Haynes Ford Transit Diesel Owners Workshop Manual 1859600190, 9781859600191

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Owners Wo Tea Dees

Digitized by the Internet Archive in 2023 with funding from Kahle/Austin Foundation

htips://archive.org/details/fordtransitdieseQ0O00mead

ord ransit lesel wners

orkshop anual John S Mead Models covered All Ford Transit models with normally-aspirated and turbocharged 2.5 litre Diesel engines Does not cover petro! engine models, Transit 4 x 4, or specialist bodywork/conversions

Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

|

Restoring and Preserving our Motoring Heritage

Acknowledgements Thanks are due to Champion Spark Plug, who supplied replacement component information, to Holt Lloyd Limited who supplied the illustrations showing bodywork repair, and to Duckhams Oils, who provided lubrication data. Certain other illustrations are the copyright of the Ford Motor Company Limited, and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford and Newbury Park who helped in the production of this manual.

© Haynes Publishing 1995 A book in the Haynes Owners Workshop Manual Series

Few people can have had the luck to realise their dreams to quite the same extent and in such a remarkable fashion as John Haynes, Founder and Chairman of the Haynes Publishing Group. Since 1965 his unique approach to workshop manual publishing has proved so successful that millions of Haynes Manuals are now solid every year throughout the world, covering literally thousands of different makes and models of cars, vans and motorcycles. A continuing passion for cars and motoring led to the founding in 1985 of a Charitable Trust dedicated to the restoration and preservation of our motoring heritage. To inaugurate the new Museum, John Haynes donated virtually his entire private collection of 52 cars. Now with an unrivalled international collection of over 210 veteran, vintage and classic cars and motorcycles, the Haynes Motor Museum in Somerset is well on the way to becoming one of the most interesting Motor Museums in the world. A 70 seat video cinema, a cafe and an extensive motoring bookshop, together with a specially constructed one kilometre motor circuit, make a visit to the Haynes Motor Museum a truly unforgettable experience. Every vehicle in the museum is preserved in as near as possible mint condition and each car is run every six months on the motor circuit. Enjoy the picnic area set amongst the rolling Somerset hills. Peer through the William Morris workshop windows at cars being restored, and browse through the extensive displays of fascinating motoring memorabilia. From the 1903 Oldsmobile through such classics as an MG Midget to the mighty ‘E’ type Jaguar, Lamborghini, Ferrari Berlinetta Boxer, and Graham Hill's Lola Cosworth, there is something for everyone, young and old alike, at this Somerset Museum.

Printed by J. H. Haynes & Co. Ltd., Sparkford, Nr Yeovil, Somerset BA22 7JJ, England All rights reserved. No part of this book transmitted in any form or by any mechanical, including photocopying, information storage or retrieval system, writing from the copyright holder.

may be reproduced or means, electronic or recording or by any without permission in

ISBN 1 85960 019 0 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library.

We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which

they do not inform us. No liability can be accepted by the authors

Haynes Motor Museum

or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Situated mid-way between London and Penzance, the Haynes Motor Museum is located just off the A303 at Sparkford, Somerset (home of the Haynes Manual) and is open to the public 7 days a week all year round, except Christmas Day and Boxing Day.

95-312

Telephone 01963 440804.

Contents

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Preliminary sections (SEEN GA Sot 1 IE NR SRE OOF Ta eS ar A PE eS ee Pr COS LSAT ETRIEEL 2 1AM b SC TIS INOS cat rg rane: Ate Wt DCR etc a TOME Nice Teg! Soho MIAETTESTTS CaN ae ter. art He 9 Sec eae ae ea a

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lc OR GITICN SAIN oR OTS a ES Ue, ae MeO a 8 aE SAP oct TH ee Can Pn LESS) OPN IRE RETIN. EN T6 [Se Becerra rE le aes a eee ee SRO Ute Crk PEyingiopare patts.and-vemnicle iclantificatlor:MUMbOrS .vacscs+

33.6 Typical seat belt floor fixings A B

Lap belt buckle Right-hand belt buckle

GC D

Left-hand belt buckle

Lap belt

ensure that the tag engages correctly in the “B” pillar. 20 _ Tighten the retaining bolts to the specified torque settings.

Rear seat belts and stalks 21 Various combinations of rear seat belts may be fitted, according to vehicle type and specification. The removal and refitting procedures are essentially the same as those described previously for the front seat belts, but it will be necessary in some instances to remove the relevant interior trim for access. Refer to Section 30, if necessary, for interior trim details. Ensure that all attachment bolts are tightened to the specified torque when refitting.

12-1

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Contents Section Air bag control module - removal and refitting ........cccccscscscssssseeeeee 29 Air bag unit - removal and refitting.........c..:ccccsccsssesescossscesescseseeeeees 28

Battery check and maintenance...........ccccccsssccssescesscesees See Chapter 1 Baller removal ancirerittinGec sect eee en See Chapter 5 Bulbs (exterior: lights) - [email protected] 14 Bullosi(intenion lights)'= [email protected] ceca cacsacteeses 18 Cigarette lighter - rernoval and refitting .....0....cccccccececesescsseseseeeeeees 11 Clocks iremovaliandirefittingr on sta .crcee 12 Compact disc player - removal and refitting ......0...c.cccesesecsceseseeeee 24 Electrical fault-finding - general information ..........ccccscescesseseeeeeeee 2 Exterior light units - removal and refitting ...........c:cccccseseeseeseseeeeeeeee 16 Fuel and temperature gauge (tachograph models) - removal ACCUM eemerreecte er cest eset hier tere ire ue eee el nN 8 Fuses and relays - general information .............:ccccscesssseesessessenses 3 General information and preCautions. ...........cccccccessssscessesseseensenceaes 1 Headlight beam alignment - checking and adjustment ................. 13 FLOWN LSMMOVall AMG) NeTILLIMG)|....¢sx¥ue ONS SNINSYA1HSIT

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Notes

IND-1

Index SS

SS

SSS

SSS

SSS

SSS

SSS

Note: References throughout this index relate to Chapter and page numbers, separated by a hyphen.

A

propeller shaft — 1-20, 8-4 rear hub — 8-9, 8-12

A-pillar — 11-23 About this manual! — 0-5 ABS — 9-19, 9-20 Accelerator — 4-12

Acknowledgements — 0-2 Aerial — 12-21 Air bag — 10-19, 12-22 Air cleaner — 1-1, 1-23, 4-3 Air conditioning — 1-18, 3-12 Alternator — 5-3, 5-4 drivebelt — 1-13

Amplifier — 12-21 Anti-lock braking systern (ABS) — 9-19, 9-20 Anti-roll bar — 10-12, 10-17 Anti-stall speed — 1-23 Anti-theft system — 12-23 Antifreeze mixture — 1-26 Automatic transmission — 7B-1 et seq fault diagnosis — 0-24 fluid level check — 1-22 linkage lubrication — 1-20 removal — 2B-7, 2B-8 selector quadrant bulb — 12-16

Big-end bearings — 2B-20, 2B-23 Bleeding brake hydraulic system — 9-3 fuel system — 4-3 power steering — 10-31 Block — 2B-17 Blower (heater) motor — 3-9, 3-10 switch — 12-8 Body damage — 11-2, 11-4

Body electrical system — 12-1 et seq Bodywork and fittings — 11-1 et seq Bonnet — 11-4, 11-5 lubrication — 1-19 release cable/latch — 11-4 Brake bands (automatic transmission) — 7B-2

Braking system — 1-17, 9-1 et seq caliper — 9-7, 9-8 disc — 9-9 drum — 9-9 fault diagnosis — 0-25 fluid — 1-10, 1-26 light — 12-14, 12-17 line check — 1-21

master cylinder — 9-13, 9-14 pads — 9-4 pedal — 9-19, 9-21

B B-pillar — 11-23 Balljoints (track rod end) — 10-24 Battery check/charging — 1-12 electrolyte level — 1-9 flat — 0-19 removal and refitting — 5-2 Beam axle (front) — 10-15, 10-15

Bearings big-end — 2B-20, 2B-23 clutch release — 6-5

engine — 2B-20, 2B-22 main — 2B-20, 2B-22

pipes and hoses — 9-4 road test — 1-22 shoes — 1-18, 9-9 stop-light switch — 12-8 vacuum pump — 9-16 wheel cylinder — 9-13 Brushes alternator — 5-4 starter motor — 5-5 Bulbs — 12-3, 12-9, 12-10, 12-13, 12-15 Bump stop (beam axle front suspension) — 10-17 Bumpers — 11-20, 11-21 Bush lubrication (steering) — 1-19 Buying spare parts and vehicle identification numbers — 0-9

IND-2

Index

Cc

E

C-pillar — 11-23 Cables accelerator — 4-12

Earth fault (finding) — 12-5 Electric window switch — 12-8 Electrical system (body) — 12-1 et seq

bonnet release — 11-4

check — 1-12

clutch — 1-20, 6-2

fault diagnosis — 0-26

downshift (automatic transmission) — 7B-2, 7B-3

road test — 1-22

handbrake — 9-18

Electrical systems (engine) — 5-1 et seq

heater/ventilation control — 3-9

Electrolyte level — 1-9

Electronic module (ABS) — 9-20 Electronic Programmed Injection Control system — 4-21, 4-23 Emissions control systems — 4-19, 4-20 Engine (in-car repair) — 2A-1 et seq fault diagnosis — 0-22 mountings — 2A-19

kickdown (automatic transmission) — 7B-2, 7B-3 selector (automatic transmission) — 7B-3 speedometer — 12-12 Caliper (brake) — 9-7, 9-8 Camber — 10-31 Camshaft — 2B-12 drivebelt — 2A-7 to 2A-8

oil and filter change — 1-15

drivebelt covers — 2A-6

oil level — 1-8

removal — 2B-4, 2B-5, 2B-7, 2B-8

Capacities — 1-4

Carpets — 11-2

Engine compartment — 1-6

Environmental considerations — 0-14 Exhaust emissions control — 4-19, 4-20 Exhaust gas recirculation (EGR) system — 4-20 Exhaust manifold — 4-16

Castor — 10-31 Centre bearing check (propeller shaft) — 1-20 Charging system — 1-13, 5-3 Cigarette lighter — 12-12 Clock — 12-10, 12-12

Exhaust system — 1-21, 4-19

Clutch — 6-1 et seq

Expansion tank (cooling system) — 3-3

cable — 1-20, 6-2

Exterior lights — 12-16

fault diagnosis — 0-23 pedal — 6-3 road test — 1-22 Coil spring (front suspension) — 10-9 Compact disc player — 12-20 Compression and leakdown test — 2A-4

Exterior mirror — 11-19

Connecting rods — 2B-15, 2B-19, 2B-23

Facia — 11-22

Contents — 0-3 Conversion factors — 0-20 Coolant level — 1-8 \ renewal — 1-25 temperature sender — 3-6 Cooling fan (radiator) — 3-5 Cooling, heating and ventilation systems — 3-1 et se fault diagnosis — 0-23 hoses — 3-3

side switches — 12-8 Fan (radiator) — 3-5 Fast idle thermostatic sensor — 4-5 Fault diagnosis — 0-21 automatic transmission — 0-24 braking system — 0-25

F

clutch — 0-23

Courtesy light — 12-7, 12-15

cooling system — 0-23 electrical system — 0-26, 12-4 engine — 0-22 fuel and exhaust systems — 0-23

Crankcase — 2B-17 Crankcase emissions control — 4-20

manual transmission — 0-24 propeller shaft — 0-25

Crankshaft — 2B-16, 2B-20, 2B-22

oil seals — 2A-16 sprocket — 2A-9 Cylinder block/crankcase — 2B-17 Cylinder head — 2A-10, 2A-11, 2B-9 to 2B-11 cover — 2A-5

D

rear axle — 0-25

,

steering — 0-25 suspension — 0-25 Firing order — 2A-1 Flame plugs — 5-10 fuel reservoir — 1-26 Flat battery — 0-19 Fluids — 1-3

automatic transmission — 1-22

D-pillar — 11-23 Dents — 11-3

Differential — 8-14

brake — 1-10, 1-26

leak check — 1-14, 1-21 level checks — 1-8

power steering — 1-11

Dimensions and weights — 0-6 Direction indicator — 12-14, 12-16, 12-17

washers — 1-9 Flywheel — 2A-18

Doors — 11-5 to 11-14, 11-16, 11-17

Front brake pad check — 1-18

Disc brakes — 1-18, 9-9

check and lubrication — 1-19 inner trim panel — 11-5

Hee

Footwell trim — 11-23

Front sidelight bulb — 12-14

Fuel, exhaust and emissions control systems — 4-1 et seq

fault diagnosis — 0-23

window glass — 11-16 to 11-19 Downshift cable (automatic transmission) — 7B-2, 7B-3

Fuel filter — 1-1, 1-16, 1-24, 4-11 Fuel gauge — 12-10 12-11 ;

Drive pinion oil seal — 8-13 Drivebelt check — 1-13 Drivetrain road test — 1-22 Drop arm (steering gear) — 10-28

Fuel injection pump — 4-6 sprocket — 2A-9 Fuel injectors — 4-9, 4-11

Drag link (steering gear) — 10-29

sender unit — 4-13

Fuel fi

- 1f

Index a Fuel tank — 4-13

Fuses — 12-1, 12-2, 12-5

L Leaf spring

G Gaiters (steering gear) — 10-25 Gear lever (manual transmission) — 7A-3 Gear ratios automatic transmission — 7B-1 manual transmission — 7A-1 Gearbox — See Manual transmission

Gearchange linkage (manual transmission) — 7A-3 Glass— 11-16 to 11-19 Glow plugs — 5-10 Grille — 11-21 Guibo joint (propeller shaft) — 8-5

front suspension — 10-16 rear suspension — 10-18 Leakdown test — 2A-4

Light switch — 12-6 Load-apportioning valve (rear brakes) — 9-19 check and adjustment — 1-22 Locks — 1-19 door— 11-7, 11-8, 11-10, 11-12, 11-15

steering column — 12-6 Loudspeakers — 12-22 Lower arm (front suspension) — 10-10 to 10-12

Lubricants and fluids — 1-3

M

H Halfshaft — 8-8 Handbrake — 9-17 cables — 9-18 lever ~ 9-17 lubrication and adjustment — 1-20 Handles (door) — 11-6, 11-7, 11-10, 11-13, 11-14 Hazard warning lights -- 12-15 Headlight — 12-16 beam alignment — 12-13 bulb — 12-13 washers — 1-9, 1-12, 12-19 Headlining — 11-23 Heater — 3-7 blower motor — 3-9, 3-10 blower switch — 12-8 Heating and ventilation systems — 3-1 et seq Hinges and locks — 1-19 Horn — 12-17 switch — 12-6 Hoses — 1-14 cooling system — 3-3 power steering — 10-30 Hub (front) — 10-8, 10-9, 10-14

Main and big-end bearings — 2B-20, 2B-22 Maintenance and servicing — 1-1 et seq Manifolds — 4-15, 4-16 Manual transmission — 1-19, 7A-1 et seq fault diagnosis — 0-24 removal — 2B-7, 2B-8 Master cylinder (brake) — 9-13, 9-14 Maximum speed — 4-1, 4-4 Mirrors — 11-19 MOT test checks — 0-28 Mountings engine — 2A-19 transmission — 7A-7

N Number plate light — 12-14, 12-17

O Oils — 1-3 change — 1-15 check engine — 1-8 manual transmission — 1-19 rear axle — 1-21

idle speed and anti-stall speed — 1-23

Ignition switch — 12-6 Indicators — 12-14, 12-16, 12-17 Inhibitor switch automatic transmission — 7B-4 overdrive unit — 7A-10

Oil Oil Oil Oi! Oil Oil

cooler — 2A-20 filler cap check — 1-16

J

filter — 1-1, 1-15 pressure warning light switch — 5-10 pump — 2A-14, 2A-16 seals — 0-13 automatic transmission — 7B-4 crankshaft — 2A-16 drive pinion (rear axle) — 8-13 manual transmission — 7A-4 overdrive unit — 7A-6 speedometer drive pinion — 7A-6 Open-circuit (finding) — 12-4 Output shaft oil seal — 7A-5, 7B-4 Overdrive unit — 7A-10, 7A-11 slipjoint lubrication — 1-20 output shaft oil seal — 7A-6 Overhaul (engine) — 2B-1 et seq

Jacking, towing and wheel changing — 0-6 Jump starting — 0-19

P

Injection timing — 4-2, 4-8 Injectors — 4-9, 4-11 Iniet manifold — 4-15

Input shaft oil seal (manual transmission) — 7A-4 Instruments — 12-9 illumination — 12-9, 12-10 road test — 1-22

Instrument panel switches — 12-7

Interior light bulbs — 12-15 Interior trim — 11-23 Introduction to the Ford Transit Diesel — 0-5

K Kickdown cable (automatic transmission) — 7B-2, 7B-3

Kingpin and bush lubrication — 1-19

Pads (brake) — 9-4 Paintwork damage — 11-2 Parking light bulb — 12-14 Parts — 0-9

Index IND-4 S e Pedals accelerator — 4-12 brake — 9-19, 9-21 clutch — 6-3

Pipes fuel — 4-11 power steering — 10-30 Piston/connecting rod assemblies — 2B-15, 2B-19, 2B-23

Piston rings — 2B-21 Plastic components — 11-4 Power amplifier — 12-21

Power steering — 10-29 to 10-31 fluid level check — 1-11 pump drivebelt — 1-14 Preheating system — 1-26, 5-10

Sender units fuel gauge — 4-13 coolant temperature — 3-6 Servicing — 1-1 et seq

Servo (automatic transmission) — 7B-5 Servo unit (braking system) — 9-16 Shock absorber front — 10-13, 10-17

rear — 10-19 Shoes (brake) — 9-9 Short-circuit (finding) — 12-5

Side repeater — 12-14, 12-16 Sidelight bulb — 12-14 Sliding door — 11-10, 11-11 Sliding window — 11-18

Pressure control valve (rear brakes) — 9-18

Solenoid valve (overdrive unit) — 7A-10

Priming fuel system — 4-3 Printed circuit — 12-10, 12-11 Propeller shaft — 8-1 et seq check — 1-20 fault diagnosis — 0-25 lubrication — 1-20 Punctures — 0-7

Spare parts — 0-9 Speakers — 12-22 Special tools — 0-14, 0-17 Speedometer — 12-10, 12-10 cable — 12-12 drive automatic transmission — 7B-4, 7B-6 manual transmission — 7A-6, 7A-7 Sprockets camshaft — 2A-8 crankshaft — 2A-9

Q

panel — 11-23 Quarter window — 11-17, 11-19 Quarter

fuel injection pump — 2A-9 timing belt — 24-8

R

Starter motor — 5-4, 5-5 Starter switch — 12-6 Starting and charging systems — 5-1 et seq

Radiator — 3-3

Steering — 10-1

et seq

Radio aerial — 12-21

angles/alignment — 10-31

Radio/cassette — 12-20

check — 1-17, 1-19

anti-theft system -— 0-19

column — 10-20,

10-21,

Rear axle — 8-1 et seq fault diagnosis — 0-25

switches — 12-6 fault diagnosis — 0-25

Rear door — 11-12, 11-14

pump — 10-29

oil level check — 1-21

12-6

|

gear — 10-23, 10-25, 10-28 to 10-31

Rear hub — 8-9, 8-12 Rear light cluster — 12-14, 12-17 Regulator (alternator) — 5-4 Regulator (door window) — 11-16

road test — 1-22 wheel — 10-19 Stop solenoid — 4-6 Stop-light — 12-8, 12-14

Relays — 12-3, 12-5

Stub axle — 10-9, 10-14

Sump - 2A-13

|

Repair procedures — 0-13

Suspension and steering — 10-1 et seq

|

Respraying — 11-3 Reversing light switch — 7A-6 Rings (piston) — 2B-21 Road test — 1-22

Suspension check — 1-17 fault diagnosis — 0-25 front — 10-9 to 10-17

Release bearing (clutch) — 6-5

Roadwheel check — 1-17, 1-22

Rocker cover — 2A-5 Rocker gear — 2A-10 Roll bars — 10-12, 10-17 Routine maintenance and servicing - 1-1 et seq procedures — 1-8 et seq

schedule — 1-4

Rubber gaiter (steering gear) — 10-25

lower arm (front) — 10-10 to 10-12

rear — 10-18, 10-19 road test — 1-22 Switches — 12-6 blower (heater) — 12-8

brake stop-light — 12-8

cooling system — 3-6

courtesy light — 12-7 electric window — 12-8

| |

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|

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I | i

facia — 12-8

heater blower — 12-8

Ss ;

Safety first! — 0-11 a Congunang een % al, ; cooling system — electrical system engine electrical fuel and exhaust

3-2 — 12-4 — 5-2 systems — 4-3, 4-21

Scratches — 11-2 Seat belts — 1-13, 11-25 Seats — 11-24

Selector (automatic transmission) — 7B-4

cable — 7B-3

horn — 12-6

ignition — 12-6 inhibitor (automatic transmission) — 7B-4 instrument panel — 12-7 light — 12-6 oil pressure warning light — 5-10 overdrive unit — 7A-10 reversing light — 7A-6 starter — 12-6 steering column — 12-6 stop-light — 12-8 window — 12-8

wiper — 12-6

|

index

IND-5

+ Tachograph — 12-11 Tachometer — 12-10 Tailgate — 11-14, 11-15 check and lubrication — 1-19 washer — 1-9, 1-12, 12-20 wiper motor — 12-20 Tappets — 2B-12 TDC (locating) — 2A-5 Temperature control system (air cleaner) — 1-24 Temperature gauge — 12-10, 12-11 sender unit — 3-6 Tensioner (timing belt) — 2A-8, 2A-9 Thermostat (cooling system) — 3-6 Throttle cable — 4-12 Timing belt — 2A-7 to 2A-9 cover — 2A-6 Toe setting — 10-2, 10-31 Tools and working facilities — 0-15 Top Dead Centre (locating) — 2A-5 Towing — 0-6 Track rod end balijoint — 10-24

Tracking — 10-2, 10-31 Transmission — See Manual or Automatic transmission Trim panels door — 11-5 footwell — 11-23 pillars — 11-23 rear quarter panel — 11-23 Turbocharger — 4-16, 4-17, 4-19 Tyre pressures — 1-2 Tyres — 1-10

U Underbody — 11-2 check — 1-21 views — 1-6, 1-7 Universal joint check (propeiler shaft) — 1-20

Upholstery and carpets — 11-2

Vacuum diaphragm (automatic transmission) — 7B-4 Vacuum governor (automatic transmission) — 7B-5, 7B-6 Vacuum pump (brakes) — 9-16 Vacuum servo unit (braking system) — 9-16 Valves — 2B-10 clearances — 2A-1, 2A-10 Vehicle identification numbers — 0-9 Ventilation system — 3-7 to 3-11 Vents (ventilation system) — 3-11

Viscous cooling fan (radiator) — 3-5

W Warning lights — 12-9, 12-10, 12-12 Washers — 12-19 fluid level — 1-9 system check — 1-12

Water pump -- 3-7 drivebelt — 1-13 Weights — 0-6

Wheel (steering) — 10-19 Wheels alignment — 10-2, 10-31 bearings (front) — 10-9, 10-14 changing — 0-7

check — 1-17, 1-22 Wheel cylinder — 9-13 Wheel sensor (ABS) — 9-21 Window glass — 11-16 to 11-19

Window regulator — 11-16 Window switch — 12-8 Windscreen — 11-19, 11-21 washers — 12-19 wiper motor — 12-18 Wiper arms — 12-18 Wiper blades — 1-2, 1-12 Wiper motor tailgate — 12-20 windscreen — 12-18 Wiper switch — 12-6 Wiring check — 1-18 Wiring diagrams — 12-24 et seq Working facilities — 0-15

Sei o

IND

Models covered by this Manual eG

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