FUSE F18
Is the fuse OK?
Yes
GO to E5.
No
ground.
Yes
GO to E8.
No
GO to E6.
E6: CHECK FUSE F9
Is the fuse OK?
Yes
GO to E7.
No

2
ground.
Yes
GO to E13.
No
E8: CHECK THE VOLTAGE AT THE PCM
2 Disconnect Connector C417 from the PCM.
C417, pin G4, circuit 30-RE8 (RD), wiring harness
side and ground.

Yes
GO to E9.
No
(RD) between PCM and fuse F20 with the aid of the
C418, pin C1, to bridge circuit 91S-RH9 (BK/BU),
C419, pin K3, circuit 15-RJ14A (GN/YE), wiring
C419, pin K2, circuit 15-RJ14B (GN/YE), wiring
C419, pin J1, circuit 15-RJ14C (GN/YE), wiring

Yes
GO to E10.
No
- If battery voltage is not measured during one
measurement:LOCATE and REPAIR the break in the
affected circuit between the PCM and soldered
- If battery voltage is not measured during all of the
measurements:LOCATE and REPAIR the break in
the relevant circuit 15-RE21 (GN/OG) between fuse
F18 and soldered connection S65 using the Wiring

C418, pin C3, circuit 15-RE17 (GN/BU), wiring

Yes
GO to E19.
No
GO to E11.
E11: CHECK THE CIRCUIT BETWEEN THE INERTIA FUEL SAFETY-SHUT-OFF SWITCH
AND THE PCM FOR OPEN CIRCUIT
Disconnect Connector C885 from the inertia fuel
2
safety shut-off switch.
3 Measure the resistance between the inertia fuel
safety shut-off switch, connector C885, pin 1,
circuit 15-RE17 (GN/BU), wiring harness side and
the PCM, connector C418, pin C3, circuit 15-RE17
(GN/BU), wiring harness side.
Yes
GO to E12.
No
(GN/BU) between the inertia fuel safety shut-off
switch and the PCM with the aid of the Wiring
E12: CHECK THE VOLTAGE AT THE INERTIA FUEL SAFETY-SHUT-OFF SWITCH
Measure the voltage between the inertia fuel safety
2
shut-off switch, connector C885, pin 2, circuit 15-
RE17A (GN/BU), wiring harness side and ground.
Yes
CHECK and if necessary RENEW the inertia fuel
safety shut-off switch. CHECK operation of system.
No
between the inertia fuel safety shut-off switch and
the CJB with the aid of the Wiring Diagrams. CHECK
C417, pin G4, circuit 30-RE8 (RD), wiring harness
side and ground.

Yes
GO to E14.
No
between the PCM and fuse F20 using the Wiring
Use a fused test lead (1 A) at the PCM, connector
3
C418, pin C1, to bridge circuit 91S-RH9 (BK/BU),
C419, pin K3, circuit 15-RJ14A (GN/YE), wiring
Yes
GO to E19.
No
GO to E15.
E15: CHECK THE VOLTAGE AT THE POWER SUPPLY RELAY
1 Disconnect voltage supply relay from socket C1008.

Yes
GO to E16.
No
system.
E16: CHECK THE VOLTAGE AT THE POWER SUPPLY RELAY

Yes
GO to E17.
No
system.
E17: CHECK FOR OPEN CIRCUIT BETWEEN THE POWER SUPPLY RELAY AND THE PCM
(BK/BU), wiring harness side and PCM, connector
C418, pin C1, circuit 91S-RH9 (BK/BU), wiring
harness side.
Yes
GO to E18.
No
(BK/BU) between the power supply relay and the
PCM using the Wiring Diagrams. CHECK operation of
system.
E18: CHECK FOR OPEN CIRCUIT BETWEEN THE POWER SUPPLY RELAY AND THE PCM
(GN/RD) wiring harness side and the PCM,
connector C419, pin K1, circuit 15-RJ14A (GN/YE),
Yes
system.
No
E19: CHECK THE GROUND CONNECTION OF THE PCM
connector C419, pin K4, circuit 91-RE8C (BK/YE),
connector C419, pin J2, circuit 91-RE8A (BK/YE),
connector C417, pin M4, circuit 91-RE8E (BK/YE),
connector C417, pin L4, circuit 91-RE8F (BK/YE),

connector C418, pin H4, circuit 91-RE8B (BK/YE),
connector C418, pin G4, circuit 91-RE8D (BK/YE),
the cases?
Yes
GO to E20. ,
No
- If a resistance of more than 2 Ohm is measured in
one of the measurements:LOCATE and REPAIR the
break in the relevant circuit between the PCM and
all of the measurements?LOCATE and REPAIR the
break in circuit 91-RN2 (BK/BU) between soldered
connection S53 and ground connection G22 using
E20: CHECK THE CIRCUIT BETWEEN THE PCM AND THE DLC FOR OPEN CIRCUIT
connector C418, pin A4, circuit 4-EG7 (vehicles
with ABS: 4-EG7A) (GY/RD), wiring harness side
and the DLC, connector C200, pin 6, circuit 4-EG7
(GY/RD), wiring harness side.

Yes
GO to E21.
No
PCM and the DLC using the Wiring Diagrams.
E21: CHECK THE CIRCUIT BETWEEN THE PCM AND THE DLC FOR OPEN CIRCUIT
CAUTION: The following measurement must only be performed using the WDS
digital multimeter. Failure to observe this instruction can lead to damage.
connector C418, pin A3, circuit 5-EG7 (vehicles
with ABS: 5-EG7A) (BU/RD), wiring harness side
and the DLC, connector C200, pin 14, circuit 5-EG7
(BU/RD), wiring harness side.

Yes

No
PCM and the DLC using the Wiring Diagrams.
PINPOINT TEST F : FUEL-FIRED ADDITIONAL HEATER NOT

NOTE: Ensure that the fuel-fired booster heater is switched on during fault diagnosis with
WDS. If necessary, bridge the ambient temperature thermo switch.
F1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
Yes
GO to F2.
No
F2: CHECK FUSE F11
Is the fuse OK?
Yes
GO to F3.
No
ground.
Yes
GO to F4.
No
correctly
F4: CHECK FUSE F27
Is the fuse OK?
Yes
GO to F5.
No

3
ground.
Yes
GO to F6.
No
correctly
F6: CHECK THE VOLTAGE AT THE FUEL FIRED ADDITIONAL HEATER
2 Disconnect Connector C878 of the fuel fired
additional heater.
Measure the voltage between the fuel fired

3
RD18 (RD), wiring harness side and ground.
Yes
GO to F7.
No
F7: CHECK THE VOLTAGE AT THE FUEL FIRED ADDITIONAL HEATER

RD18 (GN/RD), wiring harness side and ground.

Yes
GO to F8.
No
between fuse F27 and the fuel-fired additional

heater with the aid of the Wiring Diagrams. CHECK
F8: CHECK GROUND CONNECTION OF FUEL FIRED BOOSTER HEATER
Measure the resistance between the fuel fired

2
Yes
GO to F9.
No
(BK) between the fuel fired additional heater and
F9: CHECK THE CIRCUIT BETWEEN THE FUEL-FIRED ADDITIONAL HEATER AND THE
DATA LINK CONNECTOR (DLC) FOR OPEN CIRCUIT
1 Measure the resistance between the fuel-fired

EE11 (WH/VT), wiring harness side and the DLC,
Yes
CHECK and if necessary RENEW the fuel-fired
additional heater. CHECK operation of system.
No
between the fuel-fired booster heater and the DLC
PINPOINT TEST G : PARKING AID MODULE NOT COMMUNICATING WITH

THE DIAGNOSTIC UNIT

G1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
Yes
GO to G2.
No
G2: CHECK FUSE F44
Is the fuse OK?
Yes
GO to G3.
No
G3: CHECK THE VOLTAGE AT FUSE F44
3
ground.
Yes
GO to G4.
No
system.
G4: CHECK THE VOLTAGE AT THE PARKING AID MODULE
2 Disconnect Connector C622 of the parking aid
module.
4 Measure the voltage between the parking aid

Yes
GO to G6.
No
GO to G5.
G5: CHECK CIRCUIT BETWEEN THE PARKING AID MODULE AND CJB FOR OPEN
CIRCUIT

side and the parking aid module, connector C622,
pin 1, circuit 15-GN10 (GN/YE), wiring harness side.

Yes
No
between the parking aid module and CJB using the
G6: CHECK THE GROUND CONNECTION OF THE PARKING AID MODULE
(BK/YE), wiring harness side and ground.

Yes
GO to G7.
No
LOCATE and RECTIFY the break in circuit 91-GN10
(BK/YE) between the parking aid module and
G7: CHECK THE CIRCUIT BETWEEN THE PARKING AID MODULE AND THE DATA LINK
(WH/RD), wiring harness side and the DLC,

Yes
CHECK the parking aid module if necessary INSTALL
a new one. CHECK operation of system.
No
(WH/RD) between the parking aid module and the

DLC with the aid of the Wiring Diagrams. CHECK
PINPOINT TEST H : DOOR LOCKING MODULE NOT COMMUNICATING WITH

THE DIAGNOSTIC UNIT
H1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
Yes
GO to H2.
No
H2: CHECK FUSE F63
Is the fuse OK?
Yes
GO to H3.
No
H3: TEST THE VOLTAGE AT FUSE F63
ground.
Yes
GO to H4.
No
system.
H4: CHECK FUSE F30
Is the fuse OK?
Yes
GO to H5.
No
ground.
Yes
GO to H6.
No

H6: CHECK FUSE F44
Is the fuse OK?
Yes
GO to H7.
No
3
ground.
Yes
GO to H8.
No
system.
H8: CHECK THE VOLTAGE AT THE DOOR LOCKING MODULE
module.

Yes
GO to H10.
No
GO to H9.
H9: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE DOOR LOCKING MODULE

Yes
No

system.
module, connector C451, pin 2, circuit 29-AA17A
Yes
GO to H12.
No
GO to H11.
H11: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE DOOR LOCKING
MODULE
2
C17, pin 5, circuit 29-AA17A (OG/WH), wiring
connector C451, pin 2, circuit 29-AA17A (OG/WH),
Yes
No
LOCATE and REPAIR the open circuit in 29-AA17A
system.
module.

Yes
GO to H14.
No
GO to H13.
H13: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE DOOR LOCKING
MODULE
C14, pin 7, circuit 15-DA7 (GN/YE), wiring harness
side and the door locking module, connector C452,
pin 7, circuit 15-AA17 (GN/YE), wiring harness side.

Yes
No
between the door lock module and the CJB using
H14: CHECK THE GROUND CONNECTION OF THE DOOR LOCKING MODULE

Yes
GO to H15.
No
between the door lock module and ground
connection G15 with the aid of the Wiring Diagrams.
H15: CHECK THE CIRCUIT BETWEEN THE DOOR LOCKING MODULE AND THE DATA
LINK CONNECTOR (DLC) FOR OPEN CIRCUIT
(WH/GN), wiring harness side and the DLC,

Yes
CHECK and if necessary RENEW the door locking
module. CHECK operation of system.
No

(WH/GN) between the door locking module and the
PINPOINT TEST I : INSTRUMENT CLUSTER NOT COMMUNICATING WITH

THE DIAGNOSTIC UNIT
I1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
3 Select the powertrain control module (PCM) with
the diagnostic tester.
Yes
GO to I2.
No
GO to Pinpoint Test K.
I2: CHECK FUSE F48
Is the fuse OK?
Yes
GO to I3.
No
ground.
Yes
GO to I4.
No
GO to I13.
I4: CHECK FUSE F37
Is the fuse OK?
Yes
GO to I5.
No
ground.
Yes
GO to I11.
No
GO to I6.
I6: CHECK FUSE F8

Is the fuse OK?
Yes
GO to I7.
No
2
ground.
Yes
GO to I8.
No
I8: CHECK THE VOLTAGE AT THE CJB
3 Measure the voltage between the CJB, connector
C11, pin 7, circuit 75-DA1 (YE), wiring harness side
and ground.

Yes
No
GO to I9.
I9: CHECK THE CIRCUIT BETWEEN THE CJB AND THE IGNITION SWITCH FOR OPEN
CIRCUIT.
2 Disconnect Connector C456 from the ignition
switch.
C11, pin 7, circuit 75-DA1 (YE), wiring harness side
and the ignition switch, connector C456, Pin 6,
circuit 75-DA1 (YE), wiring harness side.

Yes
GO to I10.
No

(YE) between the ignition switch and the CJB using
I10: CHECK THE VOLTAGE AT THE IGNITION SWITCH
2 Measure the voltage between the ignition switch,
connector C456, pin 4, circuit 30-BB9 (RD), wiring
harness side, and ground.

Yes
CHECK the ignition switch, if necessary INSTALL a
new one. CHECK operation of system.
No
LOCATE and REPAIR the break in circuit 30-BB9
(RD) between the ignition switch and the BJB with
system.
I11: CHECK FUSE F59
Is the fuse OK?
Yes
GO to I12.
No
RENEW fuse F59 (7.5 A). CHECK operation of
ground.
Yes
GO to I16.
No
I13: CHECK FUSE F3
Is the fuse OK?
Yes
GO to I14.
No
ground.

Yes
GO to I15.
No
I15: CHECK THE CIRCUIT BETWEEN THE CJB AND THE BJB FOR OPEN CIRCUIT
2
C16, pin 10, circuit 30-DA2 (RD), wiring harness
side and the BJB, fuse F3, circuit 30-DA2 (RD),
Yes
No
(RD) between the BJB and the CJB with the aid of
I16: CHECK THE VOLTAGE AT THE INSTRUMENT CLUSTER
2 Disconnect Instrument cluster connector C813.
(OG), wiring harness side and ground.

Yes
GO to I18.
No
GO to I17.
I17: CHECK FOR OPEN CIRCUIT BETWEEN THE CJB AND THE INSTRUMENT CLUSTER
C11, pin 8, circuit 29-GG14 (OG), wiring harness
side and the instrument cluster, connector C813,
Pin 1, circuit 29-GG14 (OG), wiring harness side.

Yes
No
LOCATE and REPAIR the break in circuit 29-GG14
(OG) between the instrument cluster and the CJB

system.
1 Disconnect connector C809 of instrument cluster.
(YE/BU), wiring harness side and ground.

Yes
GO to I20.
No
GO to I19.
C11, pin 2, circuit 75-GG14 (YE/BU), wiring
C809, Pin 14, circuit 75-GG14 (YE/BU), wiring
harness side.

Yes
No
(YE/BU) between the instrument cluster and CJB

Yes
GO to I22.
No
GO to I21.

side and the instrument cluster, connector C813,
Pin 6, circuit 15-GG14 (GN/RD), wiring harness
side.

Yes
No
between the instrument cluster and the CJB using
I22: CHECK THE GROUND CONNECTION OF THE INSTRUMENT CLUSTER
(BK/OG), wiring harness side and ground.

Yes
GO to I23.
No
LOCATE and REPAIR the open in circuit between
instrument cluster and ground G41, by using the
I23: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DATA LINK
cluster, connector C813, pin 21, circuit 4-EC13A
connector C200, pin 3, circuit 4-EC13A (GY/VT),

Yes
GO to I24.

No
LOCATE and REPAIR the break in circuit 4-EC13A
(GY/VT) between the instrument cluster and the
DLC using the Wiring Diagrams. CHECK operation of
system.
connector C200, pin 11, circuit 5-EC13A (BU/WH),

Yes
GO to I25.
No
(BU/WH) between the instrument cluster and the
cluster, connector C813, pin 23, circuit 4-EC8
connector C200, pin 6, circuit 4-EC8 (GY/VT), wiring
harness side.

Yes
GO to I26.
No
LOCATE and REPAIR the break in circuit 4-EC8
DLC using the Wiring Diagrams. CHECK operation of
system.


Yes
No
PINPOINT TEST J : NO COMMUNICATIONS POSSIBLE VIA THE ISO 9141

BUS
J1: CHECK FUSE F10
Is the fuse OK?
Yes
GO to J2.
No
J2: CHECK THE VOLTAGE AT FUSE F10
ground.
Yes
GO to J3.
No
J3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)
side and ground.

Yes
GO to J4.
No
J4: CHECK THE GROUND CONNECTION OF THE DLC

Yes
GO to J5.
No
of system.
J5: CHECK THE GROUND CONNECTION OF THE DLC

Yes
GO to J6.
No
of system.
J6: PERFORM NETWORK TEST
NOTE: The number of modules connected to the ISO 9141 bus depends on the vehicle
equipment level. Therefore not every vehicle will have all the modules mentioned below.
ESP module C830
Parking aid module C622
Fuel-fired booster heater 878

Door locking module C451
Yes
No
3).
to J7.
J7: CHECK FOR OPEN CIRCUIT BETWEEN THE SAFETY RESTRAINT CONTROL MODULE
(RCM) AND THE DATA LINK CONNECTOR (DLC)
WARNINGS:

2 Disconnect Connector C424 from restraints control
module (RCM).
4 Measure the resistance between the restraints
control module (RCM), connector C424, pin 7,
circuit 8-EE7 (WH/RD), wiring harness side and the
DLC, connector C200, pin 7, circuit 8-EE10
(WH/BK), wiring harness side.

Yes
GO to J8.
No
LOCATE and REPAIR the break in circuit 8-EE10
(WH/BK) between the DLC and soldered connection
S10 using the Wiring Diagrams. CHECK operation
of system.
J8: TEST THE ISO 9141 BUS FOR A SHORT TO VOLTAGE
C200, pin 7, circuit 8-EE10 (WH/BK), wiring

Yes
LOCATE and RECTIFY the short to voltage supply in
No
GO to J9.
J9: CHECK THE ISO 9141 BUS FOR A SHORT TO GROUND

Yes
CHECK and if necessary RENEW the restraint
control module (RCM). CHECK system operates
correctly
No
circuits connected to soldered connection S10 with
operates correctly
PINPOINT TEST K : FAULTY COMMUNICATIONS BETWEEN THE MODULES -

MS CAN BUS.
K1: CHECK FUSE F10
Is the fuse OK?
Yes
GO to K2.
No

K2: CHECK THE VOLTAGE AT FUSE F10
2
ground.
Yes
GO to K3.
No
K3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)
C200, pin 16, circuit 30-RA1 (OG), wiring harness
side and ground.

Yes
GO to K4.
No
(OG) between DLC and CJB using the Wiring
K4: CHECK THE GROUND CONNECTION OF THE DLC (PIN 4)

Yes
GO to K5.
No
of system.
K5: CHECK THE GROUND CONNECTION OF THE DLC (PIN 5)

Yes
GO to K6.
No
of system.
K6: CHECK THE MS CAN BUS FOR SHORT CIRCUIT
1 Disconnect the ground cable from the battery.
connector C200, between pin 3, circuit 4-EC13A
(GY/RD), wiring harness side and pin 11, circuit 5-
EC13A (BU/WH), wiring harness side.
Is a resistance of between 55 and 65 Ohm measured?

Yes
GO to K7.
No
If a resistance of between 115 and 125 Ohms is
measured: GO to K10.
If a resistance of between 115 and 125 Ohms is
not measured: GO to K15.
K7: PERFORM NETWORK TEST
NOTE: The number of modules connected to the CAN bus depends on the equipment
levels of the vehicle. Therefore not every vehicle will have all the modules mentioned
below.
2 Disconnect Connector C443 from the audio
module.
Es it possible to establish a connection to the
instrument cluster via the MS CAN bus?
Yes
No
GO to K8.
K8: CHECK THE MS CAN BUS FOR A SHORT TO VOLTAGE SUPPLY

C200, pin 3, circuit 4-EC13A (GY/RD), wiring
Measure the voltage between the DLC, connector

5
C200, pin 11, circuit 5-EC13A (BU/WH), wiring
Yes
the relevant circuit using the Wiring Diagrams.
No
GO to K9.
K9: CHECK THE MS CAN BUS FOR A SHORT TO GROUND
connector C200, pin 3, circuit 4-EC13A (GY/RD),
Measure the resistance between the DLC,

3
both cases?
Yes
No
relevant circuit using the Wiring Diagrams. CHECK
module.
connector C200, between pin 3, circuit 4-EC13
EC13 (BU/WH), wiring harness side.

Is a resistance of between 115 and 120 Ohm
measured?
Yes
GO to K13.
No
GO to K11.
K11: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DATA LINK
1 Disconnect Connector C813 from the electronic
instrument cluster.

Yes
GO to K12.
No
K12: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR
CONTINUITY
(GY/RD), wiring harness side and the DLC,
connector C200, pin 3, circuit 4-EC10M (GY),

Yes
No
(GY/RD) between the instrument cluster and the
DLC using the Wiring Diagrams. CHECK operation
of system.
K13: CHECK FOR OPEN CIRCUIT BETWEEN THE AUDIO MODULE AND THE DLC
pin 3, circuit 4-EC13 (GY/VT), wiring harness side.

Yes
GO to K14.
No
K14: CHECK FOR OPEN CIRCUIT BETWEEN THE AUDIO MODULE AND THE DLC
pin 11, circuit 5-EC13 (BU/WH), wiring harness
side.

Yes
No
K15: PERFORM NETWORK TEST
below.
module.
Es it possible to establish a connection to the
instrument cluster via the MS CAN bus?
Yes
No
GO to K16.
K16: CHECK THE MS CAN BUS FOR A SHORT TO VOLTAGE SUPPLY
C200, pin 3, circuit 4-EC13 (GY/RD), wiring

C200, pin 11, circuit 5-EC13 (BU/WH), wiring

Yes
No
GO to K17.
K17: CHECK THE MS CAN BUS FOR A SHORT TO GROUND
connector C200, pin 3, circuit 4-EC13 (GY/RD),

3
both cases?
Yes
GO to K18.
No
EC13 (BU/WH), wiring harness side.

both cases?
Yes
TEST the GEM and RENEW as necessary. CHECK
No
LOCATE and REPAIR the short in the relevant
circuit using the Wiring Diagrams. CHECK
PINPOINT TEST L : FAULTY COMMUNICATIONS BETWEEN THE MODULES -

HS CAN BUS.

L1: CHECK FUSE F10
Is the fuse OK?
Yes
GO to L2.
No
L2: CHECK THE VOLTAGE AT FUSE F10
ground.
Yes
GO to L3.
No
L3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)
side and ground.

Yes
GO to L4.
No
(RD) between DLC and CJB using the Wiring
L4: CHECK THE GROUND CONNECTION OF THE DLC (PIN 4)

Yes
GO to L5.
No

of system.
L5: CHECK THE GROUND CONNECTION OF THE DLC (PIN 5)

Yes
GO to L6.
No
of system.
L6: CHECK THE HS CAN BUS FOR SHORT CIRCUIT
1 Disconnect the ground cable from the battery.
EC7 (BU/RD), wiring harness side.
Is a resistance of between 55 and 65 Ohm measured?

Yes
GO to L7.
No
- If a resistance of between 115 and 125 Ohm is
measured:GO to L10.
- If a resistance of between 115 and 125 Ohm is
not measured:GO to L15.
L7: PERFORM NETWORK TEST
below.
1 Connect the ground cable to the battery.
ABS module C831
Instrument Cluster C813


PCM?
Yes

No
3).
to L8.
L8: CHECK THE HS CAN BUS FOR A SHORT TO VOLTAGE SUPPLY
C200, pin 6, circuit 4-EC7 (GY/RD), wiring harness
side and ground.

5
C200, pin 14, circuit 5-EC7 (BU/RD), wiring
Yes
No
GO to L9.
L9: CHECK THE HS CAN BUS FOR A SHORT TO GROUND

connector C200, pin 14, circuit 5-EC7 (BU/RD),
both cases?
Yes
No
L10: CHECK INSTRUMENT CLUSTER

Is a resistance of between 115 and 125 Ohm

measured?
Yes
GO to L11.
No
GO to L13.
L11: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR
CONTINUITY

Yes
GO to L12.
No
L12: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR
CONTINUITY

Yes
No
DLC using the Wiring Diagrams. CHECK operation
of system.
L13: CHECK THE CIRCUIT BETWEEN THE PCM AND THE DLC FOR OPEN CIRCUIT

connector C418, pin A4, circuit 4-EC7 (GY/RD),
pin 6, circuit 4-EC7 (GY/RD), wiring harness side.

Yes
GO to L14.
No
(GY/RD) between the PCM and the DLC using the
L14: CHECK THE CIRCUIT BETWEEN THE PCM AND THE DLC FOR OPEN CIRCUIT
connector C418, pin A3, circuit 5-EC7 (BU/RD),
pin 14, circuit 5-EC7 (BU/RD), wiring harness side.

Yes
No
(BU/RD) between the PCM and the DLC using the
L15: PERFORM NETWORK TEST
below.
1 Connect the ground cable to the battery.
ABS module C831
Instrument Cluster C813


PCM?
Yes
No
3).

to L16.
L16: CHECK THE HS CAN BUS FOR A SHORT TO VOLTAGE SUPPLY
C200, pin 6, circuit 4-EC7 (GY/RD), wiring harness
side and ground.

5
C200, pin 14, circuit 5-EC7 (BU/RD), wiring
Yes
No
GO to L17.
L17: CHECK THE HS CAN BUS FOR A SHORT TO GROUND

3
connector C200, pin 14, circuit 5-EC7 (BU/RD),
both cases?
Yes
GO to L18.
No
L18: CHECK THE HS CAN BUS FOR SHORT CIRCUIT

Yes
No
LOCATE and REPAIR the short in the relevant
circuit using the Wiring Diagrams. CHECK

Module Configuration - Module
Configuration
Print
General Procedures
1. Load the CD from the diagnostic tester.

2. Select the "Module Configuration" menu.
3. Select the relevant module. The vehicle data
must be read off before the module is removed.
If the relevant module is not communicating with
the diagnostic tester, contact the Hotline and
quote the vehicle identification number (VIN).
4. Read off the module code and/or vehicle data
from the defective module.
5. Remove the defective module and install the new
module as described in the operation
PCM / Module - Passive Anti-Theft System
(PATS)
Module - ABS
Module - Airbag
Instrument Cluster
Central Timer Module (CTM)
6. Using the diagnostic tester, configure the new
module according to the model variant.
7. Separate the diagnostic tester from the DLC.
8. Check the operation of the relevant system(s).

Wiring Harnesses - Wiring Harness Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Equipment
Ford approved diagnostic tool
2. 2. Check the electrical connectors for security, damage and incorrect connection. If
the electrical connectors are broken, damaged or incorrectly connected, repair or
replace the components as required. TEST the system for normal operation before
proceeding to the next step.
3. 3. Disconnect the electrical connectors and check for the following:
Moisture in the connector due to misaligned, damaged or missing seals.

Contamination from leaking fluids in the region of the connector.
Damaged or oxidised connector pins.
Disengaged connector pins (this can be checked by carefully pressing on the individual
pins).
4. 4. If any of the conditions listed are present, repair or replace the components as
required. TEST the system for normal operation before proceeding to the next step.

Wiring harness.
Component.
5. 5. Check the wiring harness for the following:
Incorrect routing or installed too tightly.

Pinched or kinked sections.
Chafed insulation.
Security and orientation of retaining clips.
Damage in areas where the wiring harness is subjected to noise, vibration and harshness
(NVH). For example, transmission or suspension systems.
6. 6. If any of the conditions listed are present, repair or replace the components as
required. TEST the system for normal operation. If the concern persists, REFER to
the digital multimeter function of the Ford approved diagnostic tool to check the
integrity of the wiring harness and electrical connectors.

Wiring Harnesses - Passenger Compartment Wiring
Harness—Vehicles Built Up To: 04/2009
Print

Removal
CAUTION: Proceed with care when removing or installing the dashboard and make sure that the surface of the
dashboard is not scratched or damaged.
1. Remove the left-hand front wheel.
2.
3.
4.
5.
6.

8. Remove the passenger air bag module.
Refer to: Passenger Air Bag Module - Vehicles Built Up To: 04/2009 (501-20B
Supplemental Restraint System, Removal and Installation).
9. Remove the gearshift lever assembly.
Refer to: Gearshift Lever (308-06 Manual Transmission/Transaxle External

Controls, Disassembly and Assembly).
and Installation).
11. Left and right-hand side trim.
Refer to: Cowl Side Trim Panel (501-05 Interior Trim and Ornamentation,
Refer to: Audio Unit - Vehicles Built Up To: 08/2006 (415-01A Audio Unit,
Refer to: Audio Unit - Vehicles Built From: 08/2008 (415-01A Audio Unit,
13. Remove the instrument cluster.
Refer to: Instrument Cluster (413-01 Instrument Cluster, Removal and

Installation).
14.
15.
16.
17.
18.
19.

20.
21.
22.
23.
24.
25.
26.

27.
28.
29.
30.
31.
32.
33.

34.
35.
36.
37.
38.
39.
40.

41.
42.
43.
44.
45.
46.
47.

48.
On both sides.
49.
On both sides.
50.
On both sides.
51.
52.
On both sides.
53.
On both sides.
54. Remove the dashboard together with the dashboard crossmember.

55. Remove the left and right-hand B-pillar trim.

Refer to: B-Pillar Trim Panel - Van (501-05 Interior Trim and Ornamentation,
Refer to: B-Pillar Trim Panel - Short Wheelbase Kombi (501-05 Interior Trim
Refer to: B-Pillar Trim Panel - Long Wheelbase Kombi (501-05 Interior Trim and
56. Remove the headliner.
Refer to: Headliner - Van (501-05 Interior Trim and Ornamentation, Removal
and Installation).
Refer to: Front Headliner - Short Wheelbase Kombi (501-05 Interior Trim and
Refer to: Front Headliner - Long Wheelbase Kombi (501-05 Interior Trim and
Refer to: Rear Headliner - Short Wheelbase Kombi (501-05 Interior Trim and
Refer to: Rear Headliner - Long Wheelbase Kombi (501-05 Interior Trim and
57. Remove the left and right-hand rear side trim.
Refer to: Rear Quarter Trim Panel (501-05 Interior Trim and Ornamentation,
58. Remove the right and left-hand front seats.
Refer to: Front Seat - Vehicles Built Up To: 04/2009 (501-10 Seating, Removal
and Installation).
Refer to: Front Seat - Vehicles With: Fold Flat Seat (501-10 Seating, Removal
and Installation).
59. Remove the rear seats.
60.
61.
62.
On both sides.
63.

64.
65.
66.

67.
On both sides.
68.
On both sides.
69.
70.

71.
Installation
WARNING: Screw new nuts and steering shaft bolts into the dashboard crossmember. Failure to follow this
1. NOTE: Connect a new passenger compartment wiring harness to the
disconnected connector of the fuel pump module.
Disconnect the fuel pump module connector from the new wiring harness.
2.
3.
1. Stripped ends of the wires
2. Crimp connector
4. CAUTION: When crimping the connector ensure that the cross section
of the connector matches that of the cable, and that the associated

opening of the crimping pliers is used.
NOTE: After crimping the connection, test it by performing a pull test.
5. NOTE: Using the hot air blower, heat the shrink sleeving of the crimp
connector until the sleeving is tight on the connection and sealant
emerges from each end.
6.

Wiring Harnesses - Passenger Compartment Wiring
Harness—Vehicles Built From: 04/2009
Print

General Equipment
4 mm drill bit
Blind rivet gun
Draw cord
Electric drill
Hot air gun
Removal
4.

6.
7.

and Installation).
10. On both sides.
and Installation).
11.
12.
13.

15. Torque: 9 Nm
16. Torque: 8 Nm

17.
18. Torque: 25 Nm
19.
20.
21.

22. Torque: 25 Nm
23. On both sides.
24. On both sides.
Refer to: Audio Unit - Vehicles Built From: 04/2009, Vehicles With: Navigation
26.
27. Torque: 10 Nm
28. Torque: 10 Nm

29.
30. Torque: 28 Nm
31. Torque: 25 Nm
32. Remove the passenger seat.
and Installation).
33. Remove the rear seats.
34. Refer to: Front Headliner - Short Wheelbase Kombi (501-05 Interior Trim and
Refer to: Front Headliner - Long Wheelbase Kombi (501-05 Interior Trim and
Refer to: Rear Headliner - Short Wheelbase Kombi (501-05 Interior Trim and

Refer to: Rear Headliner - Long Wheelbase Kombi (501-05 Interior Trim and
35. On both sides.
Refer to: Rear Quarter Trim Panel - Short Wheelbase Kombi (501-05 Interior
Trim and Ornamentation, Removal and Installation).
Refer to: Rear Quarter Trim Panel - Long Wheelbase Kombi (501-05 Interior
Trim and Ornamentation, Removal and Installation).
36. On both sides.
37. On both sides.
38. On both sides.
39.
40. On both sides.
41.
On both sides.

42.
43. General Equipment: Draw cord

46.
On both sides.
47.
On both sides.
48.
49.

50.
51.
Installation

2. Cut the fuel pump module connector from the new wiring harness.

3. Remove the insulation at the cable ends.
4. Insert the stripped ends of the wires into the crimp connector.
5. Crimp the connection.
6. Heat the shrink sleeving.
General Equipment: Hot air gun

Wiring Harnesses - Instrument Panel
Wiring Harness
Print
Removal
CAUTION: Proceed with care when removing or installing the dashboard and make
sure that the surface of the dashboard is not scratched or damaged.
1. Remove the left-hand front wheel.

2.
3.
4.
5.
6.

8. Remove the passenger air bag module.
Refer to: Passenger Air Bag Module - Vehicles

Built Up To: 04/2009 (501-20B Supplemental
Restraint System, Removal and Installation).
9. Remove the gearshift lever assembly.
Refer to: Gearshift Lever (308-06 Manual

Transmission/Transaxle External Controls,
Refer to: A-Pillar Trim Panel (501-05 Interior

Trim and Ornamentation, Removal and
Installation).
11. Left and right-hand side trim.
Refer to: Cowl Side Trim Panel (501-05 Interior

Installation).
Refer to: Audio Unit - Vehicles Built Up To:

Installation).
Installation).
13. Remove the instrument cluster.
Refer to: Instrument Cluster (413-01 Instrument

14.
15.

16.
17.
18.
19.
20.

21.
22.
23.
24.
25.

26.
27.
28.
29.
30.

31.
32.
33.
34.
35.

36.
37.
38.
39.
40.

41.
42.
43.
44.
45.

46.
47.
48.
On both sides.
49.
On both sides.
50.
On both sides.

51.
52.
On both sides.
53.
On both sides.
54. Remove the dashboard together with the

dashboard crossmember.
55.
56.

57.
58.
59.

60.
Installation
WARNING: Screw new nuts and steering shaft bolts into the dashboard
crossmember. Failure to follow this instruction may result in personal injury.
1.

2. Follow the disassembly procedure in reverse
order.

Wiring Harnesses - Instrument Panel Wiring Harness—
Print

General Equipment
4 mm drill bit
Blind rivet gun
Electric drill
Removal
WARNINGS:
The supplemental restraint system (SRS) is active for a certain length of time after the power supply has been
disconnected. Wait for a minimum of 3 minutes before disconnecting or removing any SRS components.
Make sure that the vehicle electrical system is fully depowered and no other power source is connected.
4.

6.
7.

and Installation).
10. On both sides.
and Installation).
11.
12.
13.

15. Torque: 9 Nm

16. Torque: 8 Nm
17.
18. Torque: 25 Nm
19.
20.

21.
22.
23. Torque: 25 Nm
24. Refer to: Instrument Cluster - Vehicles Built From: 04/2009 (413-01
Instrument Cluster, Removal and Installation).
25. General Equipment: Flat-bladed screwdriver

26.
27.
28. On both sides.
29.

Vehicles without navigation system
Vehicles with navigation system

31. Refer to: Audio Unit - Vehicles Built From: 04/2009, Vehicles With: Navigation
32.
33.
All vehicles
34.
35. Torque: 10 Nm

36. Torque: 10 Nm
37.
38. Torque: 28 Nm
39. Torque: 25 Nm
40.

41.
42.
43.

44.
Installation

Wiring Harnesses - Engine Compartment Wiring
Harness
Print

Removal
1. Remove the right- and left-hand headlamps.
Refer to: Headlamp Assembly - Vehicles Built Up To: 04/2009 (417-01 Exterior
Lighting, Removal and Installation).
Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and
Installation).
3. Remove air cleaner.
Refer to: Air Cleaner (303-12 Intake Air Distribution and Filtering, Removal and
Installation).
Refer to: Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-
TDDi (Lynx) Diesel (75 PS/90 PS) (303-12 Intake Air Distribution and Filtering,
5.
6.

7.
8.
9.

10.
11.
12.
13.
All Vehicles
14.
15.
1. Torque: 22 Nm

16.
17.
18.
19.
20. Torque: 8 Nm

21.
22.
23.
24. Remove the front wheel and tire assemblies.
25.
26.

27.
28.
29. Remove the front bumper cover.
Refer to: Front Bumper Cover - Vehicles Built Up To: 08/2006 (501-19
Bumpers, Removal and Installation).
Refer to: Front Bumper Cover - Vehicles Built From: 08/2006 (501-19 Bumpers,
30.
31.
32.
33.

34.
35.
36.
37.

39.
40. Torque: 5 Nm

41.
42.
43.
44.

Installation
1. NOTE: Coat the rubber grommet on the washer pump with soap prior to
installation.
Follow the disassembly procedure in reverse order.

Anti-Theft - Active - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Item Nm lb-ft lb-in

Anti-theft alarm horn retaining bolt 22 16 -

Anti-Theft - Active - Anti-Theft - Active Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Central locking/anti-theft warning system - component location

1 - Door locking module, right-hand front door, left-hand side analogous
2 - Alarm horn (LHD, behind glove compartment)
3 - Radio
4 - Central locking/anti-theft warning system control unit
5 - Alarm horn (RHD, behind glove compartment)
6 - Engine hood switch
7 - Door contact switch, right-hand side, left-hand side analogous /
tailgate or rear door contact switch
8 - Door locking module tailgate / rear doors analogous
9 - Door locking module, right-hand sliding door, left-hand side analogous
10 - Door contact switch, right-hand sliding door, left-hand side analogous
Central locking/anti-theft warning system overview

1 - Door locking module, front door, right-hand side
2 - Door locking module, front door, left-hand side
3 - Door locking module, sliding door, right-hand side
4 - Door locking module, sliding door, left-hand side
5 - Door locking module tailgate, rear doors analogous
6 - Engine hood switch
7 - Door contact switches: front doors, sliding doors, tailgate or rear
doors
8 - Remote control
9 - Antenna in wiring harness
10 - Radio
11 - Alarm horn
12 - Turn signal lamps
13 - Interior light
15 - Central locking/anti-theft warning system control unit
Locking/unlocking functions of the central and double locking system without

remote control

A,B - Lock sliding doors. (Vehicles with central locking do not have a lock
cylinder)
1 - Lock
C,E - Lock/unlock front doors
1 - Centrally lock all doors
2.3 - Double lock all doors
4 - On van, unlock the door
4.5.6 - On van, unlock all the doors
4 - On Combi, unlock all the doors
D - Lock/unlock hood (only mechanically)
1 - Unlock the latch
2 - Open the engine hood latch
F - Lock/unlock tailgate/rear doors
1 - Centrally lock all doors
2.3 - Double lock all doors
4 - On van, unlock the tailgate or rear doors
4.5.6 - On van, unlock all the doors
-

4 On Combi, unlock all the doors

Anti-Theft - Active - Anti-Theft - Active Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Refer to Wiring Diagrams Cell 419–01A, Anti–Theft—Active for schematic and connector
information.
Misaligned door(s) Fuse(s)
Misaligned hood Wiring harness
Door latch(es) Electrical connector(s)
Actuating rod(s) Vehicle battery
Door lock cylinder(s) Door ajar switch(es)
Cable(s) Anti-theft alarm and double locking module

Anti-Theft - Active - Anti-Theft Alarm
Horn
Print
1. Open and lower the glove box.
(s).

1 - Anti-theft alarm horn electrical connector
2 - Anti-theft alarm horn retaining bolt
3 - Anti-theft alarm horn
Item 2 : Anti-theft alarm horn retaining bolt
NOTE: Make sure that the mating faces of the anti-theft alarm horn bracket and cross-
vehicle beam are clean to insure a good electrical ground contact.

Anti-Theft - Passive - Anti-Theft - Passive Transit/Tourneo Connect 2002.5 (06/2002-)
Print

information.
General Equipment
Ignition lock cylinder Fuse(s)
Passive anti-theft system (PATS) ignition key Wiring harness
Use of a non-encoded PATS ignition key Electrical connector
More than one PATS key in close proximity of the PATS (s)
transceiver Relay(s)
Central junction box (CJB) CJB
Powertrain control module (PCM) PCM
Instrument cluster PATS transceiver
Ignition switch
Instrument cluster
4. 4. If the concern is not visually evident, use the WDS to retrieve any diagnostic
trouble codes (DTCs) and refer to the DTC index.
Diagnostic Trouble Code (DTC) Index
Indicator
WDS Flash
DTC Code Description/Condition Possible Source Action
0000 - No DTCs, vehicle OK - -
B1681 11 PATS transceiver signal is not PATS transceiver REFER to the WDS.
received wiring, transceiver Select the PATS test
connector, and follow the
transceiver, CJB, instructions on the
PCM or instrument screen.
cluster
B1232. 12 PATS transceiver antenna coil fault. PATS transceiver Install a new PATS
B2103 vehicle does not start transceiver.
REFER to: Passive
Anti-Theft System
(PATS) Transceiver
(419-01B Anti-Theft
- Passive, Removal
and Installation).
TEST the system for
normal operation.
B1600 13 Non-PATS key or damaged PATS encoded REFER to the WDS.
encoded ignition key, or no key ignition key Select the PATS test

code received. Vehicle does not and follow the
start instructions on the
screen.
B2431 13 PATS transponder programming Ignition key REFER to the WDS.
failed, crypto transponder only, Select the PATS test
Vehicle does not start and follow the
instructions on the
screen.
B1602 14 Partial key read of PATS key, PATS encoded REFER to the WDS.
vehicle does not start ignition key or Select the PATS test
PATS transceiver and follow the
instructions on the
screen.
B1601 15 Incorrect key code, unprogrammed PATS encoded REFER to the WDS.
PATS key (keycode format OK), ignition key Select the PATS test
vehicle does not start (20 second and follow the
anti-scan invoked) instructions on the
screen.
U1147 16 Incorrect key being used, vehicle Ignition key Use correct ignition
does not start key. REFER to the
WDS. Select the
PATS test and follow
the instructions on
the screen.
U2510 16 Controller area network (CAN) Circuit, PCM or REFER to the WDS.
communication link between the instrument cluster Select the PATS test
PCM and instrument cluster, and follow the
vehicle does not start instructions on the
screen.
B1213 21 Number of programmed PATS Incorrect number REFER to the WDS.
encoded keys below minimum. of keys Select the PATS test
Vehicle does not start programmed or and follow the
PATS encoded instructions on the
ignition key screen.
B2141 22 NVM Configuration failure. No New PCM or fuel REFER to the WDS.
security ID exchange between PCM injection pump Select the PATS test
and fuel injection pump control control module and follow the
module, vehicle does not start instructions on the
screen.
B2139 23 Data mismatch (received data does New PCM or fuel REFER to the WDS.
not match what was expected). injection pump Select the PATS test
Security messages do not match control module and follow the
between PCM and fuel injection instructions on the
pump control module, vehicle does screen.
not start
P1260 - PCM disabled PCM or instrument REFER to the WDS.
cluster Select the PATS test
and follow the
instructions on the
screen.

Anti-Theft - Passive - Passive Anti-Theft
System (PATS) Transceiver
Print
Removal
1. Using a thin bladed screwdriver, release
the locking tang.
2. Disconnect the audio control switch
3. Disconnect the PATS transceiver electrical

connector.
4. Remove the PATS transceiver.

1. Remove the PATS transceiver retaining
screw.
2. Remove the PATS transceiver.
Installation

Cellular Phone - Portable Support
Electronics (PSE) Module—LHD FWD, Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1.
2.
Installation

Electronics (PSE) Module—RHD FWD, Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1.
2.
Installation

Electronics (PSE) Module—LHD FWD, Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1.
2.
Installation

Electronics (PSE) Module—RHD FWD, Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1.
2.
3.
4.

Installation

Cellular Phone - Handset Holder Transit/Tourneo Connect 2002.5 (06/2002-)
Print
1. Remove the floor console.

For additional information, refer to: Floor Console
(501-12 Instrument Panel and Console, Removal
and Installation).
(s).

1 - Handset adapter
See Removal Detail
2 - Handset holder retaining screws
3 - Handset holder
See Removal Detail
Removal Details
Item 1 : Handset adapter
1. Press in the locking tangs to release the handset

adapter.
Item 3 : Handset holder
1. Unclip the cellular phone wiring harness and

antenna from the floor console.

2. Unclip the cellular phone wiring harness and
antenna from the handset holder.
3. Release the locking clip and remove the handset

holder from the floor console.

Multifunction Electronic Modules - Central
Timer Module (CTM)
Print

information.
NOTE: The central timer module (CTM) is integrated in the instrument cluster (ICL).
Visual Inspection
Electrical
Fuse(s)
Wiring harness
the instrument cluster (ICL) with WDS and RECTIFY any displayed faults in
accordance with the fault description. CHECK the operation of the system.
5. 5. If no fault code is stored, CONTINUE with the Symptom Chart.
Symptom Chart
Symptom Chart

Central timer module (CTM) not * Fuse(s) * REFER to Section 418-00
communicating with the diagnostic * Circuit(s) Module Communications
unit * Instrument cluster Network.
(ICL) or CTM
Self-test cannot be activated * Fuse(s) * REFER to Section 413-01
* Circuit(s) Instrument Cluster.
(ICL) or CTM

Multifunction Electronic Modules - Anti-
Theft Alarm and Double Locking Module
Print
Removal
1. Remove the glove compartment.

2. Remove the footwell trim panel.
All vehicles
3. Disconnect the anti-theft alarm and double
locking module electrical connectors.
4. Remove the anti-theft alarm and double locking

module.
Installation

Multifunction Electronic Modules - Anti-
Theft Alarm and Double Locking Module— Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1.
2.
3.
4.

Installation

Body System - General Information -
Specifications
Print
Item Specification
Butyl sealer, fluid C9AZ-19554B ESB-M4G162-A
Caulking strip D6AZ-19560-A ESB-M4G32-A
Rubber seal adhesive E8AZ-19552-A ESB-M2G14-A
Silicone grease C0AZ-19553-AA ESR-M13P4-A

Body System - General Information - Body Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Outer skin area

The bodywork gap dimensions have been drastically reduced and correspond to the
standards and demands of modern bodywork construction technology such as that for the
new Ford Fiesta or Ford Fusion.
One piece, very flat side panels improve the optical impression of the whole vehicle because
of the lack of joints and sealant beads in the visible area. Furthermore, possible water leaks
and wind noise are eliminated by this method of bodywork construction.
The special design of the side panels optimises the interior load space.

1 - Turn indicators
2 - Main headlamp
3 - Fog lights
4 - Mounting points
Large headlamps with the latest free-form reflector technology and a large transparent
plastic lens made of knock-resistant polycarbonate. They are installed between the upper
edge of the bumper and the front edge of the engine hood. This unit is very easily installed
and aligned.

1 - Retaining bolts with star head
2 - Reflector element/brake light
NOTE: The third brake light is built into the rear door/tailgate. This construction prevents
the brake light from being damaged during loading and unloading.
All windows which do not open are glued in place. Wind noise is minimised as much as
possible in this way. Glued, structural glass also supports the vehicle body in this area.
The front bumper cover is made of a single plastic shell, which continues into the area of
the wheel house cover.
The rear bumper is made of sheet steel, and is provided with a slip resistant coating. The
optional parking aid is integral with the rear bumper and can be separated when the
bumper is detached.
Both roof variants have weight optimised reinforcements to stiffen the roof construction and
mounting points for optional roof rack systems.

1 - Single bump strip
2 - Triple bump strip
The bump strips on the lower body area between the front and rear wheels may be a single
or triple design (not yet decided in production).
Load space and seats
The body outer panel is protected from damage from the inside (e.g. by the load) by
various double panels or reinforcements.

Depending on bodywork and equipment variants, the following load capacities are
available:
Wheel Normal load Load volume with folding Maximum load length
base volume in m³ seat in m³ in mm Remarks
Short 2.8 3.4 1773 2
(SWB) Europalettes
Long 3.6 4.2 2020
(LWB)
Because of the nearly vertical side panels and rear area, the Transit Connect has approx.
100 mm wider through loading height in the roof area compared with competitor vehicles.
Furthermore, the standard Europalettes can be loaded without problem.
D-rings are provided in the reinforced floor area for securing a load. 6 securing points are
provided in the box van, 4 securing points in the bus.
Various fixing points are provided on the reinforced side panel areas for easy installation of
interior equipment or side covers. These facilities make the provision of additional fixing
points unnecessary. Advantage: No corrosion problems.
The load space separators between the driver/passenger compartment and the load
space are available in different designs (grille, closed steel panel separator). They
protect the driver/passenger from loose components coming from the rear during
severe braking or in the event of an accident. These separators can be very easily
changed or expanded as required. The following variants are planned:
Simple protective grille in a ladder form behind the driver's seat
Half height steel panel separator across the whole vehicle width
Completely closed steel panel - also with glass insert in upper area
Completely closed steel panel with through loading facility
Depending on equipment level, various floor coverings are intended for the load space. This
has benefits for the NVH performance of the bodywork.
A folding passenger seat is available to further increase the load capacity. When necessary
this can be folded forward against the fascia crash padding thus making it possible to use
the complete load space.
The rear seats are divided 1/3 to 2/3 and can independently be folded down or removed
completely.

1 - Remove the head restraint
2 - Fold the seat back down onto the cushion
3 - Unlatch the seat
4 - Move the seat into the vertical position and remove it
5 - Insert the seat vertically, fold it backwards and engage it
6 - Fold the backrest up
7 - Engage the backrest in the end position
8 - Install the head restraint
Attached parts
Doors
Reinforcement tubes made of high-strength steel in the front doors increase occupant
safety by protecting from the effects of forces occurring during a side impact.
The exterior mirrors are mounted on the doors.
Fast exit and entry are made possible by the very wide opening doors and the high seat
position.

1 - Hinge half, body side
2 - Positioning bolts
3 - Securing nuts for positioning bolts
The front door hinges are mounted by double bolts on the door and body sides.
A positioning aid on the bodywork halves of the hinges allows easy setting of the door
alignment after the initial base setting - e.g. during body repairs in the A-pillar area. The
painted door does not need to be adjusted again.
Sliding doors
The vehicles are available without, with one or with two sliding doors. Depending on the
model variant, glazed sliding doors can be supplied.
The stiff construction of the sliding doors (double panels) helps to reduce noise, having a
beneficial effect on the NVH performance of the vehicle and improving the closing
properties of the doors.
The guides and mechanical elements of the sliding doors are integrated into the side panel
of the vehicle.
Tailgate and rear doors
Because of the special side panel construction, optimal access is provided to the load space.
The tailgate/rear doors are equipped with reinforced hinges.
The rear doors can be secured at 90 and 180 degrees and permit the vehicle to be easily
loaded from the rear with Europalettes.
Wheel house covers

1 - Wheel house cover
2 - Retaining bolt
Plastic wheel house covers are installed on the front and rear wheel housings. These covers
are clipped and bolted in position at several points.
A clip lever must be used for removal in order to prevent any damage to the fender or side
panel or to the wheel house cover itself.
Hood
The hood is easily accessible for paint damage free panel beating.
Each hinge is double bolted on both sides. There is also a positioning bolt on the bodywork
side. The hinges can be adjusted on the bodywork side within the tolerance range of the
oversize holes.

1 - Area for paint damage free panel beating
2 - Mounting points, hood side
3 - Mounting points, bodywork side
4 - Positioning bolts
Spare wheel
The spare wheel is located under the vehicle floor panel behind the fuel tank. It can be let
down using a cable winch, also when the vehicle is laden. Winch operation is possible with
the tailgate/rear doors open.

Safety and bodywork construction
The safety concept of the Transit Connect is of a energy absorbent crash area (front
crossmember in combination with two crash elements and intentional yield points on the
side members) in the frontal area. Maximum occupant protection is provided by the very
rigid passenger compartment.
Load bearing elements (side members) of the bodywork structure are particularly rigid
because of the special material thicknesses and also the use of high-strength steel.
Stabilisation of the whole body structure is achieved by the use of various reinforcements
(especially in the floor and rear areas).
The vehicle is 3-star categorised according to the Euro NCAP.
The rigid body structure contains a high number of high-strength steel components,
particularly in the passenger compartment area. This is surrounded by energy absorbent
components in order to allow the maximum survival space and to minimise the acceleration
forces which are transferred to the occupants.
A steel cross-member behind the plastic bumpers concentrates the crash energy which
arises and passes it into the intended areas (side members) of the bodywork structure.

1 - Crossmember
2 - Crash element
3 - Longitudinal members with designated yield points
A bolted-on cross member between the A-pillars stabilises the body structure, especially in
the event of a side impact, and prevents the steering column from excessively entering the
interior.
With the intention of reducing knee and head injuries, the fascia crash padding has been
optimised by the installation of very rigid components outside the crash zone.
The steering column is provided with a designated yield point, in order to minimise head
and chest injuries.
All seats are equipped with a 3-point seat belt. In addition the driver's seat belt buckle is
equipped with a pretensioner.
The front seats are equipped with wedge shaped seat cushions. In the event of a frontal
collision, these prevent the front seat occupants from sliding under the seat belts.
Height adjustable driver and passenger seat belts are standard.

All seats have height adjustable head restraints.
On Combi vehicles, the mounting points of the second row of seats are reinforced according
to the ISOFIX standard to allow mounting of child seats.
Hood lock panel
The hood lock panel consists of a load bearing steel panel element which is bolted to the
bodywork in the area of the apron panel using a number of bolts.
An additional plastic element is located on this steel panel element, onto which, among
other things, the front headlamps and the radiator grille are secured.
This construction permits easier accident repair because no differing materials are
combined in one component.
The plastic element has no load bearing function and can be repaired after an accident by
following the rules given in "Repairing Plastic Parts".
Floor assembly
The floor assembly is made from three individual segments in production.

In order to create various welded joints, four sheet steel plates are present on the floor
assembly during production manufacture, and these can also be used during repairs after
an accident. Because of this, the side member can be separated in the region of the
bulkhead at the original joint and replaced.
The openings provided in the bus at the rear of the floor assembly for seat mountings are
each blanked off on the van using a steel plate.
A PVC coating is applied to the whole underbody in order to provide corrosion protection
and to improve the NVH performance.

1 - Floor assembly, front part
2 - Floor assembly, middle part
3 - Floor assembly, rear part
The rear part of the floor assembly is very rigidly constructed by the use of several
crossmembers between the side members.
On the bus variants, additional stiffening in the rear area is provided by reinforced seat
mounting points.

1 - Crossmember in rear area
-

2 Reinforcements of the seat mounting points

Body System - General Information - Body
System
Print
Symptom Chart.
Mechanical
Dust Leaks
Water Leaks
Symptom Chart
Symptom Chart

Dust Leaks * Displaced sealer. * Refer to the service procedure below.
* Damaged body parts. * Refer to the service procedure below.
* Missing underbody grommets. * Refer to the service procedure below.
* Misaligned doors. * Refer to the service procedure below.
* Misaligned glass. * Refer to the service procedure below.
Water Leaks * Displaced sealer. * Refer to the service procedure below.
* Damaged body parts. * Refer to the service procedure below.
* Missing underbody grommets. * Refer to the service procedure below.
* Misaligned doors. * Refer to the service procedure below.
* Misaligned glass. * Refer to the service procedure below.
Sealer locations should be considered when checking for dust or water leaks. The forward
motion of the vehicle causes any unsealed small opening in the lower section of the body to
permit air and dust to be drawn into the body. Opening the ventilator air ducts will equalise
these pressures. Dust accumulates in the luggage compartment body opening and may
move into the luggage compartment.
To eliminate dust leakage, determine the exact point at which the dust enters. Under
certain conditions, water may also enter the body at any point where dust can enter.
To determine the exact location of a dust leak, it may be necessary to remove the following
trim panels from the vehicle:
Scuff plate. REFER to Section 501-05 Interior Trim and Ornamentation.

C - Pillar trim. REFER to Section 501-05 Interior Trim and Ornamentation.
Rear seat backrest and frame, and rear seat cushion and frame. REFER to Section 501-
10 Seating.
Luggage compartment floor covering
Spare tire
Roof opening panel.
After removing the trim panel(s), the location of most leaks will be evident. The entrance of

dust is usually indicated by a point of dust or silt. Seal these leaks, then road test the
vehicle on a dusty road to ensure all leaks are sealed. A suitable Leak Detector can locate
dust leaks, wind and water leaks.
After the road test, check for indications of a dust pattern around the door openings, cowl
side trim panel, lower part of the quater panel and in the luggage compartment.
Sometimes leaks can be located by putting bright lights under the vehicle, with the above
components removed, and checking the interior of the body joints and weld lines. A light
will show through where leaks exist.

Front End Body Panels - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print

Fender splash shield retaining bolts 4 - 35
Fender retaining bolts 12 9 -
Windshield wiper retaining nuts 23 17 -
Hood hinge to fender retaining bolts 25 18 -
Hood hinge to hood retaining bolts 12 9 -
Cowl panel grille retaining bolts 12 9 -

Front End Body Panels - Fender Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Removal
1. Remove the cowl panel retaining bolt.
2. Remove the trim panel moulding.
3. Remove the fender retaining bolt.
4. Remove the left-hand windshield washer

reservoir retaining bolt.

Tires.
6. Remove the fender lower splash shield.

7. Remove the fender splash shield.
9. Detach the left-hand windshield washer reservoir

from the fender and secure it to one side.
container.
10. Disconnect the turn lamp electrical connector.

12. Remove the fender extension front retaining
bolts.
13. Remove the fender extension rear retaining bolt.
14. Remove the fender extension.

Remove the clips.
15. Detach the bumper cover from the fender.
16. Remove the fender lower retaining bolt.

18. Remove the fender.
Installation

Front End Body Panels - Radiator Grille
Opening Panel—Vehicles Built Up To: Transit/Tourneo Connect 2002.5 (06/2002-)
04/2009
Print
Removal
All vehicles
2. Remove the hood latch. For additional
information, refer to Section 501-14 Handles,
Locks, Latches and Entry Systems.
3. Remove the front bumper cover. For additional
information, refer to Section 501-19 Bumpers.
5. Remove the headlamps. For additional
information, refer to Section 417-01 Exterior
Lighting.
6. Remove the fender retaining bolts on both sides.
7. Remove the fender upper retaining bolts on both

sides.
8. Remove the radiator grille opening panel to the

front end structure retaining bolt on both sides.
9. Detach the wiring harness from the radiator grille

opening panel on both sides.

10. Remove the radiator grille opening panel.
Installation

Front End Body Panels - Radiator Grille Opening Panel—
Print

Removal
1. Refer to: Headlamp Assembly - Vehicles Built From: 04/2009 (417-01 Exterior
Lighting, Removal and Installation).
2.

3. Refer to: Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-
TDDi (Lynx) Diesel (75 PS/90 PS) (303-12 Intake Air Distribution and Filtering,
Refer to: Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS/90
PS/110 PS), Vehicles Built From: 08/2006 (303-12 Intake Air Distribution and
All vehicles
4.
5. On both sides.
6. On both sides.
Torque: 7 Nm

7.
1. Torque: 7 Nm
2. Torque: 25 Nm
8. Torque: 25 Nm
9.
1. Torque: 7 Nm
2. Torque: 25 Nm
10. Torque: 25 Nm

11. Torque: 25 Nm
12. On both sides.
Torque: 7 Nm
13. Torque: 11 Nm
14.
1. Torque: 25 Nm
2. Torque: 7 Nm
15.

Installation

Body Closures - Specifications Transit/Tourneo Connect 2002.5 (06/2002-)
Print
Item Nm lb-ft lb-in

Striker plate retaining screws 25 18 -
Front door check strap to door pillar retaining screws 25 18 -
Door check strap to door retaining nuts 10 - 89
Front door hinge retaining bolts 28 21 -
Rear door check strap to door pillar retaining screws 12 9 -
Rear door hinge retaining screws 25 18 -
Liftgate hinge retaining nuts 10 - 89
Liftgate guide to body retaining nuts 5 - 44
Liftgate guide to liftgate retaining screws 10 - 89
Sliding door check strap to body retaining nuts 10 - 89
Sliding door arm to sliding door retaining screws 25 18 -
Sliding door guide retaining screws 9 - 80

Body Closures - Sliding Door Alignment Transit/Tourneo Connect 2002.5 (06/2002-)
Print
General Procedures
1. NOTE: Make sure that the sliding door is in

the fully closed position.
Check the alignment of the sliding door in
relation to the front door and the upper edge of
the sliding door frame.
Note any misalignment.
2. Open the sliding door.

3. NOTE: Note the position of the upper arm on
the sliding door.
NOTE: With the aid of another technician,
hold the sliding door in the fully open
position.
Adjust the sliding door upper arm to align the
sliding door in relation to the front door and the
upper edge of the sliding door frame if
necessary.
1. Loosen the retaining screws two turns.
2. Adjust the sliding door upper arm.
4. Tighten the sliding door upper arm retaining
screws.
5. NOTE: The striker plate adjustment is carried

out by adjusting the retaining plate position
on the C-pillar.
Adjust the striker plate to align the sliding door
in relation to the C-pillar if necessary.
2. Using a suitable soft faced hammer, adjust
the striker plate.

6. Tighten the striker plate retaining screws.
7. NOTE: Note the position of the rear arm on

the sliding door.
NOTE: With the aid of another technician,
hold the sliding door in the fully open
position.
Adjust the sliding door rear arm to align the
sliding door in relation to the front door and the
upper edge of the sliding door frame if
necessary.
2. Adjust the sliding door rear arm.
8. Tighten the sliding door rear arm retaining
screws.
9. Close the sliding door.

Check the alignment of the sliding door in
relation to the front door and the upper edge of
the sliding door frame.
Check that the alignment of the sliding door is
flush to between +0.00 mm and -1.5 mm in
relation to the front door and the vehicle body
panel.
Note any misalignment.

12. Open the sliding door.
13. NOTE: Note the position of the sliding door
guides on the sliding door.
Adjust the sliding door guides in relation to the
sliding door if necessary.
2. Adjust the sliding door guides.
14. Tighten the sliding door guide retaining screws.

15. CAUTION: Protect the C-pillar using a
soft cloth to prevent damage.
NOTE: The striker plate adjustment is carried
out by adjusting the retaining plate position
on the C-pillar.
NOTE: Note the position of the striker plate
on the C-pillar.
Adjust the striker plate in relation to the C-pillar
if necessary.
2. Using a suitable soft faced hammer, adjust
the striker plate inwards if necessary.
3. Using a suitable lever, adjust the striker
plate outwards if necessary.
16. Tighten the striker plate retaining screws.
17. Close the sliding door.

Check that the alignment of the sliding door is
flush to between +0.00 mm and -1.5 mm in
relation to the front door and the vehicle body
panel.

Interior Trim and Ornamentation -
Specifications
Print

Safety belt upper anchor retaining bolt 40 30 -
Safety belt lower anchor retaining bolt 35 26 -

Interior Trim and Ornamentation - A-Pillar
Trim Panel
Print
Removal
1.
1. If equipped.
Installation

Interior Trim and Ornamentation - B-Pillar
Trim Panel—Van
Print
(s).

1 - Front door scuff plate trim panel
2 - Front door scuff plate trim panel retaining clips
3 - Front door opening weatherstrip
See Removal Detail
4 - B-pillar trim panel
5 - B-pillar trim panel retaining clips
Removal Details
Item 3 : Front door opening weatherstrip
1. Detach the front door weatherstrip.
Item 5 : B-pillar trim panel retaining clips
1. Install the B-pillar trim panel retaining clips to

the B-pillar trim panel.
Item 2 : Front door scuff plate trim panel retaining clips
1. Install the front door scuff plate trim panel

retaining clips to the front door scuff plate trim
panel.

Trim Panel—Short Wheelbase Kombi
Print
Removal
1.
1. Torque: 40 Nm
2. Torque: 35 Nm
2.
3.
4.

Installation

Trim Panel—Long Wheelbase Kombi
Print
Removal
1.
1. Torque: 40 Nm
2. Torque: 35 Nm
2.
3.
4.

Installation

Interior Trim and Ornamentation - C-Pillar
Trim Panel—Kombi
Print
Removal
1. Refer to: D-Pillar Trim Panel - Kombi (501-05

Interior Trim and Ornamentation, Removal and
Installation).
2.
3.
Installation

Interior Trim and Ornamentation - D-
Pillar Trim Panel—Kombi
Print
Removal
1.
2.
Installation

Interior Trim and Ornamentation - Front
Door Trim Panel—Vehicles With: Power Transit/Tourneo Connect 2002.5 (06/2002-)
Windows
Print

(s).

1 - Front door latch remote control handle bezel retaining screw
2 - Front door latch remote control handle bezel
3 - Door pull handle cover
4 - Door pull handle retaining screws
5 - Door pull handle
6 - Power window switch
See Removal Detail
-

-
7 Exterior mirror control switch
See Removal Detail
8 - Door trim panel retaining screws
9 - Door trim panel
See Removal Detail
Removal Details
Item 6 : Power window switch
1. Detach the power window switch electrical

connector.
Item 7 : Exterior mirror control switch
1. Detach the extirior mirror control switch

Item 9 : Door trim panel
1. To remove the door trim panel:

1. Pull the lower section of the door trim
panel away from the door.
2. Lift the door trim panel upwards and
detach from the door glass interior
weather seal.

Door Trim Panel—Vehicles With: Manual Transit/Tourneo Connect 2002.5 (06/2002-)
Windows
Print
(s).

1 - Front door latch remote control handle bezel retaining screw
2 - Front door latch remote control handle bezel
3 - Door pull handle cover
4 - Door pull handle retaining screws
5 - Door pull handle
6 - Window regulator handle retaining clip
See Removal Detail
7 - Window regulator handle
8 - Window regulator handle spacer
9 - Exterior mirror control gaiter
10 - Exterior mirror control retaining ring
-

-
11 Door trim panel retaining screws
12 - Door trim panel
See Removal Detail
Removal Details
Item 6 : Window regulator handle retaining clip
1. Fabricate a hook using a suitable piece of wire.

1. Remove window regulator handle retaining
clip.
2. Remove window regulator handle.
Item 12 : Door trim panel
1. To remove the door trim panel:

1. Pull the lower section of the door trim
panel away from the door.
2. Lift the door trim panel upwards and
detach from the door glass interior
weather seal.

Interior Trim and Ornamentation -
Headliner—Van
Print

2. Remove the A-pillar trim panels.
For additional information, refer to A pillar trim
panel in this section.
(s).

1 - Interior/map reading lamp
See Removal Detail
2 - Left-hand sun visor retaining screws
3 - Left-hand sun visor
4 - Left-hand sun visor retaining clip screw
5 - Left-hand sun visor retaining clip
-

-
6 Right-hand sun visor retaining screws
7 - Right-hand sun visor
8 - Right-hand sun visor retaining clip screw
9 - Right-hand sun visor retaining clip
10 - Interior/map reading lamp bezel retaining screws
11 - Headliner tray retaining screws
12 - Headliner tray retaining screws
13 - Headliner tray
14 - Headliner retaining clips
15 - Headliner
Removal Details
Item 1 : Interior/map reading lamp
1. Disconnect the interior/map reading lamp


Headliner—Short Wheelbase Kombi
Print
Removal
1.

2.
3.

All vehicles
4. On both sides.
5.
6.

7.
1. On both sides.
Torque: 40 Nm
2. On both sides.
Torque: 35 Nm
8. On both sides.

Installation).
9.

Installation

Headliner—Long Wheelbase Kombi
Print
Removal
1. On both sides.

Installation).
2.
3. On both sides.
4.
5.

6.
1. On both sides.
Torque: 40 Nm
2. On both sides.
Torque: 35 Nm
7.

Installation

Interior Trim and Ornamentation - Rear
Headliner—Short Wheelbase Kombi
Print
Removal
1. On both sides.
Refer to: D-Pillar Trim Panel - Kombi (501-05

Installation).
2. On both sides.
Refer to: C-Pillar Trim Panel - Kombi (501-05

Installation).
3.
1. On both sides.
Torque: 40 Nm
2. On both sides.
Torque: 35 Nm

4. Refer to: Overhead Console (501-12 Instrument
Panel and Console, Removal and Installation).
All vehicles
5.

Installation

Headliner—Long Wheelbase Kombi
Print
Removal
1.
1. On both sides.
Torque: 40 Nm
2. On both sides.
Torque: 35 Nm
2.
Installation

Interior Trim and Ornamentation - Cowl
Side Trim Panel
Print
(s).

1 - Front door scuff plate trim panel
2 - Front door scuff plate trim panel retaining clips
3 - Front door opening weatherstrip
See Removal Detail
4 - Cowl side trim panel
5 - Cowl side trim panel retaining clips
Removal Details
Item 3 : Front door opening weatherstrip
1. Detach the front door opening weatherstrip.
Item 5 : Cowl side trim panel retaining clips
1. Install the cowl side trim panel retaining clips to

the cowl side trim panel.
Item 2 : Front door scuff plate trim panel retaining clips
1. Install the front door scuff plate trim panel

retaining clips to the front door scuff plate trim
panel.

Quarter Trim Panel
Print
(s).

1 - Rear quarter trim panel
See Removal Detail
2 - Rear quarter trim panel speaker
See Removal Detail
3 - Rear safety belt
See Removal Detail
4 - Rear quarter trim panel retaining clips
Removal Details
Item 1 : Rear quarter trim panel

1. Detach the rear quarter trim panel lower clips
and lift upwards to detach the upper clips.
Item 2 : Rear quarter trim panel speaker
1. Disconnect the rear quarter trim panel speaker

Item 3 : Rear safety belt
1. Detach the rear safety belt from the rear quarter

trim panel.
Item 4 : Rear quarter trim panel retaining clips
1. Install the rear quarter trim panel retaining clips

to the rear quarter trim panel.

Quarter Trim Panel—Short Wheelbase Transit/Tourneo Connect 2002.5 (06/2002-)
Kombi
Print
Removal
1. If equipped.
2. Refer to: D-Pillar Trim Panel - Kombi (501-05

Installation).
3.
4.
Installation
1. To install, reverse removal procedure.

Quarter Trim Panel—Long Wheelbase Transit/Tourneo Connect 2002.5 (06/2002-)
Kombi
Print
Removal
1.
2.
3.
Installation

Quarter Trim Panel—Bus
Print
Removal
1.
2.
Installation

Rear View Mirrors - Rear View Mirrors Transit/Tourneo Connect 2002.5 (06/2002-)
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information.
Fuse(s)
Relay
Damaged mirror(s) Damaged wiring harness
Damaged switch Loose or corroded connectors
Mirror motor
Switch
Chart.
Symptom Chart
Symptom Chart

The mirrors are * Exterior mirror * CARRY OUT the Exterior Mirror Control
inoperative control switch. Switch Component Test. REFER to the Wiring
Diagrams.
A single mirror is * Exterior mirror * CARRY OUT the Exterior Mirror Control
inoperative control switch. Switch Component Test. REFER to the Wiring
Diagrams.
* Circuit(s). * GO to Pinpoint Test B.
* Exterior mirror
motor(s).
A single mirror does not * Exterior mirror * CARRY OUT the Exterior Mirror Control
function with switch logic control switch. Switch Component Test. REFER to the Wiring
Diagrams.
* Exterior mirror
motor(s).
The heated exterior * Heated rear * CARRY OUT the Heated Rear Window Control
mirror does not defrost window control Switch Component Test. REFER to the Wiring
switch. Diagrams.
* Relay. * GO to Pinpoint Test D.
* Circuit(s).
* Heated mirror
element(s).
Pinpoint Tests

PINPOINT TEST A : THE MIRRORS ARE INOPERATIVE
A1: CHECK THE INTERIOR LIGHT DELAY FUNCTION.
1 CHECK the interior light delay function.
Does the interior light delay function operate correctly?
Yes
GO to A2.
No
CHECK the Generic Electronic Module (GEM)
operation. REFER to Section 419-10 Multifunction
Electronic Modules.
A2: CHECK THE VOLTAGE TO THE EXTERIOR MIRROR CONTROL SWITCH CIRCUIT
NOTE: The circuit numbers and wiring colors change at C51
1 Disconnect Exterior Mirror Control Switch C741.
3 Measure the voltage between the exterior mirror
control switch C741 pin 6, circuit 29-AD12 (OG/YE),

Yes
GO to A3.
No
REPAIR circuit 29-AD12 (OG/YE). TEST the system
A3: CHECK THE EXTERIOR MIRROR CONTROL SWITCH GROUND CIRCUIT FOR
CONTINUITY
NOTE: The circuit number changes at soldered joint S197
2 Measure the resistance between the exterior mirror
control switch C741 pin 4, circuit 31-AD12 (BK),

Yes
GO to A4.
No
REPAIR circuit 31-AD12 (BK). TEST the system for
normal operation.
A4: CHECK CIRCUIT 32-AD1 (WH/RD) FOR CONTINUITY
NOTE: The circuit number and wiring colors change at splice S200
1 Disconnect Driver Exterior Mirror C807.
control switch C741 pin 3, circuit 32-AD1 (WH/RD),

harness side and the driver exterior mirror C807 pin
1, circuit 32-AD6 (WH), harness side.

Yes
No
REPAIR circuit 32-AD1 (WH/RD). TEST the system
PINPOINT TEST B : A SINGLE MIRROR IS INOPERATIVE

B1: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH
AND THE INOPERATIVE EXTERIOR MIRROR
NOTE: The circuit numbers and wiring colors change at splice S200.
1 Disconnect Inoperative Exterior Mirror C807 or
C808.
harness side and the inoperative exterior mirror:
Driver exterior mirror C807 pin 1, circuit 32-AD6

(WH), harness side.
Passenger exterior mirror C808 pin 1, circuit 32-

AD9 (WH/GN), harness side.

Yes
INSTALL a new exterior mirror. TEST the system for
normal operation.
No
REPAIR circuit 32-AD6 (WH) or circuit 32-AD9
(WH/GN). TEST the system for normal operation.
PINPOINT TEST C : A SINGLE MIRROR DOES NOT FUNCTION WITH

SWITCH LOGIC
C1: CHECK THE EXTERIOR MIRROR FUNCTIONS WITH SWITCH LOGIC
2 OPERATE the exterior mirror control switch.
Does the exterior mirror function with switch logic?
Yes
No
Driver exterior mirror UP/DOWN inoperative GO to
C2. . Driver exterior mirror LEFT/RIGHT inoperative
GO to C5. . Passenger exterior mirror UP/DOWN
inoperative GO to C8. . Passenger exterior mirror
LEFT/RIGHT inoperative GO to C11. .

C2: CHECK THE DRIVER EXTERIOR MIRROR UP/DOWN CIRCUIT
3 OPERATE the exterior mirror control switch to
select the driver exterior mirror.
4 Measure the voltage between the driver exterior
mirror C807 pin 2, circuit 34-AD7 (BU/RD), harness
side and pin 1, circuit 32-AD6 (WH), harness side.
OPERATE the exterior mirror control switch UP

and DOWN.
Is the voltage greater than 10 volts when the exterior

mirror control switch is moved to the UP position and is
the polarity reversed when moved to the DOWN
position?
Yes
normal operation.
No
GO to C3.
C3: CHECK CIRCUIT 34-AD7 (BU/RD) FOR CONTINUITY
control switch C741 pin 1, circuit 34-AD7 (BU/RD),
harness side and the exterior mirror C807 pin 2,
circuit 34-AD7 (BU/RD), harness side.

Yes
GO to C4.
No
REPAIR circuit 34-AD7 (BU/RD). TEST the system
C4: CHECK CIRCUIT 32-AD6 (WH) FOR CONTINUITY
circuit 32-AD6 (WH), harness side.

Yes

normal operation.
No
REPAIR circuit 32-AD6 (WH). TEST the system for
normal operation.
C5: CHECK THE DRIVER EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
NOTE: The circuit numbers and wiring colors change at splice S200
3 OPERATE the exterior mirror control switch to
select the driver exterior mirror.
C807 pin 3, circuit 33-AD8 (YE/BU), harness side
and C807 pin 1, circuit 32-AD6 (WH), harness side.
OPERATE the exterior mirror control switch LEFT

and RIGHT.

mirror control switch is moved to the LEFT position and
is the polarity reversed when moved to the RIGHT
position?
Yes
normal operation.
No
GO to C6.
C6: CHECK CIRCUIT 33-AD8 (YE/BU) FOR CONTINUITY
control switch C741 pin 7, circuit 33-AD8 (YE/BU),
circuit 33-AD8 (YE/BU), harness side.

Yes
GO to C7.
No
REPAIR circuit 33-AD8 (YE/BU). TEST the system
C7: CHECK CIRCUIT 32-AD6 (WH) FOR CONTINUITY
harness side and the mirror C807 pin 1, circuit 32-
AD6 (WH), harness side.

Yes
normal operation.
No
REPAIR circuit 32-AD6 (WH). TEST the system for
normal operation.
C8: CHECK THE PASSENGER MIRROR UP/DOWN CIRCUIT
1 Disconnect Passenger Exterior Mirror C808.
C808 pin 2, circuit 34-AD10 (BU/YE), harness side
and C808 pin 1, circuit 32-AD9 (WH/GN), harness
side.
OPERATE the exterior mirror control switch UP

and DOWN.

mirror control switch is moved to the UP position and is
the polarity reversed when moved to the DOWN
position?
Yes
normal operation.
No
GO to C9.
C9: CHECK CIRCUIT 34-AD10 (BU/YE) FOR CONTINUITY
control switch C741 pin 2, circuit 34-AD10 (BU/YE),
harness side and exterior mirror C808 pin 2, circuit
34-AD10 (BU/YE), harness side.

Yes
GO to C10.
No

REPAIR circuit 34-AD10 (BU/YE). TEST the system
C10: CHECK CIRCUIT 32-AD9 (WH/GN) FOR CONTINUITY
circuit 32-AD9 (WH/GN), harness side.

Yes
INSTALL a new mirror. TEST the system for normal
operation.
No
REPAIR circuit 32-AD9 (WH/GN). TEST the system
C11: CHECK THE PASSENGER EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
NOTE: The circuit numbers and wiring colors change at splice S200
1 Disconnect Passenger Mirror C808.
C808 pin 3, circuit 33-AD11 (YE/VT), harness side
and C808 pin 1, circuit 32-AD9 (WH/GN), harness
side.
OPERATE the exterior mirror control switch LEFT

and RIGHT.

mirror control switch is moved to the LEFT position and
is the polarity reversed when moved to the RIGHT
position.
Yes
normal operation.
No
GO to C12.
C12: CHECK CIRCUIT 33-AD11 (YE/VT) FOR CONTINUITY
control switch C741 pin 5, circuit 33-AD11 (YE/VT),
circuit 33-AD11 (YE/VT), harness side.

Yes
GO to C13.
No
REPAIR circuit 33-AD11 (YE/VT). TEST the system
C13: CHECK CIRCUIT 32-AD9 (WH/GN) FOR CONTINUITY
circuit 32-AD9 (WH/GN), harness side.

Yes
normal operation.
No
REPAIR circuit 32-AD9 (WH/RD). TEST the system
PINPOINT TEST D : THE HEATED EXTERIOR MIRROR DOES NOT DEFROST

D1: CHECK THE OPERATION OF THE HEATED REAR WINDOW
1 Ignition ON.
2 OPERATE the heated rear window control switch.
Does the heated rear window function correctly?
Yes
GO to D2.
No
REPAIR the heated rear window. REFER to Section
501-11 Glass, Frames and Mechanisms.
D2: CHECK THE VOLTAGE TO THE INOPERATIVE EXTERIOR MIRROR
2 Disconnect Inoperative Exterior Mirror C807 or
C808.
4 OPERATIVE the heated rear window control switch.
5 Measure the voltage between the:
Driver exterior mirror C807 pin 4, circuit 15S-

HB35 (GN/BK), harness side and ground.
Passenger exterior mirror C808 pin 4, circuit 15S-
HB36 (GN/OG), harness side and ground.

Yes
GO to D3.
No
REPAIR circuit 15S-HB35 (GN/BK) or circuit 15S-
HB36 (GN/OG). TEST the system for normal

operation.
D3: CHECK THE INOPERATIVE EXTERIOR MIRROR GROUND CIRCUIT FOR
CONTINUITY
Driver exterior mirror C807 pin 5, circuit 31-HB35


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