Ford Transit since 2000, repair e-manual (in Russian)

Content

Your Ford Transit car

• Introduction
• Safety first!
• Troubleshooting an emergency
  • If your car's engine does not start
  • Starting the engine from an additional power source
  • Wheel replacement
  • Towing
  • Leak detection
• Weekly checks
  • Introduction
  • Checks under the hood of the car
  • Engine oil level
  • Coolant level
  • Level of a brake liquid and a working liquid of coupling
  • Power Steering fluid level
  • Tire condition and air pressure in tires
  • Washer fluid level
  • Windshield wipers
  • Battery
  • Electrical systems
• Working fluids and lubricants
• Tire pressure

Operation

• General information
• Dashboard
• Pointers and devices
• Actions in an emergency

Regular maintenance

• Maintenance specifications
• Maintenance schedule
• Maintenance procedures
• General information
• Regular maintenance
• Replacement of engine oil and filter
• Maintenance and charging of the battery
• Checking the auxiliary drive belt
• Checking the electrical system
• Checking hoses and leaks
• Checking the condition of the fuel filter and draining the water
• Replacing the fuel filter
• Checking the electrical wires in the engine compartment
• Air conditioning system check
• Seat belt inspection
• Checking the concentration of antifreeze
• Checking the wheels, steering and suspension
• Checking the CV joint and anther of the drive shaft
• Check of the central bearing and the universal hinge of a propshaft
• Grease universal pivot joint propshaft
• Exhaust system check
• Check of highways of fuel and brake system under the bottom of a body
• Checking the wear of the brake pads
• Check of serviceability and adjustment of a lay brake
• Checking and lubricating doors and hood
• Checking the tightening torque of wheels
• Road test
• Reset maintenance indicator
• Replacement of air filter
• Checking the transmission oil level
• Checking the rear axle oil level
• Brake fluid replacement
• Replacing coolant
• Replacing an auxiliary drive belt

Repair procedures without removing the engine from the engine compartment - car models equipped with 2.0 l engine

• General information
• Compression and tightness check - description and explanation
• Gas distribution phases - adjustment
• Camshaft cover - removal and installation
• Timing chain cover - removing and installing
• Crankshaft pulley - removing and installing
• Chain of drive timing - removal, inspection and installation
• Tensioner and sprockets for timing chain - Removal, inspection and installation
• Camshaft and hydraulic lifters - removal and installation
• Camshaft seal - replacement
• The head of the block of cylinders - removal, check and installation
• Crankcase - removal and installation
• Oil pump - removal and installation
• Engine oil pressure switch warning switch - removing and installing
• Oil cooler - removal and installation
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine / gearbox mountings - check and replace
• Intake manifold - removal, inspection and installation
• Exhaust manifold - removal and installation

Repair procedures without removing the engine from the engine compartment - car models equipped with a 2.4L engine

• General information
• Compression and tightness check - description and explanation
• Gas distribution phases - adjustment
• Camshaft cover - removal and installation
• Timing chain cover - removing and installing
• Crankshaft pulley - removing and installing
• Chain of drive timing - removal, inspection and installation
• The timing chain sprocket and sprockets - removal, inspection and installation
• Camshaft and hydraulic lifters - removal and installation
• The head of the block of cylinders - removal, check and installation
• Crankcase - removal and installation
• Oil pump - removal and installation
• Engine oil pressure switch warning switch - removing and installing
• Oil filter housing and oil cooler - removing and installing
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine / gearbox mountings - check and replace
• Intake manifold - removal, inspection and installation
• Exhaust manifold - removal and installation

Removing the engine from the engine compartment and the overhaul procedure

• General information
• Major engine repairs - general information
• Removing engine / gearbox - methods and precautions
• Engine / gearbox assembly (front-drive vehicle models) - removal, disconnection and installation
• Engine / gearbox assembly (rear-wheel drive models) - removal, disconnection and installation
• Engine overhauling - sequence of disassembly
• Cylinder head - disassembly
• Cylinder head and valve mechanism - cleaning and checking
• Cylinder head - assembly
• Piston / connecting rod assembly - removal and inspection
• Crankshaft removal
• Cylinder block / crankcase - cleaning and inspection
• The main bearing and the lower end of the connecting rod - check
• Engine overhaul - assembly sequence
• Piston rings - installation
• Crankshaft - installation
• Piston / connecting rod assembly - installation
• The engine is the beginning of traffic after major repairs

Cooling, ventilation and heating system

• General information and precautions
• Cooling hoses - detach and replace
• Thermostat - removal, inspection and installation
• The cooling fan with electric drive assembly - removal and installation
• Cooling fan cover (car models equipped with 2.4 l engine) - removal and installation
• Radiator fan with viscous coupling - removal and installation
• Radiator - removal, inspection and installation
• Water pump - removal and installation
• Components of the heater / ventilation system - removal and installation
• Heater / air conditioning controls - removal and installation
• Air conditioning system - general information and precautions
• Components of the air conditioning system - removal and installation

The power supply and exhaust system

• General information and precautions
• Common rail system - the necessary information
• Power system - refueling and pumping
• Air filter assembly and air ducts - removing and installing
• Accelerator pedal - removal and installation
• Fuel tank - removal and installation
• Fuel level sensor - removal, inspection and installation
• Fuel Injection System - Inspection
• Electronic components of the fuel injection system (models of cars equipped with a 2.0-liter engine) - removal and installation
• Electronic components of the fuel injection system (models of cars equipped with a 2.4-liter engine) - removal and installation
• High-pressure fuel pump (fuel pump) (models of cars equipped with a 2.0-liter engine) - removal and installation
• High-pressure fuel pump (fuel pump) (models of cars equipped with a 2.4-liter engine) - removal and installation
• Fuel injectors - removal, inspection and installation
• Fuel rail (common rail system) - removal and installation
• Turbocharger - general information, removal and installation
• Intercooler - general information,   removal and installation
• Exhaust system - general information and component replacement

Control systems for harmful emissions

• General information
• Exhaust gas recirculation system - checking and replacing components
• Catalytic converter - general information, removal and installation

Starting and recharging systems

• General information, precautions and disconnection of the negative battery terminal
• Detection of malfunctions in the electrical system - general information
• Battery - check and charge
• Battery - removal and installation
• Recharging system - check
• Auxiliary drive belt - removal and installation
• Generator - removal and installation
• Generator - check and general repair
• Start-up system - check
• Starter - removal and installation
• Starter - check and overhaul
• Pre- and post-start heating systems - general information
• Glow plugs - check, remove and install

Clutch

• General information
• Hydraulic clutch system - pumping
• Clutch master cylinder - removal and installation
• Clutch release cylinder - removal, check and installation
• Clutch slave cylinder - removing and installing
• Clutch release mechanism - removal, inspection and installation
• Clutch pedal - removal and installation
• Clutch assembly - removal, inspection and installation

Automatic transmission

• General information
• Gear shift cables - Adjustment
• Gear lever - removal and installation
• Gear shift cables - removing and installing
• Vehicle speed sensor - removing and installing
• Oil seals - replacement
• Reversing light switch - removal and installation
• Gearbox - removing and installing
• Major overhaul of the gearbox - general information
• Draining and refueling gearbox oil - general information

Manual transmission

• General information
• Gear lever - removal and installation
• Vehicle speed sensor - removing and installing
• Oil seals - replacement
• Reversing light switch - removal and installation
• Five-speed gearbox - removal and installation
• Six-speed gearbox - removal and installation
• Transmission supports - check and replace
• Major overhaul of the gearbox - general information
• Transmission oil - draining and refueling

Drive shafts, propshaft and rear axle

• General information
• Drive shafts - removal and installation
• Bellow of the internal SHR of the drive shaft - replacement
• Anther of external drive roller SHRUS - replacement
• Intermediate shaft support bearing - replacement
• Drive shafts - check and replacement of CV joints
• Drive shaft - removal and installation
• Central propshaft bearing - replacement
• Flexible rubber joint of propshaft - removal and installation
• Universal driveshaft joints - replacement
• Rear axle (front-wheel drive models) - removal and installation
• Rear axle (rear-wheel drive models) - removal and installation
• Axles of the rear axle (wheels with single tires) - removal and installation
• Rear axle axles (dual-tire tires) - removing and installing
• Rear hub and bearing (front-drive vehicle models) - removal, overhaul and installation
• Rear hub and bearing (rear-wheel drive models) - removal, overhaul and installation
• Drive pinion packing (rear axle) - replacement
• Differential assembly (rear axle) - overhaul

Brake system

• General information
• Hydraulic system - air removal
• Hydraulic connections and hoses - replacement
• Front brake pads are replacement
• Front disc brake - checking, removing and installing
• Front brake caliper - removal, overhaul and installation
• Rear drum brake - removal, inspection and installation
• Rear brake pads - replacement
• Rear working cylinder - removal, overhaul and installation
• Master brake cylinder - removal, overhaul and installation
• Brake pedal - removal and installation
• Vacuum brake booster - checking, removing and installing
• Vacuum brake booster check valve and vacuum hose - removal, inspection and installation
• Vacuum pump - removal and installation
• Parking brake lever - removal and installation
• Parking brake cables - removal and installation
• Brake light switch - removal, installation and adjustment
• Parking brake warning light switch - removal and installation
• Anti-lock braking system (ABS) and traction control system - general information
• Anti-lock components (ABS) and traction control systems - removal and installation
• Load balancing valve - general information

Suspension and steering

• General information
• Front hub assembly - removal and installation
• Front hub bearings - check and replace
• Rotary Fist - removing and installing
• Front suspension bracket - removing and installing
• Front suspension - overhaul
• The lower lever of a forward suspension bracket - removal and installation
• Sleeves of the bottom lever of a forward suspension bracket - replacement
• Ball joint of swivel fist - replacement
• Front anti-roll bar - removal and installation
• Front subframe - removal and installation
• Leaf spring of the rear axle - removal and installation
• Rear shock absorber - removal and installation
• Rear anti-roll bar - removal and installation
• Steering wheel - removal and installation
• The mechanism of locking the ignition and steering column - removal and installation
• Steering column - removal and installation
• Steering gear - removal and installation
• Anthers of steering gear - replacement
• The tip of the tie rod - removal and installation
• Power steering pump - removal and installation
• Power steering fluid cooler - removing and installing
• Hydraulic power steering system - pumping
• Adjusting the installation angles and steering angle - general information

Body structure and components

• General information
• Body and frame - maintenance
• Upholstery and rugs - maintenance
• Elimination of minor body damage - repairs
• Removing serious body damage - general information
• Hood - removal, installation and adjustment
• Hood retainer - removal and installation
• Door trim panels - removal and installation
• Front door components - removal and installation
• Front door - removal, installation and adjustment
• Components of the side sliding door - removal and installation
• Side sliding door - removal, installation and adjustment
• Rear door components - removal and installation
• Rear doors - removal, installation and adjustment
• Components of the tailgate - removal and installation
• The luggage compartment door - removal, installation and adjustment
• Front door glass - removal and installation
• The regulator of window forward door - removal and installation
• Front door winch - removal and installation
• Windscreen / rear window and fixed / movable glasses - removal and installation
• External mirrors - removal and installation
• Front bumper - removal and installation
• Rear bumper - removal and installation
• Radiator grille panel - removal and installation
• Windscreen intake panels - removing and installing
• Internal cladding panels - removal and installation
• Seats - removal and installation
• Components of seat belts - removal and installation
• Luke - general information
• Dashboard paneling components - removal and installation

Electrical equipment and electrical systems

• General information and precautions
• Detection of malfunctions in the electrical system - general information
• Fuses and relays - general information
• Switches - removal and installation
• Dashboard - removal and installation
• Components of the dashboard (models of cars produced before July 2003) - removal and installation
• Tachograph - removal and installation
• Removing and installing watches
• Adjusting the height of the headlights / fog lights - general information
• Lamps (external lighting) - replacement
• Lamps (interior lighting) - replacement
• The case of headlights for external lighting - removal and installation
• Servo drive for height adjustment of headlights - removal and installation
• Acoustic signal - removal and installation
• Wiper arms - removal and installation
• Servo and windshield wiper retractor - removing and installing
• Rear window wiper motor - removing and installing
• Windscreen / rear window washer reservoir - removing and installing
• Audio module - removal and installation
• Speakers - removal and installation
• Anti-theft system - general information
• Airbag System - general information and precautions
• Components of the airbag system - removal and installation
• Electrical circuits

Applications

• Overall dimensions and weight
• Vehicle identification numbers
• General repair procedures
• Lifting the car with a jack, the points of the pillars
• Disconnecting the negative battery terminal
• Tools and devices
• Checking the technical condition of the car
• Troubleshooting

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