Transit 1995 (08.1994-07.2000) Workshop Manual Manual Pages - Full Index

Transit 1995 (08.1994-07.2000) Workshop Manual

• Mechanical Repairs
  • 1 General Information
    • 100 About this Manual
      • 100-04 Feedback Forms
        • Description and Operation
          • What to Do if You Discover an Error
      • 100-03 How to Use this Manual
        • Description and Operation
          • Introduction
      • 100-02 Important Safety Instructions
        • Description and Operation
          • Introduction
      • 100-01 Introduction
        • Description and Operation
          • 100-01 Introduction|General
    • 101 General Service Information
      • 101-01 Health and Safety Precautions
        • Description and Operation
          • Introduction
      • 101-02 Vehicle Identification
        • Description and Operation
          • Vehicle Identification Number (VIN) Plate Location
      • 101-06 Road or Roller Testing
        • Description and Operation
          • Road or Roller Testing
      • 101-03 Standard Workshop Practices
        • Description and Operation
          • Vehicle in Workshop
      • 101-05 Solvents, Sealers and Adhesives
        • Description and Operation
          • Introduction
          • SpecificationsGeneral Specification
      • 101-04 Application and Use of Specifications
        • Description and Operation
          • Bolt Head Identification Marks ‐ Standard Hardware
  • 2 Chassis
    • 211 Wheels, Tyres
      • 211-01 Wheels, Tyres
        • SpecificationsGeneral Specifications
    • 212 Braking System
      • 212-01 Standard Braking System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 212-01 Standard Braking System|Description and Operation
          • Removal and Installation
            • Load Apportioning Valve – Adjust (12 136 0)
            • Brake Disc – Check Runout (12 221 0)
            • Brake System Hydraulic Fluid – Replace (12 154 4)
            • Pistons – Front Caliper – Remove and Install (12 247 4)
            • Disc Pads – Front – Replace (12 233 0)
            • Caliper Assembly – Front – Remove and Install (12 243 0)
            • Disc – Front Brake – Remove and Install (12 223 0)
            • Shoes – Rear Brake – Remove and Install (12 285 0)
            • Cylinder – Rear Wheel – Overhaul (Cylinder removed) (12 305 8)
            • Cylinder – Rear Wheel – Remove and Install (12 305 0)
            • Vacuum Pump – Remove and Install (12 414 0)
            • Master Cylinder – Overhaul (Cylinder removed) (12 343 8)
            • Plate – Rear Brake Carrier – Remove and install (12 313 0)
            • Brake Pedal – Remove and Install (12 333 0)
            • Master Cylinder – Remove and Install (12 343 0)
            • Lever Assembly – Handbrake – Remove and Install (12 664 0)
            • Servo – Remove and Install (12 451 0)
            • Load Apportioning Valve – Remove and Install (12 752 0)
            • Handbrake – Adjust (12 662 0)
            • Primary Cable – Handbrake – Remove and Install (12 673 0)
            • Rear Cable – Handbrake – Replace (12 675 0)
            • Vacuum Hose – Servo – Replace (12 481 0)
            • Bracket and Bush Assembly – L.A.V. – Remove and Install (12 753 0)
      • 212-02 Anti‐Lock Braking System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 212-02 Anti‐Lock Braking System|Description and Operation
          • Removal and Installation
            • Master Cylinder (97¾ MY onwards) - Remove And Install (12 343 0)
            • Brake Fluid Reservoir (Up to 97¾ MY) - Remove And Install (12 341 0)
            • Brake Fluid Reservoir (97¾ MY onwards) - Remove And Install (12 341 0)
            • Brake System - Bleed (12 141 0)
            • Master Cylinder (Up to 97 MY) - Remove And Install (12 343 0)
            • Hydraulic Unit (Up to 97¾ MY) - Remove And Install (12 580 0)
            • Module - Anti‐Lock Braking System - Remove And Install (12 780 0)
            • Wheel Sensor - Front (Up to 97¾ MY) - Remove And Install (12 784 0)
            • Hydraulic Unit (97¾ MY onwards and 98¼ MY onwards fitted wit BTCS) - Remove And Install (12 580 0)
            • Wheel Sensor - Front (97¾ MY onwards) - Remove And Install (12 784 0)
            • Wheel Sensor - Rear (97¾ MY onwards) - Remove And Install (12 785 0)
            • Wheel Sensor - Rear (Up To 97¾ MY) - Remove And Install (12 785 0)
            • Sensor - Brake Pedal Travel - Remove And Install (12 790 0)
    • 213 Steering
      • 213-01 Manual Steering
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 213-01 Manual Steering|Description and Operation
          • Removal and Installation
            • Steering Wheel – Centralise (13 523 3)
            • Steering Wheel – Remove and Install (13 524 0)
            • Steering Gear assembly – Remove and Install (13 116 0)
            • Steering Column Assembly – Remove and Install (13 542 0)
            • Bellows – Steering Rack – Replace (13 134 0)
            • Flexible Coupling – Steering Column – Remove and Install (13 566 0)
      • 213-02 Power Assisted Steering
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 213-02 Power Assisted Steering|Description and Operation
          • Removal and Installation
            • Steering Gear Assembly – Remove and install (13 116 0)
            • Power Steering System – Bleed (13 416 1)
            • Pump Assembly – Power steering – Remove and Install (Petrol) (13 434 0)
            • Pump Assembly – Power steering – Remove and Install (Diesel with PTC or Air Con) (13 434 0)
            • Fluid Hoses – Power Steering – Replace (13 442 0)
            • Pump Assembly – Power steering – Remove and Install (Diesel) (13 434 0)
    • 214 Front Axle and suspension
      • 214-01 Front Suspension
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 214-01 Front Suspension|Description and Operation
          • Removal and Installation
            • Toe‐In – Adjust (14 111 3)
            • Front Crossmember – Remove and Install (14 234 0)
            • Front Wheel Alignment – Check (14 111 0)
            • Front Crossmember – Remove and Install (Front axle assembly removed) (14 234 4)
            • Stub Axle – Remove and Install (14 363 0)
            • Hub Assembly - Front - Renew (Hub Assembly Removed) (14 371 6)
            • Wheel Bearings – Adjust (14 403 0)
            • Hub Assembly – Front – Remove and Install (14 371 0)
            • Bump Stop – Remove and Install (Front spring removed) (14 682 4)
            • Wheel Bearing - Front Inner And Outer (Hub Assembly Removed) - Renew (14 411 4)
            • Arm Assembly – Lower – Remove and Install (14 707 0)
            • Front Spring – Remove and Install (14 621 0)
            • Bush - Lower Arm - Renew (Lower Arm Removed) (14 723 5)
            • Stud - Front Wheel - Renew (14 443 0)
            • Connecting Link – Stabiliser Bar – Remove and Install (Stabiliser bar removed) (14 757 4)
            • Stabiliser Bar – Remove and Install (14 752 0)
            • Shock Absorber – Remove and Install (14 791 0)
            • Bush - Front Shock Absorber - Renew (Shock Absorber Removed) (14 796 4)
            • Bush - Stabiliser Bar To Lower Arm - Renew (Stabiliser Bar Removed) (14 759 4)
            • Bush - Front Suspension Bracket (One Side) - Renew (14 726 0)
            • Ball Joint - Lower Arm - Renew (14 735 0)
    • 215 Rear Axle
      • 215-01 Rear Axle, Type 34
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 215-01 Rear Axle, Type 34|Description and Operation
          • Removal and Installation
            • Rear Axle and Suspension Assembly - Remove and Install (15 212 0)
            • Differential Assembly - Remove and Install (15 254 0)
            • Rear Axle Assembly - Remove and Install (15 214 0)
            • Bearing - Rear Wheel - Centre - Renew (hub assembly removed) (15 418 5)
            • Seal - Drive Pinion - Renew (15 302 0)
            • Differential Assembly - Dismantle and Assemble (carrier with differential removed) (15 254 8)
            • Centre Bearing - Driveshaft - Renew (one) (driveshaft removed) (15 564 4)
            • Rear Spring Assembly - Remove and Install (one side) (15 621 0)
            • Driveshaft Assembly - Remove and Install (15 514 0)
      • 215-02 Rear Axle, Type 51 A
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Rear Axle Assembly ‐ Remove and Install (15 214 0)
          • Rear Axle ‐ Dismantle and Assemble (Rear Axle Installed) (Type 51A and 53) (15 215 0)
          • Seal ‐ Drive Pinion ‐ Renew (15 302 0)
          • Bearing ‐ Rear Wheel ‐ Centre ‐ Renew (Hub Assembly Removed) (15 418 5)
      • 215-03 Rear Axle, Type 53
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Rear Axle Assembly ‐ Remove and Install (15 214 0)
          • Bearings ‐ Rear Wheel ‐ Inner and Outer ‐ Renew (Hub Assembly Removed) (15 413 4)
          • Seal ‐ Drive Pinion ‐ Renew (15 302 0)
  • 3 Powertrain
    • 316 Manual Transmission and Clutch
      • 316-01 Section Title
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Remove and install transmission (16 114 0)
          • Transmission Assembly ‐ Dismantle and Reassemble (Transmission Removed) (16 118 8)
      • 316-02 Automatic Clutch
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 316-02 Automatic Clutch|Description and Operation
          • Removal and Installation
            • Gear Lever ‐ Manual Transmission ‐ Remove and Install (16 524 0)
            • Module ‐ Automatic Clutch ‐ Remove and Install (33 685 0)
            • Slave Cylinder ‐ Clutch ‐ Remove and Install (16 862 0)
            • Hydraulic Unit ‐ Automatic Clutch ‐ Remove and Install (16 841 0)
    • 317 Automatic Transmission
      • 317-01 A4LD Automatic Transmission Assembly
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Brake Bands - Adjust (17 132 0)
          • Automatic Transmission - Remove and Install (17 214 0)
          • Automatic Transmission - Dismantle and Assemble (transmission removed) (17 214 8)
          • Solenoid - Downshift - Remove and Install (17 687 0)
          • Cable - Downshift - Adjust (17 682 0)
          • Start Inhibitor Switch - Remove and Install (17 694 0)
          • Speedometer Drive Gear - Remove and Install (17 382 0)
          • Cable - Selector - Adjust (17 666 0)
          • Gear Selector Mechanism - Remove and Install (17 634 0)
          • Cable - Selector - Remove and Install (17 667 0)
          • Pipes - Automatic Transmission Fluid Cooler (both) - Remove and Install (17 857 0)
          • Throttle Pressure Valve - Remove and Install (17 710 0)
    • 321 Basic Engine
      • 321-01 2,0 DOHC 8V Engine
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-01 2,0 DOHC 8V Engine|Description and Operation
          • Removal and Installation
            • Compression ‐ Engine Hot ‐ Check (21 111 0)
            • Engine-Transmission Assembly ‐ Remove and Install (21 132 0)
            • Engine and Transmission Assembly (Vehicles with air conditioning)Remove and Install (21 132 0)
            • Oil Pressure ‐ Check ‐ Engine Hot (21 113 0)
            • Engine ‐ Remove and Install (21 134 0)
            • Engine ‐ Remove and Install (Vehicles with air conditioning) (21 134 0)
            • Cylinder Head ‐ Remove and Install (21 163 0)
            • Engine ‐ Dismantle and Assemble (engine removed) (21 134 8)
            • Camshafts ‐ Remove and Install (21 284 0)
            • Valve Seat ‐ Cut (valve removed) (21 231 9)
            • Valve Stem Oil Seals ‐ Renew (21 238 0)
            • Valves ‐ Remove and Install (all) (cylinder head removed) (21 217 4)
            • Timing Chain ‐ Renew (21 314 0)
            • Oil Seal ‐ Crankshaft Rear ‐ Renew (engine or transmission removed) (21 468 4)
            • Oil Seal ‐ Crankshaft Front ‐ Renew (21 467 0)
      • 321-02 2.5 Diesel Engine (70 PS)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-02 2.5 Diesel Engine (70 PS)|Description and Operation
          • Removal and Installation
            • Oil Pressure ‐ Engine Hot ‐ Check (21 113 0)
            • Compression Pressure ‐ Check ‐ Engine Hot (21 111 0)
            • Seals ‐ Valve Stem ‐ Renew (21 238 0)
            • Oil Pump ‐ Disassemble and Assemble (oil pump removed) (21 714 8)
            • Cylinder Head ‐ Remove and Install (21 163 0)
            • Crankshaft Rear Oil Seal ‐ Renew (engine or transmission removed) (21 468 4)
      • 321-03 2.5 Diesel Engine (76 PS)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-03 2.5 Diesel Engine (76 PS)|Description and Operation
          • Removal and Installation
            • Oil Pressure ‐ Engine Hot ‐ Check (21 113 0)
            • Compression Pressure ‐ Engine Hot ‐ Check (21 111 0)
            • Engine-Transmission Assembly ‐ Remove and Install (21 132 0)
            • Engine ‐ Remove and Install (21 134 0)
            • Engine ‐ Dismantle and Reassemble (engine removed) (21 134 8)
            • Cylinder Head ‐ Remove and Install (21 163 0)
            • Seals ‐ Valve Stem ‐ Renew (21 238 0)
            • Camshaft Oil Seal ‐ Renew (21 288 0)
            • Seal ‐ Crankshaft Rear ‐ Renew (Engine or Transmission Removed) (21 468 4)
            • Oil Pump ‐ Dismantle and Assemble (Oil Pump Removed) (21 714 8)
            • Seal ‐ Crankshaft Front ‐ Renew (21 467 0)
            • Timing Belt ‐ Remove and Install (21 304 0)
      • 321-04 2,5 Turbocharged-TCI Diesel Engine (85 PS)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-04 2,5 Turbocharged-TCI Diesel Engine (85 PS)|Description and Operation
          • Removal and Installation
            • Oil Pressure ‐ Engine Hot ‐ Check (21 113 0)
            • Compression ‐ Engine Hot ‐ Check (21 111 0)
            • Engine and Transmission Assembly ‐ Remove and Install (21 132 0)
            • Engine Assembly ‐ Remove and Install (21 134 0)
            • Cylinder Head ‐ Renew (Cylinder Head Removed) (21 165 6)
            • Cylinder Head ‐ Remove and Install (21 163 0)
            • Seal ‐ Crankshaft Rear ‐ Renew (Engine or Transmission Removed) (21 468 4)
            • Oil Pump ‐ Disassemble and Assemble (Pump Assembly Removed) (21 714 8)
      • 321-05 2.5 Turbocharged Diesel Engine (100 PS)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-05 2.5 Turbocharged Diesel Engine (100 PS)|Description and Operation
          • Removal and Installation
            • Oil Pressure ‐ Engine Hot ‐ Check (21 113 0)
            • Compression ‐ Engine Hot ‐ Check (21 111 0)
            • Engine Assembly ‐ Remove and Install (21 134 0)
            • Engine and Transmission Assembly ‐ Remove and Install (21 132 0)
            • Sump ‐ Remove and Install (21 154 0)
            • Cylinder Head ‐ Remove and Install (21 163 0)
            • Seal ‐ Crankshaft Rear ‐ Renew (Engine or Transmission Removed) (21 468 4)
            • Seals ‐ Valve Stem ‐ Renew (All) (21 238 0)
            • Oil Pump ‐ Dismantle and Assemble (Pump Assembly Removed) (21 714 8)
      • 321-06 2.5 TCI Diesel Engine (115 PS)
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 321-06 2.5 TCI Diesel Engine (115 PS)|Description and Operation
          • Removal and Installation
            • Oil Pressure ‐ Engine Hot ‐ Check (21 113 0)
            • Compression Pressure ‐ Engine Hot ‐ Check (21 111 0)
            • Engine and Transmission Assembly ‐ Remove and Install (21 132 0)
            • Engine Assembly ‐ Remove and Install (21 134 0)
            • Seal ‐ Crankshaft Rear ‐ Renew (Engine or Transmission Removed) (21 468 4)
            • Cylinder Head ‐ Renew (Cylinder Head Removed) (21 165 6)
            • Cylinder Head ‐ Remove and Install (21 163 0)
    • 323 Fuel System
      • 323-01 General Fuel System
        • Description and Operation
          • 323-01 General Fuel System|Description and Operation
          • Removal and Installation
            • Air Cleaner Assembly (Diesel Variants) - Remove and Install (23 174 0)
            • Element - Air Cleaner (Petrol Variants) - Remove And Install (23 184 0)
            • Air Cleaner Assembly (Petrol Variants) - Remove And Install (23 174 0)
            • Cable - Accelerator (Petrol Variants) - Adjust (23 811 0)
            • Fuel Tank - Remove And Install (23 554 0)
            • Fuel Filter (Diesel Variants) - Renew (23 545 0)
            • Fuel Pump (Petrol Variants) - Renew (23 534 0)
            • Element - Air Cleaner (Diesel Variants) - Remove And Install (23 184 0)
            • Fuel Filter (Petrol Variants) - Renew (23 545 0)
            • Element - Fuel Filter (Diesel Variants) - Renew (23 546 0)
            • Fuel Pump (Diesel Variants) - Renew (23 534 0)
            • Switch - Fuel Shut-off - Renew (33 577 0)
            • Cable - Accelerator (Petrol Variants) - Remove And Install (23 826 0)
      • 323-03 Diesel Injection Equipment
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 323-03 Diesel Injection Equipment|Description and Operation
          • Removal and Installation
            • Fuel Injection Pump - Remove And Install (23 414 0)
            • Fuel Injector - Renew (23 455 0)
            • Turbocharger - Remove And Install (23 612 0)
      • 323-02 Petrol Injection Equipment
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 323-02 Petrol Injection Equipment|Description and Operation
          • Removal and Installation
            • Fuel Pressure Regulator - Remove And Install (23 266 0)
            • Fuel Injector - Renew (23 455 0)
      • 323-04 Liquefied Petroleum Gas (LPG) System
        • Description and Operation
          • 323-04 Liquefied Petroleum Gas (LPG) System|Description and Operation
          • Removal and Installation
            • Fuel Line Venting
            • Fuel Filter Venting
            • LPG Leak Test
            • Fuel Tank Mounting Frame
            • Fuel Tank Filler Valve
            • Fuel Filter Element
            • Flexible Hoses
            • Fuel Filter
            • Fuel Lines
            • Fuel Injection Supply Manifold
            • Fuel Injectors
        • SpecificationsGeneral Specification
      • 323-05 Compressed Natural Gas (CNG) System
        • Description and Operation
          • 323-05 Compressed Natural Gas (CNG) System|Description and Operation
          • Removal and Installation
            • Low‐Pressure Leak Test
            • Fuel System Pressure Release
            • High‐Pressure Leak Testing
            • Fuel Tank Evacuation
            • Low‐Pressure Fuel Lines
            • High‐Pressure Fuel Lines
            • Fuel Pressure Regulator
            • Fuel Injection Supply Manifold
            • Fuel Tank Mounting Frame
            • Fuel Tank Filler Valve
            • Fuel Pressure Regulator Filter Element
            • Fuel Tank
            • Fuel Tank Pressure Sensor
            • Fuel Injectors
            • Fuel Tank Filler Pipe One‐Way Valve
        • SpecificationsGeneral Specification
    • 324 Cooling System
      • 324-01 Petrol Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 324-01 Petrol Engines|Description and Operation
          • Removal and Installation
            • Cooling System - Pressure Test (24 111 0)
            • Cooling System - Drain And Refill (24 122 0)
            • Radiator - Remove And Install (24 254 0)
            • Drain Plug - Radiator - Renew (24 256 0)
            • Water Pump Assembly - Remove And Install (24 404 0)
            • Expansion Tank - Remove And Install (24 284 0)
            • Thermostat - Remove And Install (24 454 0)
      • 324-02 Diesel Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 324-02 Diesel Engines|Description and Operation
          • Removal and Installation
            • Cooling System - Pressure Test (24 111 0)
            • Cooling System - Drain And Refill (24 122 0)
            • Clutch - Viscous Fan - Remove And Install (24 215 0)
            • Drain Plug - Radiator - Renew (24 256 0)
            • Water Pump Assembly - Remove And Install (24 404 0)
            • Expansion Tank - Remove And Install (24 284 0)
            • Thermostat - Remove And Install (24 454 0)
            • Radiator - Remove And Install (24 254 0)
            • Shut-off Valve - Heater - Remove And Install (34 329 0)
    • 325 Exhaust System
      • 325-01 Exhaust System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 325-01 Exhaust System|Description and Operation
          • Removal and Installation
            • Muffler - Front (Petrol) - Remove And Install (25 223 0)
            • Muffler - Rear (Petrol) - Remove And Install (25 243 0)
            • Muffler - Front (Diesel) - Remove And Install (25 223 0)
            • Catalytic Converter (Diesel) - Remove And Install (25 250 0)
            • Exhaust System (Petrol and Diesel) - Remove And Install (25 204 0)
            • Muffler - Rear (Diesel) - Remove And Install (25 243 0)
            • Exhaust Pipe - Front (Diesel with Downpipe-Catalytic Converter Assembly) - Remove And Install (25 260 0)
            • Exhaust Pipe - Front (Diesel) - Remove And Install (25 260 0)
            • Catalytic Converter (Petrol) - Remove And Install (25 250 0)
    • 326 Starting System
      • 326-01 Starting System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 326-01 Starting System|Description and Operation
          • Removal and Installation
            • Starter Motor (Petrol) - Remove And Install (26 204 0)
            • Starter Motor (Diesel) - Remove And Install (26 204 0)
    • 329 Engine Management
      • 329-01 Engine Management ‐ DOHC 8V Engines
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 329-01 Engine Management ‐ DOHC 8V Engines|Description and Operation
          • Removal and Installation
            • Sensor - Engine Coolant Temperature - Remove And Install (21 190 0)
            • Pipe - Exhaust Manifold To Exhaust Gas Recirculation Valve (96 EEC Variants) - Remove And Install (23 301 0)
            • Pipe - Exhaust Manifold To Exhaust Gas Recirculation Valve (95 EEC Variants) - Remove And Install (23 301 0)
            • Diverter - Secondary Air Injection (96 EEC Variants) - Remove And Install (23 335 0)
            • Regulator - Exhaust Gas Recirculation Vacuum - Remove And Install (23 313 0)
            • Valve - Idle Air Control - Remove And Install (23 323 0)
            • Pump - Secondary Air Injection (96 EEC Variants) - Remove And Install (23 339 0)
            • Valve-gasket - Exhaust Gas Recirculation - Renew (23 312 0)
            • Valve - Secondary Air Injection Switching (96 EEC Variants) - Remove And Install (23 336 0)
            • Sensor - Throttle Position - Remove And Install (23 325 0)
            • Module - Powertrain Control - Remove And Install (29 200 0)
            • Sensor - Camshaft Position - Remove And Install (29 232 0)
            • Sensor - Crankshaft Position - Remove And Install (29 230 0)
            • Sensor - Heated Oxygen (Pre catalytic converter) - Renew (29 220 0)
            • Sensor - Heated Oxygen (Post catalytic converter) - Renew (29 220 0)
            • Module - Electronic Ignition System - Remove And Install (29 205 0)
            • Sensor - Mass Air Flow - Renew (29 226 0)
            • Valve - Evaporative Emission Canister Purge - Remove And Install (33 772 0)
            • Canister - Evaporative Emission - Remove And Install (29 250 0)
            • Transducer - Exhaust Gas Recirculation System Pressure - Remove And Install (29 242 0)
            • Sensor - Intake Air Temperature - Remove And Install (29 622 0)
      • 329-02 Engine Management – Turbocharged Diesel Engines
        • Description and Operation
          • 329-02 Engine Management – Turbocharged Diesel Engines|Description and Operation
          • Removal and Installation
            • Valve-gasket - Exhaust Gas Recirculation - Renew (23 312 0)
            • Pipe - Exhaust Manifold To Exhaust Gas Recirculation Valve - Remove And Install (23 301 0)
            • Regulator - Exhaust Gas Recirculation Vacuum - Remove And Install (23 313 0)
            • Module - Powertrain Control - Remove And Install (29 200 0)
            • Sensor - Crankshaft Position - Remove And Install (29 230 0)
            • Sensor - Manifold Absolute Pressure - Remove And Install (29 224 0)
            • Sensor - Accelerator Pedal Position - Remove And Install (29 228 0)
            • Sensor - Intake Air Temperature - Remove And Install (29 622 0)
            • Cooler - Exhaust Gas Recirculation Charge - Remove And Install (29 252 0)
      • 329-03 Engine Management - Normally Aspirated Diesel Engines
        • Description and Operation
          • 329-03 Engine Management - Normally Aspirated Diesel Engines|Description and Operation
          • Removal and Installation
            • Pipe - Exhaust Manifold To Exhaust Gas Recirculation Valve (70PS Variants) - Remove And Install (23 301 0)
            • Valve-gasket - Exhaust Gas Recirculation (76PS Variants) - Renew (23 312 0)
            • Pipe - Exhaust Manifold To Exhaust Gas Recirculation Valve (76PS Variants) - Remove And Install (23 301 0)
            • Valve-gasket - Exhaust Gas Recirculation (70PS Variants) - Renew (23 312 0)
  • 4 Electrical
    • 431 Charging System
      • 431-01 Charging System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 431-01 Charging System|Description and Operation
          • Removal and Installation
            • Battery - Remove And Install (31 214 0)
            • Drive Belt - Alternator (Diesel) - Remove And Install (31 413 0)
            • Tensioner - Drive Belt - Alternator - Remove And Install (31 415 0)
            • Drive Belt - Alternator (Petrol) - Remove And Install (31 413 0)
            • Alternator Assembly (Diesel) (97¾ MY onwards) - Remove And Install (31 414 0)
            • Alternator Assembly (Petrol) - Remove And Install (31 414 0)
            • Alternator Assembly (Diesel) (Up to 97½MY) - Remove And Install (31 414 0)
    • 432 Exterior Electrical System
      • 432-01 Exterior Electrical Systems
        • Description and Operation
          • Removal and Installation
            • Headlamps ‐ Align (Both Sides) (32 113 0)
            • Linkage ‐ Windscreen Wiper ‐ Remove and Install (32 554 0)
            • Wiper Pivot Shaft ‐ Front ‐ Remove and Install (32 563 0)
            • Wiper Arm ‐ Adjust (all) (32 591 0)
            • Headlamp ‐ Remove and Install (32 115 0)
            • Motor ‐ Headlamp Levelling ‐ Remove and Install (32 650 0)
            • Motor ‐ Windscreen Wiper ‐ Remove and Install (32 524 0)
    • 433 Interior Electrical Systems
      • 433-01 Basic Interior Electrical System
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 433-01 Basic Interior Electrical System|Description and Operation
          • Removal and Installation
            • Bulb - Stepwell Lamp - Side Load Door - Remove And Install (33 117 0)
            • Lamp - Stepwell - Side Load Door - Remove And Install (33 113 0)
            • Lamp - Interior (Middle) - Remove And Install (33 112 0)
            • Lamp - Interior (Front-Rear) - Remove And Install (33 112 0)
            • Lamp - Interior (Rear Door) - Remove and Install (33 112 0)
            • Printed Circuit - Instrument Cluster (Cluster not fitted with Tachograph) - Remove And Install (Instrument Cluster Removed) (33
            • Bulb - Heater Control Illuminating - Remove And Install (33 128 0)
            • Bulb - Hazard Warning Switch - Remove And Install (33 146 0)
            • Bulb - Quadrant Lamp - Remove And Install (33 134 0)
            • Instrument Cluster Assembly (Cluster not fitted with Tachograph) - Remove And Install (33 214 0)
            • Sender Unit - Fuel Tank (Diesel) - Remove And Install (33 286 0)
            • Tachograph Assembly - Remove And Install (33 274 0)
            • Sender Unit - Fuel Tank (Petrol) - Remove And Install (33 286 0)
            • Cable - Speedometer - Inner And Outer - Remove And Install (33 256 0)
            • Printed Circuit - Instrument Cluster (Cluster fitted with Tachograph) - Remove and Install (Instrument Cluster removed) (33 224
            • Clock - Remove And Install (33 374 0)
            • Switch - Direction Indicator - Remove And Install (33 522 0)
            • Switch - Horn - Renew (33 523 0)
            • Lock Barrel - Ignition Switch - Remove And Install (33 513 0)
            • Cigar Lighter Assembly - Remove And Install (33 384 0)
            • Switch - Door Mirror Control - Remove And Install (33 519 0)
            • Switch - Dipper - Remove And Install (33 516 0)
            • Switch - Headlamp Levelling - Remove And Install (33 515 0)
            • Switch - Courtesy Lamp - Remove And Install (33 524 0)
            • Switch - Light - Remove And Install (33 514 0)
            • Switch - Window Operating - Remove And Install (33 532 0)
            • Switch - Rear Wash-Wipe - Remove And Install (33 547 0)
            • Switch - Oil Pressure Warning Light - Remove And Install (33 554 0)
            • Switch - Rear Fog Lamp - Remove And Install (33 557 0)
            • Switch - Thermal - Radiator Fan - Remove And Install (33 555 0)
            • Switch - Reversing Lamp - Remove And Install (33 528 0)
            • Switch - Windscreen Wash-wipe - Remove And Install (33 544 0)
            • Switch - Headlamp Wash - Remove And Install (33 545 0)
            • Switch - Stop Lamp - Remove And Install (33 548 0)
            • Switch - Windscreen Wiper - Remove And Install (33 542 0)
            • Switch - Auxiliary-Fog Lamp - Remove And Install (33 556 0)
            • Switch - Brake Fluid Warning Light - Remove And Install (33 552 0)
            • Switch - Interior Lamp - Remove And Install (33 526 0)
            • Switch - Heated Rear Window - Remove And Install (33 572 0)
            • Switch - Blower Motor - Heater - Remove and Install (33 574 0)
            • Switch - Heated Front Seat - Remove And Install (33 587 0)
            • Switch - Hazard Flasher - Remove And Install (33 558 0)
            • Control Assembly - Radiator Fan Speed - Remove And Install (33 640 0)
            • Switch - Heated Windscreen - Remove And Install (33 571 0)
            • Switch - Heated Door Mirror - Remove And Install (33 592 0)
            • Relay - Indicator Flasher - Remove And Install (33 722 0)
            • Vehicle Speed Sensor - Remove And Install (33 654 0)
            • Module - Immobiliser - Remove and Install (33 660 0)
            • Transceiver - Immobiliser - Remove And Install (33 662 0)
      • 433-02 Anti‐Theft Alarm and Double Locking Systems
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 433-02 Anti‐Theft Alarm and Double Locking Systems|Description and Operation
          • Removal and Installation
            • Switch - Door Lock (Rear Door) - Key Activated - Alarm System - Remove And Install (33 506 0)
            • Switch - Door Lock (Front Door) - Key Activated - Alarm System - Remove And Install (33 506 0)
            • Switch - Door Ajar (Front Door) - Remove And Install (33 507 0)
            • Contact Plate (Sliding Side Door) - Remove And Install (33 530 0)
            • Switch - Door Ajar (Rear Door) - Remove And Install (33 507 0)
            • Switch - Hood - Remove And Install (33 539 0)
            • Transceiver - Immobiliser (PATS) - Remove And Install (33 662 0)
            • Horn - Alarm System - Remove And Install (33 774 0)
            • Switch - Contact (Sliding Side Door) - Remove And Install (33 541 0)
            • Module - Anti-theft Alarm-Double Locking - Remove And Install (33 644 0)
            • Module - Immobiliser (PATS) - Remove and Install (33 660 0)
    • 434 Heating, Ventilation and Air Condidtioning
      • 434-01 Heating and Ventilation
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-01 Heating and Ventilation|Description and Operation
          • Removal and Installation
            • Heater Assembly ‐ Remove and Install (34 354 0)
            • Heater Controls ‐ Front ‐ Remove and Install (34 311 0)
            • Heater Radiator ‐ Remove and Install (heater removed) (34 364 4)
            • Blower Motor ‐ Remove and Install (34 374 0)
            • Alternator ‐ Electrically Enhanced Heater ‐ Remove and Install (34 392 0)
            • Element ‐ Electrically Enhanced Heater ‐ Remove and Install (34 390 0)
            • Vent ‐ Face Level (Centre) ‐ Remove and Install (34 489 0)
      • 434-02 Air Conditioning
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-02 Air Conditioning|Description and Operation
          • Removal and Installation
            • Control Panel ‐ Refrigeration System ‐ Remove and Install (Transit Refrigerated Van) 34 305 0
            • Blower Motor ‐ Rear ‐ Remove and Install (34 376 0)
            • Refrigerant Lines ‐ Disconnect and Connect (air conditioning drained)
            • Refrigerant ‐ Air Conditioning ‐ Drain and Fill (34 620 0)
            • Evaporator ‐ Air Conditioning ‐ Remove and Install (34 622 0)
            • Compressor ‐ Air Conditioning ‐ Remove and Install (34 626 0)
            • Clutch ‐ Air Conditioning Compressor ‐ Remove and Install (34 628 0)
            • Condenser ‐ Air Conditioning ‐ Remove and Install (34 632 0)
            • Line ‐ Accumulator-Dehydrator to Evaporator ‐ Remove and Install (34 644 0)
            • Line ‐ Accumulator-Dehydrator to Condenser ‐ Remove and Install (34 643 0)
            • Accumulator-Dehydrator ‐ Air Conditioning ‐ Remove and Install (34 630 0)
            • Rear Evaporator ‐ Air Conditioning ‐ Remove and Install (34 700 0)
            • Accumulator-Dehydrator ‐ Refrigeration System ‐ Remove and Install (Transit refrigerated van) 34 810 0
            • Line ‐ Rear Evaporator to Dehydrator ‐ Remove and Install (34 720 0)
            • Rear Expansion Valve ‐ Air Conditioning ‐ Remove and Install (34 702 0)
            • Line ‐ Rear Evaporator to Condenser ‐ Remove and Install (34 721 0)
            • Fan Motor ‐ Air Conditioning ‐ Remove and Install (34 650 0)
            • Line ‐ Evaporator to Condenser ‐ Remove and Install (34 645 0)
            • Evaporator ‐ Refrigeration System ‐ Remove and install (Transit refrigerated van) 34 811 0
            • Flush the refrigeration system (Transit refrigerated van) 34 818 0
            • Fan Motor ‐ Refrigeration System ‐ Remove and Install (Transit refrigerated van) 34 812 0
            • Expansion valve ‐ Refrigeration System ‐ Renew (Transit refrigerated van) (34 813 0)
      • 434-03 Additional Heater
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 434-03 Additional Heater|Description and Operation
          • Removal and Installation
            • Heater Assembly - Rear - Remove and Install (34 358 0)
    • 438 Audio Systems
      • 438-01 In‐Car Entertainment
        • Description and Operation
          • 438-01 In‐Car Entertainment|Description and Operation
          • Removal and Installation
            • Speaker - Front Door - Remove And Install (38 268 0)
            • Power Amplifier - Radio Receiver-Cassette Player - Remove And Install (38 456 0)
            • Compact Disc Player - Remove And Install (38 445 0)
            • Radio Receiver-Cassette Player - Remove And Install (38 222 0)
            • Radio Antenna - Manual - Remove And Install (38 352 0)
            • Radio Loudspeaker - Loadspace Trim Panel - Remove And Install (38 284 0)
  • 5 Body and Paint
    • 540 Seats, Seat Belts, Air Bags
      • 540-01 Seats
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-01 Seats|Description and Operation
          • Removal and Installation
            • Seat Assembly - Rear (Dual 17 Seat Bus) - Remove And Install (40 120 0)
            • Seat Assembly - Rear (Fixed Seat) - Remove And Install (40 120 0)
            • Seat Assembly - Rear (Single 17 Seat Bus) - Remove And Install (40 120 0)
            • Seat Assembly - Front Bench (Fixed Seat) - Remove And Install (40 103 0)
            • Seat Assembly - Front Bench (Tipping Seat) - Remove And Install (40 103 0)
            • Seat Assembly - Rear (Triple 17 Seat Bus) - Remove And Install (40 120 0)
            • Seat Assembly - Rear (Fold Fold Seat) - Remove And Install (40 120 0)
            • Seat Assembly - Front Bucket (Low Series) - Remove And Install (40 100 0)
            • Cover And Pad Assembly - Backrest - Rear Seat (17 Seat Bus) - Remove And Install (40 127 0)
            • Cover And Pad Assembly - Cushion - Rear Seat (17 Seat Bus) - Remove And Install (40 124 0)
            • Adjuster Assembly - Seat Slide (4 and 6 Way Seat) - Remove And Install (Seat Removed) (40 422 4)
            • Catch - Rear (Tipping) Seat Backrest - Remove And Install (40 534 0)
            • Slide - Front Seat - Remove And Install (Seat Removed) (40 420 4)
      • 540-02 Seat Belts
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-02 Seat Belts|Description and Operation
          • Removal and Installation
            • Belt And Stalk - Front Seat (Single Seat) - Remove And Install (40 212 0)
            • Belt And Stalk - Front Seat (Tipping Bench Centre) - Remove And Install (40 212 0)
            • Belt And Stalk - Front Seat (Fixed Bench Outer) - Remove And Install (40 212 0)
            • Belt And Stalk - Front Seat (Fixed Bench Seat) - Remove And Install (40 212 0)
            • Belt and Stalk - Rear Seat (Fold Fold Seat) - Remove and Install (40 240 0)
            • Belt And Stalk - Front Seat (Tipping Bench Outer) - Remove And Install (40 212 0)
            • Belt And Stalk - Rear Seat - Left Or Right (Dual) - Remove And Install (40 240 0)
            • Belt And Stalk - Rear Seat - Left Or Right (Single) - Remove And Install (40 240 0)
            • Stalk - Rear Seat (Centre Three Point) - Remove And Install (40 245 0)
            • Belt And Stalk - Rear Seat - Left Or Right (Triple) - Remove And Install (40 240 0)
            • Belt And Stalk - Rear Seat - Left Or Right (17 Seat Bus) - Remove And Install (40 240 0)
            • Belt - Rear Seat (Centre Three Point) - Remove And Install (40 248 0)
      • 540-03 Air Bags
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 540-03 Air Bags|Description and Operation
          • Removal and Installation
            • Control Module – Air Bag – Remove and Install (33 650 0)
            • Clockspring - Air Bag Control - Remove and Install (33 392 0)
            • Module - Driver Air Bag - Remove And Install (40 700 0)
            • Module ‐ Air Bag(s) ‐ Deploy (Outside the vehicle) (40 702 0)
            • Module - Passenger Air Bag - Remove And Install (40 701 0)
    • 541 Body Closures
      • 541-01 Body Closures
        • SpecificationsGeneral Specifications
        • Description and Operation
          • 541-01 Body Closures|Description and Operation
          • Removal and Installation
            • Door Assembly - Front - Passenger Side - Remove And Install (41 315 0)
            • Hood Assembly - Remove and Install (41 214 0)
            • Door Assembly - Front - Driver Side - Remove And Install (41 316 0)
            • Cable - Hood Release - Remove and Install (41 224 0)
            • Safety Catch - Hood - Remove and Install (41 236 0)
            • Handle - Door Exterior - Remove And Install (41 333 0)
            • Barrel - Door Lock - Remove And Install (41 336 0)
            • Remote Control Assembly - Front Door Lock - Remove And Install (41 353 0)
            • Lock Assembly - Front Door - Remove And Install (41 351 0)
            • Exterior Handle - Rear Door (Loadspace) - Remove And Install (41 622 0)
            • Lock And Rod Assembly - Rear Door (Loadspace) - Remove And Install (41 628 0)
            • Barrel - Rear Door Lock (Loadspace) - Remove And Install (41 625 0)
            • Remote Control Assembly - Rear Door Lock - Remove And Install (41 354 0)
            • Lock Assembly - Rear Door (Loadspace) - Remove And Install (41 629 0)
            • Weatherstrip - Door Aperture - Replace (41 375 0)
            • Rear Door (Loadspace) - Remove And Install (41 615 0)
            • Latch Assembly - Rear Door (Loadspace) - Remove And Install (41 627 0)
            • Tailgate Assembly - Remove and Install (41 654 0)
            • Lock Assembly - Rear Door (Right‐Hand) (Loadspace) (High Roof) - Remove And Install (41 629 0)
            • Handle - Tailgate Exterior - Remove And Install (41 662 0)
            • Lock Assembly - Rear Door (Left‐Hand) (Loadspace) (High Roof) - Remove And Install (41 629 0)
            • Barrel - Tailgate Lock - Remove and Install (41 664 0)
            • Lock Assembly - Tailgate - Remove and Install (41 666 0)
            • Support Strut - Tailgate - Remove And Install (one) (41 685 0)
    • 542 Windows
      • 542-01 Windows
        • Description and Operation
          • 542-01 Windows|Description and Operation
          • Removal and Installation
            • Windscreen - Remove And Install (42 114 0)
            • Glass - Fixed Quarter Window - Front Door - Remove And Install (42 214 0)
            • Glass - Tailgate Window - Remove And Install (42 654 0)
            • Glass - Rear Window - Side - Remove And Install (42 616 0)
            • Glass - Side Door Window - Remove and Install (42 414 0)
            • Weatherstrip - Door Window - Front - Remove And Install (42 330 0)
            • Glass - Rear Door Window (42 634 0)
            • Glass - Door Window - Front - Remove And Install (42 314 0)
            • Regulator Assembly - Door Window - Remove And Install (42 338 0)
            • Glass - Fixed Rear Quarter Window - Remove And Install (42 514 0)
            • Glass - Partition Panel - Remove And Install (42 464 0)
    • 543 Interior and Exterior Trim
      • 543-01 Interior trim
        • Removal and Installation
          • Headlining (Bus, 14 Seats) Remove and Install (one) (43 612 0)
          • Trim Panel ‐ A‐Pillar ‐ Remove and Install (43 616 0)
          • Trim Panel ‐ C‐Pillar ‐ Remove and Install (43 618 0)
          • Headlining (Bus, 9 Seats) Remove and Install (43 612 0)
          • Handle (A‐pillar) Remove and Install (43 655 4)
          • Headlining (delivery van) remove and install (complete) (43 612 0)
          • Crash Padding ‐ Facia ‐ Remove and Install (43 644 0)
          • Trim Panel ‐ B‐Pillar ‐ Remove and Install (43 617 0)
          • Refrigerated Compartment Trim ‐ Sliding Door ‐ Remove and Install (Transit refrigerated van) (43 708 0)
          • Panel ‐ Cowl Side Trim ‐ Remove and Install. (43 735 0)
          • Trim Panel ‐ Front Door ‐ Remove and Install (43 705 0)
          • Trim Panel ‐ Rear Door (Sliding Door) Remove and Install (one) (43 706 0)
          • Trim Panel ‐ Rear Door ‐ Remove and Install (43 706 0)
          • Panel ‐ Door Trim ‐ Rear (Loadspace) ‐ Remove and Install (43 707 0)
          • Handle (B‐pillar) Remove and Install (One) (43 655 4)
          • Panel ‐ Tailgate Trim ‐ Remove and Install (43 744 0)
          • Panel ‐ Load Space Trim (Left) ‐ Remove and Install (43 746 0)
          • Panel ‐ Load Space Trim (Right) ‐ Remove and Install (43 746 0)
      • 543-02 Exterior Trim
        • SpecificationsGeneral Specifications
        • Removal and Installation
          • Mirror - Door - Remove and Install (43 364 0)
          • Bumper Assembly - Front - Remove and Install (43 423 0)
          • Grille Assembly - Cowl Top Outer - Remove and Install (43 230 0)
          • Insulation Panel - Hood - Remove and Install (43 221 0)
          • Bumper Assembly - Rear - Remove and Install (43 443 0)
          • Air Vent Panel - Remove and Install (43 178 0)
          • Grille - Radiator - Remove and Install (43 232 0)