service FORD TRANSIT 2017 5.G Service Manual

You are required to submit your warranty
dispute to BBB AUTO LINE before asserting
in court any rights or remedies conferred
by California Civil Code Section 1793.22(b).
You are also required to use BBB AUTO
LINE before exercising rights or seeking
remedies created by the Federal
Magnuson-Moss Warranty Act, 15 U.S.C.
sec. 2301 et seq. If you choose to seek
redress by pursuing rights and remedies
not created by California Civil Code Section
1793.22(b) or the Magnuson-Moss
Warranty Act, resort to BBB AUTO LINE is
not required by those statutes.
THE BETTER BUSINESS
BUREAU (BBB) AUTO LINE
PROGRAM (U.S. ONLY)
Your satisfaction is important to Ford
Motor Company and to your dealer. If a
warranty concern has not been resolved
using the three-step procedure outlined
earlier in this chapter in the Getting the
Services you need section, you may be
eligible to participate in the BBB AUTO
LINE program.
The BBB AUTO LINE program consists of
two parts – mediation and arbitration.
During mediation, a representative of the
BBB will contact both you and Ford Motor
Company to explore options for settlement
of the claim. If an agreement is not reached
during mediation or you do not want to
participate in mediation, and if your claim
is eligible, you may participate in the
arbitration process. An arbitration hearing
will be scheduled so that you can present
your case in an informal setting before an
impartial person. The arbitrator will
consider the testimony provided and make
a decision after the hearing.
Disputes submitted to the BBB AUTO LINE
program are usually decided within forty
days after you file your claim with the BBB.
You are not bound by the decision, and
may reject the decision and proceed to
court where all findings of the BBB Auto
Line dispute, and decision, are admissible
in the court action. Should you choose to
accept the BBB AUTO LINE decision, Ford
is then bound by the decision, and must
comply with the decision within 30 days
of receipt of your acceptance letter.
BBB AUTO LINE Application: Using the
information provided below, please call or
write to request a program application.
You will be asked for your name and
address, general information about your
new vehicle, information about your
warranty concerns, and any steps you have
already taken to try to resolve them. A
Customer Claim Form will be mailed that
will need to be completed, signed and
returned to the BBB along with proof of
ownership. Upon receipt, the BBB will
review the claim for eligibility under the
Program Summary Guidelines.
You can get more information by
calling BBB AUTO LINE at
1-800-955-5100, or writing to:
BBB AUTO LINE
3033 Wilson Boulevard, Suite 600
Arlington, Virginia 22201
BBB AUTO LINE applications can also be
requested by calling the Ford Motor
Company Customer Relationship Center
at 1-800-392-3673.
Note:
Ford Motor Company reserves the
right to change eligibility limitations, modify
procedures, or to discontinue this process
at any time without notice and without
obligation.
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UTILIZING THE
MEDIATION/ARBITRATION
PROGRAM (CANADA ONLY)
For vehicles delivered to authorized
Canadian dealers. In those cases where
you continue to feel that the efforts by Ford
of Canada and the authorized dealer to
resolve a factory-related vehicle service
concern have been unsatisfactory, Ford of
Canada participates in an impartial third
party mediation/arbitration program
administered by the Canadian Motor
Vehicle Arbitration Plan (CAMVAP).
The CAMVAP program is a straight forward
and relatively speedy alternative to resolve
a disagreement when all other efforts to
produce a settlement have failed. This
procedure is without cost to you and is
designed to eliminate the need for lengthy
and expensive legal proceedings.
In the CAMVAP program, impartial
third-party arbitrators conduct hearings at
mutually convenient times and places in
an informal environment. These impartial
arbitrators review the positions of the
parties, make decisions and, when
appropriate, render awards to resolve
disputes. CAMVAP decisions are fast, fair,
and final as the arbitrator
’s award is
binding on both you and Ford of Canada.
CAMVAP services are available in all
Canadian territories and provinces. For
more information, without charge or
obligation, call your CAMVAP Provincial
Administrator directly at 1-800-207-0685
or visit www.camvap.ca. GETTING ASSISTANCE
OUTSIDE THE U.S. AND
CANADA
Before exporting your vehicle to a foreign
country, contact the appropriate foreign
embassy or consulate. These officials can
inform you of local vehicle registration
regulations and where to find unleaded
fuel.
If you cannot find unleaded fuel or can only
get fuel with an anti-knock index lower
than is recommended for your vehicle,
contact our Customer Relationship Center.
The use of leaded fuel in your vehicle
without proper conversion may damage
the effectiveness of your emission control
system and may cause engine knocking or
serious engine damage. Ford Motor
Company or Ford of Canada is not
responsible for any damage caused by use
of improper fuel. Using leaded fuel may
also result in difficulty importing your
vehicle back into the United States.
If your vehicle must be serviced while you
are traveling or living in Asia-Pacific Region,
Sub-Saharan Africa, U.S. Virgin Islands,
Central America, the Caribbean, and Israel,
contact the nearest authorized dealer. If
the authorized dealer cannot help you,
contact:
FORD MOTOR COMPANY
Customer Relationship Center
1555 Fairlane Drive
Fairlane Business Park #3
Allen Park, Michigan 48101
U.S.A.
Telephone: (313) 594-4857
Fax: (313) 390-0804
Email: [email protected]
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For customers in Guam, the
Commonwealth of the Northern Mariana
Islands (CNMI), America Samoa, and the
U.S. Virgin Islands, please feel free to call
our Toll-Free Number: (800) 841-FORD
(3673).
If your vehicle must be serviced while you
are traveling or living in Puerto Rico,
contact the nearest authorized dealer. If
the authorized dealer cannot help you,
contact:
FORD MOTOR COMPANY
Customer Relationship Center
1555 Fairlane Drive
Fairlane Business Park #3
Allen Park, Michigan 48101
U.S.A.
Telephone: (800) 841-FORD (3673)
FAX: (313) 390-0804
Email: [email protected]
www.ford.com.pr
If your vehicle must be serviced while you
are traveling or living in the Middle East,
contact the nearest authorized dealer. If
the authorized dealer cannot help you,
contact:
FORD MOTOR COMPANY
Customer Relationship Center
1555 Fairlane Drive
Fairlane Business Park #3
Allen Park, Michigan 48101
U.S.A.
Ford: 80004443673
Lincoln: 80004441067
If calling from the UAE: 80004441066
If calling from the Kingdom of Saudi
Arabia:
8008443673
If calling from Kuwait: 22280384
FAX: +971 4 3327266
Email: [email protected]
www.me.ford.com If you buy your vehicle in North America
and then relocate to any of the above
locations, register your vehicle
identification number (VIN) and new
address with Ford Motor Company by
emailing
[email protected].
If you are in another foreign country,
contact the nearest authorized dealer. In
the event your inquiry is unresolved,
communicate your concern with the
dealership ’s Sales Manager, Service
Manager or Customer Relations Manager.
If you require additional assistance or
clarification, please contact the respective
Customer Relationship Center as
previously listed.
Customers in the U.S. should call
1-800-392-3673.
ORDERING ADDITIONAL
OWNER'S LITERATURE
To order the publications in this portfolio,
contact Helm, Incorporated at:
HELM, INCORPORATED
47911 Halyard Drive
Plymouth, Michigan 48170
Attention: Customer Service
Or to order a free publication catalog, call
toll free: 1-800-782-4356
Monday-Friday 8:00 a.m. - 6:00 p.m. EST
Helm, Incorporated can also be reached
by their website:
www.helminc.com
(Items in this catalog may be purchased
by credit card, check or money order.)
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GENERAL INFORMATION
Have your vehicle serviced regularly to help
maintain its roadworthiness and resale
value. There is a large network of
authorized dealers that are there to help
you with their professional servicing
expertise. We believe that their specially
trained technicians are best qualified to
service your vehicle properly and expertly.
They are supported by a wide range of
highly specialized tools developed
specifically for servicing your vehicle.
If your vehicle requires professional service,
an authorized dealer can provide the
necessary parts and service. Check your
warranty information to find out which
parts and services are covered.
Use only recommended fuels, lubricants,
fluids and service parts conforming to
specifications. Motorcraft® parts are
designed and built to provide the best
performance in your vehicle.
Precautions
•
Do not work on a hot engine.
• Make sure that nothing gets caught in
moving parts.
• Do not work on a vehicle with the
engine running in an enclosed space,
unless you are sure you have enough
ventilation.
• Keep all open flames and other burning
material (such as cigarettes) away
from the battery and all fuel related
parts.
Working with the Engine Off
1. Set the parking brake and shift to park
(P).
2. Switch off the engine.
3. Block the wheels. Working with the Engine On WARNING
To reduce the risk of vehicle damage
and/or personal burn injuries, do not
start your engine with the air cleaner
removed and do not remove it while the
engine is running. 1.
Set the parking brake and shift to park
(P).
2. Block the wheels.
OPENING AND CLOSING THE
HOOD
Opening the Hood 1. Pull the hood release lever.
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Adding Engine Oil
WARNINGS
Only add oil when the engine is cold.
If the engine is hot, wait 10 minutes
for the engine to cool down.
Do not remove the filler cap when
the engine is running.
1. Remove the engine oil filler cap.
2. Add engine oil that meets Ford
specifications. See Capacities and
Specifications (page 281).
3. Replace the engine oil filler cap. Turn it until you feel a strong resistance.
Note: Do not add oil further than the
maximum mark. Oil levels above the
maximum mark may cause engine damage.
Note: Soak up any spillage with an
absorbent cloth immediately.
CHANGING THE ENGINE OIL
AND OIL FILTER WARNINGS
Prolonged and repeated skin contact
with mineral oil will result in the
removal of natural fats from the skin,
leading to dryness, irritation and dermatitis.
In addition, used engine oil contains
potentially harmful contaminants, which
may cause skin cancer. If skin contact
occurs, wash the area thoroughly with
soap or skin cleanser and water
immediately. Do not dispose of engine oils or oil
filters in the household refuse or the
public sewage system. Use an
authorized waste disposal facility. Do not remove the oil pan drain plug
when the engine is running. WARNINGS
Do not remove the oil filter when the
engine is running.
1.
Remove the oil pan drain plug and wait
for the oil to drain into a suitable
container.
2. Renew the oil filter.
3. Reinstall the oil pan drain plug.
4. Refill the engine with new oil that meets Ford specifications. See
Capacities and Specifications (page
281).
Note: Do not add oil further than the
maximum mark. Oil levels above the
maximum mark may cause engine damage.
Note: Soak up any spillage with an
absorbent cloth immediately.
5. Reset the Intelligent Oil Life Monitor. See
Oil Change Indicator Reset
(page 218).
Engine Lubrication for Severe
Service Operation
The following conditions define severe
service operation. The Intelligent Oil Life
Monitor will determine engine oil and oil
filter change intervals.
• Frequent or extended idling.
• Frequent low-speed operation at
25 mph (40 km/h)
or less.
• Frequent severe dust condition
operation.
• Frequent off-road operation.
• Sustained ambient temperatures of
-9°F (-23°C)
or below.
• Sustained ambient temperatures of
100°F (38°C)
or above.
• Sustained towing operation above
1,000 mi (1,600 km)
.
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5. Check the coolant level in the coolant
reservoir the next few times you drive
your vehicle. If necessary, add enough
prediluted engine coolant to bring the
coolant level to the correct level.
If you have to add more than 1.1 qt (1 L) of
engine coolant per month, have your
vehicle checked as soon as possible.
Operating an engine with a low level of
coolant can result in engine overheating
and possible engine damage.
Note: During normal vehicle operation, the
coolant may change color from orange to
pink or light red. As long as the coolant is
clear and uncontaminated, this color change
does not indicate the coolant has degraded
nor does it require the coolant to be drained,
the system to be flushed, or the coolant to
be replaced.
Note: In case of emergency, you can add a
large amount of water without coolant in
order to reach a vehicle service location.
Water alone, without coolant, can cause
engine damage from corrosion, overheating
or freezing. When you reach a service
location, you must have the cooling system
drained and refilled with prediluted coolant
approved to the correct specification. See
Capacities and Specifications (page 281).
Do not use the following as a coolant
substitute:
• Alcohol.
• Methanol.
• Brine.
• Any coolant mixed with alcohol or
methanol antifreeze.
Alcohol and other liquids can cause engine
damage from overheating or freezing.
Do not add extra inhibitors or additives to
the coolant. These can be harmful and
compromise the corrosion protection of
the coolant. Recycled Coolant
We do not recommend the use of recycled
coolant as an approved recycling process
is not yet available.
Dispose of used engine coolant in an
appropriate manner. Follow your
community's regulations and standards
for recycling and disposing of automotive
fluids.
Severe Climates
If you drive in extremely cold climates:
•
It may be necessary to increase the
coolant concentration above 50%.
• A coolant concentration of 60%
provides improved freeze point
protection. Coolant concentrations
above 60% decrease the overheat
protection characteristics of the
coolant and may cause engine
damage.
If you drive in extremely hot climates:
• You can decrease the coolant
concentration to 40%.
• Coolant concentrations below 40%
decrease the freeze and corrosion
protection characteristics of the
coolant and may cause engine
damage.
Vehicles driven year-round in non-extreme
climates should use prediluted coolant for
optimum cooling system and engine
protection.
Coolant Change
At specific mileage intervals, as listed in
the scheduled maintenance information,
the coolant should be changed. Add
prediluted coolant approved to the correct
specification. See
Capacities and
Specifications (page 281).
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Fail-Safe Cooling
Fail-safe cooling allows you to temporarily
drive your vehicle before any incremental
component damage occurs. The fail-safe
distance depends on ambient
temperature, vehicle load and terrain.
How Fail-Safe Cooling Works
If the engine begins to overheat, the
coolant temperature gauge moves toward
the red zone:
A warning lamp illuminates and
a message may appear in the
information display.
If the engine reaches a preset
over-temperature condition, the engine
automatically switches to alternating
cylinder operation. Each disabled cylinder
acts as an air pump and cools the engine.
When this occurs, your vehicle still
operates, however:
• Engine power is limited.
• The air conditioning system turns off.
Continued operation increases the engine
temperature, causing the engine to
completely shut down. Your steering and
braking effort increases in this situation.
When the engine temperature cools, you
can re-start the engine. Have your vehicle
checked as soon as possible to minimize
engine damage.
When Fail-Safe Mode Is Activated WARNINGS
Fail-safe mode is for use during
emergencies only. Operate your
vehicle in fail-safe mode only as long
as necessary to bring your vehicle to rest
in a safe location and seek immediate
repairs. When in fail-safe mode, your WARNINGS
vehicle will have limited power, will not be
able to maintain high-speed operation, and
may completely shut down without
warning, potentially losing engine power,
power steering assist, and power brake
assist, which may increase the possibility
of a crash resulting in serious injury. Never remove the coolant reservoir
cap when the engine is running or
hot.
Your vehicle has limited engine power
when in the fail-safe mode, drive your
vehicle with caution. Your vehicle does not
maintain high-speed operation and the
engine may operate poorly.
Remember that the engine is capable of
automatically shutting down to prevent
engine damage. In this situation:
1. Pull off the road as soon as safely
possible and switch the engine off.
2. If you are a member of a roadside assistance program, we recommend
that you contact your roadside
assistance service provider.
3. If this is not possible, wait a short period for the engine to cool.
4. Check the coolant level. If the coolant level is at or below the minimum mark,
add prediluted coolant immediately.
5. When the engine temperature cools, you can re-start the engine. Have your
vehicle checked as soon as possible to
minimize engine damage.
Note: Driving your vehicle without repair
increases the chance of engine damage.
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Engine Coolant Temperature
Management (If Equipped)
WARNING
To reduce the risk of crash and injury,
be prepared that the vehicle speed
may reduce and the vehicle may not
be able to accelerate with full power until
the coolant temperature reduces. If you tow a trailer with your vehicle, the
engine may temporarily reach a higher
temperature during severe operating
conditions, for example ascending a long
or steep grade in high ambient
temperatures.
At this time, you may notice the coolant
temperature gauge moves toward the red
zone and a message may appear in the
information display.
You may notice a reduction in vehicle
speed caused by reduced engine power.
In order to manage the engine coolant
temperature. Your vehicle may enter this
mode if certain high-temperature and
high-load conditions take place. The
amount of speed reduction depends on
vehicle loading, grade and ambient
temperature. If this occurs, there is no need
to pull off the road. You can continue to
drive your vehicle.
The air conditioning may automatically
turn on and off during severe operating
conditions to protect the engine from
overheating. When the coolant
temperature decreases to the normal
operating temperature, the air conditioning
turns on.
If the coolant temperature gauge moves
fully into the red zone, or if the coolant
temperature warning or service engine
soon messages appear in your information
display, do the following: 1. Pull off the road as soon as safely
possible and shift the transmission into
park (P).
2. Leave the engine running until the coolant temperature gauge needle
returns to the normal position. After
several minutes, if the temperature
does not drop, follow the remaining
steps.
3. Switch the engine off and wait for it to
cool. Check the coolant level.
4. If the coolant level is at or below the minimum mark, add prediluted coolant
immediately.
5. If the coolant level is normal, restart the engine and continue.
AUTOMATIC TRANSMISSION
FLUID CHECK
The automatic transmission does not have
a transmission fluid dipstick.
Have an authorized dealer check and
change the transmission fluid at the
correct service interval. See
Scheduled
Maintenance (page 427). Your
transmission does not consume fluid.
However, if the transmission slips, shifts
slowly or if you notice a sign of leaking
fluid, contact an authorized dealer.
Do not use supplemental transmission
fluid additives, treatments or cleaning
agents. The use of these materials may
affect transmission operation and result
in damage to internal transmission
components.
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3. Pull the headlamp toward the front of
your vehicle to disengage it from its
locating points and then lift the
headlamp up. 4. Disconnect the electrical connectors.
Note:
When you install the headlamp, make
sure that you correctly attach the electrical
connector.
Note: When you install the headlamp, make
sure that you correctly engage its locating
points.
CHANGING A BULB WARNINGS
Switch all of the lamps and the
ignition off. Failure to follow this
warning could result in serious
personal injury. WARNINGS
Bulbs become hot when in use. Let
them cool down before you remove
them.
Use the correct specification bulb. See
Bulb Specification Chart (page 236).
The following instructions describe how to
remove the bulbs. Install in the reverse
order unless otherwise stated.
Note: LED lamps are not serviceable. See
an authorized dealer.
Headlamp Parking lamp and direction
indicator lamp.
A
Headlamp high beam.
B
Headlamp low beam and
daytime running lamp.
C
Side marker lamp.
D
Note: You may have to remove a cover to
gain access to the bulb.
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BCD
A

3.
Turn the bulb holder counterclockwise
and remove it. Tail and brake lamp.
A
Reversing lamp.
B
Rear clearance lamp.
C
4. Remove the bulb by pulling it straight
out.
Central High Mounted Brake Lamp
This is not a serviceable item, see an
authorized dealer if it fails. License Plate Lamp
1. Carefully release the spring clip.
2. Remove the lamp.
3.
Turn the bulb holder counterclockwise
and remove it. Pull the bulb straight
out.
Interior Lamp
Vehicles with Interior Sensors 1. Carefully remove the lens.
2. Remove the bulb.
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B
C
4
E175746 3
2
1
E72789 1
2
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