Transit 2000.5 (01.2000-05.2006): Mechanical Repairs
Also for this vehicle: Transit 1995 (08.1994-07.2000), Transit 2006.5 (04.2006-), Transit Connect L4-2.0L (2010).
General
Body & interior
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
1 General Information › 100 Service Information10 pages
100-00 General Information › Description and Operation5 pages
- 100-01 Identification Codes › Description and Operation › Identification Codes
100-04 Noise, Vibration and Harshness › Diagnosis and Testing2 pages
2 Chassis178 pages
204 Suspension41 pages
204-00 Suspension System - General Information4 pages
- Specifications
Diagnosis and Testing3 pages
- Suspension System
General Procedures2 pages
204-01 Front Suspension16 pages
- Specifications
Description and Operation15 pages
Diagnosis and Testing14 pages
- Front Suspension
Removal and Installation13 pages
- Front Wheel Bearing
- Front Wheel Bearing and Wheel Hub - FWD
- Front Wheel Bearing and Wheel Hub - RWD
- Lower Arm
- Front Stabilizer Bar - Vehicles With: Solid Stabilizer Bar Link
- Front Stabilizer Bar - Vehicles With: Ball Joint Stabilizer Bar Link
- Lower Arm Bushing
- Wheel Knuckle
- Lower Arm Ball Joint - RWD
- Lower Arm Ball Joint - FWD
- Driver Side Strut and Spring Assembly
- Passenger Side Strut and Spring Assembly
- Disassembly and Assembly › Front Strut and Spring Assembly
- Front Suspension
204-02 Rear Suspension8 pages
- Specifications
Description and Operation7 pages
- Rear Suspension
Diagnosis and Testing6 pages
- Rear Suspension
Removal and Installation5 pages
204-04 Wheels and Tires3 pages
Description and Operation › Diagnosis and Testing2 pages
- Specifications
204-05 Vehicle Dynamic Suspension10 pages
- Specifications
Description and Operation9 pages
Diagnosis and Testing8 pages
- Vehicle Dynamic Suspension
205 Driveline41 pages
205-00 Driveline System - General Information › Diagnosis and Testing2 pages
205-01 Driveshaft4 pages
Diagnosis and Testing3 pages
- Driveshaft
Removal and Installation2 pages
- Specifications
205-02A Rear Drive Axle-Differential19 pages
- Specifications
Description and Operation18 pages
- Rear Drive Axle and Differential - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y
- Rear Drive Axle and Differential - VIN Plate Axle Code: E-F-H-J-K-L-R
Diagnosis and Testing16 pages
- Rear Drive Axle and Differential
General Procedures15 pages
- Drive Pinion Depth Shim Selection - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y
In-vehicle Repair14 pages
- Rear Wheel Bearing and Axle Shaft Seal
- Drive Pinion Flange and Drive Pinion Seal - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y
- Drive Pinion Flange and Drive Pinion Seal - VIN Plate Axle Code: E-F-H-J-K-L-R
- Drive Pinion Bearing Cups - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y
- Drive Pinion - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y
- Drive Pinion Bearing Cups - VIN Plate Axle Code: E-F-H-J-K-L-R
- Drive Pinion - VIN Plate Axle Code: E-F-H-J-K-L-R
- Differential Case - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y
- Differential Case - VIN Plate Axle Code: E-F-H-J-K-L-R
Removal and Installation5 pages
205-02B Wheel Hubs and Bearings - Full Floating Axle8 pages
Diagnosis and Testing7 pages
- Wheel Hubs and Bearings
Removal and Installation6 pages
- Specifications
205-04 Front Drive Halfshafts8 pages
Description and Operation7 pages
- Front Drive Halfshafts
Diagnosis and Testing6 pages
- Specifications
206 Brake System62 pages
206-00 Brake System - General Information7 pages
Description and Operation6 pages
- Brake System
Diagnosis and Testing5 pages
- Specifications
206-02 Drum Brake8 pages
Description and Operation7 pages
- Drum Brake
Diagnosis and Testing6 pages
- Specifications
206-03 Front Disc Brake9 pages
- Specifications
Description and Operation8 pages
Diagnosis and Testing7 pages
- Front Disc Brake
206-05A Parking Brake and Actuation8 pages
Description and Operation7 pages
- Parking Brake
Diagnosis and Testing6 pages
- Parking Brake
General Procedures5 pages
- Specifications
206-05B Parking Brake and Actuation - Vehicles With: Parking Brake Assist11 pages
- Specifications
Description and Operation10 pages
- Parking Brake
Diagnosis and Testing9 pages
- Parking Brake
General Procedures8 pages
206-06 Hydraulic Brake Actuation6 pages
Description and Operation5 pages
- Hydraulic Brake Actuation
Diagnosis and Testing4 pages
- Hydraulic Brake Actuation
Removal and Installation3 pages
- Specifications
206-07 Power Brake Actuation6 pages
- Specifications
Description and Operation5 pages
- Brake Booster
Diagnosis and Testing4 pages
206-09 Anti-Lock Control7 pages
- Specifications
Description and Operation6 pages
- Anti-Lock Control
Diagnosis and Testing5 pages
211 Steering System34 pages
211-00 Steering System - General Information6 pages
- Specifications
Diagnosis and Testing5 pages
211-02 Power Steering13 pages
Description and Operation12 pages
- Power Steering
Diagnosis and Testing11 pages
- Power Steering
Removal and Installation10 pages
- Power Steering Pump - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Power Steering Pump - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Power Steering Pump - 2.3L DOHC-16V
- Power Steering Pump Pulley - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Power Steering Pump to Steering Gear Pressure Line - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Power Steering Pump to Steering Gear Pressure Line - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Durato
- Power Steering Pump to Steering Gear Pressure Line - 2.3L DOHC-16V
- Steering Gear to Fluid Cooler Return Hose
- Power Steering Fluid Cooler
- Steering Gear
- Specifications
211-03 Steering Linkage6 pages
Description and Operation5 pages
- Steering Linkage
Diagnosis and Testing4 pages
- Steering Linkage
Removal and Installation3 pages
- Specifications
211-04 Steering Column6 pages
Description and Operation5 pages
- Steering Column
Diagnosis and Testing4 pages
- Steering Column
Removal and Installation3 pages
- Specifications
211-05 Steering Column Switches › Diagnosis and Testing3 pages
- Steering Column Switches
Removal and Installation2 pages
3 Powertrain381 pages
303 Engine236 pages
303-00 Engine System - General Information › Diagnosis and Testing26 pages
- Engine
General Procedures25 pages
- Camshaft Bearing Journal Diameter
- Camshaft End Play
- Camshaft Bearing Journal Clearance
- Camshaft Lobe Lift
- Camshaft Surface Inspection
- Crankshaft Main Bearing Journal Diameter
- Crankshaft Main Bearing Journal Clearance
- Crankshaft End Play
- Cylinder Bore Taper
- Piston Pin to Bore Diameter
- Piston Inspection
- Piston Ring End Gap
- Piston Diameter
- Piston Pin Diameter
- Piston Ring-to-Groove Clearance
- Connecting Rod Large End Bore
- Valve Stem Diameter
- Valve Seat Inspection
- Flywheel Inspection
- Flywheel Clutch Surface Inspection
- Flywheel Inspection - Vehicles With: Dual Mass Flywheel
- Cylinder Block Distortion
- Cylinder Head Distortion
- Exhaust Manifold Cleaning and Inspection
- Bearing Inspection
303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel26 pages
- Specifications
Description and Operation25 pages
- Engine
Diagnosis and Testing24 pages
- Engine
In-vehicle Repair23 pages
- Intake Manifold - Vehicles Built From: 04-2003, Vehicles Without: Common Rail Fuel Injection
- Intake Manifold - Vehicles Built Up To: 04-2003, Vehicles Without: Common Rail Fuel Injection
- Intake Manifold - Vehicles With: Common Rail Fuel Injection
- Valve Cover - 75 PS-90 PS
- Valve Cover - 120 PS
- Crankshaft Front Seal
- Valve Cover - 135 PS
- Engine Front Cover - 75 PS
- Engine Front Cover - 90 PS-120 PS
- Valve Springs
- Valve Seals
- Valves
- Camshafts
- Exhaust Manifold
- Cylinder Head
- Oil Pan
- Oil Pump
- Crankshaft Rear Seal
Removal5 pages
- Engine - Vehicles With: Exhaust Gas Recirculation (EGR)
Disassembly4 pages
- Engine
Disassembly and Assembly of Subassemblies3 pages
303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel23 pages
Description and Operation22 pages
- Engine
Diagnosis and Testing21 pages
- Engine
In-vehicle Repair20 pages
- Intake Manifold
- Valve Cover - Vehicles Without: Common Rail Fuel Injection
- Valve Cover - Vehicles With: Common Rail Fuel Injection
- Crankshaft Front Seal
- Engine Front Cover
- Valve Seals
- Valve Springs
- Valves
- Camshafts
- Camshaft Seal
- Exhaust Manifold
- Cylinder Head
- Oil Pan
- Oil Pump
- Crankshaft Rear Seal
Removal5 pages
- Engine
Disassembly4 pages
- Engine
Disassembly and Assembly of Subassemblies3 pages
- Cylinder Head
Assembly2 pages
- Specifications
303-01C Engine - 2.3L DOHC-16V19 pages
Description and Operation18 pages
- Engine
Diagnosis and Testing17 pages
- Engine
In-vehicle Repair16 pages
- Intake Manifold
- Engine Front Cover
- Valve Seals
- Valves
- Camshafts
- Timing Chain
- Exhaust Manifold
- Cylinder Head
- Oil Pan
- Oil Pump
- Crankshaft Rear Seal
Removal5 pages
- Engine
Disassembly4 pages
- Engine
Disassembly and Assembly of Subassemblies3 pages
- Cylinder Head
Assembly2 pages
- Specifications
303-03 Engine Cooling20 pages
- Specifications
Description and Operation19 pages
- Engine Cooling
Diagnosis and Testing18 pages
General Procedures17 pages
- Cooling System Draining, Filling and Bleeding
Removal and Installation16 pages
- Thermostat - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Thermostat - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Thermostat - 2.3L DOHC-16V
- Thermostat Housing - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Thermostat Housing - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Coolant Pump - 2.4L Duratorq-TDCi (Puma) Diesel
- Coolant Pump - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Coolant Pump - 2.3L DOHC-16V
- Radiator - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Radiator - 2.3L DOHC-16V
- Radiator - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Cooling Fan
- Cooling Fan Motor and Shroud - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel, Vehicles With: Air Conditioning
- Cooling Fan Motor and Shroud - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel,
- Cooling Fan Motor and Shroud - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel,
- Cooling Fan Shroud - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel, Vehicles Without: Air Conditioning
- Cooling Fan Motor and Shroud - 2.3L DOHC-16V
- Engine Cooling
303-04A Fuel Charging and Controls - 2.4L Duratorq-Di (Puma) Diesel10 pages
Description and Operation9 pages
- Fuel Charging and Controls
Diagnosis and Testing8 pages
- Fuel Charging and Controls - Vehicles With: Exhaust Gas Recirculation (EGR)
General Procedures7 pages
- Specifications
303-04B Fuel Charging and Controls - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel8 pages
Description and Operation7 pages
- Fuel Charging and Controls
Diagnosis and Testing6 pages
- Specifications
303-04C Fuel Charging and Controls - 2.3L DOHC-16V5 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Fuel Charging and Controls
Removal and Installation2 pages
- Fuel Charging and Controls
303-04D Fuel Charging and Controls - Turbocharger5 pages
- Specifications
Description and Operation4 pages
- Turbocharger
Diagnosis and Testing3 pages
303-04E Fuel Charging and Controls - Liquified Petroleum Gas (LPG)9 pages
- Specifications
Description and Operation8 pages
- Fuel Charging and Controls
Diagnosis and Testing7 pages
303-04F Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel9 pages
- Specifications
Description and Operation8 pages
- Fuel Charging and Controls
Diagnosis and Testing7 pages
- Fuel Charging and Controls
General Procedures6 pages
303-04G Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel8 pages
- Specifications
Description and Operation7 pages
- Fuel Charging and Controls
Diagnosis and Testing6 pages
- Fuel Charging and Controls
Removal and Installation5 pages
303-05 Accessory Drive9 pages
- Specifications
Description and Operation8 pages
- Accessory Drive
Diagnosis and Testing7 pages
- Accessory Drive
Removal and Installation6 pages
- Accessory Drive Belt - 2.4L Duratorq-Di (Puma) Diesel
- Accessory Drive Belt - 2.4L Duratorq-TDCi (Puma) Diesel
- Accessory Drive Belt - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Power Steering Pump Belt
- Accessory Drive Belt - 2.3L DOHC-16V
- Accessory Drive Belt - Vehicles Without: Accessory Drive Belt Tensioner
303-06 Starting System6 pages
Description and Operation5 pages
- Starting System
Diagnosis and Testing4 pages
- Specifications
303-07A Glow Plug System - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel6 pages
- Specifications
Description and Operation5 pages
- Glow Plug System
Diagnosis and Testing4 pages
303-07B Glow Plug System - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel6 pages
Description and Operation5 pages
- Glow Plug System
Diagnosis and Testing4 pages
- Specifications
303-07C Engine Ignition - 2.3L DOHC-16V4 pages
Description and Operation3 pages
- Engine Ignition
Diagnosis and Testing2 pages
- Specifications
303-08 Engine Emission Control12 pages
- Specifications
Description and Operation11 pages
Diagnosis and Testing10 pages
- Engine Emission Control
Removal and Installation9 pages
- Exhaust Gas Recirculation (EGR) Valve - 2.4L Duratorq-Di (Puma) Diesel
- Exhaust Gas Recirculation (EGR) Valve - 2.4L Duratorq-TDCi (Puma) Diesel
- Exhaust Gas Recirculation (EGR) Valve - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Exhaust Gas Recirculation (EGR) Valve - 2.0L Duratorq-TDCi (Puma) Diesel
- Exhaust Gas Recirculation (EGR) Valve - 2.3L DOHC-16V
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - 2.3L DOHC-16V
- Exhaust Gas Recirculation (EGR) Cooler - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - 2.0L Duratorq-Di (Puma) Diesel (85 PS-100 PS)
- Exhaust Gas Recirculation (EGR) Cooler - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Pum
- Engine Emission Control
303-12 Intake Air Distribution and Filtering6 pages
- Specifications
Description and Operation5 pages
Diagnosis and Testing4 pages
- Intake Air Distribution and Filtering
303-13 Evaporative Emissions › Description and Operation3 pages
- Evaporative Emissions
Diagnosis and Testing2 pages
303-14 Electronic Engine Controls16 pages
- Specifications
Description and Operation15 pages
- Electronic Engine Controls
Diagnosis and Testing14 pages
- Electronic Engine Controls
Removal and Installation13 pages
- Crankshaft Position (CKP) Sensor - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Crankshaft Position (CKP) Sensor - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Vehicle Speed Sensor (VSS) - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Crankshaft Position (CKP) Sensor - 2.0L Duratorq-TDCi (Puma) Diesel
- Vehicle Speed Sensor (VSS) - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Powertrain Control Module (PCM)
- Knock Sensor (KS) - 2.4L Duratorq-TDCi (Puma) Diesel
- Cylinder Head Temperature (CHT) Sensor - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Pum
- Cylinder Head Temperature (CHT) Sensor - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Fuel Temperature Sensor - 2.0L Duratorq-TDCi (Puma) Diesel
- Fuel Temperature Sensor - 2.4L Duratorq-TDCi (Puma) Diesel
- Injector Driver Module (IDM) - 2.0L Duratorq-TDCi (Puma) Diesel
- Ignition Signal Filter
308 Manual Transmission-Transaxle, Clutch and Transfer Case109 pages
308-00 Manual Transmission-Transaxle and Clutch - General Information10 pages
308-01A Clutch - Vehicles With: MT-755 pages
- Specifications
Diagnosis and Testing4 pages
308-01B Clutch - Vehicles With: VXT-753 pages
Diagnosis and Testing2 pages
- Specifications
308-01C Clutch - Vehicles With: MT825 pages
308-02A Clutch Controls - Vehicles With: MT-755 pages
Description and Operation4 pages
- Clutch Controls
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
- Specifications
308-02B Clutch Controls - Vehicles With: VXT-755 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
- Clutch Controls
308-02C Clutch Controls - Vehicles With: MT825 pages
- Specifications
Description and Operation4 pages
Diagnosis and Testing3 pages
- Clutch Controls
Removal and Installation2 pages
- Clutch Controls
308-03A Manual Transmission-Transaxle - Vehicles With: MT-7518 pages
- Specifications
Description and Operation17 pages
Diagnosis and Testing16 pages
- Manual Transmission
General Procedures15 pages
- Transmission Draining and Filling
Removal14 pages
- Transmission - 2.4L Duratorq-Di (Puma) Diesel, Vehicles With: Automated Gearshift
- Transmission - 2.4L Duratorq-Di (Puma) Diesel, Vehicles Without: Automated Gearshift
- Transmission - 2.3L DOHC-16V
Disassembly11 pages
- Transmission
Disassembly and Assembly of Subassemblies10 pages
- Manual Transmission
308-03B Manual Transmission-Transaxle - Vehicles With: VXT-7512 pages
- Specifications
Description and Operation11 pages
- Manual Transaxle
Diagnosis and Testing10 pages
- Manual Transaxle
In-vehicle Repair9 pages
308-03C Manual Transmission-Transaxle - Vehicles With: MT8211 pages
- Specifications
Description and Operation10 pages
Diagnosis and Testing9 pages
- Manual Transmission
General Procedures8 pages
- Transmission Draining and Filling
In-vehicle Repair7 pages
- Input Shaft Seal
- Output Shaft Seal
Removal5 pages
- Transmission
Disassembly4 pages
- Transmission
Disassembly and Assembly of Subassemblies3 pages
- Synchronizers
Assembly2 pages
- Manual Transmission
308-06A Manual Transmission-Transaxle External Controls - Vehicles With: MT-753 pages
- Specifications
Description and Operation2 pages
308-06B Manual Transmission-Transaxle External Controls - Vehicles With: VXT-755 pages
- Specifications
Description and Operation4 pages
- External Controls
Diagnosis and Testing3 pages
- External Controls
Removal and Installation2 pages
308-06C Manual Transmission-Transaxle External Controls - Vehicles With: MT823 pages
- Specifications
Description and Operation2 pages
308-11 Manual Transmission-Transaxle Automated Gearshift System19 pages
- Specifications
Description and Operation18 pages
Diagnosis and Testing17 pages
- Automated Gearshift System
Removal and Installation16 pages
- Hydraulic Pressure Unit (HPU)
- Hydraulic Pressure Accumulator
- Hydraulic Pressure Sensor
- Hydraulic Fluid Temperature Sensor
- Hydraulic Pressure Unit (HPU) Wiring Harness
- Gearshift Actuator
- Gearshift Actuator Position Sensor
- Gearshift Shaft Connector
- Clutch Actuator
- Gearshift Hydraulic Fluid Lines
- Clutch Actuator Position Sensor
- Gearshift Hydraulic Fluid Reservoir
- Driver Interface Module
- Transmission Control Module (TCM)
- Steering Wheel Gearshift Controls
- Input Shaft Speed (ISS) Sensor
- Automated Gearshift System
309 Exhaust System › 309-00 Exhaust System5 pages
Description and Operation4 pages
- Specifications
310 Fuel System31 pages
310-00A Fuel System - General Information › Description and Operation7 pages
310-00B Fuel System - General Information - Liquified Petroleum Gas (LPG) › Description and Operation8 pages
310-01A Fuel Tank and Lines7 pages
Description and Operation6 pages
- Fuel Tank and Lines
Diagnosis and Testing5 pages
- Specifications
310-01B Fuel Tank and Lines - Liquified Petroleum Gas (LPG)6 pages
Description and Operation5 pages
- Fuel Tank and Lines
Diagnosis and Testing4 pages
- Fuel Tank and Lines
Removal and Installation3 pages
- Specifications
310-02A Acceleration Control - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel- › Diagnosis and Testing2 pages
- 310-02B Acceleration Control - 2.3L DOHC-16V › Diagnosis and Testing › Acceleration Control
4 Electrical180 pages
412 Climate Control System90 pages
412-00 Climate Control System - General Information10 pages
- Specifications
Diagnosis and Testing9 pages
412-01 Air Distribution and Filtering › Description and Operation4 pages
Diagnosis and Testing3 pages
- Air Distribution and Filtering
Removal and Installation2 pages
- Air Distribution and Filtering
412-02A Heating and Ventilation9 pages
- Specifications
Diagnosis and Testing8 pages
- Heating and Ventilation
Removal and Installation7 pages
412-02B Auxiliary Heating11 pages
- Specifications
Description and Operation10 pages
- Auxiliary Heater
- Booster Heater
Diagnosis and Testing8 pages
- Auxiliary Heater
- Booster Heater
Removal and Installation6 pages
412-03A Air Conditioning16 pages
- Specifications
Description and Operation15 pages
Diagnosis and Testing14 pages
- Air Conditioning
Removal and Installation13 pages
- Air Conditioning (A-C) Compressor - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Di
- Air Conditioning (A-C) Compressor - 2.3L DOHC-16V
- Clutch and Clutch Field Coil - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel-
- Clutch and Clutch Field Coil - 2.3L DOHC-16V
- Evaporator Core
- Evaporator Core Orifice - RHD
- Evaporator Core Orifice - LHD
- Suction Accumulator
- Low-Pressure Cutoff Switch
- High-Pressure Cutoff Switch - 2.3L DOHC-16V-2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- High-Pressure Cutoff Switch - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel
- Condenser Core - Vehicles With: Charge Air Cooler
- Condenser Core - Vehicles Without: Charge Air Cooler
- Air Conditioning
412-03B Auxiliary Climate Control8 pages
- Specifications
Description and Operation7 pages
Diagnosis and Testing6 pages
- Auxiliary Climate Control
412-04 Control Components › Description and Operation6 pages
- Control Components
Diagnosis and Testing5 pages
412-05 Refrigeration26 pages
- Specifications
Description and Operation25 pages
- Refrigeration
Diagnosis and Testing24 pages
- Refrigeration
General Procedures23 pages
- Stationary Refrigeration Pressure Regulator Adjustment
Removal and Installation22 pages
- Refrigeration Control Assembly
- Refrigeration Accumulator
- Refrigeration Compressor
- Stationary Refrigeration Accumulator
- Stationary Refrigeration Compressor
- Stationary Refrigeration Compressor Belt
- Refrigeration Drier-Filter
- Refrigeration Evaporator Core
- Refrigeration Condenser Core - Vehicles With: Charge Air Cooler
- Refrigeration Condenser Core - Vehicles Without: Charge Air Cooler
- Refrigeration High-Pressure Cutoff Switch
- Refrigeration Low-Pressure Cutoff Switch
- Refrigeration Bypass Control Pressure Switch
- Stationary Refrigeration Pressure Regulator
- Refrigeration Control Module
- Stationary Refrigeration Non-Return Valve
- Refrigeration Clutch and Clutch Field Coil
- Stationary Refrigeration Clutch and Clutch Field Coil
- Stationary Refrigeration Power Supply Switch Box
- Stationary Refrigeration Motor
- Stationary Refrigeration Power Supply Socket
- Stationary Refrigeration Power Supply Transformer
413 Instrumentation and Warning Systems20 pages
- 413-00 Instrument Cluster and Panel Illumination › Diagnosis and Testing › Instrument Cluster and Panel Illumination - Vehicles With: Central Junction Box (CJB)
413-01 Instrument Cluster › Description and Operation6 pages
- Instrument Cluster - Vehicles Built From: 07-2003
- Instrument Cluster - Vehicles Built Up To: 07-2003
Diagnosis and Testing4 pages
- 413-06 Horn › Diagnosis and Testing › Horn
413-07 Clock › Diagnosis and Testing2 pages
413-13 Parking Aid6 pages
- Specifications
Description and Operation5 pages
- Parking Aid
Diagnosis and Testing4 pages
- Parking Aid
General Procedures3 pages
413-17 Tachograph › Diagnosis and Testing4 pages
- Tachograph
- Digital Tachograph
Removal and Installation2 pages
414 Battery and Charging System19 pages
414-00 Charging System - General Information › Description and Operation4 pages
414-01 Battery, Mounting and Cables9 pages
- Specifications
Description and Operation8 pages
Diagnosis and Testing7 pages
- Battery
General Procedures6 pages
- Battery Disconnect and Connect
Removal and Installation5 pages
- Battery
- Jump Start Point to Starter Motor Solenoid Cable - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel
- Battery to Jump Start Point Cable
- Jump Start Point to Starter Motor Solenoid Cable - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq
- Jump Start Point to Starter Motor Solenoid Cable - 2.3L DOHC-16V
- Battery and Cables
414-02 Generator and Regulator6 pages
- Specifications
Description and Operation5 pages
415 Information and Entertainment Systems8 pages
- 415-00 Information and Entertainment System - General Information › Diagnosis and Testing › Audio System - Vehicles With: Central Junction Box (CJB)
415-01 Audio Unit › Description and Operation3 pages
- Audio System
Diagnosis and Testing2 pages
415-02 Antenna › Description and Operation3 pages
- Antenna
Diagnosis and Testing2 pages
- 415-03 Speakers › Diagnosis and Testing › Speakers
417 Lighting27 pages
417-01 Exterior Lighting23 pages
Description and Operation › Diagnosis and Testing22 pages
- Headlamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)
- Headlamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)
- Stoplamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)
- Stoplamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)
- Turn Signal and Hazard Lamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)
- Turn Signal and Hazard Lamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)
- Parking, Rear and License Plate Lamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)
- Parking, Rear and License Plate Lamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)
- Fog Lamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)
- Fog Lamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)
- Reversing Lamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)
- Reversing Lamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)
- Trailer Lamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)
- Trailer Lamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)
- Headlamp Leveling - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)
- Headlamp Leveling - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)
General Procedures6 pages
- Headlamp Adjustment
- Headlamp Masking
- Front Fog Lamp Adjustment
Removal and Installation3 pages
- Specifications
- 417-02 Interior Lighting › Diagnosis and Testing › Interior Lighting
417-04 Daytime Running Lamps (DRL) › Description and Operation3 pages
418 Electrical Distribution3 pages
418-00 Module Communications Network › Description and Operation2 pages
- 418-01 Module Configuration › General Procedures › Module Configuration
419 Electronic Feature Group13 pages
419-01A Anti-Theft - Active4 pages
Description and Operation3 pages
- Anti-Theft - Active
Diagnosis and Testing2 pages
- Specifications
419-01B Anti-Theft - Passive › Description and Operation7 pages
- Anti-Theft - Passive
Diagnosis and Testing6 pages
- Anti-Theft - Passive - Vehicles With: Central Junction Box (CJB)
General Procedures5 pages
- Erasing All Key Codes Using Diagnostic Equipment - Vehicles With: Central Junction Box (CJB)
- Key Programming Using Two Programmed Keys - Vehicles With: Central Junction Box (CJB)
- Key Programming Switch State Control - Vehicles With: Central Junction Box (CJB)
- Anti-Theft Security Access - Vehicles With: Central Junction Box (CJB)
- Removal and Installation › Passive Anti-Theft System (PATS) Transceiver
419-10 Multifunction Electronic Modules › Description and Operation › Diagnosis and Testing2 pages
5 Body and Paint184 pages
501 Body and Paint177 pages
501-00 Body System - General Information4 pages
- Specifications
Description and Operation3 pages
501-02 Front End Body Panels6 pages
- Specifications
Description and Operation5 pages
- Front End Body Panels
General Procedures4 pages
- Hood Alignment
Removal and Installation3 pages
501-03 Body Closures2 pages
501-05 Interior Trim and Ornamentation13 pages
- Specifications
Removal and Installation12 pages
- 501-08 Exterior Trim and Ornamentation › Removal and Installation › Rear Quarter Panel Moulding
501-09 Rear View Mirrors4 pages
- Specifications
Description and Operation3 pages
- Rear View Mirrors
Diagnosis and Testing2 pages
501-10 Seating17 pages
- Specifications
Description and Operation16 pages
Diagnosis and Testing15 pages
- Seats
Removal and Installation14 pages
- Front Seat Backrest
- Double Passenger Seat
- Front Seat
- Seat Track
Disassembly and Assembly10 pages
- Seats - Vehicles With: Central Junction Box (CJB)
501-11 Glass, Frames and Mechanisms17 pages
- Specifications
Description and Operation16 pages
- Glass, Frames and Mechanisms
Diagnosis and Testing15 pages
- Glass, Frames and Mechanisms - Vehicles With: Central Junction Box (CJB)
Removal and Installation14 pages
- Front Door Window Glass
- Front Quarter Window Glass
- Second Row Side Window Glass
- Sliding Door Window Glass
- Third Row Side Window Glass
- Rear Door Window Glass
- Rear Door Window Glass - Chassis Double Cab
- Partition Panel Window Glass
- Rear Window Glass - Chassis Double Cab
- Liftgate Window Glass
- Front Door Window Regulator
- Front Door Window Regulator and Motor
- Windshield Glass
- Front Door Glass Top Run
501-12 Instrument Panel and Console3 pages
- Specifications
Removal and Installation2 pages
501-14 Handles, Locks, Latches and Entry Systems27 pages
Description and Operation26 pages
- Handles, Locks, Latches and Entry Systems
Diagnosis and Testing25 pages
- Locks, Latches and Entry Systems
General Procedures24 pages
- Remote Transmitter Programming
Removal and Installation23 pages
- Hood Latch
- Front Door Latch
- Sliding Door Latch
- Liftgate Latch
- Rear Door Latch - Van-Kombi-Bus
- Rear Door Latch - Chassis Double Cab
- Rear Door Lower Latch
- Rear Door Upper Latch
- Exterior Sliding Door Handle
- Exterior Front Door Handle
- Exterior Rear Door Handle LH - Van-Kombi-Bus
- Exterior Rear Door Handle - Chassis Double Cab
- Exterior Rear Door Handle RH - Van-Kombi-Bus
- Liftgate Release Handle
- Front Door Lock Cylinder
- Hood Lock Cylinder
- Rear Door Lock Cylinder - Van-Kombi-Bus
- Sliding Door Lock Cylinder
- Rear Door Lock Cylinder - Chassis Double Cab
- Liftgate Lock Cylinder
- Front Door Latch Remote Control
- Rear Door Latch Remote Control - Chassis Double Cab
- Sliding Door Latch Remote Control
- Specifications
501-16 Wipers and Washers7 pages
- Specifications
Diagnosis and Testing6 pages
- 501-17 Roof Opening Panel › Removal and Installation › Escape Hatch
501-19 Bumpers5 pages
- Specifications
Removal and Installation4 pages
501-20A Safety Belt System8 pages
- Specifications
Description and Operation7 pages
Diagnosis and Testing6 pages
- Safety Belt System
501-20B Supplemental Restraint System11 pages
Description and Operation10 pages
- Air Bag Supplemental Restraint System (SRS)
Diagnosis and Testing9 pages
- Specifications
501-25 Body Repairs - General Information26 pages
- Specifications
Description and Operation25 pages
- Description and Usage of Body Repair Literature
- Health and Safety Precautions
- Symbols
- Environmental Regulations
- Body Construction
- Body Sheet Metal
- Diagnosis and Damage Evaluation
- Tools and Equipment for Body Repairs
- Establish Repair Method
- Straightening
- Alignment Check
- Complete Panel Replacement-Partial Replacement
- Corrosion Prevention
- Corrosion Damage-Corrosion Repair
- Sealer, Underbody Protection Material and Adhesives
- Cutting Technique
- Panel Beating Technique and Smart Repairs
- Paintless Dent Removal
- Joining Techniques
- Plastic Repairs
- Special Repair Techniques
- Impact of Insufficient Repair Quality
- Water Leaks
- Noise, Vibration and Harshness
- Wind Noise
501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks4 pages
- Specifications
Description and Operation3 pages
- Body and Frame
General Procedures2 pages
501-27 Front End Sheet Metal Repairs › Removal and Installation5 pages
501-29 Side Panel Sheet Metal Repairs6 pages
501-30 Rear End Sheet Metal Repairs10 pages
502 Frame and Mounting › 502-00 Uni-Body, Subframe and Mounting System7 pages