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Battery check Ford Transit 2000 - 2006 Diesel 2.0

OnDemand step-by-step maintenance & repair BETA

Ford Transit 2000 - 2006  | 2.0 Battery check

  • time 5 minutes
  • difficulty 1
The battery is located behind the driver's seat. If you have to replace the battery or alternator, click below
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Battery removal & replacement

Disconnection

1 Numerous systems fitted to the vehicle require battery power to be available at all times, either to ensure their continued operation (such as the clock) or to maintain control unit memories which would be erased if the battery were to be disconnected. Whenever the battery is to be disconnected therefore, first note the following, to ensure that there are no unforeseen consequences of this action:
  1. First, on any vehicle with central locking, it is a wise precaution to remove the key from the ignition, and to keep it with you, so that it does not get locked in, if the central locking should engage accidentally when the battery is reconnected.
  2. Depending on vehicle and specification, the Ford anti-theft alarm system may be of the type which is automatically activated when the vehicle battery is disconnected and/or reconnected. To prevent the alarm sounding on models so equipped, switch the ignition on, then off, and disconnect the battery within15 seconds. If the alarm is activated when the battery is reconnected, deactivate the alarm by locking and unlocking one of the front doors
  3. If a security-coded audio unit is fitted, and the unit and/or the battery is disconnected, the unit will not function again on reconnection until the correct security code is entered. Details of this procedure, which varies according to the unit fitted, are given in the vehicle audio system operating instructions. Ensure you have the correct code before you disconnect the battery. If you do not have the code or details of the correct procedure, but can supply proof of ownership and a legitimate reason for wanting this information, a Ford dealer may be able to help.
  4. The engine management powertrain control module (PCM) is of the ‘self-learning’ type, meaning that as it operates, it also monitors and stores the settings which give optimum engine performance under all operating conditions. When the battery is disconnected, these settings are lost and the PCM reverts to the base settings programmed into its memory at the factory. On restarting, this may lead to the engine running/idling roughly for a short while, until the PCM has re-learned the optimum settings. This process is best accomplished by taking the vehicle on a road test (for approximately 15 minutes), covering all engine speeds and loads, concentrating mainly in the 2500 to 3500 rpm region.
  5. On all models, when reconnecting the battery after disconnection, switch on the ignition and wait 10 seconds to allow the electronic vehicle systems to stabilise and re-initialise.

Removal

2 The battery is located inside the vehicle beneath the driver’s seat. Two batteries may be fitted on certain models.
3 Move the driver’s seat fully forward, then open the battery box cover (see illustration) .
Move the driver’s seat fully forward, then open the battery box cover
4 Disconnect the lead at the negative (–) terminal by unscrewing the retaining nut and removing the terminal clamp (see illustration) . Where two batteries are fitted, disconnect the lead at the negative (–) terminal on the second battery in the same way. Note that the battery negative (–) and positive (+) terminal connections are stamped on the battery case.
Disconnect the lead at the battery negative (–) terminal by unscrewing the retaining nut and removing the clamp
5 Disconnect the lead at the positive (+) terminal by lifting the plastic terminal cover, unscrewing the retaining nut and removing the terminal clamp. Where two batteries are fitted, disconnect the lead at the positive (+) terminal on the second battery in the same way.
6 Unscrew the three retaining bolts and remove the battery retaining clamp (see illustration) .
Unscrew the bolts and remove the battery retaining clamp (one of three arrowed)
7 Disconnect the battery breather hose and carefully lift the battery from its location and remove it from the vehicle. Make sure the battery is kept upright at all times.

Refitting

Note: As a precaution, before refitting the battery check that all doors are unlocked.
8 Refitting is a reversal of removal, but smear petroleum jelly on the terminals after reconnecting the leads to reduce corrosion, and always reconnect the positive lead(s) first, followed by the negative lead(s).
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Alternator replacement

Removal

Note: A new steering column flexible coupling lower pinch bolt and nut will be required for refitting. A new auxiliary drivebelt will also be required on models without air conditioning.
1 Move the driver’s seat fully forward, open the battery box cover and disconnect the battery negative terminal.
5 On models with air conditioning, release the tension on the auxiliary drivebelt, and slip the belt off the alternator pulley. On models without air conditioning, remove the auxiliary drivebelt by cutting through it with a sharp knife.
11 Remove the auxiliary drivebelt.
19 Refit or renew the auxiliary drivebelt, then refit the splash shield around the crankshaft pulley.
24 Refit the auxiliary drivebelt.
2 Firmly apply the handbrake, then jack up the front of the vehicle and support it securely on axle stands.
3 Turn the steering wheel to set the roadwheels in the straight-ahead position, then remove the ignition key to lock the column.
4 Undo the two fasteners and remove the splash shield around the crankshaft pulley.
6 Undo the nut and remove the lower pinch bolt securing the steering column intermediate shaft flexible coupling to the steering gear pinion shaft (see illustration) . Note that a new pinch bolt and nut will be required for refitting. Where fitted, extract the circlip from the base of the flexible coupling.
Undo the nut and remove the pinch bolt (arrowed) securing the flexible coupling to the steering gear pinion shaft
7 Slide the flexible coupling up and off the steering gear pinion shaft and move the intermediate shaft to one side.
8 Unplug the wiring connector from the rear of the alternator, then undo the nut to disconnect the wiring terminal from the alternator.
9 Unscrew the upper mounting bolt and the two lower mounting bolts, then withdraw the alternator downwards from the block.
10 Firmly apply the handbrake, then jack up the front of the vehicle and support it securely on axle stands.
12 Unscrew the alternator upper mounting bolt (see illustration) .
Alternator upper mounting bolt (arrowed) . . .
13 Unscrew the alternator lower, front mounting bolt and, where fitted, lift off the splash shield (see illustration) .
. . . and lower mounting bolts (arrowed)
14 Unplug the wiring connector from the rear of the alternator, then undo the nut to disconnect the wiring terminal from the alternator.
15 Unscrew the remaining lower mounting bolt, then withdraw the alternator downwards from the block.

Refitting

16 Manoeuvre the alternator into position and refit the upper and lower mounting bolts. Progressively tighten the bolts to 48 Nm (35 Ibf ft).
17 Reconnect the wiring to the alternator and tighten the terminal retaining nut securely.
18 Reconnect the steering column flexible coupling using a new pinch bolt and nut tightened to 23 Nm (17 Ibf ft). Where applicable, refit the circlip to the base of the flexible coupling.
20 On completion, reconnect the battery negative terminal.

2.4 litre engines

21 Manoeuvre the alternator into position and refit the lower, rear mounting bolt. Tighten the bolt finger tight only at this stage.
22 Reconnect the wiring to the alternator and tighten the terminal retaining nut securely.
23 Place the splash shield (where fitted) in position and refit the lower front retaining bolt finger tight only. Refit the upper retaining bolt, then progressively tighten all three retaining bolts to 48 Nm (35 Ibf ft).
25 On completion, reconnect the battery negative terminal.
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