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Fluid level checks Ford Transit 2000 - 2006 Diesel 2.0

OnDemand step-by-step maintenance & repair BETA

Ford Transit 2000 - 2006  | 2.0 Fluid level checks

  • time 5 to 30 minutes
  • difficulty 1

Underbonnet check points

2.0 litre engines 1 Engine oil level dipstick 2 Engine oil filler cap 3 Coolant reservoir (expansion tank) 4 Washer fluid reservoir 5 Fuse/relay box 6 Power steering fluid reservoir 7 Brake and clutch fluid reservoir
2.4 litre engines 1 Engine oil level dipstick 2 Engine oil filler cap 3 Coolant reservoir (expansion tank) 4 Washer fluid reservoir 5 Fuse/relay box 6 Power steering fluid reservoir 7 Brake and clutch fluid reservoir

Engine oil level

1 • Make sure that the vehicle is on level ground.
2 • The oil level must be checked with the engine at normal operating temperature, however, wait at least 5 minutes after the engine has been switched off.
HINT: If the oil is checked immediately after driving the vehicle, some of the oil will remain in the upper engine components, resulting in an inaccurate reading on the dipstick.

The correct oil

3 Modern engines place great demands on their oil. It is very important that the correct oil for your vehicle is used.
Engine oil grade Multigrade engine oil, viscosity SAE 5W/30 to Ford specification WSS-M2C913-B

Vehicle care

4 ● If you have to add oil frequently, you should check whether you have any oil leaks. Place some clean paper under the vehicle overnight, and check for stains in the morning. If there are no leaks, then the engine may be burning oil.
5 ● Always maintain the level between the upper and lower dipstick marks (see photo 3). If the level is too low, severe engine damage may occur. Oil seal failure may result if the engine is overfilled by adding too much oil.
The dipstick is brightly coloured for easy identification (see Underbonnet check points for exact location). Withdraw the dipstick.
Using a clean rag or paper towel remove all oil from the dipstick. Insert the clean dipstick into the tube as far as it will go, then withdraw it again.
Note the level on the end of the dipstick, which should be between the upper (MAX) mark and lower (MIN) mark. Approximately 2.0 litres of oil will raise the level from the lower mark to the upper mark.
Oil is added through the filler cap. Unscrew the cap and top-up the level. A funnel may help to reduce spillage. Add the oil slowly, checking the level on the dipstick frequently. Avoid overfilling (see Vehicle care). If you need to renew the oil and filter, click below
- Close + Open

Engine oil and filter change

HINT: Frequent oil and filter changes are the most important preventative maintenance procedures which can be undertaken by the DIY owner. As engine oil ages, it becomes diluted and contaminated, which leads to premature engine wear.
1 Before starting this procedure, gather together all the necessary tools and materials. Also, make sure that you have plenty of clean rags and newspapers handy, to mop up any spills. Ideally, the engine oil should be warm, as it will drain more easily and more built-up sludge will be removed with it. Take care not to touch the exhaust or any other hot parts of the engine when working under the vehicle. To avoid any possibility of scalding and to protect yourself from possible skin irritants and other harmful contaminants in used engine oils, it is advisable to wear gloves when carrying out this work.
2 Access to the underside of the vehicle will be greatly improved if it can be raised on a lift, driven onto ramps, or jacked up and supported on axle stands. Whichever method is chosen, make sure that the vehicle remains level, or if it is at an angle, that the drain plug is at the lowest point.
3 Remove the oil filler cap, then unscrew the engine oil drain plug (located at the lowest point of the sump) about half a turn. Position the draining container under the drain plug, then remove the plug completely – recover the sealing washer (see illustration and Haynes Hint) .
HINT: Keep the plug pressed into the sump while unscrewing it by hand the last couple of turns. As the plug releases from the threads, move it away sharply, so the stream of oil issuing from the sump runs into the pan, not up your sleeve.
Engine oil drain plug location (arrowed)
4 Allow some time for the oil to drain, noting that it may be necessary to reposition the container as the oil flow slows to a trickle.
5 After all the oil has drained, wipe off the drain plug with a clean rag, and fit a new sealing washer. Note that on some models the seal is integral and the complete drain plug must be renewed. Clean the area around the drain plug opening, and fit the plug. Tighten the plug to 23 Nm (17 Ibf ft).
6 Move the container into position under the oil filter, which is located on the front of the cylinder block (front wheel drive models), or the left-hand side of the cylinder block (rear wheel drive models).
7 Unscrew the oil filter plastic cover from the bottom of the oil filter housing, then remove and discard the paper element (see illustrations) .
Unscrew the oil filter housing cover . . .
. . . and discard the paper element
8 Remove the O-ring seal and obtain a new one (see illustration) . Clean the filter housing and cover.
Removing the O-ring seal
9 Fit the new O-ring seal onto the cover and lubricate it with a little engine oil.
10 Locate the new paper element on the cover, then screw the assembly into the filter housing and tighten it to 25 Nm.
11 Remove the old oil and all tools from under the vehicle, then lower the vehicle to the ground.
12 Remove the dipstick, then unscrew the oil filler cap from the camshaft cover. Fill the engine, using the correct grade and type of oil. An oil can spout or funnel may help to reduce spillage. Pour in half the specified quantity of oil first, then wait a few minutes for the oil to fall to the sump. Continue adding oil, a small quantity at a time, until the level is up to the lower mark on the dipstick. Refit the filler cap.
Engine oil quantity:
  2.0 litre engines 6.5 litres
  2.4 litre engines 7.0 litres
Engine oil grade Multigrade engine oil, viscosity SAE 5W/30 to Ford specification WSS-M2C913-B
13 Start the engine and run it for a few minutes, then check for leaks. Note that there may be a delay of a few seconds before the oil pressure warning light goes out when the engine is first started, as the oil circulates through the engine oil galleries and the new oil filter before the pressure builds up.
14 Switch off the engine, and wait a few minutes for the oil to settle in the sump once more. With the new oil circulated and the filter completely full, recheck the level on the dipstick, and add more oil as necessary.
15 Dispose of the used engine oil and filter safely. Do not discard the old filter with domestic household waste. The facility for waste oil disposal provided by many local council refuse tips and/or recycling centres generally has a filter receptacle alongside.

Coolant level

Warning: Do not attempt to remove the expansion tank pressure cap when the engine is hot, as there is a very great risk of scalding. Do not leave open containers of coolant about, as it is poisonous.

Vehicle care

6 ● Adding coolant should not be necessary on a regular basis. If frequent topping-up is required, it is likely there is a leak. Check the radiator, all hoses and joint faces for signs of staining or wetness, and rectify as necessary.
7 ● It is important that antifreeze is used in the cooling system all year round, not just during the winter months. Don’t top up with water alone, as the antifreeze will become diluted.
The coolant level varies with the temperature of the engine and is visible through the expansion tank. When the engine is cold, the coolant level should be between the MAX and MIN marks on the side of the tank. When the engine is hot, the level will rise slightly.
If topping-up is necessary, wait until the engine is cold. Slowly unscrew the expansion tank cap, to release any pressure present in the cooling system, and remove it.
Add a mixture of water and antifreeze to the expansion tank until the coolant is up to the MAX level mark. Refit the cap and tighten it securely. Should you need to replace the coolant, click below
- Close + Open

Coolant replacement

Warning: Never remove the expansion tank filler cap when the engine is running, or has just been switched off, as the cooling system will be hot, and the consequent escaping steam and scalding coolant could cause serious injury. If the engine is hot, the electric cooling fan may start rotating even if the engine is not running, so be careful to keep hands, hair and loose clothing well clear when working in the engine compartment.

Cooling system draining

Warning: Wait until the engine is cold before starting this procedure.
1 To drain the system, first remove the expansion tank filler cap. Place a thick cloth over the expansion tank cap, then turn the cap anticlockwise as far as the first stop and wait for any pressure to be released, then depress it and turn it further anticlockwise to remove it.
2 If additional working clearance is required, apply the handbrake, then jack up the front of the vehicle and support it on axle stands.
3 Place a large drain tray underneath the radiator, and unscrew the radiator drain plug (see illustration) . Allow the coolant to drain into the tray.
Radiator drain plug (shown with radiator removed)
4 The cylinder block may also be drained by removing the drain plug located on the exhaust manifold side of the engine at the flywheel end (see illustration) .
Cylinder block drain plug
5 On completion, retighten the drain plugs securely. Where necessary, lower the vehicle to the ground.

Cooling system flushing

6 If coolant renewal has been neglected, or if the antifreeze mixture has become diluted, then in time, the cooling system may gradually lose efficiency, as the coolant passages become restricted due to rust, scale deposits, and other sediment. The cooling system efficiency can be restored by flushing the system clean.
7 The radiator should be flushed independently of the engine, to avoid unnecessary contamination.

Radiator flushing

8 Disconnect the top and bottom hoses and any other relevant hoses from the radiator.
9 Insert a garden hose into the radiator top inlet. Direct a flow of clean water through the radiator, and continue flushing until clean water emerges from the radiator bottom outlet.
10 If after a reasonable period, the water still does not run clear, the radiator can be flushed with a good proprietary cleaning agent. It is important that the manufacturer’s instructions are followed carefully. If the contamination is particularly bad, remove the radiator, insert the hose in the radiator bottom outlet, and reverse-flush the radiator.

Engine flushing

11 Remove the thermostat, then, if the radiator top hose has been disconnected from the engine, temporarily refit the thermostat housing cover and reconnect the hose.
13 On completion of flushing, refit the thermostat and reconnect the hoses.
12 With the top and bottom hoses disconnected from the radiator, insert a garden hose into the radiator top hose. Direct a clean flow of water through the engine, and continue flushing until clean water emerges from the radiator bottom hose.

Cooling system filling

14 Before attempting to fill the cooling system, make sure that all hoses and clips are in good condition, and that the clips are tight. Note that an antifreeze mixture must be used all year round, to prevent corrosion of the engine components.
15 Fill the system via the expansion tank, with the correct antifreeze mixture, until the coolant level reaches the MAX mark on the side of the expansion tank. Refit the expansion tank filler cap.
Coolant quantity 10 litres
Anti-freeze type Motorcraft Super Plus 2000 antifreeze to Ford specification WSS-M97B44-D
16 Start the engine and allow it to idle until it reaches normal operating temperature, then allow it to idle for a further 5 minutes.
17 Switch off the engine and allow it to cool for at least 30 minutes.
18 Remove the filler cap and top-up the coolant level to the MAX mark on the expansion tank. Refit and tighten the cap.

Antifreeze mixture

19 Ford state that, if the only antifreeze used is Ford’s own purple Super Plus, it will last for ten years. This is subject to it being used in the recommended concentration, unmixed with any other type of antifreeze or additive, and topped-up when necessary using only that antifreeze type, mixed with clean water. If any other type of antifreeze is (or has been) added, the ten year life period no longer applies; in this case, the system must be drained and thoroughly flushed before fresh coolant mixture is poured in.
20 If any antifreeze other than Ford’s is to be used, the coolant must be renewed at regular intervals to provide an equivalent degree of protection. The conventional recommendation is to renew the coolant every two years.
21 To give the recommended standard mixture ratio for this antifreeze, 40% (by volume) of antifreeze must be mixed with 60% of clean, soft water. If you are using any other type of antifreeze, follow its manufacturer’s instructions to achieve the correct ratio.
22 It is best to make up slightly more than the system’s specified capacity, so that a supply is available for subsequent topping-up. However, note that you are unlikely to fully drain the system at any one time (unless the engine is being completely stripped), and the capacities quoted are therefore slightly academic for routine coolant renewal.
23 Before adding antifreeze, the cooling system should be completely drained, preferably flushed, and all hoses checked for condition and security. Fresh antifreeze will rapidly find any weaknesses in the system.
24 After filling with antifreeze, a label should be attached to the expansion tank, stating the type and concentration of antifreeze used, and the date installed. Any subsequent topping-up should be made with the same type and concentration of antifreeze. If topping-up using antifreeze to Ford’s specification, note that a 50/50 mixture is permissible, purely for convenience.
25 Do not use engine antifreeze in the windscreen/tailgate washer system, as it will damage the vehicle’s paintwork. A screen wash additive should be added to the washer system in its maker’s recommended quantities.
Anti-freeze type Motorcraft Super Plus 2000 antifreeze to Ford specification WSS-M97B44-D

Brake (and clutch) fluid level

Warning: Brake fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it.
Warning: Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness.
HINT: The fluid level in the reservoir will drop slightly as the brake pads wear down, but the fluid level must never be allowed to drop below the MIN mark.

Before you start

8 • Make sure that your vehicle is on level ground.
9 • Cleanliness is of great importance when dealing with the braking system, so take care to clean around the reservoir cap before topping up. Use only clean brake fluid.

Safety first!

10 ● If the reservoir requires repeated topping-up this is an indication of a fluid leak somewhere in the system, which should be investigated immediately.
11 ● If a leak is suspected, the vehicle should not be driven until the braking system has been checked. Never take any risks where brakes are concerned
The MAX and MIN marks are indicated on the front of the reservoir. The fluid level must be kept between the marks at all times.
If topping-up is necessary, first wipe clean the area around the filler cap to prevent dirt entering the hydraulic system. Unscrew the reservoir cap.
Carefully add fluid, taking care not to spill it onto the surrounding components. Use only DOT 4 fluid as mixing different types can cause damage to the system. After topping-up to the correct level, securely refit the cap and wipe off any spilt fluid.

Power steering fluid level

12 • Park the vehicle on level ground.
13 • Set the steering wheel straight-ahead.
14 • The engine should be turned off.
HINT: For the check to be accurate, the steering must not be turned once the engine has been stopped.

Safety first!

15 ● The need for frequent topping-up indicates a leak, which should be investigated immediately.
The fluid level is visible through the reservoir body. When the engine is cold, the level should be up to the MAX mark on the side of the reservoir.
If topping-up is required, wipe clean the area around the reservoir filler neck and unscrew the filler cap from the reservoir.
When topping-up, use the specified type of fluid and do not overfill the reservoir. When the level is correct, securely refit the cap.
Power steering fluid Automatic transmission fluid to Ford specification WSA-M2C195-A

Screen washer fluid level

16 ● Screenwash additives not only keep the windscreen clean during bad weather, they also prevent the washer system freezing in cold weather – which is when you are likely to need it most. Don’t top-up using plain water, as the screenwash will become diluted, and will freeze in cold weather.
Warning: On no account use engine coolant antifreeze in the screen washer system – this may damage the paintwork.
The reservoir for the windscreen and rear window (where applicable) washer systems is located on the front left-hand side of the engine compartment. If topping-up is necessary, remove the filler cap.
When topping-up the reservoir a screenwash additive should be added in the quantities recommended on the bottle. It could also be time to replace the wiper blades. For details, click below
- Close + Open

Wiper blade replacement

Check the condition of the wiper blades. If they are cracked or show any signs of deterioration, or if the glass swept area is smeared, renew them. Wiper blades should be renewed annually.
To remove a windscreen wiper blade, pull the arm fully away from the screen until it locks. Swivel the blade through 90º, then squeeze the locking clip, and detach the blade from the arm. When fitting the new blade, make sure that the blade locks securely into the arm, and that the blade is orientated correctly.
Don’t forget to check the tailgate wiper blade as well (where applicable) which is removed in the same way.
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