engine FORD TRANSIT CONNECT 2015 2.G Repair Manual

CHANGING THE 12V BATTERY
WARNINGS
Batteries normally produce explosive
gases which can cause personal
injury. Therefore, do not allow
flames, sparks or lighted substances to
come near the battery. When working near
the battery, always shield your face and
protect your eyes. Always provide proper
ventilation. When lifting a plastic-cased battery,
excessive pressure on the end walls
could cause acid to flow through the
vent caps, resulting in personal injury and
damage to the vehicle or battery. Lift the
battery with a battery carrier or with your
hands on opposite corners. Keep batteries out of reach of
children. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or
clothing. Shield your eyes when working
near the battery to protect against possible
splashing of acid solution. In case of acid
contact with skin or eyes, flush
immediately with water for a minimum of
15 minutes and get prompt medical
attention. If acid is swallowed, call a
physician immediately. Your vehicle is equipped with a
Motorcraft® maintenance-free battery
which normally does not require additional
water during its life of service.
Note:
If your battery has a cover/shield,
make sure it is reinstalled after the battery
has been cleaned or replaced.
Note: See an authorized dealer for low
voltage battery access, testing, or
replacement. When a low voltage battery replacement
is necessary, see an authorized dealer to
replace the low voltage battery with a Ford
recommended replacement low voltage
battery that matches the electrical
requirements of the vehicle
To ensure proper operation of the battery
management system (BMS), do not allow
a technician to connect any electrical
device ground connection directly to the
low voltage battery negative post. A
connection at the low voltage battery
negative post can cause inaccurate
measurements of the battery condition
and potential incorrect system operation.
Note:
If a person adds electrical or
electronic accessories or components to the
vehicle, the accessories or components may
adversely affect the low voltage battery
performance and durability and may also
affect the performance of other electrical
systems in the vehicle.
For longer, trouble-free operation, keep the
top of the battery clean and dry. Also,
make certain the battery cables are always
tightly fastened to the battery terminals.
If you see any corrosion on the battery or
terminals, remove the cables from the
terminals and clean with a wire brush. You
can neutralize the acid with a solution of
baking soda and water.
When a battery replacement is required,
the battery should only be replaced with
a Ford recommended replacement battery
that matches the electrical requirements
of the vehicle.
Because your vehicle ’s engine is
electronically-controlled by a computer,
some engine control settings are
maintained by power from the low voltage
battery. Some engine computer settings,
like the idle trim and fuel trim strategy,
optimize the driveability and performance
of the engine. Some other computer
settings, like the clock and radio station
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presets, are also maintained in memory by
power from the low voltage battery. When
a technician disconnects and connects the
low voltage battery, these settings are
erased. Complete the following procedure
in order to restore the settings:
1. With the vehicle at a complete stop,
set the parking brake.
2. Shift the transmission into P.
3. Turn off all accessories.
4. Step on the brake pedal and start the vehicle.
5. Run the engine until it reaches normal operating temperature. While the
engine is warming up, complete the
following: Reset the clock. See Audio
System (page 251). Reset the power
windows bounce-back feature. See
Windows and Mirrors
(page 73).
Reset the radio station presets. See
Audio System
(page 251).
6. Allow the engine to idle for at least one
minute. If the engine turns off, step on
the accelerator to start the engine.
7. While the engine is running, step on the
brake pedal and shift the transmission
to N.
8. Allow the engine to run for at least one
minute by pressing on the accelerator
pedal.
9. Drive the vehicle at least 10 miles (16 kilometers) to completely relearn the
idle and fuel trim strategy.
Note: If you do not allow the engine to
relearn the idle and fuel trim strategy, the
idle quality of your vehicle may be adversely
affected until the engine computer
eventually relearns the idle trim and fuel
trim strategy. Note:
Always dispose of automotive
batteries in a responsible manner. Follow
your local authorized standards for disposal.
Call your local authorized recycling center
to find out more about recycling automotive
batteries.
Note: It is recommended that the negative
battery cable terminal be disconnected from
the battery if you plan to store your vehicle
for an extended period of time.
CHECKING THE WIPER
BLADES Run the tip of your fingers over the edge of
the blade to check for roughness.
Clean the wiper blades with washer fluid
or water applied with a soft sponge or
cloth.
CHANGING THE WIPER
BLADES
You can manually move the wiper arms
when you switch the ignition off. Pull the
wiper blade and wiper arm away from the
glass. This allows for ease of wiper blade
replacement and cleaning under the wiper
blades.
Replace wiper blades at least once per
year for optimum performance.
Poor wiper quality can be improved by
cleaning the wiper blades and the
windshield.
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CHANGING THE ENGINE AIR
FILTER
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. When changing the air filter element, use
only the air filter element listed. See
Capacities and Specifications (page
246).
For EcoBoost equipped vehicles: When
servicing the air cleaner, it is important that
no foreign material enter the air induction
system. The engine and turbocharger are
susceptible to damage from even small
particles.
Change the air filter element at the proper
interval. See
Maintenance (page 185).
Note: Failure to use the correct air filter
element may result in severe engine
damage. The customer warranty may be
void for any damage to the engine if the
correct air filter element is not used. EcoBoost Engines
1. Remove the retaining screws that
secure the air filter housing cover.
2. Carefully lift the air filter housing cover.
3. Remove the air filter element from the
air filter housing.
4. Wipe any dirt or debris from the air filter
housing and cover to make sure no dirt
gets in the engine and to make sure you
have a good seal.
5. Install a new air filter element. Be careful not to crimp the filter element
edges between the air filter housing
and cover. This could cause filter
damage and allow unfiltered air to
enter the engine if not properly seated.
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6. Install the air filter housing cover.
7. Install the retaining screws to secure
the air filter housing cover to the air
filter housing.
2.5L Engine 1.
Release the clamps that secure the air
filter housing cover.
2. Carefully lift the air filter housing cover. 3.
Remove the air filter element from the
air filter housing.
4. Wipe any dirt or debris from the air filter
housing and cover to make sure no dirt
gets in the engine and to make sure you
have a good seal.
5. Install a new air filter element. Be careful not to crimp the filter element
edges between the air filter housing
and cover. This could cause filter
damage and allow unfiltered air to
enter the engine if not properly seated.
6. Install the air filter housing cover.
7. Engage the clamps to secure the air filter housing cover to the air filter
housing.
TECHNICAL SPECIFICATIONS
- 1.6L ECOBOOST™ WARNING
The air conditioning refrigerant
system contains refrigerant R-134a
under high pressure. Only qualified
personnel should service the air
conditioning refrigerant system. Opening
the air conditioning refrigerant system can
cause personal injury. Capacities
Capacity
Item
6.3 qt (6 L)
Engine cooling system
4.3 qt (4.05 L)
Engine lubrication system - including the oil filter
4.0 qt (3.75 L)
Engine lubrication system - excluding the oil filter
0.8 qt (0.75 L)
Engine oil top-up - raise the level on the dipstick
from minimum to maximum
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Specification
Name
-
Penetrating and Lock Lubricant
XL-1
If you use oil and fluids that do not meet
the defined specification and viscosity
grade, this may lead to:
• Component damage which is not
covered by the vehicle warranty.
• Longer engine cranking periods.
• Increased emission levels.
• Reduced engine performance.
• Reduced fuel economy.
• Degraded brake performance.
Use of synthetic or synthetic blend motor
oil is not mandatory. Only use fluid that
meets Ford specifications. Motor oils of
the recommended viscosity grade that
meet API SN requirements and display the
API Certification Mark for gasoline engines
are also acceptable. Do not use oil labeled
with API SN service category unless the
label also displays the API certification
mark. An oil that displays this symbol conforms
to current engine, emission system and
fuel economy performance standards of
the International Lubricant Standardization
and Approval Committee (ILSAC).
Do not use supplemental engine oil
additives because they are unnecessary
and could lead to engine damage that may
not be covered by your vehicle warranty.
Note:
Ford recommends using DOT 4 Low
Viscosity (LV) High Performance Brake Fluid
or equivalent meeting WSS-M6C65-A2. Use
of any fluid other than the recommended
fluid may cause degraded brake
performance and not meet the Ford
performance standards. Keep brake fluid
clean and dry. Contamination with dirt,
water, petroleum products or other
materials may result in brake system
damage and possible failure.
Note: Automatic transmissions that require
MERCON LV transmission fluid should only
use MERCON LV transmission fluid. The
use of any other fluid may cause
transmission damage.
TECHNICAL SPECIFICATIONS
- 2.5L WARNING
The air conditioning refrigerant
system contains refrigerant R-134a
under high pressure. Only qualified
personnel should service the air
conditioning refrigerant system. Opening
the air conditioning refrigerant system can
cause personal injury. 207
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Capacities
Capacity
Item
8.5 qt (8 L)
Engine cooling system
5.7 qt (5.4 L)
Engine lubrication system - including the oil filter
5.4 qt (5.1 L)
Engine lubrication system - excluding the oil filter
0.8 qt (0.75 L)
Engine oil top-up - raise the level on the dipstick
from minimum to maximum
9.0 qt (8.5 L)
Automatic transmission fluid 1
15.85 gal (60 L)
Fuel tank
3.1 qt (2.9 L)
Windshield washer fluid
1.5 lb (0.68 kg)
A/C refrigerant
1.9 lb (0.875 kg)
A/C refrigerant - with auxiliary system
4.6 fl oz (136 ml)
A/C refrigerant compressor oil
7.4 fl oz (220 ml)
A/C refrigerant compressor oil - with auxiliary system
1 Approximate dry fill capacity. Actual amount may vary during fluid changes.
Specifications
Materials Specification
Name
WSS-M2C945-A
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor
Oil (U.S.)
XO-5W20-QSP (U.S.)
WSS-M2C945-A
Motorcraft® SAE 5W-20 Full Synthetic Motor Oil (U.S.)
XO-5W20-QFS (U.S.)
WSS-M2C938-A
Motorcraft® MERCON® LV Automatic Transmission Fluid
(U.S.) MERCON® LV
XT-10-QLVC (U.S.)
WSS-M97B44-D2
Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.)
VC-3DIL-B (U.S.)
WSS-M6C65-A2
Motorcraft® DOT 4 LV High Performance Motor Vehicle
Brake Fluid
PM-20
WSS-M14P19-A
Motorcraft® Premium Windshield Wash Concentrate with
Bitterant (U.S.)
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Specification
Name
ZC-32-B2 (U.S.)
ESB-M1C93-B
Motorcraft® Multi-Purpose Grease Spray
XL-5
WSH-M17B19-A
Motorcraft® R-134a Refrigerant (U.S.)
YN-19 (U.S.)
WSH-M1C231-B
Motorcraft® PAG Refrigerant Compressor Oil
YN-12-D
ESA-M1C75-B
Premium Long-Life Grease
XG-1-E1
-
Penetrating and Lock Lubricant
XL-1
If you use oil and fluids that do not meet
the defined specification and viscosity
grade, this may lead to:
• Component damage which is not
covered by the vehicle warranty.
• Longer engine cranking periods.
• Increased emission levels.
• Reduced engine performance.
• Reduced fuel economy.
• Degraded brake performance.
Use of synthetic or synthetic blend motor
oil is not mandatory. Only use fluid that
meets Ford specifications. Motor oils of
the recommended viscosity grade that
meet API SN requirements and display the
API Certification Mark for gasoline engines
are also acceptable. Do not use oil labeled
with API SN service category unless the
label also displays the API certification
mark. An oil that displays this symbol conforms
to current engine, emission system and
fuel economy performance standards of
the International Lubricant Standardization
and Approval Committee (ILSAC).
Do not use supplemental engine oil
additives because they are unnecessary
and could lead to engine damage that may
not be covered by your vehicle warranty.
Note:
Ford recommends using DOT 4 Low
Viscosity (LV) High Performance Brake Fluid
or equivalent meeting WSS-M6C65-A2. Use
of any fluid other than the recommended
fluid may cause degraded brake
performance and not meet the Ford
performance standards. Keep brake fluid
clean and dry. Contamination with dirt,
water, petroleum products or other
materials may result in brake system
damage and possible failure.
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CLEANING PRODUCTS
For best results, use the following products
or products of equivalent quality:
•
Motorcraft Bug and Tar Remover
(ZC-42)
• Motorcraft Custom Bright Metal
Cleaner (ZC-15)
• Motorcraft Detail Wash (ZC-3-A)
• Motorcraft Dusting Cloth (ZC-24)
• Motorcraft Engine Shampoo and
Degreaser (U.S. only) (ZC-20)
• Motorcraft Engine Shampoo (Canada
only) (CXC-66-A)
• Motorcraft Multi-Purpose Cleaner
(Canada only) (CXC-101)
• Motorcraft Premium Glass Cleaner
(Canada only) (CXC-100)
• Motorcraft Premium Quality
Windshield Washer Fluid (Canada
only) [CXC-37-(A, B, D or F)]
• Motorcraft Premium Windshield Wash
Concentrate with Bitterant (U.S. only)
(ZC-32-B2)
• Motorcraft Professional Strength
Carpet & Upholstery Cleaner (ZC-54)
• Motorcraft Premium Leather and Vinyl
Cleaner (ZC-56)
• Motorcraft Spot and Stain Remover
(U.S. only) (ZC-14)
• Motorcraft Ultra-Clear Spray Glass
Cleaner (ZC-23)
• Motorcraft Wheel and Tire Cleaner
(ZC-37-A)
CLEANING THE EXTERIOR
Wash your vehicle regularly with cool or
lukewarm water and a neutral pH
shampoo, we recommend Motorcraft
Detail Wash. •
Never use strong household detergents
or soap, for example dish washing or
laundry liquid. These products can
discolor and spot painted surfaces.
• Never wash your vehicle when is hot to
the touch, or during strong or direct
sunlight.
• Dry your vehicle with a chamois or soft
terry cloth towel to eliminate water
spotting.
• Immediately remove fuel spillages, bird
droppings, insect deposits and road tar.
These may cause damage to your
vehicle ’s paintwork or trim over time.
We recommend Motorcraft Bug and
Tar Remover.
• Remove any exterior accessories, for
example antennas, before entering a
car wash.
Note: Suntan lotions and insect repellents
can damage painted surfaces. If these
substances come in contact with your
vehicle, wash the affected area as soon as
possible.
Exterior Chrome Parts
• Apply a high quality-cleaning product
to bumpers and other chrome parts.
Follow the manufacturer ’s instructions.
We recommend Motorcraft Custom
Bright Metal Cleaner.
• Do not apply the cleaning product to
hot surfaces. Do not leave the cleaning
product on chrome surfaces longer
than the time recommended.
• Using other non-recommended
cleaners can result in severe and
permanent cosmetic damage.
Note: Never use abrasive materials, for
example steel wool or plastic pads as they
can scratch the chrome surface.
Note: Do not use chrome cleaner, metal
cleaner or polish on wheels or wheel covers.
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Exterior Plastic Parts
For routine cleaning we recommend
Motorcraft Detail Wash. If tar or grease
spots are present, we recommend
Motorcraft Bug and Tar Remover.
Stripes or Graphics (If Equipped)
Do not use a commercial or high-pressure
sprayer on the surface or edge of stripes
and graphics. This can damage them and
cause the edges to peel away from the
vehicle surface.
Underbody
Flush the complete underside of your
vehicle frequently. Keep body and door
drain holes free of debris or foreign
material.
WAXING
Regular waxing is necessary to protect your
car's paint from the elements. We
recommend that you wash and wax the
painted surface once or twice a year.
When washing and waxing, park your
vehicle in a shaded area out of direct
sunlight. Always wash your vehicle before
applying wax.
• Use a quality wax that does not contain
abrasives.
• Follow the manufacturer ’s instructions
to apply and remove the wax.
• Apply a small amount of wax in a
back-and-forth motion, not in circles. •
Do not allow wax to come in contact
with any non-body (low-gloss black)
colored trim. The wax will discolor or
stain the parts over time.
•Roof racks.
• Bumpers.
• Grained door handles.
• Side moldings.
• Mirror housings.
• Windshield cowl area.
• Do not apply wax to glass areas.
• After waxing, your car's paint should
feel smooth, and be free of streaks and
smudges.
CLEANING THE ENGINE
Engines are more efficient when they are
clean because grease and dirt buildup keep
the engine warmer than normal.
When washing:
• Take care when using a power washer
to clean the engine. The high-pressure
fluid could penetrate the sealed parts
and cause damage.
• Do not spray a hot engine with cold
water to avoid cracking the engine
block or other engine components.
• Spray Motorcraft Engine Shampoo and
Degreaser on all parts that require
cleaning and pressure rinse clean. In
Canada, use Motorcraft Engine
Shampoo.
• Never wash or rinse the engine while it
is hot or running; water in the running
engine may cause internal damage.
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•
Never wash or rinse any ignition coil,
spark plug wire or spark plug well, or
the area in and around these locations.
• Cover the battery, power distribution
box, and air filter assembly to prevent
water damage when cleaning the
engine.
CLEANING THE WINDOWS AND
WIPER BLADES
Car wash chemicals and environmental
fallout can result in windshield and wiper
blade contamination. Dirty windshield and
wipers will result in poor windshield wiper
operation. Keep the windshield and wiper
blades clean to maintain windshield wiper
performance.
To clean the windshield and wiper blades:
• Clean the windshield with a
non-abrasive glass cleaner.
• For windshields contaminated with
tree sap, chemicals, wax or bugs, clean
the entire windshield using steel wool
(no greater than 0000 grade) in a
circular motion and rinse with water.
• Clean the wiper blades with isopropyl
rubbing alcohol or windshield washer
concentrate.
Note: Do not use razor blades or other
sharp objects to clean or remove decals
from the inside of the heated rear window.
The vehicle warranty does not cover
damage caused to the heated rear window
grid lines.
CLEANING THE INTERIOR WARNINGS
Do not use cleaning solvents, bleach
or dye on the vehicle
’s safety belts,
as these actions may weaken the
belt webbing. WARNINGS
On vehicles equipped with
seat-mounted airbags, do not use
chemical solvents or strong
detergents. Such products could
contaminate the side airbag system and
affect performance of the side airbag in a
collision. For fabric, carpets, cloth seats, safety belts
and seats equipped with side airbags:
•
Remove dust and loose dirt with a
vacuum cleaner.
• Remove light stains and soil with
Motorcraft Professional Strength
Carpet & Upholstery Cleaner.
• If grease or tar is present on the
material, spot-clean the area first with
Motorcraft Spot and Stain Remover. In
Canada, use Motorcraft Multi-Purpose
Cleaner.
• If a ring forms on the fabric after spot
cleaning, clean the entire area
immediately (but do not oversaturate)
or the ring will set.
• Do not use household cleaning
products or glass cleaners, which can
stain and discolor the fabric and affect
the flame retardant abilities of the seat
materials.
CLEANING THE INSTRUMENT
PANEL AND INSTRUMENT
CLUSTER LENS WARNING
Do not use chemical solvents or
strong detergents when cleaning the
steering wheel or instrument panel
to avoid contamination of the airbag
system. 213
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