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Ford Transit 2002 Manuals
Manuals and User Guides for Ford Transit 2002. We have
1
Ford Transit 2002 manual available for free PDF download: Owner's Manual
Ford Transit 2002 Owner's Manual (2797 pages)
Brand:
Ford
| Category:
Automobile
| Size: 187.96 MB
Table of Contents
General Information-About this Manual
1
Description and Operation
1
Special Tools
1
Important Safety Instructions
1
Overview Procedures
2
Inspection and Verification
2
Symptom Chart
2
Pinpoint Tests
2
Component Tests
3
Graphics
3
Special Tools and Torque Figures
3
Health and Safety Precautions
4
Acids and Alkalis
4
Air Bags
4
Air Conditioning Refrigerant
5
Air Conditioning Refrigerant-Do Nots
5
Adhesives and Sealers
5
Hot Melt Adhesives
6
Anaerobic, Cyanoacrylate (Super-Glues) and Other Acrylic Adhesives
6
Isocyanate (Polyurethane) Adhesives/Sealers
6
Antifreeze
6
Asbestos
7
Battery Acids
7
Brake Fluids (Polyalkylene Glycols)
7
Chemical Materials
7
Chemical Materials-Do Nots
8
Chlorofluorocarbons (CFC)
8
Corrosion Protection Materials
8
Dusts
9
Electric Shock
9
Exhaust Fumes
9
Diesel Engine
9
Fire
10
First Aid
10
Foams-Polyurethane
10
Gasoline (Petrol)
11
Gas-Oil (Diesel Fuel)
11
Kerosene (Paraffin)
11
Alternative Fuel
11
Gas Cylinders
12
General Workshop Tools and Equipment
12
High Pressure Air, Lubrication and Oil Test Equipment
12
Legal Aspects
13
Lubricants and Greases
13
Transmission Fluids
13
Control Measures
13
Safety Data Sheets
14
Used Engine Oil
14
Environmental Precautions
14
Noise
14
One Pack
15
Two Pack
15
Solder
15
Solvents
15
Suspended Loads
16
Viton
16
Resistance Welding
17
Arc Welding
17
Gas Welding (and Cutting)
17
Warning Symbols on Vehicles
17
Standard Workshop Practices
20
Vehicle in Workshop
20
Towing the Vehicle
20
Connecting a Slave Battery Using Jumper Cables
20
Component Cleaning
21
Calibration of Essential Measuring Equipment
22
Solvents, Sealants and Adhesives
23
Road/Roller Testing
24
Pre-Test Checks
24
Starting the Engine
24
Road or Roller Testing
24
Brake Testing
25
Diesel Fuel Systemvhealth and Safety Precautions
26
Battery and Battery Charging Health and Safety Precautions
28
Supplemental Restraint System (SRS) Health and Safety Precautions
29
Identification Codes
31
VIN (an Example of VIN Shown)
32
Vehicle Certification Label (Typical) or VIN Plate
33
Jacking
38
Lifting
39
Noise, Vibration and Harshness (NVH)
40
Diagnostic Theory
40
Know the System
40
Know the Probability of Certain Conditions Developing
40
Do Not Cure the Symptom and Leave the Cause
41
Be Positive the Cause Is Found
41
Diagnostic Charts
41
How to Use this Diagnostic Procedure Section
42
Customer Interview
42
Identify the Condition
42
Noise Diagnostic Procedure
42
Noise Conditions
43
Clicking, Popping or Grinding Noises
43
Vibration Conditions
43
Road Test
43
Road Test Quick Checks
44
Road Conditions
45
Vehicle Preparation
45
Power Steering Conditions
45
Power Steering Operation Noise Check
45
Steering System NVH Concerns
46
Power Steering Moan Noise
47
Power Steering Whine Noise
48
Power Steering Hiss Noise
49
Power Steering Lock Stop Impact Knock Noise
49
Power Steering Mechanical Knock Noise (PAS Off)
49
Power Steering Mechanical Knock Noise (PAS On)
50
Power Steering Hammer Knock (Hydraulic) Noise
50
Power Steering Hydraulic Knock/Clonk Noise
50
Power Steering Column Knock Noise
51
Power Steering Toc-Toc Noise
51
Power Steering Grinding Noise
51
Test Condition
51
Power Steering Zip Noise
52
Driveline Noise and Vibration
52
Suspension Noise and Vibration
52
Pinpoint Test A: Shake and Vibration While Driving
53
Pinpoint Test B: Tip-In Moan
53
Pinpoint Test C: Idle Boom/Shake/Vibration/Shudder
54
Pinpoint Test D: Wheel End Vibration Analysis
54
Pinpoint Test E: Non-Axle Noise
55
Powertrain/Drivetrain Mount Neutralizing
57
Suspension System-General Information-Specifications
58
Front Suspension-Front Suspension
60
Overview
60
Front Suspension-Front Wheel Bearing
63
Removal
63
Installation
64
Front Suspension-Lower Arm
66
General Equipment
66
Front Suspension-Front Stabilizer Bar
68
Front Suspension-Wheel Knuckle
74
Front Suspension-Front Strut and Spring Assembly
80
Front Suspension-Lower Arm Ball Joint
82
Disassembly
84
Assembly
85
Rear Suspension-Specifications
86
Torque Specifications
86
Rear Suspension-Rear Suspension
87
Rear Axle
87
Wheel Suspension
88
Rear Suspension-Wheel Spindle
90
Rear Suspension-Rear Stabilizer Bar
91
Rear Suspension-Spring
93
Rear Suspension-Beam Axle
96
Rear Suspension-Wheel Hub
100
Rear Suspension-Rear Stabilizer Bar Link
101
Wheels and Tires-Specifications
102
Wheels and Tires-Wheels and Tires
103
Additional Tyre Identification Markings
104
Maximum Speed Rating
105
Winter Tyres
105
Wheels and Tyres
106
Diagnosis and Testing
107
Visual Inspection Chart
107
Tire Wear Diagnosis
107
Tire Vibration Diagnosis
107
Vehicle Speed Sensitive
108
Engine Speed Sensitive
108
Front Drive Halfshafts-Specifications
112
Front Drive Halfshafts-Front Drive Halfshafts
113
Front Drive Halfshafts-Front Halfshaft LH
115
Front Drive Halfshafts-Front Halfshaft RH
119
Front Drive Halfshafts-Intermediate Shaft
123
Front Drive Halfshafts-Inner Constant Velocity (CV) Joint Boot
127
Front Drive Halfshafts-Outer Constant Velocity (CV) Joint Boot
130
Front Drive Halfshafts-Halfshaft Bearing
132
Brake System - General Information
135
Pinpoint Test A: Pedal Goes down Fast
141
Pinpoint Test B: Pedal Eases down Slowly
142
Pinpoint Test C: Brake Lock up During Light Brake Pedal Force
143
Pinpoint Test D: Excessive Brake Pedal Effort
143
Pinpoint Test E: Brake Noise
144
Pinpoint Test F: Slow or Incomplete Brake Pedal Return
145
Hydraulic Leak Check
146
Brake System Check
146
Brake Pedal Reserve Check
146
Brake Booster Functional Test
146
Brake Master Cylinder
147
Normal Conditions
147
Abnormal Conditions
147
Bypass Condition Test
148
Non-Pressure Leaks
148
Brake System Bleeding
149
Brake System Leak Check
150
Brake Load Sensor Proportioning Valve Adjustment
151
Brake Disc Runout Check
152
Drum Brake-Specifications
154
Lubricants, Fluids, Sealers and Adhesives
154
Drum Brake Dimensions
154
Drum Brake
155
Drum Brake-Brake Shoes
156
Drum Brake-Wheel Cylinder
158
Drum Brake-Brake Backing Plate
160
Front Disc Brake-Specifications
161
Front Disc Brake Dimensions
161
Front Disc Brake-Front Disc Brake
162
Front Disc Brake-Brake Pads
163
Front Disc Brake-Brake Caliper
165
Front Disc Brake-Brake Disc
167
Disassembly and Assembly
168
Rear Disc Brake-Specifications
170
Rear Disc Brake
171
Rear Disc Brake-Brake Caliper
173
Rear Disc Brake-Brake Pads
174
Parking Brake and Actuation-Specifications
179
Parking Brake and Actuation-Parking Brake
180
Pinpoint Test A: the Parking Brake will Not Apply
182
Pinpoint Test B: the Parking Brake will Not Release
183
Parking Brake and Actuation-Parking Brake Cable Adjustment
185
Parking Brake and Actuation-Parking Brake Control
187
Parking Brake and Actuation-Parking Brake Cable
188
Hydraulic Brake Actuation-Specifications
191
Hydraulic Brake Actuation-Hydraulic Brake Actuation
192
Brake Pedal
192
Brake Pedal and Bracket—Vehicles Built up To: 04/2009
194
Brake Pedal and Bracket—Vehicles Built From: 04/2009
200
Hydraulic Brake Actuation-Brake Master Cylinder—Lhd FWD
205
Hydraulic Brake Actuation-Brake Master Cylinder-RHD FWD
208
Hydraulic Brake Actuation-Brake Fluid Reservoir
213
Power Brake Actuation-Specifications
216
Power Brake Actuation-Power Brake System
217
Power Brake Actuation-Brake Booster-LHD FWD
218
Power Brake Actuation-Brake Booster-RHD FWD
220
Power Brake Actuation-Brake Vacuum Pump
225
Anti-Lock Control-Specifications
231
Anti-Lock Control
232
Anti-Lock Control-Hydraulic Control Unit (HCU)
233
Anti-Lock Control-Rear Wheel Speed Sensor
238
Anti-Lock Control-Rear Wheel Speed Sensor Ring
240
Anti-Lock Control-Anti-Lock Brake System (ABS) Module
242
Anti-Lock Control-Traction Control-Specifications
247
Anti-Lock Control-Traction Control
248
Function
249
Solenoid Valves in the Hydraulic Control Unit
249
Inlet and Outlet Solenoid Valve Pairs for One Wheel Brake
249
Electronic Control Unit
250
Schematic Diagram of the MK 25 ABS Control Unit
250
Block Circuit Diagram
251
Warning Lamps in the Instrument Cluster
252
Warning Lamp ABS
252
Warning Lamp TCS
252
Braking System Warning Lamp
252
Anti-Lock Control-Traction Control-Rear Wheel Speed Sensor
254
Anti-Lock Control-Stability Assist-Anti-Lock Control-Stability Assist
255
Control Diagram
255
System Operation
256
Normal Braking
256
ABS Braking
256
Active Braking
256
Principles of Operation
257
How the System Works for Understeer
258
How the System Works for Oversteer
258
Emergency Brake Assist (EBA)
258
Trailer Stability Control
259
Emergency Brake Light
259
Component Description
259
Opto-Electronic Steering Wheel Rotation Sensor
259
ABS/ESP Module or Hydraulic Control Unit (HCU)
260
Combined Yaw Rate Sensor and Lateral Acceleration Sensor
261
Front Wheel Sensor
262
Rear Wheel Sensor
262
Anti-Lock Control-Stability Assist-Hydraulic Control Unit (HCU)
263
Anti-Lock Control-Stability Assist-Yaw Rate Sensor
269
Anti-Lock Control-Stability Assist-Steering Wheel Rotation Sensor
270
Steering System-General Information-Specifications
271
Steering System-General Information
272
Steering Linkage
273
Steering Gear Checks after a Collision
274
Steering Gear Housing
274
Tie-Rods
274
Check for Power Steering Fluid Leaks
274
Power Steering System Flushing-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec
276
Power Steering System Flushing-1.8L Duratorq-Tdci (Lynx) Diesel
280
Power Steering System Bleeding
286
Power Steering System Filling
289
Power Steering-Specifications
291
Power Steering
292
Power Steering Pump-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec
294
Power Steering Fluid Cooler-Vehicles Built up To: 08/2006
300
Power Steering Fluid Cooler-Vehicles Built From: 08/2006
303
Power Steering Pump to Steering Gear Pressure Line
305
Power Steering-Steering Gear
313
Transmission Jack
313
Power Steering-Steering Gear Bushing
320
Steering Linkage-Specifications
322
Steering Linkage-Tie Rod End
324
Steering Linkage-Tie Rod
326
Steering Linkage-Steering Gear Boot
329
Steering Column-Specifications
331
Steering Column
333
Steering Column-Steering Wheel
336
Steering Column Switches-Ignition Switch
341
Engine System-General Information
343
Engine/Transmission Combinations
343
Engine Oil Leaks
348
Ultraviolet (UV) Testing
348
Measure the Compression Pressure
348
Measure the Compression Pressure (1.8L Engine)
348
Measure the Compression Pressure (1.8L Diesel Engine)
355
Measure the Oil Pressure (1.8L Engine)
360
Measure the Oil Pressure (1.8L Diesel Engine)
361
Valve Train Analysis-Static (Engine Off)
363
Engine System-General Information-Camshaft Bearing Journal Diameter
364
Engine System-General Information-Camshaft Bearing Journal Clearance
365
Engine System-General Information-Camshaft End Play
366
Engine System-General Information-Camshaft Surface Inspection
367
Engine System-General Information-Camshaft Lobe Lift
368
Engine System-Crankshaft Main Bearing Journal Diameter
369
Engine System-General Information-Crankshaft End Play
370
Engine System-General Information-Cylinder Bore Taper
371
Engine System-General Information-Piston Inspection
372
Engine System-General Information-Piston Pin to Bore Diameter
373
Engine System-General Information-Piston Diameter
374
Engine System-General Information-Piston Ring End Gap
375
Engine System-General Information-Piston Ring-To-Groove Clearance
376
Engine System-General Information-Piston Pin Diameter
377
Engine System-General Information-Connecting Rod Large End Bore
378
Engine System-General Information-Valve Stem Diameter
379
Engine System-General Information-Flywheel Inspection
380
Engine System-Flywheel Inspection-Vehicles With: Dual Mass Flywheel
381
Engine System-General Information-Cylinder Head Distortion
382
Engine System-General Information-Cylinder Block Distortion
383
Engine System-Exhaust Manifold Cleaning and Inspection
384
Engine System-General Information-Bearing Inspection
385
Engine System-General Information-Valve Seat Inspection
386
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Specifications
387
Engine Data
387
Engine Oil
387
Capacities
387
Oil System
388
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Engine
390
Engine Management
390
Engine Emission Control
391
Diagnosis
391
Engine Power and Torque
391
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Valve Clearance Adjustment
393
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Intake Manifold
395
In-Vehicle Repair
395
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Crankshaft Front Seal
399
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Valve Springs
401
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Valve Seals
403
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Valves
405
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Camshafts
408
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Camshaft Seal
411
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Timing Belt
413
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Exhaust Manifold
422
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Cylinder Head
424
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Oil Pump
434
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Crankshaft Rear Seal
438
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Valve Cover
441
Engine-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec-Oil Pan
443
Engine Codes
494
Crankshaft Timing Sprocket
494
Timing Belt Drive
495
Valve Tappet, Adjusting Shims
495
Cylinder Head
496
Crankshaft Oil Seals
496
Crankcase Ventilation
497
Oil Sump
497
Location of the Engine Code on the Cylinder Block of the Duratorq
498
1.8L Duratorq Tdci
502
Common Rail Fuel Injection System
502
Emission Control
503
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Valve Clearance
505
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Exhaust Manifold
507
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Intake Manifold
508
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Valve Cover
510
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Valve Seals
514
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Camshaft Seal
516
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Camshafts
518
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Crankshaft Front Seal
520
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Crankshaft Rear Seal
522
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Timing Belt-75 PS/90 PS
525
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Oil Cooler-RHD FWD
612
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Oil Filter Element
613
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Oil Pan
614
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Oil Pump
617
Engine-1.8L Duratorq-Cylinder Head-Removal and Installation
622
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Engine-Removal
635
Engine-1.8L Duratorq-Diesel Engine (Common Rail Injection)-Disassembly
651
Engine-Vehicles Without: Common Rail Fuel Injection
668
Disassembly and Assembly of Subassemblies
680
Cylinder Head-Vehicles Without: Common Rail Fuel Injection
694
Engine-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel-Engine
754
Engine Cooling-Specifications
771
Engine Cooling
772
Worldwide Diagnostic System (WDS)
772
Pressure Test
774
Radiator Leak Test, Removed from Vehicle
775
Coolant Expansion Tank Cap Pressure Test
775
Thermostat Test
775
Engine Cooling-Cooling System Flushing
779
Engine Cooling-Cooling System Backflushing
780
Engine Cooling-Cooling System Draining, Filling and Bleeding
781
Engine Cooling-Thermostat-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec
783
Engine Cooling-Thermostat-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel
785
Engine Cooling-Thermostat Housing-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec
786
Removal Details
787
Engine Cooling-Thermostat Housing-1.8L Duratorq-Tddi (Lynx) Diesel
789
Engine Cooling-Thermostat Housing-1.8L Duratorq-Tdci (Lynx) Diesel
792
Engine Cooling-Water Pump-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec
795
Engine Cooling-Water Pump-1.8L Duratorq-Tdci/Tddi (Lynx) Diesel
798
Laminated Card
798
Engine Cooling-Radiator
803
Engine Cooling-Cooling Fan Motor
806
Engine Cooling-Cooling Fan Motor and Shroud
807
Fuel Charging and Controls-1.8L Duratec-DOHC (85Kw/115Ps)-Zetec
809
Fuel Charging and Controls-1.8L Duratec-DOHC-Zetec-Throttle Body
811
1.8L Duratec-DOHC-Zetec-Fuel Charging Wiring Harness
813
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