![Ford van manual Ford van manual](/uploads/1/2/4/9/124919454/553537064.jpg)
- 2Foreword
- 2Group Index
- 3How to Use This Manual
- 3Component Parts and Work to Be Done
- 4Symbol
- 5Abbreviations Used in This Manual
- 7Wire Color
- 8General Information
- 8Contents
- 9Warning/Caution/Note
- 11Suzuki AN650K3 ('03-Model) View
- 11Serial Number Location
- 11Fuel, Oil and Engine Coolant Recommendation Fuel
- 12Engine Oil and Transmission Oil
- 12Final Gear Oil
- 12Brake Fluid
- 12Anti-Freeze/Engine Coolant
- 13Liquid Amount of Water/Engine Coolant
- 14Break-In Procedures
- 14Cylinder Identification
- 15Information Labels
- 16Specifications
- 16Dimensions and Dry Mass
- 16Engine/Drive Train
- 17Electrical
- 17Capacities
- 18Country and Area Codes
- 19Periodic Maintenance
- 20Periodic Maintenance Schedule
- 20Periodic Maintenance Chart
- 21Lubrication Points
- 22Maintenance and Tune-up Procedures
- 22Air Cleaner
- 24Spark Plug Removal
- 24Heat Range
- 25Carbon Deposits
- 25Spark Plug Gap/Installation
- 25Electrodes Condition
- 25Tappet Clearance
- 27Tappet Clearance Adjustment
- 29Intake Side
- 29Tappet Shim Selection Table
- 30Exhaust Side
- 31Fuel Hose
- 31Engine Oil and Oil Filter
- 31Engine Oil Replacement
- 32Oil Filter Replacement
- 33Transmission Oil Replacement
- 33Final Gear Oil Replacement
- 34CVF Filter
- 36Engine Idle Speed
- 36Throttle Cable Play
- 36Minor Adjustment
- 37Major Adjustment
- 38Cooling System
- 38Engine Coolant Level Check
- 38Engine Coolant Change
- 39Air Bleeding the Cooling Circuit
- 40Radiator Hoses
- 40Brake Fluid Level Check
- 41Brake Pads
- 42Air Bleeding the Brake Fluid Circuit
- 43Tire Tread Condition
- 44Tire Pressure
- 44Steering
- 44Front Fork
- 45Rear Suspension
- 45Exhaust Pipe Bolt and Muffler Mounting Bolt
- 46Chassis Bolts and Nuts
- 48Compression Pressure Check
- 48Compression Pressure Specification
- 48Compression Test Procedure
- 49Oil Pressure Check
- 49Oil Pressure Specification
- 49Oil Pressure Test Procedure
- 50Automatic Clutch Inspection
- 50Initial Engagement Inspection
- 50Clutch 'Lock-Up' Inspection
- 51Brake-Lock Inspection
- 52Engine
- 53Engine Components Removable With Engine in Place
- 53Center of Engine
- 53Right Side of Engine
- 53Left Side of Engine
- 54Engine Removal and Remounting
- 54External Parts
- 61Engine Remounting
- 62Muffler
- 63Engine Disassembly
- 63Starter Motor
- 63Oil Pressure/Level Switch
- 63Cylinder Head Cover
- 64Cylinder Head, and Cylinder
- 65Piston
- 65Oil Hose
- 65Generator Cover
- 66Generator
- 67Starter Clutch
- 68Cam Chain
- 68Water Pump
- 68Oil Filter
- 69Separation of Crankcase
- 70Drive Shaft
- 70Balancer Shaft
- 71Oil Pump
- 71Oil Pressure Regulator
- 71Piston Cooling Nozzle
- 72Crankshaft
- 72Primary Driven Gear
- 72Return Oil Pump
- 73Engine Component Inspection and Service
- 74Cam Position Sensor
- 74Cam Face
- 74Camshaft Runout
- 75Camshaft Journal Wear
- 76Cam Chain Tension Adjuster
- 76Cam Chain Guide
- 77Valve and Valve Spring Diassembly
- 77Cylinder Head Distortion
- 78Valve Stem Deflection
- 78Valve Stem Wear
- 78Valve Stem Runout
- 78Valve Head Radial Runout
- 79Valve Face Wear
- 79Valve Sprign
- 80Valve Guide Servicing
- 81Valve Seat Width Inspection
- 81Valve Seat Servicing
- 82Initial Seat Cut
- 82Top Narrowing Cut
- 83Bottom Narrowing Cut
- 83Final Seat Cut
- 84Valve and Valve Spring Reassembly
- 85Intake Pipe
- 85Cylinder Distortion
- 86Cylinder Bore
- 87Piston and Piston Ring
- 87Piston Diameter
- 87Piston to Cylinder Clearance
- 87Piston Pins and Pin Bore
- 88Piston Ring to Groove Clearance
- 88Piston Ring Free End Gap and Piston Ring End Gap
- 89Clutch
- 90Clutch Drive Plates/Clutch Driven Plates No.2 Inspection
- 91Clutch Driven Plate No.2 Inspection
- 91Clutch Spring Free Height
- 91Clutch Plate Concaved Washer Inspection
- 94Starter Clutch View
- 95Starter Torque Limiter
- 95Oil Pump Inspection
- 95Oil Pressure Regulator/Oil Sump Filter
- 96Crank Balancer
- 96Drive Shaft Disassembly
- 98Conrod/Crankshaft
- 98Conrod Small End I.D.
- 98Conrod Big End Side Clearance
- 98Conrod-Crank Pin Bearing Inspection
- 99Conrod-Crank Pin Bearing Selection
- 100Conrod I.D.
- 100Crank Pin O.D.
- 100Bearing Thickness
- 100Bearing Assembly
- 101Crankcase-Crankshaft Bearing Inspection
- 101Crankcase-Crankshaft Bearing Selection
- 102Crankshaft Journal Bearing Replacement
- 105Crankshaft Thrust Clearance
- 106Oil Jet
- 107Crankcase
- 107Oil Pressure Switch
- 107Bearing Disassembly
- 108Bearing Inspection
- 108Bearing Reassembly
- 108Oil Seal Disassembly
- 109Oil Seal Reassembly
- 110Engine Reassembly
- 110Primary Driven Gear/Crankshaft
- 111Oil Sump Filter
- 111Oil Pump/Oil Pressure Regulator
- 112Crank Balancer Shaft
- 120Piston Ring
- 123Cam Shaft
- 124Position of Camshafts and Sprockets
- 126Oil Level Switch
- 127Drive Train
- 128Drive Train Construction
- 129Removal and Disassembly
- 130Inspection and Replacement
- 130Gears
- 130Oil Seals
- 131Bearings
- 132Final Driven Gear Hub
- 133Reassembly and Remounting
- 135Cvt
- 136CVT Assembly Removal and Installation
- 138CVT Assembly Installation
- 139CVT Disassembly and Reassembly
- 140CVT Disassembly
- 140CVT Casing/Cover
- 143Secondary Pulley Assembly
- 144CVT Belt
- 144Primary Pulley
- 145CVT Inspection
- 145Primary Pulley Inspection
- 145Secondary Pulley Inspection
- 146Secondary Pulley Disassembly
- 146CVT Motor
- 147Secondary Pulley Reassembly
- 147CVT Bely Inspection
- 148CVT Casing/Cover Inspection
- 148CVT Casing/Cover Disassembly
- 149CVT Casing/Cover Reassembly
- 150Primary Slide Pulley Idle Gear Inspection
- 150CVT Primary Pulley Shims Adjustment
- 150CVT Cover Depth Measurement
- 150Primary Pulley Height Measurement
- 152Shim Selection Table
- 153CVT Reassembly
- 153Primary Pulley Assembly
- 154CVT Belt Installation
- 161CVT Belt Brake-In Procedures
- 161Clamp Location
- 162FI System/ CVT System
- 163Precautions in Servicing
- 163Electrical Parts
- 163Connector/Coupler
- 164Fude
- 164ECM/CVT Control Unit/Various Sensors
- 166Electrical Circuit Inspection Procedure
- 166Open Circuit Check
- 167Continuity Check
- 167Voltage Check
- 168Short Circuit Check (Wire Harness to Ground)
- 169Using the Tester
- 170FI System Technical Features Injection Time (Injection Volume)
- 171Compensation of Injection Time (Volume)
- 171Injection Stop Control
- 172FI System Parts Location
- 174FI System Wiring Diagram
- 175CVT System Technical Features
- 176CVT System Parts Location
- 179Self-Diagnosis Function
- 179User Mode
- 180Dealer Mode
- 181TPS Adjustment
- 182Fail-Safe Function
- 183FI System/CVT System Troubleshooting Customer Complaint Analysis
- 185Self-Diagnostic Procedures
- 185Self-Diagnosis Reset Procedure
- 186Malfunction Code and Defective Condition
- 188'C11' CMP Sensor Circuit Malfunction
- 189'C12' CKP Sensor Circuit Malfunction
- 190'C13' IAP Sensor Circuit Malfunction
- 192'C14' TP Sensor Circuit Malfunction
- 194'C15' ECT Sensor Circuit Malfunction
- 195'C16' Speed Sensor Circuit Malfunction
- 197'C21' IAT Sensor Circuit Malfunction
- 198'C22' AP Sensor Circuit Malfunction
- 200'C23' to Sensor Circuit Malfunction
- 201'C24' or 'C25' Ignition System Malfunction
- 201'C32' or 'C33' Fuel Injector Circuit Malfunction
- 202'C40' IAC Valve Circuit Malfunction
- 202'C41' FP Relay Circuit Malfunction
- 202'C42' IG Switch Circuit Malfunction
- 203'C44' HO2 Sensor (HO2S) Circuit Malfunction (E-02,19)
- 205'C50' CVT Serial Communication Circuit Malfunction
- 206'C51' CVT Motor Circuit Malfunction
- 208'C52' CVT Pulley Position Sensor (PPS) Circuit Malfunction
- 210'C53' CVT Speed Sensor Circuit Malfunction
- 212'C54' CVT Secondary Pulley Revolution Sensor Circuit MalÂfunction
- 214'C55' CVT Engine Revolution Signal Circuit Malfunction
- 215'C56' CVT Throttle Position Signal Circuit Malfunction
- 216'C58' CVT Reduction Ratio Disagreement
- 217Throttle Position Sensor (TPS) Setting
- 217CMP/CKP Sensor
- 217IAP Sensor
- 218TP Sensor
- 218ECT Sensor
- 218Speed Sensor
- 218IAT/AP Sensor
- 219To Sensor
- 219H02 Sensor (E-02,19)
- 219CVT Pulley Position Sensor
- 219CVT Secondary Pulley Revolution Sensor
- 220Fuel System and Throttle Body
- 221Fuel System
- 221Fuel Tank Components
- 222Fuel Tank Removal
- 223Fuel Tank Installation
- 223Fuel Tank Pressure Control (FTPC) Valve Inspection
- 224Fuel Pressure Inspection
- 225Fuel Pump Inspection
- 225Fuel Discharge Amount Inspection
- 225Fuel Pump Relay Inspection
- 226Fuel Pump Components
- 226Fuel Pump/Fuel Level Gauge Removal and Disassembly
- 229Fuel Mesh Filter Inspection and Cleaning
- 229Fuel Level Gauge Inspection
- 229Fuel Meter Inspection
- 230Fuel Pump/Fuel Level Gauge Reassembly and Installation
- 233Throttle Body Components
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