Ford 2002 Bantam Compact Pickup Truck Manuals

Ford 2002 Bantam Compact Pickup Truck Manuals

Manuals and User Guides for Ford 2002 Bantam Compact Pickup Truck. We have 1 Ford 2002 Bantam Compact Pickup Truck manual available for free PDF download: Workshop Manual

Ford 2002 Bantam Workshop Manual

Ford 2002 Bantam Workshop Manual (1664 pages)

Brand: Ford | Category: Automobile | Size: 47 MB

Table of Contents

Main Index
2
General Information
2
General Information
3
Table of Contents
4
Description and Operation
6
About this Manual
6
- Introduction
  6
- Replacement Parts
  6
- Special Tools
  6
- Important Safety Instructions
  6
- Warnings, Cautions and Notes in this Manual
  6
- How to Use this Manual
  6
  - Inspection and Verification
    7
  - Sympton Chart
    7
  - Pinpoint Tests
    7
  - Component Tests
    7
- Samples
  7
Health and Safety Precautions
8
- Acids and Alkalis
  8
- Air Bags
  8
- Air Conditioning Refrigerant
  8
- Introduction
  8
- Adhesives and Sealers
  9
  - Water-Based Adhesives/Sealers
    9
  - Hot Melt Adhesives
    9
- Antifreeze
  10
- Asbestos
  10
- Battery Acids
  10
- Chemical Materials
  10
- Brake and Clutch Linings and Pads
  10
- Brakes Fluids (Polyalkylene Glycols)
  10
- Brazing
  10
- Chlorofluorocarbons (CFC)
  11
- Clutch Fluids
  11
- Dusts
  11
- Electric Shock
  11
- Clutch Linings and Pads
  11
- Corrosion Protection Materials
  11
- Cutting
  11
- Dewaxing
  11
- Exhaust Fumes
  12
- Gasolene (Petrol) Engine
  12
- Fibre Insulation
  12
- First Aid
  12
- Engine Oils
  12
- Fire
  12
- Fluoroelastomer
  12
- Foams - Polyurethane
  13
- Fuels
  13
  - Gasoline (Petrol)
    13
  - Alternative Fuel
    13
- Freon
  13
- Gas Cylinders
  14
- General Workshop Tools and Equipment
  14
- High Pressure Air, Lubrication and Oil Test Equipment
  14
- Legal Aspects
  14
- Gases
  14
- Gaskets (Fluoroelastomer)
  14
- Halon
  14
- Lubricants and Greases
  15
  - Used Engine Oil
    15
  - Health Protection Precautions
    15
  - Environmental Precautions
    15
- Noise
  15
- Noise Insulation Materials
  15
- O-Rings (Fluoroelastomer)
  15
- Paints
  15
- Pressurized Equipment
  16
- Solder
  16
- Solvents
  16
- Suspended Loads
  16
- Sound Insulation
  16
- Transmission Brake Bands
  16
- Underseal
  16
- Viton
  16
- Welding
  17
  - Resistance Welding
    17
  - Arc Welding
    17
  - Gas Welding (and Cutting)
    17
- Warning Symbols on Vehicles
  18
- White Spirit
  19
Standard Workshop Practices
20
- Vehicle in Workshop
  20
- Alternative Fuel
  20
- Alternative Fuel - Do's
  20
- Alternative Fuel - Do Nots
  20
- Towing the Vehicle
  21
- Connecting a Slave Battery Using Jumper Cables
  21
- Component Cleaning
  22
- Cleaning Methods
  22
- Calibration of Essential Measuring Equipment
  22
Solvents, Sealers and Adhesives
23
- General Specifications
  23
- Introduction
  23
Road/Roller Testing
24
- Pre-Test Checks
  24
- Starting the Engine
  24
- On Road or Roller Test Check
  24
- Brake Testing
  25
- Identification Codes
  26
- Vehicle Identification Number (VIN)
  27
- Vehicle Identification Number
  28
- World Manufacturer
  28
- Year of Manufacture
  28
- Month of Manufacture
  29
- Vehicle Certification Label (Typical) or VIN Plate
  30
- Body Colour Code
  31
  - Interior Trim Colour
    31
  - Jacking and Lifting
    32
  - Jacking
    33
  - Lifting
    34
  - Noise, Vibration and Harshness
    35
- Noise, Vibration and Harshness (NVH)
  36
- Diagnostic Theory
  36
- Know the System
  36
- Diagnostic Charts
  36
- Description and Operation
  36
- Know the History of the System
  36
- Know the History of the Condition
  36
- Know the Probability of Certain Conditions Developing
  36
- Do Not Cure the Symptom and Leave the Cause
  36
- Be Positive the Cause Is Found
  36
  - Customer Interview
    38
  - Identifying the Condition
    38
- Noise Diagnostic Procedure
  38
- How to Use this Diagnostic Procedure Section
  38
- Diagnosis and Testing
  38
- Noise, Vibration and Harshness (NVH)
  38
- Inspection and Verification
  38
  - Noise Conditions
    39
  - Vibration Conditions
    39
  - Leakage Conditions
    39
  - Inoperative Conditions
    39
- Road Test Quick Checks
  40
- Vehicle Preparation
  41
- Lift Test
  41
- Road Conditions
  41
- Symptom Chart
  42
- 100-04-41A
  42
- Pinpoint Tests
  43
- 100-04-41B/53
  43
  - High Speed Shake
    46
  - Tip-In Moan
    47
  - Idle Boom/Shake/Vibration
    48
- General Procedures
  58
- Powertrain/Drive Train Mount Neutralizing
  58
- Exhaust System Neutralizing (25 001 0)
  59
- Lubricants, Fluids, Sealers and Adhesives
  60
- Specifications
  60
  - Chassis
    61
  - Suspension — General Information
    62
  - Suspension System
    63
  - Torque Sensitive
    63
  - Vehicle Speed Sensitive
    63
  - Engine Speed Sensitive
    63
  - Front Suspension
    63
  - Ball Joint – Lower, Inspection
    64
  - Suspension Unit Checks
    64
  - Vehicle Inspection
    64
  - Rear Suspension
    64
  - Lift Check
    65
  - Bench Test
    65
  - Rear Suspension
    65
- Pinpoint Tests
  71
- Pinpoint Test A: Drift Left or Right
  71
- A1: Check for Drift Left or Right
  71
- A2: Check the Steering Linkage
  71
- A3: Check the Wheel Alignment
  72
- A4: Check the Tyres
  72
- A5: Rotate the Tyres
  72
- Pinpoint Test B: Steering Wheel Off-Center
  72
- B1: Inspect the Steering Components
  72
- B2: Check the Wheel Alignment
  73
- Pinpoint Test C: Tracks Incorrectly
  73
- C1: Check the Caster Angle
  73
- C2: Check the Rear Suspension
  73
- Pinpoint Test D: Rough Ride
  74
- D1: Check the Suspension Units
  74
- Pinpoint Test E: Excessive Noise
  74
- E1: Inspect the Suspension
  74
- E2: Inspect the Springs
  74
- E3: Inspect the Front Suspension Lower Arm
  75
- E4: Inspect the Ball Joint
  75
- E5: Inspect the Front Wheel Bearings
  75
- E6: Inspect the Tyres
  75
- Pinpoint Test F: Incorrect Tyre Wear
  76
- F1: Inspect the Tyres
  76
- F2: Check for Cupped Tyres
  76
- Pinpoint Test G: Vibration
  76
- G1: Inspect the Tyres
  76
- G2: Inspect the Front Wheel Bearings
  77
- G3: Measure the Front Wheel Bearing End Play
  77
- G4: Inspect the Rear Wheel Bearings
  77
- G5: Measure the Rear Wheel Bearing End Play
  78
- G6: Measure the Wheel/Tyre Run out on the Vehicle
  78
- G7: Measure the Wheel/Tyre Run out off the Vehicle
  78
- Wheels and Tyres
  78
- G8: Match Mounting
  79
- G9: Measure the Wheel Run out
  79
- G10: Rear Hub and Stud Circle Run out
  79
- G11: Front Hub and Stud Circle Run out
  80
- G12: Wheel Balance
  80
- Front Suspension
  81
- Diagnosis and Testing
  82
- Front Suspension
  82
- Front Toe Adjustment (14 117 0)
  83
- General Procedures
  83
  - Wheel Bearing Inspection (14 117 0)
    85
  - Wheel Bearing (14 411 0)
    87
- Removal and Installation
  87
- Lower Arm
  90
- DISASSEMBLY and ASSEMBLY Strut and Spring Assembly
  104
  - Front Wheel Alignment (at Kerb Weight) - Caster and Camber
    106
  - Front Wheel Alignment (at Kerb Weight) - Total Toe Setting
    106
- Torque Specifications
  106
- Description and Operation
  109
- Rear Suspension
  109
- Diagnosis and Testing
  110
- Rear Suspension
  110
- Beam Axle and Suspension Assembly Removal (15 231 0)
  111
- Removal and Installation
  111
  - Tube - Rear Axle - Replace (15 730 0)
    114
  - Leaf Spring (15 366 0)
    117
  - Spring Bushes (15 781 0)
    119
  - Bump Rubber (15 413 4)
    120
  - Shock Absorber - Rear (15 783 4)
    122
- Specifications
  123
- Wheels and Tyres
  124
- Description and Operation
  125
- Safety Precautions
  125
- Wheels and Tyres
  125
- Winter Tyres
  126
- Tyre Wear Diagnosis
  127
- Diagnosis and Testing
  127
- Wheels and Tyres
  127
- Inspection and Verification
  127
- Symptom Chart
  128
  - Wheel and Tyre Removal
    132
  - Wheel and Tyre Installation
    132
  - Tyre Pressures - Kpa
    133
- Wheel and Tyre Size
  133
- Torque Specifications
  133
- Front Drive Halfshafts
  134
- Description and Operation
  135
- Front Drive Halfshafts
  135
- Exploded View of the Front Drive Halfshaft
  136
- Working Principle of the Front Drive Halfshafts
  137
- Handling Front Drive Halfshafts
  137
- Wheel Balancing, Front
  137
- Underbody Protection and Corrosion Prevention
  137
- Raise the Vehicle
  137
- Towing the Vehicle
  137
- Diagnosis and Testing
  138
- Front Drive Halfshafts
  138
- Symptom Chart
  138
- Halfshaft LH (14 320 0)
  139
- Removal and Installation
  139
- Outer Constant Velocity (CV) Joint
  155
- Halfshaft LH (14 320 8)
  160
- Disassembly and Assembly
  160
- Halfshaft RH (14 320 8)
  164
- Lubricants, Fluids, Sealers and Adhesives
  169
- Capacities
  169
- Fill Capacities
  169
- Torque Specifications
  169
- Brake System — General Information
  170
- Drum Brake
  170
- Brake System
  171
- Description and Operation
  171
- Visual Inspection Chart
  172
- Brake System
  172
- Diagnosis and Testing
  172
- Inspection and Verification
  172
- Road Test
  172
- Symptom Chart
  173
- Pinpoint Tests
  176
  - Brakes Pull or Drift
    178
  - Brake Warning Indicator Always on
    179
  - Vibration When Brakes Are Applied
    180
  - Pedal Goes down Fast
    181
  - Pedal Eases down Slowly
    182
  - Pedal Is Low or Feels Spongy
    183
  - Brake Lock up During Light Brake Pedal Force
    184
  - Excessive or Erratic Brake Pedal Travel
    185
  - Brakes Drag
    185
  - Excessive Brake Pedal Effort
    186
  - Brake Noise
    187
  - Slow or Incomplete Brake Pedal Return
    188
  - Hydraulic Leak Check
    188
- Component Tests
  188
- Brake System Check
  189
- Brake Pedal Reserve Check
  189
- Brake Booster Functional Test
  189
  - Brake Master Cylinder
    189
  - Abnormal Conditions
    190
  - Bypass Condition Test
    190
  - Non-Pressure Leaks
    190
  - Brake System Bleeding (12 141 0)
    191
- General Procedures
  191
- Load Active Valve (LAV)
  193
- Load Apportioning Valve Adjust
  195
- Brake Disc Run out Check
  197
- Lubricants, Fluids, Sealers and Adhesives
  199
- Front Disc Brake Specification
  199
- Drum Brake Specification
  199
- Drum Brake
  200
- DESCRIPTION and OPERATION Drum Brake
  201
- DIAGNOSIS and TESTING Drum Brake
  202
- Brake Drum Replacement (12 275 0) Removal
  203
- REMOVAL and INSTALLATION Brake Drum Replacement
  203
- SPECIFICATIONS Specifications
  214
- Front Brake Disc
  215
- DESCRIPTION and OPERATION Front Brake Disc
  215
- REMOVAL and INSTALLATION Brake Pads
  217
- Wheels and Tyres
  217
  - Brake Pads Installation
    218
  - Brake Caliper (12 243 0)
    220
- DISASSEMBLY and ASSEMBLY Brake Caliper
  222
- Specifications
  224
- Lubricants, Fluids, Sealers and Adhesives
  224
- Front Disc Brake Specification
  224
- Parking Brake and Actuation
  227
- Parking Brake
  228
- Parking Brake
  229
- Diagnosis and Testing
  229
- Inspection and Verification
  229
- Symptom Chart
  229
  - The Parking Brake will Not Release
    230
  - Parking Brake Control (12 664 0)
    232
- Removal and Installation
  232
- Parking Brake Cable and Conduit (12 675 0)
  234
- Parking Brake Warning Indicator Switch
  237
- Parking Brake Cable Adjustment (12 662 0)
  238
- General Procedures
  238
- Hydraulic Brake Actuation
  240
- Description and Operation
  241
- Hydraulic Brake Actuation
  241
- Diagnosis and Testing
  242
- Hydraulic Brake Actuation
  242
- Brake Master Cylinder (12 343 0)
  243
- Removal and Installation
  243
- Brake Pedal
  245
  - Brake Fluid Reservoir (12 341 0)
    247
  - Brake Pedal Cross-Shaft (12 338 0)
    249
- Brake Pedal and Bracket
  252
- Specifications
  255
- Lubricants, Fluids, Sealers and Adhesives
  255
- Torque Specifications
  255
- Power Brake Actuation
  256
- DESCRIPTION and OPERATION Brake Booster
  257
- Power Brake System
  258
- Diagnosis and Testing
  258
- Brake Booster (12 451 0)
  259
- Removal and Installation
  259
- Specifications
  261
- Torque Specifications
  261
- Steering System — General Information
  262
- Steering System
  263
- Principles of Operations
  263
- Inspection and Verification
  263
- Symptom Chart
  263
  - Power Steering
    263
  - Steering Linkage
    264
  - Steering Linkage
    265
- Component Tests
  265
- Steering Column
  265
- Power Steering System Filling (13 416 1)
  266
- General Procedures
  266
- Manual Steering
  277
- DESCRIPTION and OPERATION Manual Steering
  277
- DIAGNOSIS and TESTING Manual Steering
  278
- Steering Gear (13 116 0)
  279
- REMOVAL and INSTALLATION Steering Gear
  279
  - Power Steering - Petrol
    286
  - Power Steering
    287
  - Vehicles with 1.8L Endura de Engine
    288
- Description and Operation
  288
- Power Steering
  288
- Diagnosis and Testing
  290
- Power Steering
  290
- Power Steering Pump — Vehicles with 1.8L Endura de Diesel Engine
  291
- Removal and Installation
  291
- Power Steering Pump to Steering Gear Pressure Line
  321
- Steering Gear to Fluid Cooler Return Hose
  331
- Steering Linkages
  341
- Description and Operation
  342
- Steering Linkage
  342
- Diagnosis and Testing
  343
- Steering Linkage
  343
- Tie-Rod End (13 273 0)
  344
- Removal and Installation
  344
  - Steering Gear Boot (13 134 0)
    346
  - Steering Column
    348
  - Steering Wheel (13 524 0)
    350
  - Air Bag Sliding Contact (33 392 0)
    351
  - Steering Column (13 542 0)
    352
- Steering Column Switches
  356
- A3: Check Circuit 30 Rd) for Short to Ground
  362
- A4: Check for Open on Circuit 30 (Rd)
  362
- A5: Check the Ignition Switch
  363
- B1: Check for Open /Short to Ground on Circuit 75 (Ye)
  363
- No Power in Run
  364
- C1: Check Fuse 38 (60A)
  364
- C2: Check for Short to Ground on Circuit 30 (Rd)
  364
- C3: Check the Ignition Switch
  364
- C4: Check for Open on Circuits 15 (Gn) and 15 (Gn/Bu)
  365
- C5: Check the Ignition Relay Ground
  365
- C6: Check the Ignition Relay Power Feed
  365
- No Power in Start
  366
- C7: Check for Open on Circuit 15 (Gn)
  366
- D1: Check Fuse 36 (60A)
  366
- D2: Check for Short to Ground on Circuit 30 (Rd)
  367
- D3: Check the Ignition Switch
  367
- D4: Check for Short/Open on Circuit 50 (Gy)
  367
- D5: Check the Start Inhibit Relay Ground
  368
- D6: Check the Start Inhibit Relay Power Feed
  368
- D7: Check for Open on Circuit 50 (Gy/Bk)
  369
- E1: Check the Exterior Lighting
  369
- E2: Check the Wiper and Washer
  369
- Engine
  374
- Inspection and Verification
  374
- Bearing Inspection
  375
- Camshaft Journal Diameter
  376
- Camshaft Journal Clearance
  377
- Camshaft End Play
  378
- Camshaft Lobe Surface
  379
- Camshaft Lobe Lift
  380
- Crankshaft End Play
  381
- Crankshaft Main Bearing Journal Diameter
  382
- Crankshaft Main Bearing Journal Clearance
  383
- Cylinder Bore Taper
  384
- Piston Diameter
  385
- Piston Ring End Gap
  386
- Piston Pin Diameter
  387
- Piston Pin to Bore Diameter
  388
- Piston Inspection
  389
- Piston Ring-To-Groove Clearance
  390
- Connecting Rod Large End Bore
  391
- Cylinder Head Distortion
  392
- Valve Stem Diameter
  393
- Valve Seat Inspection
  394
- Exhaust Manifold Inspection
  395
- Flywheel Inspection
  395
  - Engine — 1.6L / 1.3L Rocam
    396
  - Serial Number and Engine Code Location
    399
  - Valve Train
    400
  - Rear Oil Seal Retainer
    401
  - Cylinder Head
    402
  - Oil Pan
    403
  - Camshaft Chain Drive
    404
  - Coolant Flow Control Housing
    405
  - Intake Manifold (21 183 0)
    407
  - Valve Cover (21 140 0)
    412
  - Crankshaft Front Oil Seal (21 467 0)
    415
  - Valve Seals (21 238 0)
    418
  - Camshaft (21 283 0)
    421
  - Timing Chain
    424
  - Crankshaft Rear Oil Seal
    428
  - Exhaust Manifold (21 186 0)
    430
  - Cylinder Head (21 163 0)
    433
  - Oil Pan (21 154 0)
    443
  - Oil Pump (21 154 0)
    447
  - Engine (21 132 0)
    449
  - Cylinder Head (21 165 6)
    469
  - Engine ASSEMBLY
    476
  - Engine (21 134 8)
    476
  - Engine INSTALLATION
    488
- Crankshaft
  500
- Piston
  500
- Connecting Rod
  501
- Cylinder Block
  501
- Camshaft
  501
  - Engine — 1.8L Diesel - Endura de
    505
  - Timing Belt Pulley - Crankshaft
    507
  - Crankshaft Central Bolt
    507
  - Camshaft Timing Belt
    507
  - Valve Tappets & Adjusting Shims
    508
  - Crankshaft Oil Seals
    508
  - Crankcase Ventilation
    508
  - Auxiliary Shaft Oil Seal (21 556 0)
    525
  - Timing Belt — Engines with Automatic Timing Belt Tensioner (21 304 0)
    538
  - Timing Belt — Engines with Manual Timing Belt Tensioner (21 304 0)
    553
  - Camshaft Oil Seal (21 288 0)
    570
  - Valve Clearance (21 213 0)
    669
  - Engine Cooling - 1.8L Diesel - Endura de
    680
  - Engine Cooling
    681
  - Changing Coolant
    681
  - Thermostat — Vehicles with 1.8L Endura de Diesel Engine (24 454 0)
    683
  - Coolant Expansion Tank (24 284 0)
    696
  - Cooling System Draining, Filling and Bleeding
    697
  - Cooling System Flushing
    699
  - Cooling System Back Flushing
    700
  - Heater Core Back Flushing
    701
  - Starting System - 1.8L Diesel - Endura de
    703
  - Starting System
    704
  - The Engine Does Not Crank or the Relay Clicks
    707
  - The Engine Cranks Slowly
    712
  - Unusual Starter Motor Noise
    713
  - Starter Motor — Vehicles with 1.8L Endura de Diesel Engine (26 204 0)
    715
  - Engine Emission Control — Diesel Engine
    718
  - Engine Emission Control
    719
  - Positive Crankcase Ventilation
    719
  - Exhaust Gas Re-Circulation
    719
  - Exhaust Manifold to Exhaust Gas Re-Circulation (EGR) Valve Tube (23 301 0)
    721
  - Exhaust Gas Re-Circulation (EGR) Valve (23 312 0)
    722
  - Exhaust Gas Re-Circulation (EGR) Valve — Vehicles with 1.8L Endura de Diesel Engine (23 312 0)
    724
  - Electronic Engine Controls — Diesel Engine
    728
  - Engine Emission Controls
    729
  - Electronic Engine Controls
    730
  - Crankshaft Position (CKP) Sensor — Vehicles Wi Th 1.8L Endura de Diesel Engine (29 230 0)
    731
  - Engine Coolant Temperature (ECT) Sensor (21 190 0)
    732
  - Vehicles with Diesel Engine
    736
  - Pressure Test
    741
  - Thermostat Test
    741
  - Radiator Leak Test, Removed from Vehicle
    741
  - Thermostat — Vehicles with 1.6L / 1.3L Engine (24 454 0)
    742
  - Thermostat Housing — Vehicles with 1.6L / 1.3L Engine (24 001 0)
    746
  - Water Pump — Vehicles with 1.6L / 1.3L Engine (24 404 0)
    749
  - Water Pump — Vehicles with Diesel Engine (24 404 0)
    752
  - Radiator (24 254 0)
    756
  - Cooling Fan Motor (24 222 0)
    765
  - Cooling System Draining, Filling and Bleeding (24 122 0)
    769
  - Fuel Charging and Controls
    776
  - Fuel Charging Wiring Harness
    776
  - Fuel Pressure Regulator
    776
  - Fuel Injection Supply Manifold
    777
  - Throttle Body
    777
  - Fuel Injectors
    777
  - Throttle Body (23 198 0)
    779
  - Fuel Injectors (23 455 0)
    782
  - Fuel Charging Wiring Harness (36 437 0)
    786
  - Fuel Charging and Controls — 1.8L Diesel Engine
    790
  - Idle Speed Adjustment (23 413 0) (Vehicles Without Air Conditioning)
    794
  - Idle Speed Adjustment — (Vehicles with Air Conditioning) (23 413 0)
    795
  - Fuel Injection Pump (23 414 0)
    798
  - Fuel Injection Delivery Pipes
    816
  - Waxstat Cable Adjustment
    820
  - Cable - Idle Speed Control - (Adjust)
    821
  - Accessory Drive
    826
  - Accessory Drive Belt
    827
  - Idler Pulley(S)
    827
  - Belt Tensioner
    827
  - Manual Belt Tensioner and Idler Pulley(S)
    830
  - Automatic Tensioner - Static Check
    830
  - Automatic Tensioner - Dynamic Check
    831
  - Accessory Drive Belt Tensioner — Vehicles with 1.6L / 1.3L Engine
    832
  - Accessory Drive Belt — Vehicles with 1.8L Endura de Diesel Engine (31 413 0)
    835
  - Accessory Drive Belt — Vehicles with 1.8L Endura de Diesel Engine and Air Conditioning (31 413 0)
    836
  - Starter Motor — Vehicles with 1.6L / 1.3L Engine (26 204 0)
    851
  - Engine Ignition
    857
  - Ignition Coil Pack — Vehicles with 1.6L / 1.3L Engine (22 414 0)
    859
  - Intake Air Distribution and Filtering
    863
  - Air Cleaner Intake Pipe (23 175 0)
    866
  - Air Cleaner (23 174 0)
    869
  - Powertrain Control Module (PCM) — Vehicles with Petrol Engine (29 200 0)
    876
  - Crankshaft Position (CKP) Sensor — Vehicles with 1.6L / 1.3L Engines (29 230 0)
    878
  - Power Steering Pressure (PSP) Switch — Vehicles with Petrol Engine (33 611 0)
    879
  - Throttle Position (TP) Sensor — Vehicles with 1.6L / 1.3L Engines (23 325 0)
    880
  - Engine Coolant Temperature (ECT) Sensor — Vehicles with 1.6L / 1.3L Engines
    881
  - Engine Knock Sensor — Vehicles with 1.3L Engines
    882
  - Manual Transaxle and Clutch
    890
  - Clutch Slippage
    898
  - Clutch Chatter or Shudder
    899
  - Clutch Drag
    900
  - Clutch Pedal Pulsation
    900
  - Clutch Related Vibrations
    901
  - Hard Shifting
    902
  - Fluid Leakage
    904
  - Clutch Disc Check
    905
  - Clutch Master Cylinder Check
    906
  - Clutch Pressure Plate Check
    907
  - Clutch Slave Cylinder Check
    908
  - Clutch System Bleeding (16 843 0)
    909
  - Gearshift Linkage Adjustment (16 513 0)
    911
  - Clutch
    915
  - Clutch Components
    916
  - Clutch Disc and Pressure Plate
    918
  - Clutch Controls
    922
  - Clutch Master Cylinder
    922
  - Slave Cylinder - Clutch
    922
  - Pre-Load Valve
    922
  - Clutch Operating Mechanism Components
    923
  - Clutch Master Cylinder (16 856 0)
    925
  - Clutch Slave Cylinder (16 862 0)
    927
  - Manual Transaxle
    929
  - Components of the Ib5 Manual Transmission
    931
  - Internal Gearshift Mechanism
    932
  - Input Shaft
    933
  - Output Shaft
    934
  - Double Synchronization
    935
  - Differential
    935
  - Power Flow
    936
  - First Gear
    936
  - Second Gear
    936
  - Third Gear
    936
  - Fourth Gear
    937
  - Fifth Gear
    937
  - Reverse Gear
    937
  - Input Shaft Oil Seal
    939
  - LH Halfshaft Oil Seal (14 303 0)
    941
  - RH Halfshaft Oil Seal (14 304 0)
    943
  - Transaxle — Vehicles with 1.6L / 1.3L Engine (16 114 0)
    946
  - Selector Plate (16 284 5)
    963
  - Transaxle (16 118 8)
    977
  - Transaxle (16 114 0)
    989
  - Bearing Check
    999
  - External Controls
    1004
  - Overview - Gearshift Mechanism
    1004
  - Gearshift Linkage (16 534 0)
    1007
  - Gearshift Stabilizer Bar Bushing (16 589 4)
    1012
  - Gearshift Stabilizer Bar (16 588 0)
    1013
  - Exhaust System
    1021
  - Exhaust Flexible Pipe — Vehicles with Diesel Engines
    1024
  - Muffler and Tailpipe (25 202 0)
    1026
  - Fuel System — General Information
    1030
  - Fuel System
    1031
  - Diesel Fuel System Description and Operation
    1032
  - Fuel Injection Pump
    1032
  - Light Load Retard Device
    1032
  - Cold Start Advance Solenoid
    1032
  - Fuel System Pressure Relief (23 420 0)
    1033
  - Fuel Tank Draining (23 551 0)
    1034
  - Push Connect Fittings
    1035
  - Fuel Tank and Lines — Petrol Engines
    1039
  - Fuel Tank and Lines
    1040
  - Fuel Tank (23 554 0)
    1042
  - Fuel Pump Module (23 534 0)
    1048
  - Fuel Tank Filler Pipe (23 572 0)
    1050
  - Fuel Pump to Fuel Filter Line (23 588 0)
    1051
  - Fuel Filter to Fuel Supply Manifold Line (23 590 0)
    1053
  - Fuel Return Line (23 594 0)
    1057
  - Inertia Fuel Shutoff (IFS) Switch (33 577 0)
    1061
  - Fuel Tank and Lines — Diesel Engines
    1064
  - Fuel Sender Unit (33 286 0)
    1070
  - Fuel Filter Element (23 546 0)
    1073
  - Fuel Tank to Fuel Filter Line (23 588 0)
    1074
  - Acceleration Control
    1084
  - Accelerator Cable Adjustment — Vehicles with 1.6L / 1.3L Engine (23 811 0)
    1087
  - Accelerator Cable Adjustment — Vehicles with Diesel Engine (23 811 0)
    1088
  - Electrical
    1089
  - Climate Control System — General Information
    1090
  - Climate Control System
    1091
  - No/Insufficient Heating Power
    1097
  - Pinpoint Test B
    1103
  - The Heater Blower System Is Inoperative
    1113
  - Spring Lock Coupling (34 639 1)
    1131
  - Air Conditioning (A/C) Clutch Air Gap Adjustment (34 628 6)
    1133
  - Electronic Leak Detection (34 620 5)
    1134
  - Air Conditioning (A/C) System Flushing
    1135
  - Tracer Dye Leak Detection (34 620 5)
    1139
  - Vacuum Leak Detection (34 620 5)
    1140
  - Air Conditioning (A/C) System Evacuation and Charging (34 620 2)
    1141
  - Refrigerant Oil Addition (34 621 1)
    1144
  - Air Distribution System Cleaning
    1145
  - Contaminated Refrigerant Handling (34 620 5)
    1147
  - Air Distribution and Filtering
    1149
  - Ventilation Nozzles
    1150
  - Center Vent Nozzle (34 489 0)
    1152
  - Heating and Ventilation
    1153
  - Blower Motor (34 374 0)
    1156
  - Heater Core Housing (34 354 0)
    1160
  - Heater Core (34 364 0)
    1164
  - Heater Control Valve (34 328 0)
    1168
  - Heater Core Housing (34 354 8)
    1172
  - Air Conditioning
    1176
  - Refrigerant Circuit with Fixed Orifice Tube
    1177
  - Air Conditioning System Components
    1179
  - Compressor
    1180
  - Air Conditioning (A/C) Compressor
    1182
  - Evaporator Core (34 622 0)
    1188
  - Evaporator Core Orifice (34 624 0)
    1192
  - Suction Accumulator (34 630 0)
    1195
  - Low Pressure Cut-Off Switch (34 629 0)
    1198
  - High Pressure Cut-Off Switch (34 631 0)
    1201
  - Evaporator to Condenser Line (34 645 0)
    1203
  - Suction Accumulator to Evaporator Line (34 644 0)
    1209
  - Control Components
    1214
  - Climate Control Assembly (34 300 0)
    1217
  - Blower Motor Switch (33 574 0)
    1220
  - Air Inlet Blend Door Actuator (34 606 0)
    1222
  - Instrument Cluster
    1223
  - Low Fuel Warning Indicator
    1226
  - Worldwide Diagnostic System (WDS) Tester Diagnostics – All Vehicles
    1230
  - Instrument Cluster Diagnostic Trouble Code (DTC) Index
    1230
  - Incorrect Fuel Gauge Indication
    1233
  - The Speedometer Is Inoperative
    1236
  - Incorrect Temperature Gauge Indication
    1237
  - The Tachometer Is Inoperative
    1238
  - The Low Oil Pressure Indicator Is Inoperative
    1240
  - The Brake Warning Indicator Is Inoperative – from 01/99 Onwards
    1240
  - The Charging System Warning Indicator Is Inoperative – from 01/99 Onwards
    1243
  - Instrument Cluster (33 214 0)
    1244
  - Instrument Cluster Printed Circuit (33 224 4)
    1247
  - Charging System — General Information
    1252
  - Charging System
    1253
  - The Charging System Warning Indicator Stays on
    1256
  - The Charging System Warning Indicator Is Inoperative
    1257
  - Radio Interference
    1259
  - No-Load Test
    1259
  - Load Test
    1259
  - Battery Charging
    1260
  - Battery, Mounting and Cables
    1263
  - Battery and Cables
    1264
  - Battery to Starter Motor Solenoid Cable — Vehicles with 1.6L / 1.3L Engine
    1268
  - Battery to Starter Motor Solenoid Cable — Vehicles with 1.8L Endura de Diesel Engine
    1272
  - Battery Tray (44 271 4)
    1275
  - Generator and Regulator
    1277
  - Generator — Vehicles with 1.6L / 1.3L Engine (31 414 0)
    1279
  - Generator — Vehicles with 1.8L Endura de Diesel Engine (31 414 0)
    1284
  - Generator — Vehicles with 1.8L Endura de Diesel Engine and Air Conditioning
    1287
  - Audio System — General Information
    1291
  - Audio System
    1292
  - The Audio Unit Is Inoperative/Does Not Operate Correctly
    1295
  - Poor Reception
    1298
  - Distorted Sound from One or more Speakers
    1300
  - Audio Unit
    1305
  - General Equipment
    1307
  - Antenna
    1308
  - Front Door Speaker (38 268 0)
    1316
  - Exterior Lighting
    1317
  - Headlamp System
    1319
  - Multifunction Switch
    1319
  - Side Lamps
    1319
  - License Plate Lamps
    1319
  - Exterior Lighting
    1319
  - Reversing Lamps
    1320
  - Turn Signal and Hazard Warning Lamps
    1320
  - Hazard Warning Lamp Switch
    1320
  - Turn Signal Relay
    1320
  - Central Junction Box (CJB)- Front View, Fuses
    1321
  - Central Junction Box (CJB)- Top View
    1322
  - Both Headlamps Are Inoperative
    1327
  - The Low Beams Are Inoperative
    1328
  - The High Beams Are Inoperative
    1330
  - One Low Beam Headlamp Is Inoperative
    1331
  - The Flash-To-Pass Feature Is Inoperative
    1343
  - Relays
    1344
  - Measure the Resistance between Pin 3 and 5
    1344
  - Stop Lamps
    1345
  - One or more Stop Lamps Are Inoperative
    1346
  - Stop Lamps Are on Continuously
    1349
  - Turn Signal and Hazard Lamps
    1350
  - Turn Signal Lamps Are Inoperative or on Continuously
    1353
  - One Turn Signal/Hazard Lamp Is Inoperative
    1361
  - Hazard Lamps Are Inoperative or on Continuously
    1368
  - Parking, Rear and License Lamps
    1372
  - The Parking, Rear or License Plate Lamps Are Oncontinuously
    1382
  - The Parking, Rear and License Plate Lamps Are Inoperative
    1383
  - The Reversing Lamp Is Inoperative
    1385
  - Fog Lamps
    1389
  - The Fog Lamps Are Inoperative
    1389
  - The Individual Fog Lamp Is Inoperative
    1393
  - The Fog Lamps Are on Continuously
    1395
  - Check Relay Contact in Normal Condition
    1396
  - Check Relay Contact in Activated Condition
    1396
  - Headlamp Assembly (32 115 0)
    1397
  - Rear Lamp Assembly (32 305 0)
    1398
  - Headlamp Adjustment
    1399
  - Module Communications Network
    1402
  - Communications Network
    1403
  - Powertrain Control Module (Pcm) Does Not Respond to Thewds
    1404
  - Instrument Cluster Does Not Respond to the Wds
    1404
  - Air Bag Module Does Not Respond to the Wds
    1405
  - Anti-Theft/Central Locking Module Does Not Respond to the Wds
    1406
  - No One of the Installed Modules Responds to the Wds
    1406
  - Anti-Theft — Passive
    1409
  - Passive Anti-Theft System (PATS)
    1410
  - Keys
    1410
  - Key Programming
    1410
  - Anti-Theft
    1411
  - Principles of Operation
    1411
  - Encoded Ignition Key
    1411
  - Transceiver Module
    1411
  - Diagnostic Trouble Code (DTC) Index
    1412
  - Pats Transceiver Signal Is Not Received
    1414
  - The Anti—Theft System Does Not Operate Correctly – Engine Does Not Crank but Anti-Theft Led Proves out Normally
    1417
  - Passive Anti-Theft System (PATS) Module
    1419
  - Fuel Injection Pump Actuator — Vehicles with Diesel Engine
    1420
  - Passive-Theft System (PATS) Transceiver (33 662 0)
    1424
  - Key Programming Using Two Programmed Keys (33 005 0)
    1425
  - Key Programming Switch State Control
    1427
  - Erasing All Key Codes Using Diagnostic Equipment (33 005 0)
    1428
  - Anti-Theft Security Access (33 004 0)
    1430
  - Body and Paint
    1431
  - Interior Trim and Ornamentation
    1432
  - Interior Trim
    1433
  - Front Door Trim Panel (43 705 0)
    1434
  - A-Pillar Trim Panel (43 616 0)
    1439
  - B-Pillar Trim Panel (43 617 0)
    1440
  - Cab Back Panel Trim (Plastic Panel)
    1442
  - Rear View Mirrors
    1444
  - Rear View Mirrors
    1445
  - The Mirrors Are Inoperative
    1446
  - A Single Mirror Is Inoperative
    1447
  - A Single Mirror Does Not Function with Switch Logic
    1448
  - Exterior Mirror (Electrically Operated)
    1452
  - Exterior Mirror — Manually Operated (43 364 0)
    1454
  - Exterior Mirror Glass (43 366 0)
    1456
  - Seats
    1459
  - Front Seat
    1460
  - Front Seat Cushion
    1464
  - Front Seat Backrest
    1465
  - Front Seat Cushion (40 104 0)
    1467
  - Front Seat Backrest (40 106 0)
    1469
  - Glass, Frames and Mechanisms
    1473
  - Single Power Window Is Inoperative - Driver Side
    1475
  - Front Door Window Glass (42 314 0)
    1481
  - Rear Window Glass
    1489
  - Front Door Window Regulator and Motor (42 338 0)
    1493
  - Door Window Glass Adjustment (42 001 0)
    1503
  - Instrument Panel (43 644 0)
    1507
  - Handles, Locks, Latches and Entry Systems
    1512
  - Locks, Latches and Entry Systems
    1514
  - Front Door Latch (41 351 0)
    1516
  - Hood Latch Release Handle (41 226 0)
    1520
  - Exterior Door Handle (41 333 0)
    1521
  - Door Latch Remote Control
    1523
  - Tailgate - Hinge
    1524
  - Tailgate Handle Assembly
    1525
  - Tailgate - Actuating Rods and Latches
    1526
  - Ignition Lock Cylinder (33 513 0)
    1527
  - Door Lock Cylinder (41 336 0)
    1528
  - Wipers and Washers
    1534
  - Windshield Wiper
    1535
  - Windshield Wiper Functions
    1535
  - Wiper Lever in the off Position
    1535
  - Wiper Lever in the WIPE ONCE Position
    1535
  - Wipers and Washers
    1535
  - Wiper Lever in the FAST WIPE Position
    1536
  - Windshield Washer
    1536
  - Wiper Lever in the off or INTERMITTENT Position
    1536
  - Washer Fluid Level Warning Light
    1536
  - The Wipers Are Inoperative
    1538
  - The High/Low Wiper Speeds
    1539
  - The Wipers will Not Park at the Correct Position
    1540
  - The High/Low Wiper Speeds Do Not Operate Correctly (Intermittent Wiper Mode Ok)
    1549
  - The Intermittent Wiper Speed Does Not Operate Correctly (High/Low Speeds Ok)
    1551
  - Mounting Arm and Pivot Table (32 554 0)
    1562
  - Windshield Wiper Motor (32 524 0)
    1564
  - Windshield Washer Pump (32 624 0)
    1567
  - Windshield Washer Reservoir (32 622 0)
    1569
  - Wiper Blade and Pivot Arm Adjustment (32 591 0)
    1571
  - Bumpers
    1573
  - Front Bumper (43 423 0)
    1574
  - Rear Bumperette (43 432 0)
    1576
  - Occupant Restraints — Active
    1578
  - Occupant Restraint System
    1579
  - Emergency Locking Retractor (ELR)
    1580
  - Vehicle Motion Sensor (VMS)
    1580
  - Webbing Motion Sensor (WMS)
    1580
  - Safety Belt Testing
    1581
  - Poor Retraction
    1581
  - Vehicle Motion Sensor Test
    1581
  - Front Safety Belt Retractor (40 222 0)
    1582
  - Safety Belt Buckle and Pretensioner
    1585
  - Occupant Restraints — Passive — Supplemental Air Bag System
    1588
  - Air Bag Supplemental Restraint System (SRS)
    1589
  - Lamp Fault Codes (LFC)
    1591
  - Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
    1592
  - Diagnosing Customer Concerns with Hard Dtcs / Lfcs
    1592
  - Air Bag Simulator
    1593
  - Deactivate the System
    1593
  - Prove out the System
    1593
  - Supplemental Restraint System (SRS) Operation
    1593
  - Air Bag Control Module
    1594
  - Air Bag Warning Indicator
    1594
  - Diagnostic Instructions — Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
    1595
  - Pinpoint Tests — Air Bag and Safety Belt Pretensioner Supplemental Restraint System (Srs)
    1600
  - No Communication with the Module
    1600
  - Air Bag Warning Indicator Ground Monitoring Circuit Open
    1601
  - Battery Voltage Low
    1603
  - Air Bag Warning Indicator Open Circuit or Short to Ground
    1604
  - Air Bag Warning Indicator Short to Battery
    1608
  - Driver Air Bag Short to Ground
    1610
  - Driver Air Bag Circuit Short to Battery
    1612
  - Driver Air Bag Open Circuit or High Resistance
    1614
  - Driver Air Bag Circuit Low Resistance
    1616
  - Passenger Air Bag Short to Ground
    1618
  - Passenger Air Bag Short to Battery
    1619
  - Passenger Air Bag Open Circuit or High Resistance
    1620
  - Passenger Air Bag Circuit Low Resistance
    1621
  - Driver Safety Belt Pretensioner Circuit Capacitance out of Range
    1623
  - Driver Safety Belt Pretensioner Open Circuit
    1624
  - DTC B1878 Driver Safety Belt Pretensioner Short to Battery
    1625
  - Driver Safety Belt Pretensioner Short to Ground
    1627
  - Driver Safety Belt Pretensioner Low Resistance
    1629
  - Passenger Safety Belt Pretensioner Circuit Capacitance out of Range
    1631
  - Passenger Safety Belt Pretensioner Open Circuit
    1631
  - Passenger Safety Belt Pretensioner Short to Battery
    1633
  - Passenger Safety Belt Pretensioner Short to Ground
    1635
  - Passenger Safety Belt Pretensioner Low Resistance
    1637
  - Driver Air Bag Module (40 700 0)
    1639
  - Passenger Air Bag Module (40 701 0)
    1641
  - Air Bag Control Module (33 650 0)
    1646
  - Unserviceable Air Bag Disposal
    1648
  - Scrapped Vehicle Air Bag Disposal
    1650
  - Uni-Body, Subframe and Mounting Frame — General Information
    1655
  - Subframe
    1656

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