Subject: Starter motor Failure
Model: Ford 2.0 TDCI FWD & 2.4 TDCi RWD/2.0 TDCi FWD
On inspection, the units do not exhibit any manufacturing defects. The premature failure of the unit is due to contamination of the pinion/drive area from metal dust particles produced within the Dual-mass Flywheel, when the clutch wears or becomes overheated. During scheduled servicing, it is recommended that the clutch is checked and if found to be showing signs of wear should be replaced.
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You AC should be cooling more effectively than that on MaxAC − I’d take it back and get the pressure checked to ensure you don’t have a leak. Something is funny about your problem though as MaxAC should work even with a bad blend door. MaxAC opens the recirculating air damper, shuts off the flow to the heater core and cranks the AC so you should get full cooling. If you look on this picture below you will see how it all is setup − the blend door is in the middle and controls air flow around the heater core after the AC evaporator. If the heater core is off then you should still get full cooling even if the blend door is wonky.
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Installation step the front wheel bearing for Ford Transit:
1 Remove the wheel hub (refer to the manufacturers instructions).
2 Place the bearing separator under the bearing assembly, making sure the flat side is facing up and under the bolt holes. Tighten the bearing separator by turning the nuts evenly (fig.1B).
3 Place the puller insert into the centre of the hub, see fig.1A.
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Installation Pro.Fit Kit on Ford Transit Connect. Place the DTRT and the Hook Tool in the space between the dash molding and the air vent bezel above and to the right of the radio. Use the hook tool first to gently pry up the air vent bezel sufficient enough to insert the DTRT. Use the DTRT in a gentle twisting motion around the bezel to release the eleven (11) retainer clips securing the air vent bezel to the dash molding. Place bezel off to the side. Insert four (4) Mercedes/Audi radio removal tools in the slots located in the four corners of the radio as indicated by the arrows in Picture 1. Follow radio removal instructions included with the radio removal tools part number (DM-20-22).
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This starter offers high torque, through Gear Reduction at a compact lightweight size. Installation of this starter is similar to the original OEM starter. Designed for use on Chevrolet applications with 153 or 168 tooth ring gears (flywheels).
This starter is designed for 12-VOLT systems only!! Use of this starter with higher than 12 VOLTS or long periods of Read the rest of this entry »

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REMOTE KEYLESS ENTRY (RKE) TRANSMITTER PROGRAMMING:
NOTE: A maximum of 4 Remote Keyless Entry (RKE) transmitters can be programmed to the vehicle. Programming must be done at the same time for all the RKE transmitters.
1. NOTE: Make sure the front doors are unlocked and closed, and the ignition is in the OFF position.
Turn the ignition switch from the OFF to the RUN position 4 times in rapid succession (within 6 seconds), with the fourth turn ending in OFF. If the Generic Electronic Module (GEM) successfully enters program mode, the Instrument Cluster (IC) sounds a chime.
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Instructions: There are four M10 countersunk bolts supplied with this kit.
2 x M10 x 40 (Standard Thread)
2 x M10 x 1.25 x 40 (Fine Thread)
These bolts are used to mount the upper brackets to the chassis. When the bump stop is removed the threaded hole must be examined to determine if it is a standard or fine thread.
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STEP 1 : VEHICLE COMPATIBILITY
Downloadable Firmware for Platform XK01: GMDL5X, GMDL6X, GMDL7X
Default firmware on the XK1 platform is GMDL6X. If the vehicle you are working in is not in the GMDL6X list, you will need to reprogram the XK1 platform with the desired firmware.
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The Ford supplied Sierra 4×4 Supplementary Workshop Manual is a “must have” for any owner of one of these cars. The biggest problem can be actually finding one to purchase. I got lucky and managed to get mine direct from a Ford dealer, brand new for Ł8, who was having a clearout. They do appear regularly at autojumbles and it is just a case of keep looking. The manual only covers those items unique to the 4×4 Sierra’s and Read the rest of this entry »

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Tests/Procedures: 1. Ground the Violet/Yellow wire (disarm circuit) that goes to either front door and the theft alarm module. Have the keys out of the ignition and all doors closed when grounding the wire. This should disarm the theft alarm system and prevent the theft alarm from arming. 2. Check that the interior lights do not stay on due to the wire being grounded. If they do, the illuminated entry relay will need to be removed or another method of disabling the theft alarm will have to be used. 3. Another method if the theft alarm module is faulty would be to disconnect the module and replace the Powertrain Control Module (PCM) with a new one.
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