2001, 2002, 2003, 2004, 2005 and 2006 Ford Transit Van Series VH & VJ Service and Repair Manual

This 2001–2006 Ford Transit Van Series VH & VJ Service and Repair Manual Covers

Engine & Drivetrain

Petrol Engine

• 2.3L Duratec DOHC 16-Valve Inline-4

Diesel Engines

Front-Wheel Drive Models

• 2.0L Duratorq TDDi/TDCi Inline-4
• 2.0L High-Pressure Common Rail (HPCR) TDCi Inline-4

Rear-Wheel Drive Models

• 2.4L Duratorq TDDi Inline-4
• 2.4L Duratorq TDCi Inline-4

Coverage Includes

• Engine mechanical overhaul procedures
• Common-rail fuel injection diagnostics
• Fuel pump and injector testing
• Turbocharger diagnostics and repair procedures
• Glow plug system diagnostics
• Cooling system troubleshooting
• Intake and exhaust system repairs
• Emissions control system servicing
• Front-wheel-drive and rear-wheel-drive repairs
• Propshaft and differential servicing
• MT75 and MT82 manual transmission diagnostics
• Durashift EST automated manual transmission diagnostics
• Powertrain Control Module (PCM) diagnostics and programming

The VH and VJ Transit range was available with both front-wheel-drive and rear-wheel-drive layouts and featured Ford’s Duratorq diesel engine family along with the 2.3L Duratec petrol engine.

Chassis & Suspension

• Independent front suspension repairs
• Rear leaf spring suspension servicing
• Steering system diagnostics and repair
• Hydraulic and power-assisted steering diagnostics
• Wheel alignment specifications
• Wheel bearing replacement procedures
• Suspension component testing and troubleshooting
• Heavy-duty chassis servicing procedures

Braking Systems

• Disc and drum brake servicing procedures
• Anti-lock Braking System (ABS) diagnostics
• Electronic Brakeforce Distribution (EBD) diagnostics
• Traction control system troubleshooting where equipped
• Brake hydraulic system repairs
• Parking brake service procedures
• Brake booster and master cylinder testing

Electrical & Wiring

• Complete Ford factory wiring diagrams
• Battery and charging system diagnostics
• Starting system troubleshooting
• Body Control Module diagnostics
• Power distribution schematics
• Fuse and relay identification
• Exterior and interior lighting diagnostics
• Instrument cluster diagnostics
• Central locking and security system diagnostics
• CAN network diagnostics where applicable

Air Conditioning & HVAC

• Manual and automatic climate control diagnostics
• HVAC control module testing
• Refrigerant servicing specifications
• Heating and ventilation troubleshooting
• Blower motor repairs
• Air distribution actuator diagnostics

Body & Interior

• Interior trim removal and installation procedures
• Cargo compartment servicing
• Passenger and minibus seating repairs
• Sliding side door service procedures
• Rear cargo door and tailgate repairs
• Power window and door lock diagnostics
• Exterior body repair procedures
• Airbag and occupant restraint system servicing

Diagnostics & Troubleshooting

• Ford-specific diagnostic procedures
• Diagnostic Trouble Code (DTC) lookup
• Pinpoint testing procedures
• Component testing specifications
• Scan tool diagnostics
• Service functions and adaptations
• Electrical fault tracing procedures

Common Error Codes Covered

This manual provides diagnostic and repair procedures for thousands of Ford-specific fault codes, including:

Engine Codes

• P0105 – Manifold Absolute Pressure Circuit Malfunction
• P0191 – Fuel Rail Pressure Sensor Range/Performance
• P0216 – Injection Timing Control Circuit Malfunction
• P0404 – EGR Control Circuit Range/Performance
• P1211 – Injection Control Pressure Above/Below Desired
• P1664 – Fuel Injection Pump Control Module Malfunction

Transmission Codes

• P0700 – Transmission Control System Malfunction
• P0715 – Input/Turbine Speed Sensor Circuit Fault
• P0720 – Output Speed Sensor Circuit Fault
• P0734 – Incorrect Gear Ratio
• P0902 – Clutch Actuator Circuit Low

ABS & Chassis Codes

• C0031 – Left Front Wheel Speed Sensor Fault
• C0034 – Right Front Wheel Speed Sensor Fault
• C1095 – ABS Hydraulic Pump Motor Circuit Fault
• C1278 – Yaw Rate Sensor Signal Fault

Network Communication Codes

• U0100 – Lost Communication with PCM
• U0140 – Lost Communication with Body Control Module
• U0155 – Lost Communication with Instrument Cluster
• U1900 – CAN Communication Bus Fault

Body Control Codes

• B1318 – Battery Voltage Low
• B1342 – ECU Internal Fault
• B2477 – Interior Lamp Circuit Fault
• B2552 – Central Locking System Fault

And thousands of additional diagnostic codes, wiring diagrams, service bulletins, and repair procedures.

Who Is This Manual For?

This manual is ideal for:

• Professional Ford commercial vehicle workshops
• Fleet maintenance departments
• Independent repair garages
• Mobile mechanics
• Automotive technicians
• Transit owners performing DIY repairs
• Automotive training institutions

If you are troubleshooting, maintaining, servicing, or repairing a 2001–2006 Ford Transit Van Series VH & VJ, this is the factory workshop manual you need.